Welding Assignments

Machine Tool I
Material Preparation

Often the most overlooked step in the welding process is material

preparation. Without properly cleaning your base metal, good welds are
nearly impossible to achieve. The impurities deposited on the surface of
steel during the casting /forming process can cause significant defects
which could leave a weld very porous and brittle. Not a big deal for
welding coupons, but a really big deal in the context of steel buildings and
structures like bridges. Because I want you to learn the right way, this is
something that you will be graded on for each assignment you turn in.
Below is a sequence that should be followed for each assignment.
o General Preparation
Grind off any burrs. The ends of the welding coupons will
always have burrs that need to be filed or ground off.
Grind or wire wheel any surface that is to be welded on.
Usually this will be at least one edge and at least one face.
There should be no oxidation on the surfaces to be welded
prior to welding.
o Butt Welds
In addition to the above steps, also grind a slight angle on
to the edges that will be butt together. Because our material
is so thin, this angle is very slight. The diagram below is
exaggerated, your angle should be less than what is shown
in the picture.

End View

I.

Shielded Metal Arc Welding (STICK)

Assignment #1: Beads

Using scrap metal, run some practice beads to acquaint yourself with the machine
and process. Do this until you are able to run 3 or 4 beads in a row with
consistency. This is a pull process which means that the puddle should form
behind the torch. Use a work angle of 90 degrees and a travel angle of 15 degrees
(off of 90) towards the direction of travel. End on the side of your dominant
hand.
In the horizontal position, run two (2) beads on a single welding coupon. This
will be handed in for a grade so be sure that the beads are about 5/16 wide with
a 1/8 crown, straight, and that the crater at the end of the bead is filled. Be sure
to leave space between your beads so that the slag can be chipped off cleanly.
Once you have laid two (2) beads you are happy with, bring them to me for
feedback and hand them in for grading.

Assignment #2: Butt Joint

Make four (4) butt joints completed in the horizontal position. Lay your pieces
edge to edge with a 1/16 gap between them. Tack on end, flip the part around
180 degrees and lay your bead from the un-tacked end to the tacked end. Use a
circular or C motion as you move the electrode from one end to the other.
Beads should be about 5/16 wide with a 1/8 crown, straight, and the crater at
the end of the bead should be filled. Be sure to chip off any slag and clean up the
bead with the wire wheel if necessary. When done, submit for grading. I will
grade the best 1 of your 4 butt welds.
o Pull Process
Work Angle = 90 degrees
Travel Angle = 15 degrees in the direction of travel(off of 90)
o The graphic below illustrates how to achieve four beads using only three
welding coupons. Two welds on the top and two on the bottom

END VIEW
Assignment #3: Lap Joint

Make four (4) lap welds completed in the horizontal position. The beads should
be about 5/16 wide, straight, and have little if any crown. To achieve good
penetration on both pieces, angle your electrode into the step of the joint at
about 45 degrees. Make sure that all slag has been removed and submit for
grading
o Pull Process
Work Angle = 45 degrees
Travel Angle = 15 degrees (off of 90)

END VIEW

II.

Gas Metal Arc Welding (MIG/WIRE FEED)

Assignment #1: Bead

Using scrap metal, run some practice beads to acquaint yourself with the machine
and process. Do this until you are able to run 3 or 4 beads in a row with
consistency. This is a pull process which means that the puddle should form
behind the torch. Use a work angle of 90 degrees and a travel angle of 15 degrees
(off of 90) towards the direction of travel. End on the side of your dominant
hand.
In the horizontal position, run two (2) beads on a single welding coupon. This
will be handed in for a grade so be sure that the beads are about 5/16 wide with
a 1/8 crown, straight, and that the crater at the end of the bead is filled. Try to
maintain a stick-out of wire at all times. Be sure to leave space between your
beads so that the slag can be chipped off cleanly. Once you have laid two (2)
beads you are happy with, bring them to me for feedback and hand them in for
grading

Assignment #2: Butt Joint

Make four (4) butt joints completed in the horizontal position. Lay your pieces
edge to edge with a 1/16 gap between them. Tack on end, flip the part around
180 degrees and lay your bead from the un-tacked end to the tacked end. Use a
circular or C motion as you move the electrode from one end to the other.
Beads should be about 5/16 wide with a 1/8 crown, straight, and the crater at
the end of the bead should be filled. Be sure to chip off any slag and clean up the
bead with the wire wheel if necessary. When done, submit for grading. I will
grade the best 1 of your 4 butt welds.
o Pull Process
Work Angle = 90 degrees
Travel Angle = 15 degrees in the direction of travel(off of 90)
o The graphic below illustrates how to achieve four beads using only three
welding coupons. Two welds on the top and two on the bottom

END VIEW
Assignment #3: Lap Joint

Make four (4) lap welds completed in the horizontal position. The beads should
be about 5/16 wide, straight, and have little if any crown. To achieve good
penetration on both pieces, angle your electrode into the step of the joint at
about 45 degrees. Make sure that all slag has been removed and submit for
grading
o Pull Process
Work Angle = 45 degrees
Travel Angle = 15 degrees (off of 90)

END VIEW

Assignment #4: T-Joint

Using two (2) welding coupons, orientate them into a T shape and tack the
two pieces together. Much like the lap weld, angle your torch into the
vertex of the angle at an angle of about 45 degrees. Use a standard travel
angle of about 15 degrees (off of 90). Weld several pieces together in this
alignment and submit your best piece (two welds).

END VIEW

III.

Gas Tungsten Arc Welding (TIG)

Assignment #1: Beads

Using scrap metal, run some practice beads to acquaint yourself with the machine
and process. Do this until you are able to run 3 or 4 beads in a row with
consistency. Get the feel of weaving the torch back and forth between the work
pieces. This is a push process, meaning the puddle should be formed in front of
the torch. Use a work angle of 90 degrees and a travel angle of 15-25 degrees (off
of 90) opposite the direction of travel. End opposite your dominant hand,
meaning start on the side of your dominant hand and work the other way.

In the horizontal position lay a fusion bead on a welding coupon. For this
process, lay only one bead per coupon. Once you have laid two beads that you
are happy with, bring them to me for feedback and submit them for grading. I
will grade the best of the two beads.

Assignment #2: Butt Joint

Make four (4) fusion butt welds in the horizontal position. Butt the edges of
the metal TIGHT together and tack one side. Turn the metal 180 degrees and
weld form the un-tacked to the tacked side. Try to center you bead over the joint
and get it to be about 3/16 wide. Watch for a rosy color along your joint to be
sure that you are getting full penetration of the part. When finished, clean up the
weld and submit it for grading.
o Push Process
Work Angle = 90 degrees
Travel Angle = 15-25 degrees opposite the direction of travel
(off of 90)
o The graphic below illustrates how to achieve four beads using only three
welding coupons. Two welds on the top and two on the bottom

END VIEW
Assignment #3: Lap Joint

Make four (4) fusion lap welds completed in the horizontal position.
The beads should be about 3/16 wide and straight. Angle your torch
about 45 degrees into the step of the joint to distribute the heat as evenly
as possible. Watch for a rosy color along the joint to be sure that you are
getting proper penetration on both pieces. Because you are heating more
surface in this process, you will probably have to slow your rate of travel
to get proper melting of the base metals to take place.
o

Pull Process
Work Angle = 45 degrees
Travel Angle = 15-25 degrees (off of 90) opposite the direction
of travel.

END VIEW