Sulaimani Polytechnic University

Engineering Technical College

Department of Mechanical & Manufacturing Engineering
First Stage

Workshop “Welding”

Prepared By: supervisor:

Muhamad jabar ali Mr.RAWA
Group: B
Introduction :

A welding workshop is a center where people are trained in the use of welding equipment.
There, an instructor helps professionals and students learn how to fuse or weld metals together
by pressure or heat. The goal of a welding workshop is to enable trainees to effectively use
diverse welding equipment and tools. This may include a welding machine for Oxy-acetylene
welding and tools for Arc Welding (MMA), MIG (Metal Inert Gas), and TIG (Tungsten Inert
Gas).

Additionally, welders use other advanced techniques in industries such as aviation and
shipbuilding, as well as in automotive and construction industries. Metals during welding are
melted and combined with filler materials, yielding robust and resilient joints. A welding
workshop encompasses welding machines, torches, helmets, gloves, jackets and other tools and
gears.

In welding, an important aspect that needs to be adhered to is safety, and so this is also a
priority in a welding workshop. Because of high temperatures and light (arc flash), fumes are
generated during the welding and so one needs to wear protective clothes. As for harmful
fumes, ventilation systems are needed to eliminate them. Meanwhile, workers are instructed on
safety measures to take and proper ways of using tools to minimize chances of injuries and
accidents..

In addition to welding, a workshop may also focus on tasks like cutting, grinding, and finishing
the welded joints, ensuring the work meets industry standards. Some workshops also offer the
opportunity to learn about welding design, blueprint reading, and material properties, enabling
welders to make informed decisions about their work.

Overall, a welding workshop provides the infrastructure, tools, and knowledge to master
welding techniques, which are fundamental to many industrial applications. It is a dynamic
environment where theory and practical skills come together, preparing individuals for careers
in metal fabrication and repair.

Sheet metal refers to thin, flat pieces of metal that are typically less than 6mm thick. It is one of
the most common materials used in manufacturing and construction due to its versatility,
strength, and ease of fabrication. Sheet metal is used in a wide variety of applications, including
the production of car bodies, HVAC systems, roofing, and appliances.

The process of working with sheet metal involves cutting, shaping, and assembling metal pieces
to create parts or products. This is done through various techniques such as cutting, bending,
stamping, punching, and rolling. Depending on the material and desired result, different tools
and machines are used, such as shears, press brakes, and laser cutters.

Sheet metal is available in a range of metals, including steel, aluminum, copper, and stainless
steel. Each metal has unique properties, such as corrosion resistance or strength, making it
suitable for specific applications. For example, stainless steel is often used in kitchen equipment
and medical devices due to its corrosion resistance, while aluminum is chosen for lightweight
applications like automotive parts

The sheet metal process begins with large, flat sheets of metal that are then cut to size using
tools like shears or lasers. Once the material is cut, it can be bent into shapes using press brakes
or rollers, forming products like ducts, panels, and enclosures. Additional processes like
welding or riveting are used to join parts together.

Safety is critical when working with sheet metal, as sharp edges, high-speed machinery, and
heavy equipment can pose risks. Proper protective gear such as gloves, goggles, and ear
protection is essential to ensure a safe working environment.

In summary, sheet metal is a fundamental material in manufacturing, and its versatility allows it
to be shaped into countless products. The processes used to work with sheet metal are crucial to
industries like automotive, aerospace, construction, and electronics.
Tools and Machines:

Hammer scriber ruler divider Tri square

Mask welding electrode E6011 welding hammer tool clamp saw cutting machine

Ground clamp holder clamp miller welding machine DC welding machine gamw welding machine

Resistance welding machine

Exercise Number : 1
Exercise Name: ARC&ZIGZAG Welding
Objective:

Arc Welding Objective: To obtain a lasting and firm joint between metals by employing an
electric arc as the source of heat.

Zigzag Welding Objective: To achieve the desired weld quality with controlled heat process
during welding, improving the weld penetration and also producing more uniform and defect-
free weld beads.
Procedure:
First thing we learn about machine and tools after we are cutting metal by using scriber and
ruler and saw cutting machine then we cleen metal after some practice and learning about
welding we do it we use electrode E6011 for welding first thing I do it is arc welding at the
beginning I thought it was easy but it wasn’t easy as I thought I put the mask on my face then I
do it my work I put electrode to holder clamp at 45 angles I started to do welding I thing my arc
was good but zigzag hard to my as a first time, you have to move slowly and carefully after
welding you’ll have to wait for it to get cold then we cleened by machine then we took it to the
teacher
Discussion:
Both zigzag and arc welding are widely used in the welding business and each has unique
benefits and uses.

The process of zigzag welding involves moving the weld bead back and forth in a zigzag
pattern. Better penetration and bonding are facilitated by this movement, which also helps to
distribute heat evenly over the joint. Due to its ability to accommodate distortion, this technique
works well for welding thicker materials. Additionally, it helps guarantee consistency in the
size and quality of the beads.

Arc welding, on the other hand, uses an electric arc created between an electrode and the
workpiece. The heat produced by an arc is enough to melt the two materials that are being
linked together. Stick welding (SMAW) and MIG welding (GMAW) are the two most used
varieties. Because of its versatility, arc welding can be applied to a variety of metals and
thicknesses.

To improve the welding process, particularly in fillet welds or sections that need a bigger heat-
affected zone, the zigzag motion is frequently combined with arc welding. Controlling the arc's
speed and intensity is essential for arc welding in order to get the best possible weld quality.
Exercise Number : 2
Exercise Name: butt joint
Objective:
Two pieces of material linked end-to-end or edge-to-edge form a butt joint, a simple kind of
joint. Its main goal is to establish a straightforward, robust connection between components. It
is frequently utilized in building, metalworking, and woodworking. Although butt joints are
simple to construct, reinforcing may be necessary for increased strength. Because of its
simplicity and convenience of usage, this joint is frequently utilized for projects with flat
surfaces.
Procedure:
First, cut 2 pieces of 50x50 iron. Cut with a saw-cutting machine Afterwards, they were
squeezed with tools and smoothed the edges. After that, we did some practice on the job I'm
going to do the same thing with the Arc and you can do it with Zigzag. after welding I waited
for it to cool down and then cleaned it up with a machine. and I took it to teacher I thing this
time I do it better
Discussion:
A popular method for joining two pieces of metal edge-to-edge is butt joint welding. It offers a
solid, smooth connection that is perfect for components that are flat and aligned. To guarantee a
clean weld, the process starts with adequate preparation, which includes cleaning the metal
surfaces. Tack welds are used to secure the parts in place once they have been clamped and
aligned. Depending on the material and thickness, several welding techniques, such as MIG,
TIG, or stick welding, may be used. Controlling the heat during welding is essential to prevent
warping or severe distortion. Post-weld inspection guarantees a robust and defect-free junction.
Cooling is necessary to stop the weld from rapidly contracting and breaking. After cooling any
slag or spatter is removed to finish the weld. Butt joint welding is efficient but requires
precision for optimal strength and appearance.