WELDING LAB REPORT

MUHAMMAD ABUBAKAR SHAHZAD

DEPARTMENT OF MECHANICAL ENGINEERING
 LAB LAYOUT

MIG
Welding
equipment

TIG
Welding
equipment

MIG
Welding
equipment

AC Arc
Oxyacetylene Welding
Gas Welding equipment

Spot
Welding
Equipment
Table
 Lab Session 1
“Introduction to the welding lab of U.E.T.”
1) Objective
i. To study the concepts related to welding and its applications in everyday life.
ii. To draw the layout of welding lab.

iii. To study the use and application of each welding tool available in welding lab.

2) Apparatus
i. Spot welding equipment
ii. AC arc welding equipment
iii. MIG welding equipment
iv. TIG welding equipment
v. Oxyacetylene gas welding equipment

3) Introduction
One of the most widely used coalescence technique used in all the manufacturing
industries is welding. From small one to big industries, welding is used everywhere to
join parts together. A large number of techniques are used for welding depending upon
the materials to be joined. In this experiment, we will discuss welding, types of welding
and its applications in various industries.

4) Theory
Welding
“The technique in which two or more than two parts are joined or coalesced together using
heat and/or pressure is called welding.”
The product obtained after welding is called weldment. From the definition, it is clear
that the welding can be performed by only heating the parts and then joining them or by
applying the pressure or by the use of both heat and pressure. Although most
commonly welding is a term used for metal parts but it can also be used for plastics. [1]

 Types of welding
As suggested by American Welding society there are near about 50 types of welding but in
general, there are two main categories of welding
i. Fusion welding
ii. Solid state welding
These categories are further classified into various types e.g. Fusion welding can be classified
into

(a) Arc Welding

(b) Resistance welding
(c) Oxyfuel gas welding
(d) Laser beam welding
(e) Electron beam welding

And solid-state welding can be classified into following types:

(a) Diffusion welding
(b) Friction welding
(c) Ultrasonicwelding

5) Lab safety precautions

i. Lab court should be used and tight clothes should be avoided in welding lab.
ii. Use safety gloves before welding in order to avoid any physical contact with pinch
point area.
iii. Always wear proper shoes to prevent injury.
iv. Do not eat or drink in the lab.
v. Do not cross the yellow line until asked by attendant.
vi. Do not wear jewelry and rings in the lab during welding.
 Lab Session 2
“To investigate the effect of varying current and voltage
on spot welded specimen”

1) Objective
i. To study the concepts related to Spot welding.
ii. To study the limitations and applications of spot welding.

2) Apparatus
i. Spot welding equipment
ii. Sheet Metals

3) Introduction
Spot welding is one of the most widely used type of resistance welding and find its
major importance in automotive industry to join sheet metals. In this experiment, we
will discuss spot welding, its principal, applications and the effect of varying current
and voltage on spot welded equipment.

4) Theory
 Spot welding
Spot welding is a type of electric resistence welding in which we weld metal sheets
together through a process in which contacting metal surfaces joints are joined by
heat obtained by resistsnce of current.

 Spot welding machine

Spot welding machine consists of the following components:
i. Power supply
ii. Energy storage unit
iii. Switch
iv. Welding transformer
v. Copper electrode
  Spot welding Equipment

i. In spot welding two metal sheets are weld together without using a filler
material. It is the one of the oldest known method of welding.

ii. The process involves applying pressure and heat to the weld area
using shaped alloy copper electrodes which convey an electrical
current through the weld pieces. The material melts, fusing the parts
together at which point the current is turned off, pressure from the
electrodes is maintained and the molten “nugget” solidifies to form the
joint.

iii. The welding heat is generated by the electric current, which is

transferred to the work piece through copper alloy electrodes. Copper
is used for the electrodes as it has a high thermal conductivity and low
electrical resistance compared to most other metals, ensuring that the
heat is generated preferentially in the work pieces rather than the
electrodes.

5) Procedure
i. First of all, take two sheets of small thickness and clean their surface. Also,
clean the tip of the electrodes in order to avoid any error during the
experiment.
ii. Then create a lap joint of the sheets and grasp then after wearing safety
gloves.
iii. After turning on the rocker arm spot welder, place the lap jointed sheets
between the electrodes of spot-welding equipment and firmly hold them
manually as well as using electrodes by pressing the paddle. The electrodes
should be attached at the point where spot welding is required.
iv. After holding, increase the pressure on the sheets gradually by pressing the
paddle and then give a stroke to the paddle. This will create a spot weld
between the sheets.
v. Repeat the procedure several times for multiple spots.

6) Advantages of Resistance welding

There are following advantage of resistance welding
i. No shielding gases and filler metal is required
ii. The production rate is usually high
iii. Can be efficiently performed using mechanization and automation techniques
 iv. Does not require extremely skilled operator.

Figure 1: Spot welding machine

7) Disadvantages of resistance welding

There are following drawbacks of resistance welding
i. The resistance welding equipment is mostly not economical and costs
much as compared to the air welding equipment
ii. Out of the five types of joint, only lap joint can be welded using
resistance welding.

Lab Session 3
“To investigate the effect of varying current and voltage
on arc welded specimen”
1. Objective
i. To study the concepts related to arc welding.
ii. To study the limitations and applications of arc welding. iii. To
investigate the effect the varying current and voltage on arc welded specimen.

2. Apparatus
i. Arc welding equipment
ii. Metal sheets
iii. Power supply

3. Introduction
The most extensively used type of welding is arc welding. From the very beginning to
modern era, it is used in almost all type of manufacturing or fabrication industries.
There are numerous types of arc welding and each of them finds its own applications
and uses. In this experiment, we will discuss arc welding, its applications,
advantages, disadvantages and limitations.

4. Theory
 Arc welding
Arc welding is a welding process that is used to join metal to metal by
using electricity to create enough heat to melt metal, and the melted metals,
when cool, result in a binding of the metals.

 Operating principle
An electric arc is generated when two ends of a circuit are separated by a very short
distance. The same principle is used in arc welding. First of all, the electrode is
attached with the workpiece in order to complete the circuit. After completing the
circuit, the electrode is separated from workpiece by a very small distance. This
separation generates an electric arc that is capable of producing temperature as
high as 5500°C. The temperature is so high that will melt both the base metal and
filler metal (if present). The will create the pool of base metal which will solidify and
will generate a weld. A filler metal is mostly used in arc welding in order to increase
the volume and provide additional strength.

 Electrodes
There are two basic types of arc welding:
i. Consumable electrodes arc welding
ii. Non consumable electrodes arc welding
If the electrode itself serves as a filler metal then it is called consumable electrode.
Most common types of consumable electrodes are wires and rods usually 9-18 in
long and 3/8 in diameter. Obviously, the melting temperature of the electrode metal
is less than the arc temperature. Small droplets of the electrodes keep on welding
and deposit on the surface to be welded. There are three common mechanism
through which the consumable electrode gets deposited.
5. Procedure
i. First of all, put the pieces of metals to be joined on table and align them
properly.
ii. After the precautionary measures are fulfilled, turn on the equipment and set
the value of voltage and current depending upon the thickness of sheets and
weld length.
iii. Connect one end of the equipment with the workpiece and the other end is
connected with the electrode.
iv. Join the electrode with the workpiece for small interval of time.
 v. Separate the electrode from the workpiece by a very small distance. This will
generate an electric arc that will generate beat welds on the surface.
vi. Move the electrode forward using electrode holder gradually until the entire
length is welded.
vii. Sometimes both sides of the sheets need to be welded if sheets are of high
thickness then repeat the procedure for the other side.

5. Advantages of Arc welding

There are following advantages of arc welding:
i. The arc welding equipment is not much costly and is easily affordable.
ii. Dirty Metals can also be welded using arc welding.
iii. The equipment is so simple that it does not require any industry environment
and can be performed anywhere.
iv. A strong bond is generated between metal sheets.

6. Disadvantages of Arc welding

There are following disadvantages of arc welding:
i. A skilled person is required to perform a successful arc welding.
ii. Thin sheets are difficult to be arc welded.

iii. The reactive metals e.g. aluminum and titanium etc. cannot be arc
welded.

iv. Arc welding usually needs high energy which increases the risk factor.

Figure 2 Arc Welding

 Lab Session 4
“To investigate the effect of varying current and voltage
on MIG welded specimen”
1. Objective
i. To study the concepts related to MIG welding.
ii. To study the limitations and applications of MIG welding.

2. Apparatus
i. MIG welding equipment
ii. Metal sheets
iii. Power supply

3. Introduction
MIG welding also referred to as Gas metal arc welding (GMAW) is a type of
consumable electrode arc welding in which the shielding gas provides the provided
to molten metal as well as arc. In this experiment, we will discuss the operating
principle, applications, advantages and disadvantages of MIG welding. We will also
discuss the importance of shielding gas in MIG welding.

4. Theory
 MIG Welding
Metal Inert Gas (MIG) welding is an arc welding process that
uses a continuous solid wire electrode heated and fed into the
weld pool from a welding gun. ... The gun feeds a shielding gas
alongside the electrode helping protect the weld pool from
airborne contaminants.
 MIG Welding equipment
The welding plant used to perform MIG welding is shown in figure below
 Figure 3MIG Equipment

This equipment consists of

i. Feed control
ii. Control system
iii. Gas out
iv. Gun control
v. Gun
vi. Cables
vii. Power supply
viii. Contactor
control
ix. Welding
machine
x. Voltage
control
xi. Shielding gas
source
xii. Wire feed drive
motor

 Operating Principle
The work principle of MIG welding is same as that of other type of arc welding i.e. to
produce coalescence between two surfaces using heat generated from the electric
arc between the electrode and the work. The shielding gases are used in this regard
to prevent the formation of oxides or nitrides etc. and to protect the weld.

 Filler metal in MIG Welding

Filler metal is used in welding to increase the volume and to provide additional
strength to the weld. In case of MIG welding, the electrode itself serves as filler
metal.

5. Procedure
i. First of all, put the pieces of metals to be joined on table and align them
properly. Remove any dust particle from them if present.
ii. The welder should then fulfil all the safety requirements.
iii. Then turn on the equipment and connect one end of the equipment with the
workpiece.
iv. Electron welding gun weld the sheets in which coalescent is required.
v. In case of multiple sheets, repeat the same procedure for other sheets.
 6. Applications of MIG Welding
MIG welding is not used in small or simple industries rather it is used for high volume
welding. It is a basic necessity in following industries:
i. Sheet metal industry
ii. Ship manufacturing industries
iii. Industries that manufacture pipelines
iv. Automotive industry
v. Various ferrous and non-ferrous metals are joined in fabrication industries
using MIG welding
vi. It is used for welding pipes.
vii. Automotive repair.

Lab Session 5
“To investigate the effect of gas pressureon oxy-
acetylene welded specimen”
1. Objective
i. To study the concepts related to Oxyfuel gas welding.
ii. To study the limitations, applications, advantages and disadvantages of
Oxyacetylene gas welding.
1. To investigate the effect the varying gas pressure on Gas welded specimen.
2. Apparatus
i. Oxyacetylene gas welding equipment
ii. Metal sheets to be welded

3. Introduction
Oxyfuel gas welding (OFW) is a type of fusion welding in which coalescence
between two surfaces is achieved using the heat of the flame generated by the
combustion of gases. The most common type of oxyfuel gas welding is oxyacetylene
gas welding. In this experiment, we will discuss the operating principle, applications,
advantages and disadvantages of oxyacetylene gas welding. We will also discuss
the use of gas plant as a cutting plant.

4. Theory
 Gas welding
Gas welding is the process of using heat generated from burning a fuel gas
(like acetylene) to cut and/or join metals together. 

 Working principle
Gases coming from their respective cylinders are combusted in welding torch and a
flame is generated. The flame is targeted on the surfaces to be welded which will
melt the surfaces and fusion will occur. The filler metal can also be added to the
process to increase the strength of welding. The molten pool will generate the weld
joint when it will solidify.
 Equipment
i. Oxygen cylinders
ii. · Acetylene cylinders
iii. · Pressure regulator ·
iv. Torches ·
v. Goggles
vi. · Gloves
 Filler rod
In general, the filler material used is a low fuming bronze - either a bare rod
which is dipped into a flux material or a bare rod with a flux coating on the rod
itself.

Figure 4 Gas Welding Equipment

6. Procedure
i. First of all, put the pieces of metals to be joined on table and align them
properly. Remove any dust particle from them if present.
ii. The welder should then fulfil all the safety requirements.
iii. The open the gas regulators on both cylinders and adjust the amount of
oxygen and acetylene depending upon the material to be welded.
iv. Take a filler metal rod on the basis of the nature of material going to be
welded.
 v. Grasp the welding torch in one hand and filler rod in another. Turn the torch
on and keep inserting the filler metal in the weld area over the entire weld
length.
vi. After completing turn off the gas cylinders

5. Applications of oxyacetylene gas welding

There are following applications of oxyacetylene gas welding:
i. Gas welding is used for low quantity work, in maintenance and
repair.
ii. Gas welding is especially useful is steel metal working.
iii. The OAW equipment can also be used for cutting operation.