TABLE OF CONTENTS

Chapter Pages

Title Page 1

Certification 2

Dedication 3

Acknowledgement 4

Abstract 5

CHAPTER ONE

1.0 INTRODUCTION 6

1.1 Welding 6

1.2 Welding Power Supply 6

1.3 Power Supply Designs 7

1.4 Motivation 8

1.5 Relevant of the Project 8

1.6 Objective of the Project 8

1.7 Scope and Limitation of the Project 8

CHAPTER TWO

2.0 LITERATURE REVIEW 9

2.1 Basic Welding Circuit 14

2.2 Basic Principle of Electric Arc Welding 14

2.3 Arc Welding Machine 15

2.4 Some of the basic features of AC Arc Welding 16

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CHAPTER THREE

3.0 METHODOLOGY 17

3.1 Welding Transformer: - (Using Transformer Method) 17

3.2 Construction of a Transformer 23

3.3 Arc Welding Circuit 25

3.4. Welding Arc 28

3.5 Arc Radiation 29

3.6 Materials Used 29

3.7 The Magnetic Materials 30

3.8 The Insulating Materials 30

3.9 Design Parameters 31

3.10 Maximum Core Flux Density (Bm) 31

3.11 Current Density 31

3.12 Stacking Factor (Ks) 31

3.13 Window Area (Aw) 32

3.14 Varnishing 32

3.15 Bobbing 32

3.16 Welding Transformer Design calculations 32

3.17 Standard Wire Gauge (SWG) 35

3.18 Construction of Parts 36

3.19 Insulation 38

3.20 Welding Electrodes 39

3.21 Recommended Diameters of Electrodes for Different Welding Currents. 40

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3.22 Classification of Electrodes According to Their Coatings 40

3.23 Electrode Holder 41

3.24 Ground Clamp 42

3.25 Welding Cable 42

3.26 Welding Cable 43

3.27 Defects of Electrode 44

3.28 Transformer Encapsulation/Housing 45

3.29 Necessity for Cooling 45

CHAPTER FOUR

4.0 RESULT AND DISCUSS 46

4.1 Transformer Tests 46

4.2 Short Circuit (Impedance) Test 46

4.3 Open Circuit (No Load) Test 46

4.4 Calculation 47

4.5 Welding Hazards, Precautions, Safety and Maintenance 48

4.51 Electrical Shock 48

4.5 Welding Protection 50

4.51 Eye Protection 50

4.52 Skin Protection 50

4.53 Fire and Explosion 51

4.7 Common Fault and Possible Causes in Arc Welding 52

4.8 Applications and Advantages of Welding 53

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4.9 Precautions in Arc Welding 53

4.10 Problems Encountered 54

CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATION 55

5.1 Conclusion 55

5.2 Recommendations 55

5.3 Bill of Quantity 57

Reference 58

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