 To give student basic knowledge about

welding.

 To increase the skill of welding.

 To give student more time to practice

before doing the actual task.
1. To give a basic technique of welding.

2. To increase the skill of handling welding.

3. To give more information about welding.

4. To ensure the student know how to apply welding .

 Welding is a process that uses an electric arc to join the metals
being welded. When we use arc welding is better than gas welding
. In gas welding the flame spreads over a large area, sometimes
causing heat distortion. The concentration of heat, characteristic of
arc welding, is an advantage. This heat concentration also
increases the depth of penetration and speeds up the welding
operation. Therefore, you will find that arc welding is often
practical and economical than gas welding.

All arc-welding processes have three things in common: a heat

source, filler metal, and shielding. The source of heat in arc
welding is produced by the arcing of an electrical current between
two contacts.. This should not be confined with the same term that
is also used to describe the person who is performing the welding
operation. Welding machine is either electric- or motor-powered.
In the Naval Construction Force (NCF), there are two main types
 of arc-welding processes with which you should become familiar.
They are shielded metal arc welding and gas shielded arc welding.

1.2 Tools and equipment

Electrode holder.
 This tools is use to hold the electrode stick.

welding power source

  This power source is use to supply electrical energy to the
electrode.

Earth cable.
 Use in case of an insulation failure in some appliance, this
wire connected to the metal body will provide a path for the
current to flow on the ground.

Electrode stick.
  used to conduct current through a workpiece to fuse two
pieces together.

Face shield .
 to protect the eyes from UV rays and to protect the face from
the heat.

Chipper.
  To remove the slag after welding.

Leather gloves.
 to protect the finger from the heat form from the process.

Leather apron.
  To protect the body from the heat form from the process.

Wire brush .
 To clean the work piece.
1.3 Safety precautions

There is safety precautions that we need to learn to make sure

the safety. We need to wear safety equipment before doing the
welding process. Here some precaution that need to give attension.

1. Wear safety equipment to avoid injury.

2. Remove all flammable material from the project.
3. Use suitable electrode with suitable keep voltage.
4. Do not stick the electrode to the work piece because this will
damage the power supply.
5. Keep the suitable fire extinguisher nearby.
6. Do not inhale the gas produce from the process.
1.4 Fundamentals of arc welding

Arc welding is one of processes for joining metals. By

applying constant heat, metal at the joint between two
parts is melted and caused to intermix - directly, or more
commonly, with an intermediate molten filler metal. Upon
cooling and solidification, a metallurgical bond is created.
Since the joining is an intermixture of metals, the final
weldment potentially has the same strength properties as
the metal of the parts. This is in sharp contrast to non-
fusion processes of joining in which the mechanical and
physical properties of the base materials cannot be
duplicated at the joint.

In arc welding, the intense heat

needed to melt metal is
produced by an electric arc. The
arc is formed between the actual
work and an electrode that is
Fig. 1 The basic arc-welding circuit  
manually or mechanically guided
along the joint. The electrode can either be a rod with the
purpose of simply carrying the current between the tip
and the work. Or, it may be a specially prepared rod or
wire that not only conducts the current but also melts
and supplies filler metal to the joint. Most welding in the
manufacture of steel products uses the second type of
electrode.
1.5 Operation procedure

1. Clean the surface of the work piece.

2. Position the plate close together with sufficient gap for welding.
3. Select the suitable electrode.
4. Adjust the electric current.
5. Scratch or knock the electrode into the metal surface. To strike the
arc and do a tack weld to hold the join .
6. Weld along the join and fill the welding groove completely .
7. Switch off the welding.
8. Remove the slag from welding bead.
1.6d Results and Observation.

Arc Welding

Some observation has made during the process. There is some problem
happend .

Observation from the angle

 30°

Molding size form from the welding is small. The molding is not
perfect. It is hard to ensure the molding patern.

 45°

Molding size form from the welding is fine. The molding is perfect.
Its easier to follow the molding patern.

 90°

Molding size form from the welding is big. The molding is not
perfect. Its hard to follow the pattern because the hand will get tired.
Observation from the speed

 Fast

The molding form is in small size .this is because the heat transfer
is not long enough to make the work piece mold .

 Medium

The molding form is in perfect size. This is because the heat

transfer is enough to make the work piece mold perfectly.

 Slow

The molding form is in large size. This because the heat transfer is
to much and this make the work piece mold too much.

Observation from the distance between work piece and the arc rod.

 Cm

The welding is not happened. This is the distance is to far to make

the charge transfer.
 Cm

The welding is happened. Its easy to control.

 Cm

The rodstick to the work piece. This can make the generator broke.
Its hard to do the welding process.
 A process for joining two pieces of metal in which the required high
temperature is obtained by the combustion of acetylene gas and oxygen.
The gases are thoroughly mixed in the nozzle or tip of the welding torch
to ensure perfect combustion. The weld may be formed directly between
two adjoining surfaces, but usually metal from a welding rod is fused in
between the surfaces of the joint.
 2.2 Tools and equipment

Oxygen and acetylene cylinder

 to keep the oxygen gas and acetylene gas.

High pressure blow pipe

 mixing the oxygen gas and acetylene .
Gas welding hoses.
 To transfer the gas from cylinder to the High pressure blow pipe.

Gas pressure regulator.

 Indicates the pressure of the gas.
Face shield .
 to protect the eyes from UV rays and to protect the face from
the heat.

Fire starter
 give spark to start the welding.
Leather gloves.
 to protect the finger from the heat form from the process.

Leather apron.
 To protect the body from the heat form from the process.
Wire brush .
 To clean the work piece.

Filler rod
 To make the work piece connected .

2.3 Safety precaution

There is safety precautions that we need to learn to make sure

the safety. We need to wear safety equipment before doing the
welding process. Here some precaution that needs to give
attention.

1. Wear proper protection.

2. Do not inhale the gases and the fumes.
3. Do not weld dirty or corrosion work piece.
4. Keep your head out from the fumes.
5. Wear clean fire resistance cloth.
6. Keep the suitable fire extinguisher nearby.
7. Make sure oxygen gas in good quota .
8. Make sure there is no leaking at the hoses.
2.4 Fundamentals of project

Gas tungsten arc welding (GTAW) is an electric arc welding process

that produces an arc between a no consumable electrode and the work to
be welded. The weld is shielded from the atmosphere by a shielding gas
that forms an envelope around the weld area (see Figure 2).

GTAW is versatile and can be used on ferrous and nonferrous metals

and, depending on the base metal, in all welding positions. The process
can be used to weld thin or thick
materials with or without a filler metal.

When welding thinner materials, edge

joints, and flange, filler metals are not
used. For thicker materials, an externally
fed filler wire is generally used. The type of filler metal wire to be used
is based on the chemical analysis of the base metal. The size of the filler
metal wire depends on the thickness of the base metal, which usually
dictates the welding current.

The methods of operation for GTAW can be manual or automatic.

Figure 2:
The GTAW process is versatile and can be used on ferrous and
nonferrous metals. An arc is produced between a nonconsumable
electrode and the work to be welded. The weld is shielded from the
atmosphere by a shielding gas that forms an envelope around the weld
area.
2.5 Operation procedure

1. Clean the surface of the work piece.

2. Position the plate close together with sufficient gap for welding.
3. Adjust the gas pressure.
4. Open the acytelne nozzle . Start with the spark of fire.
5. Then open the oxygen gas.
6. Weld along the join by give heat to the filler wire and fill the
welding groove completely .
7. Switch off the oxygen gas then acytelena.
8. Remove the slag from welding bead.
Results and Observation

Gas welding

Some observation has made during the process. There is some problem
happen.

Observation from the angle

 30°

Molding size form from the welding is small. The molding is not
perfect. It is hard to ensure the molding patern. This because the heat
is not enough to mold the work piece.

 45°

Molding size form from the welding is fine. The molding is perfect.
Its easier to follow the molding patern.this is because heat is enough.

 90°

Molding size form from the welding is big. The molding is not
perfect. Its hard to follow the pattern because the hand will get tired.
This is because the heat go through over the limit for the work piece.
Observation from the speed

 Fast

The molding form is in small size .this is because the heat transfer
is not long enough to make the work piece mold .

 Medium

The molding form is in perfect size. This is because the heat

transfer is enough to make the work piece mold perfectly.

 Slow

The work piece leak. This because the heat transfer is to much and
this make the work piece mold too much.

Observation from the distance between work piece and heat.

 Cm

The work piece is hard to mold. This is the distance is to far to

make the heat transfer.

 Cm

The welding is happened. Its easy to control the molding.

  Cm

The work piece easy to leak. Because the heat source is close. Heat
transfer is over the limit for the work piece.
 Gas metal arc welding (GMAW), sometimes referred to by its
subtypes metal inert gas (MIG) welding or metal active gas (MAG)
welding, is a semi-automatic or automatic arc welding process in which
a continuous and consumable and wire electrode a shielding gas are fed
through a welding gun. A constant voltage, direct current power source
is most commonly used with GMAW, but constant current systems, as
well as Alternating current, can be used. There are four primary methods
of metal transfer in GMAW, called globular, short-circuiting, spray, and
pulsed-spray, each of which has distinct properties and corresponding
advantages and limitations.
3.2 Tools and Equipment

Power source
 Used to supply electrical power to the welding.

Wire feed
 Feed filler wire.
Air cooled welding torch
 This where the wire goes out and it combined with coolent
gas.

Gas cylinder
 Used to store coolant gas such as inert gas
Filler wire
 To give heat source to molt the work piece.

Face shield .
 to protect the eyes from UV rays and to protect the face from
the heat.
Leather gloves.
 to protect the finger from the heat form from the process.

Leather apron.
 To protect the body from the heat form from the process.
Wire brush .
 To clean the work piece.
3.3 safety precaution

There is safety precautions that we need to learn to make sure

the safety. We need to wear safety equipment before doing the
welding process. Here some precaution that needs to give
attention.

1. Spray the silencer with

2. Do not inhale the gas.
3. Wear safety equipment.
4. Make sure the gas is functioning.
 3.4 Fundamental of the process

MIG stands for metal inert gas. In stick welding the flux on the
electrode melts and forms a gas to shield the puddle from the
atmosphere. The atmosphere has hydrogen, nitrogen, oxygen, and other
gases that will cause weld defects if allowed to get into the weld pool.

In MIG, a spool of solid-steel wire is fed from the machine, through a

liner, then out of a contact tip in the MIG gun. The contact tip is hot, or
electrically charged, when the trigger is pulled and melts the wire for the
weld puddle. This is accomplished in several ways. This article
discusses short-circuit welding.

In short-circuit welding, small droplets of molten wire, heated when

short-circuited, flow together to make a puddle as they touch the base
metal. Inert gas flows out of the gun and keeps the weld puddle shielded
from the atmosphere. Thus, metal inert gas. Inert means the gas will not
combine with another element; so inert gases, like helium and argon,
were used.
3.5 Steps and procedure

1. Clean the work piece .

2. Switch on the machine.
3. Then adjust the current supply to 120A ,make sure the protection
gas is exist.
4. Start the welding process by pushing the button at the nozzle.
5. Finish welding and turn off the machine.
6. Let the work piece cooled and clean it.
3.6 Results and Observation

Gas shielded arc welding

Some observation has made during the process. There is some problem happen .

Observation from the angle

 30°
The line that I made is not perfect. It is hard to control the welding.

 45°
The molding made is perfect. But it is not recommended.

 90°
The molding made is perfect .but is hard to see where the welding go.

Observation from the speed

 Fast
The molding form is in small size .this is because the heat transfer is not long enough to
make the work piece mold .

 Medium
The molding form is in perfect size. This is because the heat transfer is enough to make
the work piece mold perfectly.

 Slow
The work piece leak. This because the heat transfer is to much and this make the work
piece mold too much.
Observation from the distance between work piece and heat.

 Far from work piece

The welding does not happening because the wire dint touch the work piece.

 Medium range
The welding occur and its perfectly welded.

 Too close
Is hard because the nozzle should not touch the work piece.
1.6 learning outcome of the practice

Arc welding
From the practice that I has done, we need to welding by follow the
rule. We cannot let the electrode stick to the work piece because this will
damage the power supply.

While doing the welding we cannot make it to fast or to slow. This

will make the joining easy to break. We need to ensure that the welding
process is correct or else it would not join. The power supply is divide
into 2 section of power supply, alternate current and direct current.
Normally people use alternate current.

Gas welding
When doing the gas welding we must not apply oxygen gas more then
acetylene gas because it will blow up. When welding do not apply to
much heat at one place for long period the work piece will broken.
When turn off the gas , close the oxygen hoses first then acetylene.
 1.7 conclusion of practice

From the practical I learned how to do the welding. I also learn that arc
welding is more often used daily, because its low cost. When doing the
welding process we need to do it with medium speed because its will not
get the perfect molding.