WELDING

Prepared by

VENKATA REDDY. S
EX No: 1 Welding

DATE:
Preparation of workpiece for Butt joint by using Electric Arc Welding

Aim: Preparation of workpiece for butt joint as shown in figure.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Files,
• Machine Vice,
• Try Square
• Scriber
• Hack Saw
• Dot Punch etc.

V – butt joint
Procedure:
1. The metallic pieces are thoroughly cleaned from rust grease, oil, etc..
2. Mark the required geometry by using Scriber and Scale.
3. Cut the given metallic piece into two pieces as per dimensions shown in the figure
4. The given metallic pieces filed to the desired size.
5. On both pieces bevelled in order to have V groove.

Precautions:
1. File the sharp edges before working on the workpiece.
2. Don’t carry the Tools while working.

Result:

Viva-Voce
1. Why join preparation is Required
2. Which type of joint is preferable
3. What is the purpose of preheating?
4. Why land is provided during the preparation of joint
5. What are the properties of filler material?
 EX No: 2 Welding

DATE:
Preparation of Butt joint by using Electric Arc Welding
Aim:
To prepare butt joint as shown in figure using Electric arc welding process.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Welding transformer,
• Connecting cables,
• Electrode holder,
• Ground clamp,
• Electrodes,
• Chipping hammer,
• Welding shield etc.

V – butt joint
 Procedure:
1. The given metallic pieces filled to the desired size.
2. On both pieces bevelled in order to have V groove.
3. The metallic pieces are thoroughly cleaned from rust grease, oil, etc.
4. The metallic pieces are connected to terminals of Trans former.
5. Select electrode diameter based on thickness of work piece and holds it on the electrode
holder. Select suitable range of current for selected dia.
6. Switch on the power supply and initiates the arc by either striking arc method or touch and
drag method.
7. Take welding to be done before full welding.
8. In full welding process after completion one part before going to second part. Slag is
removed from the weld bed. With the metal wire brush or chipping hammer.
9. Then the above process will be repeated until to fill the groove with weld bed or weld metal.

Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.

Result:
Thus, the butt joint is prepared as shown in figure by using arc-welding process.
Viva-Voce
1. What is DCRP
2. What is DCSP
3. What is ACHF
4. What is the maximum temperature generated during Arc welding?
5. What is the range of Power source voltage?
Ex: No: 3 Welding
Date:

Preparation of workpiece for Lap joint by using Electric Arc Welding

Aim:
Preparation of workpiece for lap joint as shown in fig.

Material used:
Two mild steel pieces of 60X40X6 mm.
Tools and equipment used:

• Apron,
• Hand gloves,
• Metallic work Table,
• Bench vice,
• Rough flat file,
• Try square,
• Steel rule,
• Scriber
• Hack Saw
• Dot Punch
• Ball peen hammer,
Precautions:
1 File the sharp edges before working on the workpiece.
2 Don’t carry the Tools while working
 Fig: lap joint

Procedure:

1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. Mark the required geometry by using Scriber and Scale.
4. The given metallic pieces filed to the desired size.
Result:
The Preparation of workpiece for Lap joint is made, using the tools as mentioned above.

Viva-Voce
1. How the electrode is Designated
2. What are the main constituting elements in the coating of electrodes?
3. What are the most commonly used filler materials?
4. What is meant by Duty Cycle?
5. What is cycle time in AC arc welding
EX No: 4 Welding

DATE:
Preparation of Lap joint by using Electric Arc Welding

Aim:
To make a double lap joint in the given mild steel pieces by using arc welding.

Material used:
Two mild steel pieces of 60X40X6 mm.
Tools and equipment used:

• Arc welding machine,

• Mild steel electrodes,
• Electrode holder,
• Ground clamp,
• flat nose Tong,
• Face shield,
• Apron,
• Hand gloves,
• Metallic work Table,
• Bench vice,
• Rough flat file,
• Try square,
• Steel rule,
• Wire brush, Ball peen hammer, Chipping hammer.
Precautions:
1. Use goggles, gloves in order to protect the human body
2. Maintain the constant arc length.
 Fig: lap joint

Procedure:

1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap joint with the required
over lapping.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces the
arc is struck and the work pieces are tack welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack welded pieces are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on both the sides.
9. Remove the slag, spatters and clean the joint.

Result:
Viva-Voce
1. What is Magnetic Arc Blow
2. What are the Reasons of Arc Blow
3. What is the importance of Post heating in Welding
4. List out welding Defects
5. What is meant by Spatter loss
EX No: 5 Welding

DATE:
Preparation of workpiece for T- joint by using Electric Arc Welding

Aim: preparation of workpiece for butt joint as shown in figure.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Files,
• Machine Vice,
• Try Square
• Scriber
• Hack Saw
• Dot Punch etc.

T – joint
 Procedure:
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly from
rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. Mark the required geometry by using Scriber and Scale.
4. The given metallic pieces filed to the desired size.

Precautions:
1. File the sharp edges before working on the workpiece.
2. Don’t carry the Tools while working.

Result:

Viva-Voce
1. What is meant by Cryogenic Welding?
2. What is Thermite Welding
3. What is meant by Endothermic Reaction in Welding?
4. What are the Welding Techniques available?
5. Which welding technique is Preferable
EX No: 6 Welding

DATE:
Preparation of T- joint by using Electric Arc Welding

Aim:
To make a T- joint by using Electric arc welding.
Material used:

Two mild steel pieces of 60X40X6 mm.

Tools and equipment used:

• Arc welding machine,

• Mild steel electrodes,
• Electrode holder,
• Ground clamp,
• flat nose Tong,
• Face shield,
• Apron,
• Hand gloves,
• Metallic work Table,
• Bench vice,
• Rough flat file,
• Try square,
• Steel rule,
• Wire brush, Ball peen hammer, Chipping hammer.
Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
 Fig: T- joint

Procedure:

1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly
from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a T- joint.
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces
the arc is struck and the work pieces are tack welded on both the sides
7. The Perpedicularity of the T- joint is checked and the tack welded pieces are reset, if
required.
8. Welding is then carried out throughout the length of the T- joint, on both the sides.
9. Remove the slag, spatters and clean the joint.

Result:

Viva-Voce
1. Why Tungsten is preferred as Non-Consumable Electrode
2. What are the Disadvantages of TIG welding?
3. What are the advantages of TIG welding?
4. Applications of TIG welding
5. In DCSP where high amount of heat is generated
EX No: 7 Welding

DATE:
Preparation of workpiece for Outside corner joint by using Electric Arc
Welding

Aim: preparation of workpiece for Outside corner joint as shown in figure.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Files,
• Machine Vice,
• Try Square
• Scriber
• Hack Saw
• Dot Punch etc.

Outside corner – joint

 Procedure:
1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly
from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. Mark the required geometry by using Scriber and Scale.
4. The given metallic pieces filed to the desired size.

Precautions:
1. File the sharp edges before working on the workpiece.
2. Don’t carry the Tools while working.

Result:

Viva-Voce
1. What is the importance of flux in Welding?
2. Sulphur can be used as Deoxidiser?
3. Why Carbon and Nickel alloys don’t require flux
4. List out the properties of Flux
5. What is the commonly used material as Flux?
 EX No: 8 Welding

DATE:
Preparation of Outside corner joint by using Electric Arc Welding

Aim:
Preparation of Outside corner joint by using Electric arc welding.
Material used:

Two mild steel pieces of 60X40X6 mm.

Tools and equipment used:

• Arc welding machine,

• Mild steel electrodes,
• Electrode holder,
• Ground clamp,
• flat nose Tong,
• Face shield,
• Apron,
• Hand gloves,
• Metallic work Table,
• Bench vice,
• Rough flat file,
• Try square,
• Steel rule,
• Wire brush, Ball peen hammer, Chipping hammer.
Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
 Fig. Outside corner
joint

Procedure:

1. Take the two mild steel pieces of given dimensions and clean the surfaces thoroughly
from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a Outside corner joint .
4. The electrode is fitted in to the electrode holder and the welding current is set to a proper
value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding the over lapped pieces
the arc is struck and the work pieces are tack welded on both the sides
7. The Perpedicularity of the Outside corner joint is checked and the tack welded pieces are
reset, if required.
8. Welding is then carried out throughout the length of the Outside corner joint.
9. Remove the slag, spatters and clean the joint.
Result:
Viva-Voce
1. How the electrode is designated
2. Why Root gap is provided in the joint preparation
3. Is the Plastic can be welded explain
4. Give examples for Non-fusion welding Processes
5. Are different materials can be welded? Explain.
EX No: 9 Welding

DATE:
Preparation of workpiece for Butt joint by using Submerged Arc Welding

Aim: preparation of workpiece for butt joint as shown in figure.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Files,
• Machine Vice,
• Try Square
• Scriber
• Hack Saw
• Dot Punch etc.

V – butt joint
 Procedure:
1. The metallic pieces are thoroughly cleaned from rust grease, oil, etc. .
2. Mark the required geometry by using Scriber and Scale.
3. Cut the given metallic piece into two pieces as per dimensions shown in the figure
4. The given metallic pieces filed to the desired size.
5. On both pieces bevelled in order to have V groove.

Precautions:
1. File the sharp edges before working on the workpiece.
2. Don’t carry the Tools while working.

Result:
Viva-Voce
1. What is thickness of the plates can be welded economically by using SAW
2. What are the Disadvantages of SAW?
3. What are the advantages of SAW welding?
4. Applications of SAW welding
5. In DCRP where high amount of heat is generated
Ex: No: 10 Welding
Date:

To prepare a Butt joint using submerged arc welding

Aim:
To prepare butt joint using Submerged Arc welding
Apparatus required:

Name of the
S.NO Equipment Quantity
1 Scale 1
2 Scriber 1
3 Hand hack saw 1
4 Flat file 1
5 Swing scale protector 1
6 Welding machine 1
7 gloves, 1
8 Shield 1
9 Wire brush 1
10 Chipping hammer 1
11 Weld rod 1

Precautions:

1. Wear apron, shoes, nose mask, gloves and tight fitted clothes. Be careful and attentive
while working on welding job.
2. During welding don’t see the welding light rage directly without the goggle face shield.
3. Do not cool the welding piece in water.
4. Do not keep electrode holder on the welding machine.
5. No inflammable material should be present in welding shop.

Procedure:
 1. Given 2 M.S. plates are filled at an angle of 45o at surfaces to be joined.
(V groove is formed)
2. Electrode is fixed to electrode holder.

3. Connections to be given such that electrode- and work. Welding is to be done carefully
for the half-length of the plates.
4. The work piece is to be cut into two halves by hacksaw.
5. The beads are polished, etched with two percent natal solution and studied under the
microscope whose magnification factors 10X for the heat affected zone.
6. By gripping the beads b/w the jaws Tensile testing machine and load is applied until the
work piece breaks and the readings is to be noted.
7. The same procedure is repeated for the remaining half which is welded by reverse
polarity and the results are to be compared.
DIAGRAM

Result:
Viva-Voce
1. Why Tungsten is preferred as Non-Consumable Electrode
2. What are the Disadvantages of TIG welding?
3. What are the advantages of TIG welding?
4. Applications of TIG welding
5. In DCSP where high amount of heat is generated
EX No: 11 Welding

DATE: Preparation of workpiece for Butt joint by using Plasma Arc Welding

Aim: preparation of workpiece for butt joint as shown in figure.

Material required:

2 MS flat pieces of given size 60X40X6 (Dimensions in mm)

Tools required:

• Files,
• Machine Vice ,
• Try Square
• Scriber
• Hack Saw
• Dot Punch etc.

V – butt joint
 Procedure:
1. The metallic pieces are thoroughly cleaned from rust grease, oil, etc. .
2. Mark the required geometry by using Scriber and Scale.
3. Cut the given metallic piece into two pieces as per dimensions shown in the figure
4. The given metallic pieces filed to the desired size.
5. On both pieces bevelled in order to have V groove.

Precautions:
1. File the sharp edges before working on the workpiece.
2. Don’t carry the Tools while working.

Result:
Thus, the preparation of workpiece for butt joint is prepared as shown in figure .
Viva-Voce
1. Difference between Plasma and TIG welding
2. What is the principle of Plasma Arc welding
3. Name any two inert gases used in Plasma arc Welding
4. Types of Plasma arc Welding
5. What are the Advantages of Plasma arc Welding
Ex: No: 12 Welding
Date: To prepare a Butt joint using Plasma arc welding

Aim:
To prepare butt joint using Plasma arc welding

Material Used:

Name of the
S.NO Equipment Quantity
1 Scale 1
2 Scriber 1
3 Hand hack saw 1
4 Flat file 1
5 Swing scale protector 1
6 Welding machine 1
7 gloves, 1
8 Shield 1
9 Wire brush 1
10 Chipping hammer 1
11 Weld rod 1

Precautions:

• Wear apron, shoes, nose mask, gloves and tight fitted clothes. Be careful and
attentive while working on welding job.
• During welding don’t see the welding light rage directly without the goggle face
shield.
• Do not cool the welding piece in water.
• Do not keep electrode holder on the welding machine.
• No inflammable material should be present in welding shop.

Procedure:
• Given 2 M.S. plates are filled at an angle of 45o at surfaces to be joined. (V
groove is formed)
 • Electrode is fixed to electrode holder.
▪ Connections to be given such that electrode- and work .Welding is to be done carefully for the half
length of the plates.
▪ The work piece is to be cut into two halves by hacksaw.
▪ The beads are polished, etched with two percent natal solution and studied under the microscope
whose magnification factors 10X for the heat affected zone.
▪ By gripping the beads b/w the jaws Tensile testing machine and load is applied until the work piece
breaks and the readings is to be noted.
▪ The same procedure is repeated for the remaining half which is welded by reverse polarity and the
results are to be compared.

Result:

Thus, the butt joint prepared by using Plasma Arc welding equipment.

Viva-Voce
1. What are the Limitations of Plasma Arc Welding
2. Applications of Plasma Arc welding
3. What are the process parameters of Plasma arc Welding.
4. What is the highest temperature generated in the Plasma Arc Welding
5. Why DCEN polarity is preferred in Plasma arc Welding