SEMESTER 1

SESI 2014/2015

DATE
NAME &
MATRIX NUMBER

1.

NAME OF INSTRUCTOR

1.
2.
3.

EXAMINERS COMMENT

VERIFICATION STAMP

TOTAL MARKS

15

1.0OBJECTIVES
Perform basic welding practice butt joint to join two (2) metal plates

2.0EQUIPMENT
2.1Metal Arc Welding Equipment
2.2Mild Steel Plates dimension of 50 x 100 x 3 mm
2.3Mild Steel wire of 2.6 mm
2.4Chipping Hammer
2.5Pliers
2.6Leather Hand gloves
2.7Hand Shield / Head Shield
2.8Leather Apron

3.0SYNOPSIS & THEORY

A welding machine provides the electrical energy to make an arc between the flux coated
electrode and the work piece. There has to be a strong enough electric current (amps) to
melt the surface of the work piece and the end of the electrode. The machine has a control
which changes the amount of current to suit different welding conditions & electrode sizes.

Figure 3.1 Arc Welding Operation

When the arc is formed, the temperature at the point of contact rises to about 6000C..This
intense heat is concentrated at the electrode end and the point of welding. It melts a small
pool of metal in the workpiece and also melts the end of the electrode into globules of
molten metal which are forced across the arc and into the weld pool on the work. The
electrode flux coating melts, providing a gaseous shield around the arc and producing a
protective slag on the completed weld. The melting rate of the electrode metal depends on
the amount of electric current used.

FIGURE 3.2 Shielded Metal Arc Welding Equipment

4.0 PROCEDURE
4.1Each student/students will be provided with 2 piece of metal
4.2Perform either lap joint or butt joint using provided electrode
4.3Record your work parameter in Table 1
4.4Clean work piece after finish

5.0 RESULT
Fill in the result of your work parameter
Table 1
No

Parameter

Electrode diameter (mm)

Current range value (A)

6.0 DISCUSSION
6.1What is the range of current (A) that can be used to weld the two pieces of metal?

2 marks

6.2Based on the welding activity that you performed, what is the best current (A) value
that you chose? Why?

2 marks

6.3What are the defect(s) that you noticed in your welding work? Explain the factor(s) that
cause the defect(s).

6 marks

7.0 CONCLUSION
7.1Summarise in your own words what have you learn from the welding activity

5 marks

5 marks