MANUFACTURING TECHNOLOGY

(BPB 23303)

INDIVIDUAL ASSIGNMENT
SEMESTER 3
SESSION 2015/2016

Name: NUR HAFSAH BINTI MOHD RAZIB

Student Number: AP140188
Section: 1
Lecturer’s Name:
PROF. SULAIMAN BIN HJ HASAN
Question 1

Explain with clear figure and schematic drawing the following welding process

i. Gas welding
ii. Arc welding

Provide example for each process.

Gas Welding is a metal joining process in which the ends of pieces to be joined are
heated at their interface by producing coalescence with one or more gas flames (such as
oxygen and acetylene), with or without the use of a filler metal. It is a process that uses fuel
gases and oxygen to weld and cut metals.

Oxy-fuel is one of the oldest welding processes, besides forge welding. Still used in
industry, in recent decades it has been less widely utilized in industrial applications as other
specifically devised technologies have been adopted. It is still widely used for welding pipes
and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating
some types of metal-based artwork. As well, oxy-fuel has an advantage over electric welding
and cutting processes in situations where accessing electricity (e.g., via an extension cord or
portable generator) would present difficulties; it is more self-contained, and hence, often
more portable. In oxy-fuel welding, a welding torch is used to weld metals. Welding metal is
produced when two pieces are heated to a temperature that produces a shared pool of molten
metal. The molten pool is generally supplied with additional metal called filler. Filler
material depends upon the metals to be welded.
 Arc Welding is a type of welding that uses a welding power supply to create an
electric arc between an electrode and the base material to melt the metals at the welding
point. They can use either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes. The welding region is usually protected by some type of shielding
gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully
automated. First developed in the late part of the 19th century, arc welding became
commercially important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.

One of the most common types of arc welding is shielded metal arc welding
(SMAW), which is also known as manual metal arc welding (MMAW) or stick welding. An
electric current is used to strike an arc between the base material and a consumable electrode
rod or stick. The electrode rod is made of a material that is compatible with the base material
being welded and is covered with a flux that gives off vapors that serve as a shielding gas and
provide a layer of slag, both of which protect the weld area from atmospheric contamination.
The electrode core itself acts as filler material, making separate filler unnecessary.

The main advantages of arc welding are the equipment is relatively easy to use and
inexpensive. The versatility of the method makes it popular in a number of applications
including repair work and construction. In addition, the process is very versatile and requiring
little operator training. Furthermore, the equipment is portable and ideal for confined spaces.
It is become easier when the Auxiliary gas shielding is not required. Proudly to say that arc
welding is suitable for most commonly used metals and alloys.

However, weld times are rather slow, since the consumable electrodes must be
frequently replaced and because slag, the residue from the flux, must be chipped away after
welding. Furthermore, the process is generally limited to welding ferrous materials, though
specialty electrodes have made possible the welding of cast iron, nickel, aluminum, copper
and other metals.
Figure 1: Schematic diagram showing various elements of SMA welding system

Figure 2: Shielded Metal Arc Welding

.
Question 2

Describe the following method in detail

i. Tungsten Inert Gas Welding (TIG)

ii. Metal Inert Gas Welding (MIG)
iii. Plasma Arc Welding

Tungsten Inert Gas Welding (TIG) is a manual welding process that requires the
welder to use two hands to weld. What separates TIG welding from most other welding
processes is the way the arc is created and how the filler metal is added. When TIG Welding
one hand is used for holding the TIG torch that produces the arc and the other hand is to add
the filler metal to the weld joint. Because two hands are required to weld; TIG welding is the
most difficult of the processes to learn, but at the same time is the most versatile when it
comes to different metals. This process is slow but when done right it produces the highest
quality weld! TIG welding is mostly used for critical weld joints, welding metals other than
common steel, and where precise, small welds are needed.

Welding your metal

1. Put on the safety gear.

- Before operating any welding machine, make sure to put on protective eyewear,
thick, fire-resistant clothing, and a welding helmet with an eye shield.

2. Clean the welding material.

- Your surface must be clear of debris before you begin to weld.

- To prepare carbon steel, use a grinder or sander and polish it down to a bare, shiny
metal.
- For aluminum, it is best to use a dedicated stainless steel wire brush.
- For stainless steel, just wipe down the weld area with some solvent on a rag. Make
sure to store the rag and chemicals in a safe place before welding.

3. Insert the tungsten electrode into its collet.

- Unscrew the back of the electrode holder on the collet, insert the tungsten
electrode, and screw the back on again. Generally, the electrode should hang
about 1/4-inch away from the protective sheath on the collet.
4. Clamps the part together.
- Use an angle iron and/or a flat bar with c-clamps to secure the parts you want to
weld together.

5. Tack welds the parts together.

- A tack weld is a very small weld that is intended to hold a part in place until the
final weld can be completed. Place tack welds every few inches where your two
metals meet.

6. Hold the TIG torch in your hand.

- Be sure to hold it at about a 75 degree angle with the tungsten raised no more than
1/4-inch off the metal.
- Don't let the tungsten touch the work piece or it will contaminate your material.

7. Practice using the foot pedals to control the heat.

- Your weld puddle should be about ¼ inch wide. It is important to keep your
puddle size consistent throughout the weld to avoid a messy finish.

8. Pick up the filler rod in the other hand.

- Hold it so it rests horizontally at a 15 degree angle from the work piece at the base
where the torch will heat the piece.

9. Use your torch to heat up the base metal.

- The heat of the arc will create a puddle, a pool of molten metal that is used to fuse
the two pieces of metal together.
- Once there is a puddle on both pieces of metal, tap the filler rod into the molten
puddle in quick dabs to avoid clumping.
- The filler rod adds a reinforcement layer for your weld.
 10. Advance the puddle in the desired direction using your arc.
- Push the puddle the opposite direction that the torch leans.
- Think of your hand motion as that of a left-handed person operating a pencil.
While a right-handed person moves their pencil like a MIG weld, with the angles
both tilted to the right, a left-handed person has their pencil tilted to the left,
though they must push the pencil to the right.
- Continue to advance the puddle until you have welded the entire area desired

Metal Inert Gas Welding (MIG) is it’s a process of using electricity to melt and join
together pieces of metal. Compared to any other method of welding, MIG welding is, hands
down, the easiest way to weld.  Many different materials can be welded with a MIG welder;
it is just a function of changing the welding wire (electrode) and the shielding gas. In the
most basic terms, MIG is sort of like using a crafter’s hot-glue gun.  However, with the MIG
process, a continuous, consumable wire electrode (in place of a glue stick) along with a
shielding gas are fed through a welding gun.  A short circuit is created, producing intense
heat that melts the metal and allows the pieces to mix together and then fuse when cooled.
MIG welding is especially useful because it can be used to weld a wide range of metals
(including steel and stainless steel, aluminum and cast iron) as well as braze steel.

The procedures:

1. Put on the safety gear.

- You will need a full set of safety equipment to ensure your safety while welding.
This includes gloves, masks, and protective clothing.

- Make sure that all of your skin is covered to prevent overexposure from UV rays.
You will need a mask with at least a #10 shade or darker. This will help prevent
arc eye.
- If you are working in a poorly ventilated area, you will need a vapor mask to
minimize the amount of toxic vapors inhaled during the welding process.
- Wear gloves that can protect your skin from molten metal.
- Keep a CO2 extinguisher and a bucket of sand nearby for emergency fires.
2. Set the welding machine polarity to DCEP. This is reverse polarity.

3. Keep a consistent electrode length. As you are welding, keep your electrode extended
between ¼” and 3/8” from the contact tube. This will help make for a clean, regular
weld.

4. Use the proper shielding gas. Use carbon dioxide as an economical choice to provide
deeper penetration on steel. This will be too hot for thin metals though. Use argon for
aluminum welding, and a mix of argon (75%) and carbon dioxide (25%) for thinner
steel.

5. Weld a joint using a drag or push welding technique. The angle should not exceed 10
degrees in either technique. Keep the wire at the front edge of your weld pool. This
will give you greater control over your weld.
- Drag welding pulls the bead along with the tip. This will give you a deeper
penetration and a narrower bead.
- Push welding pushes the bead with the tip. This will give you a wider bead.

6. Make a flat weld. Use the welder to place material directly into the joint. You can use
a back and forth method to fill large gaps. For flat joints, hold the gun at a 90° angle.
7. Make a horizontal weld. You must lower the gun angle slightly to keep the filler from
sagging. Keep the same push or pull angle as normal. Use a back-and-forth weave
motion to fill large gaps.
- Keep the amperage the same as a flat weld. You may need to use a slightly
smaller diameter wire to keep the weld pool from getting too big.

8. Make a vertical weld. For thin materials, start at the top and move the pool down with
gravity. This keeps the arc from penetrating the material. For thicker metals, start at
the base and work up. This will help increase penetration.

9. Make an overhead weld. Use standard welding techniques, but increase your travel
speed. This will help prevent filler from falling out of the joint. You may need to
increase your gas flow rate.
- Keep your nozzle clean, as spatter will build up faster when welding overhead
 10. Finish the weld. Once you are done with the weld process, grind off any excess filler.
If the weld is defective, grind it down and re-weld the joint.

In Plasma Arc Welding (PAW) is an arc welding process, a concentrated plasma arc
is produced and directed towards the weld area. Manufacturing industry uses various types of
plasma welding, the differences depending on the shape of the nozzle and the type of arc.
Plasma arc welding is a common method of welding metals. This technique is reminiscent of
TIG welding; the electric arc burns between a tungsten electrode and the work piece. In
plasma welding, the most important difference lies in the arc being forced through a
restriction in the form of a water-cooled nozzle.