IE- 244L manufacturing process

Lab No:7

Submitted to: Dr. Tufail Habib

Submitted By: zubair khan
Registration No: 21jzind0186
Department: Industrial Engineering
Semester: 5th semester/fall 2023
Marks:
GPA MARKS

OBE MARKS

LAB REPORT RUBRIC 1

LAB REPORT RUBRIC 1

University of Engineering & Technology,

Peshawar Jalozai Campus
Lab No 6 :
To conduct an experiment to study the effect of arc welding process
parameters .
Objectives :
• Investigate the impact of arc welding process parameters, including current, voltage, travel speed,
electrode type, and shielding gas, on weld quality.
• Provide practical insights for enhancing arc welding processes, aiming for improved efficiency
and superior weld quality in varied applications.

Introduction:
Welding: Welding is a manufacturing process used to join materials, typically metals or thermoplastics, by
melting the workpieces and adding a filler material to form a pool of molten material that cools to become
a strong joint. The welding process can be broadly categorized into several types based on the heat source
and method of joining. Common welding methods include arc welding, gas welding, resistance welding,
and laser welding.
Arc Welding: Arc welding is a welding process
that uses an electric arc to generate heat and melt
the workpieces, creating a molten pool that
solidifies to form a strong joint. The electric arc is
established between an electrode and the
workpiece, and filler material (if needed) may be
added to enhance the joint. Arc welding is versatile
and widely used for its applicability to various
materials and thicknesses. The most common types
of arc welding include:

1. Flux-Cored Arc Welding (FCAW): Figure 7.1

Shielded Metal Arc Welding (SMAW or
Stick Welding):
• In SMAW, a coated electrode is used, and the arc is shielded by the flux coating on the
electrode.
• It is a portable and versatile method, suitable for various applications and environments.
2. Gas Metal Arc Welding (GMAW or MIG Welding):
• GMAW uses a continuously fed wire electrode and a shielding gas (commonly argon or a
mixture) to protect the weld pool.
• It is known for high welding speeds and is commonly used in automotive and industrial
applications.
3. Gas Tungsten Arc Welding (GTAW or TIG Welding):
• GTAW employs a non-consumable tungsten electrode and a shielding gas (typically argon)
to protect the weld area.
• It offers precise control and is suitable for thin materials
4. Flux-Cored Arc Welding (FCAW):
• FCAW uses a tubular wire electrode with flux inside, providing its own shielding.
 • It is known for high deposition rates and is often used in construction and shipbuilding.
Temporary Welding or joint :
Temporary welding refers to a welding process where joints are created with the understanding that they
will be disassembled or removed at some point in the future. The purpose of temporary welding is often
associated with fixtures, jigs, or assemblies that may need to be taken apart for maintenance, repair, or
reconfiguration. In temporary welding, the connection is not intended to be permanent, and the welding
methods employed may involve techniques that allow for easier disassembly, such as using removable
fasteners or selecting welding methods that provide a less permanent bond.
Permanent Welding or joint :
Permanent welding refers to a welding process where joints are intended to remain intact for the entire
lifespan of the welded structure or component. The purpose of permanent welding is to create durable and
lasting connections that contribute to the overall strength and stability of the assembled components. In
permanent welding, the joints are not designed for disassembly, and the welding methods employed are
chosen to create strong and enduring bonds between the materials being joined. The choice of welding
method and consumables depends on factors such as material type, joint design, and the specific
requirements of the application where a lasting connection is crucial.

Procedure :
Job title:
To make a lap joint, using the given two mild steel pieces by shielded metal arc welding
Tools and accessories:
1. Arc welding machine
2. Rough and smooth files
3. Chippings hammer
4. Tongs
5. Electrodes
6. Apron
7. Ground clamp & Electrode holder
9. Welding shield screen
10. Safety accessories
11 Wire Brush

Figure 7.2
Procedure:
1. Wear the gloves, apron safety shoes and put face shield.
2. The surface to be welded is cleaned and the edges of the plates may be filed for perfect joint and for more
strength.
3 . The welding electrode is held in an electrode holder and the ground clamp is clamped to the surface
plate and the work piece is placed on it for welding
4. The two pieces are positioned on the welding table such that, the two pieces overlapped one over the
other as shown in drawing.
5. Work pieces are tack weld at regular spacing to maintain joint gap.
6. Set the welding current to a proper value.
7. Start welding from one end of the joint.
8. The electric arc is produced melts the electrode and joins the two plates.
9. The slag formation on the welds is removed by using the chipping hammer.
10. Filling is done to remove any spatter around the weld.

Figure 7.3

Figure 7.4

Conclusion:
In conclusion, the process of creating a lap joint through shielded metal arc welding (SMAW) with the
provided mild steel pieces has been successfully executed. The utilization of SMAW allowed for the precise
application of heat, ensuring the fusion of the materials and the formation of a robust lap joint. The weld
exhibits satisfactory bead geometry, penetration depth, and overall quality.
Through this welding exercise, it is evident that the shielded metal arc welding process is well-suited for
fabricating lap joints with mild steel. The process parameters, including amperage, electrode type, and
welding technique, were carefully selected to achieve optimal results. The joint's structural integrity and
integrity are critical, and the SMAW process has proven to be effective in meeting these requirements.