TITLE & OBJECTIVES

Title: ARC AND METAL INERT GAS WELDING

Objectives:

i) To learn the difference between Arc and MIG welding.

ii) To learn welding skills.
iii) To recognize the type of metals, electrodes, and tools that used in welding.
iv) To learn the perfect welding operations.
INTRODUCTION & THEORY
Arc Welding

Arc welding is one of several fusion processes for joining metals. By applying intense
heat, metal at the joint between two parts is melted and caused to intermix - directly, or more
commonly, with an intermediate molten filler metal. Upon cooling and solidification, a
metallurgical bond is created. Since the joining is an intermixture of metals, the final
weldment potentially has the same strength properties as the metal of the parts. This is in
sharp contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the
mechanical and physical properties of the base materials cannot be duplicated at the joint.

In arc welding, the intense heat needed to melt metal is produced by an electric arc. The
arc is formed between the actual work and an electrode (stick or wire) that is manually or
mechanically guided along the joint. The electrode can either be a rod with the purpose of
simply carrying the current between the tip and the work. Or, it may be a specially prepared
rod or wire that not only conducts the current but also melts and supplies filler metal to the
joint. Most welding in the manufacture of steel products uses the second type of electrode.
 Metal Inert Gas Welding (MIG)

MIG welding, also known as Gas Metal Arc Welding (GMAW), is a process that utilizes
a continuously fed solid electrode, shielding gas from an externally supplied source, and
electrical power to melt the electrode and deposit this molten material in the weld joint. The
equipment used automatically regulates the electrical characteristics of the arc. The only
manual controls required of the welder for semi-automatic operation are travel speed, travel
direction and gun (torch) positioning. Given proper equipment settings, the power supply will
provide the necessary amperage to melt the electrode at the rate required to maintain the pre-
selected arc length (voltage). For example, an increased stick-out, produced by drawing the
torch back from the work piece, results in a reduction in current from the power supply. This
maintains the same heating of the electrode and returns the arc length to its pre-set
condition. Filler metal selection should be closely matched to the base material being welded.
In MIG Welding, the filler metal not only conducts current to the arc zone (resulting in
melting the base metal and electrode), but adds reinforcement to the completed weld joint.

MIG Welding can be used on a wide variety of metals and in a number of different base
metal thicknesses. Its successful application depends on proper selection of:

 Electrode – composition, diameter and packaging

 Shielding Gas – type (composition), purity and flow rate
 Process Variables – current, voltage, mode of metal transfer and travel speed
 Equipment – power source, welding gun and wire feeder
Apparatus:
Arc welding

No. Function Picture

1. Power Supply

AC (alternating current)

- Low maintenance costs (no moving part)

- Quiet operation

DC (direct current)

- wider variety of electrodes available

- better for welding thin metals

- allow change of polarity between work piece &

electrode

2. Cables

- Use to connect electrode holder and ground

clamp to power supply.

3. Electrode holder.

- Grip the electrode

- The grooves in the clamp enable changing the
position of electrode.
- Make sure that the handle & clamp are
insulated.
4. Ground clamp

- To complete the circuit from power supply,

through electrodes back to power supply.
- the ground clamp must be firmly attached to the
work piece
5. Electrode

- used to joining the work piece after it melt.

Metal Inert Gas Welding (M.I.G)

No. Function Picture

1. Power supply

- Their function is to supply electrical

energy to wire feeder to produce
spark.

2. Wire feeder

- The function of wire feeder is to

produce spark. Wire will carry
electric charge and the spark will
produce when wire touch the steel.

3. Gas supply

- During the project the student use the

carbon dioxide gas
- Regulators also have two types which
is ball indicator and dial indicator.
- The function of gases used in welding
is to improve the fire.
- The flow of gases is control by the
regulator
4. Gun & whip

- There are two types of gun which is

inline and handle.
- The gun parts is a wire guide, tips,
shielding and noozle, insulator and
internal gun wire driver.
- Whip characteristics is a shielding
gas, sheath, linear and power feed.
- The liner is a length of steel wound
conduit that is fitted into place and
has the welding wire running into it.

CLEANING EQUIPMENT

No. Function Picture

1. Chipping hammer

- to remove the slag

2. Steel wire brush

- to remove the dirt on the work piece

after welding process
 OTHER EQUIPMENT

No. Function Picture

1. Apron

- Made from leather to protect the clothes from the

spark and fire

2. Clipper

- To hold the workpiece when hot

- It also can used to cut wire during MIG welding
process

3. Gloves

- To protect hand from dust and from exposed to

heat when hold hot material.

4. Eye protection

- To protect our eyes and face from exposed to

excessive light and smoke from combustion.
WORK PROCEDURE:

MIG WELDING:

1. The materials were gathered together, welding machine, gas nozzle, and the metal that
want to weld. To get rid of the slag and to clean the welds, the chipping hammer and
the wire brush were needed.
2. The safety gear must be put on before weld such as the welding helmet, welding jacket,
work boots, gloves, apron and safety glasses.
3. The metal that needed to weld was marked by using the chalk.
4. A weld pool was build up. After the stable arc maintained, the pool of molten metal
was watched. Stayed where it started in second or two before moving to get the good
pool.
5. Moved the weld pool across the metal started and make sure the gas nozzle was stayed
at 90˚ angle.
6. The weld pool was moved in straight line or zigzag or small circle.
7. The joint was set. The clamps and vices were used to ensure that the joint on the metal
were firmly joint together.
8. When the welding finished, the gas nozzle was pulled back from the metal. Wait for a
few seconds to ensure that the metal was cooled. Then the wire brush was used to clean
the metal.
9. The metal was dipped into the water to cool the metal faster.
10. Make sure that before going out from the lab workshop, clean all the stuff in the lab
workshop to make the lab workshop clean.
ARC WELDING:

1. The materials were gathered together, welding machine, electrode holder with lead,
ground clamp with lead, electrodes and the metal that want to weld. To get rid of the
slag and to clean the welds, the chipping hammer and the wire brush were needed.
2. The safety gear must be put on before weld such as the welding helmet, welding
jacket, work boots, gloves, apron and safety glasses.
3. The metal that needed to weld was marked by using the chalk.
4. A weld pool was build up. After the stable arc maintained, the end of the electrode
was ignored and watch the pool of molten metal instead. Stayed where it started in
second or two before moving to get the good pool.
5. Moved the weld pool across the metal started and make sure the electrode was
stayed at 90˚ angle.
6. The weld pool was moved in straight line or zigzag or small circle.
7. The joint was set. The clamps and vices were used to ensure that the joint on the
metal was firmly joint together.
8. When the welding finished, the electrode was pulled back from the metal. Wait for
a few seconds to ensure that the metal was cooled. Then the wire brush was used
to clean the metal.
9. To cool the metal faster, dipped the metal into the water.
10. Make sure that before going out from the lab workshop, clean all the stuff in the lab
workshop to make the lab workshop clean.
DISCUSSION

Welding is very useful in joining metal parts in engineering field. Most of our furniture
made from metals are joined by welding. Nevertheless, welding can be very dangerous if
there is no safety precaution and does not follow manual. Some safety precautions can be
taken are:

a. To prevent injury to personnel, extreme caution should be exercised when using any types
of welding equipment. Injury can result from fire, explosions, electric shock, or harmful
agents. Both the general and specific safety precautions listed below must be strictly observed
by workers who weld or cut metals.

b. Do not permit unauthorized persons to use welding or cutting equipment.

c. Do not weld in a building with wooden floors, unless the floors are protected from hot
metal by means of fire resistant fabric, sand, or other fireproof material. Be sure that hot
sparks or hot metal will not fall on the operator or on any welding equipment components.

d. Remove all flammable material, such as cotton, oil, gasoline, etc., from the vicinity of
welding.

e. Before welding or cutting, warm those in close proximity who are not protected to wear
proper clothing or goggles.

f. Remove any assembled parts from the component being welded that may become warped
or otherwise damaged by the welding process.

g. Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around the
welding equipment. Accidents and/or fires may occur.

h. Keep a suitable fire extinguisher nearby at all times. Ensure the fire extinguisher is in
operable condition.

i. Mark all hot metal after welding operations are completed. Soapstone is commonly used for
this purpose.
Arc Welding

A poor welding technique and improper choice of welding parameters can cause weld
defects. For example defect may occur are, slag inclusions, undercutting, lack or fusion,
overlapping and more. The arc length is a factor affect the welding work. To strike the arc, the
electrode should be gently scraped on the work until the arc is established. The arc cannot be
too long as it will reduce penetration, produces spatter and gives a rough surface finish to the
weld. Also, if excessively short arc will cause sticking of electrode and rough deposits that are
associated with slag inclusions. The electrode should be move along in the direction of the joint
welded at an optimum speed (constant speed). At the same time, the electrode is fed downwards
to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of
penetration while if too slow will lead to arc instability, slag inclusion and poor mechanical
properties.

MIG Welding

The thing that the welder must concern by using MIG is keeping the distance between
the electrode and workpiece to prevent from electrode overheat and wastage of shield gas.
Besides that, the orientation of the nozzle for the fillet joint (as the project) should be at 45
degree from the workpiece surface.

The oxygen contain inside the weld pool should be greatly remove to prevent the less
ductile and weaker weld occur. So, any oxides at the surface of workpieces should be clean by
wire brush or chemical.
CONCLUSION
At the end of this experiment, the objectives of the welding workshop were archived.
We learn the types of welding which is MIG welding and arc welding. Other than that, we also
have been taught by the staff the skills of welding to produce the great joining. Learn how to
recognize the type of metals, electrode, and tools that used in the welding. Besides, we learn
how to adjust the volume of electric to get the perfect welding operation. Lastly, the staff
always remind us to stay safety while doing our project before and after finish.
REFERENCE

i. www.theweldinginstitute.com/education-and-development/what-is-welding/
ii. http://www.lincolnelectric.com/en-gb/support/process-and-theory/Pages/arc-welding-
detail.aspx
iii. www.harborfreight.com/welding.html
iv. http://www.gowelding.org/articles/introduction-welding/