Welding

WELDING REPORT
OBJECTIVES:
 Measure the precision and strength of welded joints, focusing on the integrity of
the connection between metal pieces.
 Evaluate the efficiency of metal cutting processes and their impact on the final
product.
 Assess the effectiveness of rust removal techniques employed and their
contribution to improved material quality.
 Familiarize participants with the equipment used in welding and workshop
settings.
EQUIPMENT USED:
1. Sandpaper
2. Welding Gloves
3. Metal scriber
4. Welding electrodes
5. Transformer/generator
6. Bench vise
7. File
8. Welding shield
9. Tongs
10. Chipping hammer
11. Ruler
12. Hacksaw
13. Welding cables
THEORY:
Welding is a crucial process for joining materials, predominantly metals, by melting their edges
or adding filler materials, followed by cooling and solidification. It finds extensive applications in
construction, fabrication, manufacturing, and automotive industries, as well as in repairing
metal parts. The welding processes explored in this workshop primarily focused on electric arc
welding. The description of the tools are mentioned below.
Ruler: A measuring tool utilized for accurate measurements of metal workpieces before
cutting or welding processes.
Hacksaw: A versatile tool with a fine-toothed blade for precisely cutting metal pieces. Its
narrow blade allows for intricate cuts, and it is easily replaceable when dull.
Metal Scriber: This tool is employed for marking and scribing lines on metal surfaces.
With its sharp, pointed tip, it scratches or etches lines into metal, aiding in creating
precise markings for cutting or welding.
File: Used for shaping and smoothing metal surfaces, a file consists of a handle and a
hardened steel blade with small, sharp teeth called "cuts." It's employed with back-and-
forth or circular motions to gradually remove material, shaping the metal or creating a
smoother surface.
Sandpaper: Commonly used in metalworking, sandpaper prepares surfaces for painting,
staining, or varnishing. It also serves to remove rust or old finishes from metal surfaces.
Transformer or Generator: This equipment generates low-voltage, high-ampere
electric current necessary for welding. It converts electrical energy into heat energy
required for the welding process.
Welding Shield: A shield or screen that protects welders and nearby individuals from
intense light and sparks during welding. While normally opaque, it allows visibility of the
sparks and surrounding area during welding.
Welding Electrodes: Consumable rods or wires that serve as filler material in welding.
They melt and fuse with the base metal, creating a strong joint.
Welding Gloves: Heat-resistant gloves designed to protect hands and arms while
handling hot materials and welding equipment.
Electrode Holder: Connected to the end of welding cables, the electrode holder securely
holds the electrode. It's lightweight, sturdy, and designed for ease of handling without
heating during operation.
Welding Cables: These cables connect the welding machine to the electrode holder and
ground clamp, facilitating the flow of electricity during welding.
Tongs: Used for handling metal workpieces during welding to prevent injury due to high
heat.
Chipping Hammer: This handheld tool features a chisel-like end used to remove slag,
the residue that forms during the welding process, ensuring a clean weld.
PROCEDURE:
The workshop commenced with the precise cutting of metal pieces using a hacksaw,
aided by measurements made with rulers and markings from metal scribers. Following
this, the surfaces of the metal pieces underwent cleaning and smoothening with hand files
and sandpaper to remove dirt and rust. Participants then connected the welding machine
to the power source, ensuring proper grounding, and donned appropriate personal
protective equipment (PPE) such as welding shields and gloves to safeguard against
sparks, UV radiation, and heat.
The welding process began with the creation of an arc by striking the electrode against
the workpiece, followed by quick withdrawal. Proper alignment of workpieces was
ensured, and starting and ending points of joints were welded first to provide a clear path
for subsequent welding. The electrode was then moved back and forth along the joint to
create a smooth and uniform weld bead, with careful observation of the weld pool and
bead quality. After completing the weld on one side, the workpiece was flipped over, and
the process was repeated. Post-welding, the workpiece was cooled with water and the
slag was promptly removed using a chipping hammer.
Welding work piece
DISCUSSION:
The workshop highlighted the necessity of practice and adherence to safety precautions in
welding. It emphasized the importance of proper safety gear and equipment to ensure a
safe working environment. Through welding, participants achieved strong and durable
bonds between metal pieces, showcasing the potential and demand for welding skills in
various industries.
CONCLUSION:
In conclusion, the workshop successfully met its objectives by demonstrating proficient
metal cutting, effective rust removal, and precise welding techniques. The utilization of
tools such as hacksaws, files, and welding machines, combined with a focus on safety,
yielded successful outcomes. The workshop not only transformed raw materials but also
enhanced participants' skills, offering valuable lessons for future projects and
emphasizing continuous improvement and safety protocols.
SAFETY PRECAUTIONS:
 Wear appropriate PPE including welding helmets, safety glasses, gloves, and
flame-resistant clothing/apron.
 Ensure good ventilation to prevent harmful fume accumulation.
 Protect skin from UV radiation emitted during welding.
 Avoid welding in confined spaces without proper ventilation.
 Follow electrical safety practices and ensure proper grounding of welding
equipment.
 Regularly inspect and maintain welding equipment for optimal performance.
 Safety remains paramount in welding, and individuals new to the practice should
seek proper training and guidance from experienced welders.

Welding

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WELDING REPORT

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