Welding Lab Report

Name: Mohit Vyas
Entry number: 2020EEB1183
Date: 20/05/2021
Experiment 01.
1) Name of the experiment: Wire Electro discharge machining process (non
conventional method).
2) Aim of the experiment:
Objective:
1) To identify the Wire-EDM as a special type of machining process.
2) To understand the physics of the material removal.
3) To understand the major components of the machine and their

functions.
Name of machine: In the machine that we will use have the following major
components.
1) Electrical components: in this component we supply Power to the

machine and EDM power. Here we generally use DC power supply.
2) Control panel: by the help of the control panel we establish interface
between user and machine. We can write a programme here to control
the movement of the wire. i.e. we can control the motion of the wire
easily with the help of control panel.
3) Mechanical panel: here we flush the dielectric which has to be in
between the workpiece and the tool.
Apart from this we also have a plant to generate deionised water which is used
as a dielectric. Dielectric should not be toxic, inflammable and it should be
partial conducting in nature. And it should be skin friendly.
3) Experimental procedure:
In WEDM process we use continuously moving wire as a tool. We will be able to
remove the material without making any physical contact.
Very high electric field is applied between the work piece and the wire. The tool
is connected with cathode (-ve). Because of the high E.F electrons starts emitting
from the cathode towards the workpiece which are present between the tool and
the workpiece after the dielectric breakdown, that is called the cold emission.
Due to the high number of charge particles, the entire gap is filled with the charge
particles and that is called plasma. Upto this, the wole process occure in on
phase.
Then we turn off the power supply and due to this the plasma channel collapse
and since there is the huge difference in pressure between outside and inside
then this plasma will go out along with some molten metal (mostly of
workpiece).
4) Output/product from the experiment:

Source : Google
5) Possible limitations of EDM:

1) Both the workpiece and tool needs to be conducting in nature.
2) We cannot use any wire for more than one time.
3) We cannot use AC power supply.
4) We have to keep extra attention on tightness of the wire because loose wire
may vary the discharge gap.
5) Vibration of the wire may happen and that will also vary the discharge gap.
6) Where it helps in Electrical engineering: This process will definitely help

in electric engineering like anywhere I need to build mold or any type of structure,
I can use WEDM to get this.
7) Conclusion:
 From this lab we come to know that how can we cut the desired shape
without touching the metal .
 WEDM products are still in use for many purposes.
 WEDM is also a good process and the main speciality is that is can be
operated by writing the programme. Which makes it more accurate.
Experiment 02.
1) Name of the experiment: Shielded metal arc-welding (SMAW) and gas
tungsten arc welding (GTAW).
2) Aim of the experiment:
a) Objectives:
1) To study and observe the various arc welding techniques through
demonstration and practice.
2) to analyze the outcome from the practicle task that has been doing.
b) Name of the machines/tools:

1) Electrodes: electrode fill the gap between the two workpieces. And the
electrodes are coated woth the shielding flux of suitable compositions
that depends upon the material that we are going to weld. This flux
metal will also melt together with the electro metallic core electrode
forming a gas and the slag. This flux protects the metal from getting
oxidized from the almosphere. In our experiment we will use E6013
electrode which is used for a mild steel and is easy to handle.
While in GTAW electrode is of tungsten alloyed with cerium and
lanthanum. And inert gases like argon (Ar) is also used in GTAW.
2) Power supply: this is used to supply power to the machine. Power supply
may be AC or DC according to requirement. But we generally prefer DC.
3) Electrode holder worktable: this is required to perform experiment with
safety and easiness.
4) Welding torch: this is only for GTAW. In this we insert our tungsten
electrode.
c) List of the hand tools:
1) Plier: hand tool used for holding the objects and cutting and bending tough
material
2) Protective sield: provides full facial protection from sparks and flying metals
and intense light from arc
3) Wire brush: Wire brush is used for cleaning rust and removing paint
4) Hammer: this is also used for cleaning rust. To remove the slag that was
formed by flux on the electrode.
5) Glove: protect hand from Spark and flying metals and Hot metal during and
after
3) Experimental procedure: (description and sketches)
a) SMAW: Firstly we have to carry the electrode in touch of the metal surface
and when we pull it back it generate an electric arc between the workpiece
and electrode. And because of that arc melting started. Electrode should be
kept at an angle of 30-45 degree to avoid unnecessary melting. We
generally keep electrode as negatively charged and metal as positively
charged to avoid weld penetration. A step down transformer os also used
to decrease the voltage and to increase the current. After the welding we
remove the slag by the help of hammer and wire brush.
b) GTAW: in this process A non-consumable Tungsten (W) electrode in the
form of a rod is used to create an Arc with the workpiece under appropriate
welding condition. And filler metal is used as a joining agent, which is
exactly of the same composition as of the base metal.. pressure should be
maintained at one bar. As compared to SMAW very less noice is produces
in this welding. Since no coating is used in the filler wire so this makes the
weld very clean.
4) Output from the experiment : seI was able to collect the following two
products of welding near me. And in both of these two products I think that
their smoothness can be increased by the help of wire brush. And in fig:4 the
have not removed the slag. I think it should also be removed. And in Fig:5
there are some extra cuts they could be minimized if we will move the
electrode properly.
5) Possible limitation of process and products:
SMAW:
1) Cracks are formed while solidification.

2) Extra slag layer is formed which has to be removed.
3) There may be insufficient or extra penetration than our requirement.
4) Undercut may happen during the process.
GTAW:
1) We cannot weld thicker metal/work piece.

2) We can only weld upto 7 mm.
3) Sometime here also we have to use wire brush to remove oxide layer.
6) Its uses in electrical engineering: Arc welding is used to add two metal
surfaces. In electrical engineering it may be used in adding any hardware part
like structure of any appliences like transistor, some other machines, etc.
7) Conclusion: In a big industry, welding is the most preferred choice to join
materials together taking consideration of the cost of welding. Besides that
welding is the more practical method since it can join two different types of
material also. And after this whole experiment we have learnt the two
different processes of welding (SMAW and GTAW). Both have their own
benefits. GTAW will give us more smooth products as compared to SMAW.

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Name: Mohit Vyas

Entry number: 2020EEB1183

1) To identify the Wire-EDM as a special type of machining process.

2) To understand the physics of the material removal.

3) To understand the major components of the machine and their

1) Electrical components: in this component we supply Power to the

4) Output/product from the experiment:

5) Possible limitations of EDM:

6) Where it helps in Electrical engineering: This process will definitely help

b) Name of the machines/tools:

1) Cracks are formed while solidification.

1) We cannot weld thicker metal/work piece.

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