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    Lab Session 04 - Arc Welding

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    Zaid Baig
    The document describes an arc welding lab session that investigates the effects of varying voltage and current on arc welded specimens. The objectives are to understand the working principle, parameters, and safety of arc welding. Students will set different voltages and currents, take observation readings, and submit a specimen and report. Arc welding works by creating an electric arc between an electrode and workpiece to melt and join metals. Parameters like voltage, current, electrode type, and arc length must be properly set and safety precautions followed.

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    © All Rights Reserved
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    Lab Session 04 - Arc Welding

    Uploaded by

    Zaid Baig
    47 views6 pages
    The document describes an arc welding lab session that investigates the effects of varying voltage and current on arc welded specimens. The objectives are to understand the working principle, parameters, and safety of arc welding. Students will set different voltages and currents, take observation readings, and submit a specimen and report. Arc welding works by creating an electric arc between an electrode and workpiece to melt and join metals. Parameters like voltage, current, electrode type, and arc length must be properly set and safety precautions followed.

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    The document describes an arc welding lab session that investigates the effects of varying voltage and current on arc welded specimens. The objectives are to understand the working principle, parameters, and safety of arc welding. Students will set different voltages and currents, take observation readings, and submit a specimen and report. Arc welding works by creating an electric arc between an electrode and workpiece to melt and join metals. Parameters like voltage, current, electrode type, and arc length must be properly set and safety precautions followed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    47 views6 pages

    Lab Session 04 - Arc Welding

    Uploaded by

    Zaid Baig
    The document describes an arc welding lab session that investigates the effects of varying voltage and current on arc welded specimens. The objectives are to understand the working principle, parameters, and safety of arc welding. Students will set different voltages and currents, take observation readings, and submit a specimen and report. Arc welding works by creating an electric arc between an electrode and workpiece to melt and join metals. Parameters like voltage, current, electrode type, and arc length must be properly set and safety precautions followed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    Lab Session: 04

    Arc Welding

    1. Title:

    To investigate the effects of varying voltage and current on arc welded specimen

    2. Problem Statement:

    Arc Welding is one of the oldest, most common and extensively utilizing welding process. It is
    being used in every field like mechanical, civil etc., so it is essential to understand the process
    properly. It is required to study different parameters involved, SOPs for the utilization of the
    equipment and possible hazards encountered while operating the equipment.

    3. Objective:

    To understand the working principle and basic operating parameters of Arc Welding.

    4. Theory:

    4.1. Introduction:
    Arc Welding is a process which melts and joins metals by heating them with an arc between a
    coated metal electrode and the workpiece. The electrode outer coating, called flux, assists in
    creating the arc and provides the shielding gas and slag covering to protect the weld from
    contamination. The electrode core provides most of the weld filler metal. When the electrode is
    moved along the workpiece at the correct speed the metal deposits in a uniform layer called a bead.

    Figure 1: Schematic of Resistance Welding


    The process is used primarily to weld iron and steels (including stainless steel) but aluminum,
    nickel and copper alloys can also be welded with this method. It dominates other welding processes
    in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity
    is popular because it can be used in the field without complicated equipment and gases.

    A suitable gap is maintained while joining two metals so that the filler material from filler rod can
    fill the gap to the required depth. This gap is

    4.2. Principal of Arc:


    A suitable gap is kept between the workpiece and electrode called arc length. A high current is
    passed through the circuit. The electric energy is converted into heat energy, producing a
    temperature of 3000°C to 4000°C. This heat melts both the base metal and the electrode, producing
    a pool of molten metal sometimes called a "crater." The crater solidifies behind the electrode as it
    is moved along the joint. The result is a fusion bond.

    4.3. Equipment:
    Setup of arc welding equipment is shown as below:

    Figure 2: Arc Welding Equipment


    4.4. Arc Shielding:
    Joining metals requires more than moving an electrode along a joint. Metals at high temperatures
    tend to react chemically with elements in the air - oxygen and nitrogen. When metal in the molten
    pool comes into contact with air, oxides and nitrides form which destroy the strength and toughness
    of the weld joint. Therefore, many arc-welding processes provide some means of covering the arc
    and the molten pool with a protective shield of gas, vapor, or slag. This is called arc shielding.
    This shielding prevents or minimizes contact of the molten metal with air. Shielding also may
    improve the weld. An example is a granular flux, which actually adds deoxidizers to the weld.
    Figure 3: Arc Shielding through flux coated electrode rod

    4.5. Welding Parameters:


    Note down the readings of current, voltage. Insert the picture of the specimen.

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    4.6. Procedure:
     Receive the specimens from the lab assistant.
     Remove the rust from the specimens by using sand paper.
     Arrange the flat pieces properly providing the gap for full penetration for butt joint (gap
    half of the thickness of flat).
     Practice striking of arc, speed and arc length control.
     Set the welding current, voltage as instructed.
     Strike the arc and make tacks at the both ends to hold the metal pieces together during the
    process.
     Lay beads along the joint maintaining proper speed and arc length (speed 100 – 150
    mm/min)
     Clean the welded zone.
     Submit the specimen to the teacher along with a one page report of the experiment.

    A general setup procedure is shown in the figure given below.

    Figure 4: Setup procedure for arc welding

    1. Workpiece: Make sure workpiece is clean before welding.


    2. Work Clamp: Place as close to the weld as possible.
    3. Electrode: Before striking an arc, insert an electrode in the electrode holder. A small
    diameter electrode requires less current than a large one. Follow recommendations of the
    electrode manufacturer when setting weld amperage.
    4. Insulated Electrode Holder
    5. Electrode Holder Position
    6. Arc Length: Arc length is the distance from the electrode to the workpiece. A short arc with
    correct amperage will give a sharp, crackling sound. Correct arc length is related to
    electrode diameter. Examine the weld bead to determine if the arc length is correct. Arc
    length for 1/16 and 3/32 in. diameter electrodes should be about 1/16 in. (1.6 mm); arc
    length for 1/8 and 5/32 in. electrodes should be about 1/8 in. (3 mm).
    4.7. Observations:
    Students are requested to insert table of their observation along with the picture of specimen.

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    4.8. Safety Precautions:


    The following safety precautions must be observed while working on arc welding equipment:
     Read the safety instructions available in the lab for arc welding setup utilization.
     Always wear lab coat before starting any work.
     During welding, do not see the arc directly without face shield.
     Keep a safe distance while operating the equipment.
     Always use goggles while working.
     Proper ventilation must be provided in the shop.
     Keep in mind the location of the fire extinguishers.

    5. To Do Assignment:

    Observe and study the spot welding process and complete the lab report as per the study
    questions given below.
    a. Discuss some of the arc welding processes.

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    b. Discuss the applications of arc welding with their pictures.

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    c. What are the advantages and limitations of this process?

    Advantages:
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    Limitations:
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