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Mohamad Afiq Afifi b.

Mohd Zafie (2013806352)


Discussion
In this workshop session, the students were given a piece of metal plate for each person. The
students were required to use the gas metal arc welding (GMAW) to weld four line on the
plate. After that, the students were required to analyse the quality of their weld by discussing
the defects resulting from the welding process.
In welding process, there are for type of defect classes which are shape defect, cracks
and cavities, lack of fusion, and also solid inclusions. These defect and quality of a weld part
are inspected mainly through the appearance of the weld part.
From the specimen, one of the defects that appear is undercutting. Undercutting is
cutting away of the base material along the edge of the weld. This defect occurs due to high
voltage, excessive travel speed, low wire-feed speed, poor torch technique, improper gas
shielding or the wrong filler wire. When the travel speed is too fats, the weld bead will be
very peaked because of its extremely fast solidification. To avoid this defect, make sure we
weld with proper technique and correct welding machine setting such as current and voltage.
Decreasing the travel speed will slowly reduce the size of the undercut and eventually
eliminate it.
Other than that, the defect appeared is irregular weld shape where the shape of the
weld was too narrow, have an excessively convex or concave surface. The possible source of
this defects are poor torch manipulation, a speed of travel that is too fast, current that is too
high or low, improper arc voltage, improper stick out, or improper shielding gas. Other than
that, the defect was also due to insufficiency of the gas. When the gas is lacking, the
solidification process will not be consistent and thus affect the weld shape. To avoid this
defect, make sure to use proper technique of welding, the current and voltage are set correctly
and also make sure the gas is sufficient.
The last defect is spatter. Spatter is made up of very fine particles of metal on the plate
surface adjoining the weld area. Spatter occur when too high current is used, too long arc
length, an irregular and unstable arc, improper shielding gas. The slag clogging the end of
weld gun can be the reason for this defect. To avoid this defect, make sure proper technique is
applied, correct current setting and always clean the weld gun nozzle so that no slag is
slogged in there.

Undercutting
Spatter

Irregular weld shape


Figure 1: Weld Specimen; Mohamad Afiq Afifi b. Mohd Zafie (2013806352)

Conclusion

As a conclusion, from this workshop session, we have study about the gas metal arc
welding (GMAW) and also the technique of welding using GMAW. We can conclude that
proper techniques and skills are required in order to get good quality welding. To obtain good
quality welding and avoid any defects, 3 things must be considered during the welding
process which are angle, arc length, and speed. These 3 things must be held constant
throughout the welding process. Make sure also we read and follow up all the SOP before
conducting the machine and follow all the safety measure in the workshop.

Title: Gas Metal Arc Welding (GMAW)

Objective : To investigate the defects and quality of welding bead due to changes in welding
such as voltage(V), current (A), and welding speed (m/min).

Recommendations
1) Install more ventilation fan. This is because during the GMAW welding process,
students are exposed to the shielding gas and this can be dangerous to the students.
2) Provide more plier or metal tong. This is because during welding process, students are
required to use plier cut the electrode tip or to hold the hot specimen after the welding
process. Insufficiency of this tool make the welding process become harder.
3) Design a machine that can make the operators hand static during the welding process.
This machine should be able to support operators hand and thus making the weld
more stable and linear along the desired weld part.
4) Provide a grinder machine so that the student can clean and polish their plate
specimen before conducting the welding process. This is to ensure students can obtain
the best welding result and quality.

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