SCHOOL OF MECHANICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

SUPERVISOR EVALUATION FORM

SUPERVISOR EVALUATION FORM

COURSE MEM460 - ENGINEERING WORKSHOP PRACTICE

LABORATORY WELDING WORKSHOP

INSTRUCTOR
MR. YUSOFF
NAME

No Name Student ID Group No REMARK

MUHAMMAD AMIRUL
1 2021829696 15
HANIF BIN AHMAD

MUHAMMAD RAFIUDDIN 2021823214 15

2
BIN RAZIF

WAN MUHAMMAD 2021829586 15

3 SYAZWAN BIN WAN
SAIFPUDDIN

NUR HEZREEN NAJWA 2021600968 15

4
BINTI ABDUL MU’IZZ

AMINUDDIN BIN ABDUL 15

5 2021643034
GHANI
 Level Very Poor Poor Satisfactory Good Excellent
Guidelines
Scale 1-2 3-4 5-6 7-8 9-10

Individu
al and
Handling Technique,
Teamwo
Equipment/ Discipline &
rk
Machinery Safety
TOTA
ASSESSMENT CRITERIA Factor Factor Factor L
CO4 – (60%)
CO2 – PO5 CO3 – PO6
PO9
(Scale 1-10) (Scale 1-10)
(Scale
1-10)

MUHAMMAD
(1) AMIRUL HANIF BIN
AHMAD

MUHAMMAD
(2) RAFIUDDIN BIN
RAZIF 0
3.5 2.0 .
5
WAN MUHAMMAD
(3) SYAZWAN BIN WAN
SAIFPUDDIN

NUR HEZREEN
(4) NAJWA BINTI
ABDUL MU’IZZ

AMINUDDIN BIN
(5)
ABDUL GHANI

Note: Comments are encouraged and given directly to the individual.

Handling Equipment – CO2-PO5 (35%) Technique, Discipline & Safety CO3-PO6
(20%)
● Know- how to apply and operate
equipment ● Safety and discipline of an individual in
terms of punctuality and obey instructions
● Properly handle equipment and obey the in handling the equipment and following
standard operating procedure; the safety instruction.
● Appropriate attire suitable in conducting ● Recognize the safety precaution aspects
lab and handling the laboratory during handling the equipment in the
equipment workshop. (do and don’t during
experimental)

Individual & Teamwork - CO4-PO9 (5%)

● Function effectively as an individual, and as a member of a team; prepared and proactive.
● Effort organized and shared among members.
● Practice 5S in a workshop.
● Punctuality
 SCHOOL OF MECHANICAL ENGINEERING
UNIVERSITI TEKNOLOGI MARA

REPORT EVALUATION FORM

REPORT EVALUATION FORM

COURSE MEM460 - ENGINEERING WORKSHOP PRACTICE

LABORATORY WELDING WORKSHOP

INSTRUCTOR
MR.YUSOFF
NAME

No Name Student ID Group No REMARK

MUHAMMAD AMIRUL HANIF BIN
1 AHMAD
2021829696 15

2 MUHAMMAD RAFIUDDIN BIN RAZIF 2021823214 15

WAN MUHAMMAD SYAZWAN BIN

3 WAN SAIFPUDDIN
2021829586 15

NUR HEZREEN NAJWA BINTI ABDUL

4 MU’IZZ
2021600968 15

5 AMINUDDIN BIN ABDUL GHANI 2021643034 15

Excellen
Level Very Poor Poor Satisfactory Good
Guidelines t
Scale 1-2 3-4 5-6 7-8 9-10
Report content Weight Score (%)
SCALE
Items/ Assessment Criteria (Report) age
(1-10)
(%)
1.0 Title ● Refer to respective lab sheets /
instructions for title of experiment. - - -

2.0 Objective(s) ● State the purpose that describes the

intention of the experiment,
- - -
investigation or accomplishment.

1.0 Introduction ● Provide an understanding of the

(Theory and experiment to relate with the body of
Background) knowledge of the experiment topic 0.25
which includes necessary diagrams,
theory and equations.

3.0 Apparatus

● List of equipment, machines,

accessories, and components involved in
the experiment with the necessary
pictures/diagrams.
● May include a brief description of the 0.25
instrumentation/set-up if necessary, to
connect with the main body of
knowledge of the topic

● Describe operating procedures and

methods applied, safety and standard to
4.0 Experimental and relate with appropriate techniques using
safety procedure available modern engineering set 0.5
up/machinery and IT tools.

● Present the final product.

● Discuss the findings; make comparisons
with known information if available.
● Elaborate on possible sources of errors,
defects and sensitivity of the product
5.0 Results & Discussion and procedure applied.
0.5
● Propose any possible improvements in
the project. (set-up ideas for a future
project)
● Any recommendation to improve the
workshop in term of societal, health,
safety, legal and cultural issues
●List references to methods and related
6.0 References studies with the appropriate style of
report writing. (At least 5). 0.25
Report content Weight Score (%)
SCALE
Items/ Assessment Criteria (Report) age
(1-10)
(%)
● Able to comprehend and write effective
reports and design documentation; and
7.0 Report delivery give and receive clear instructions
(Formatting and writing skill, Language, 0.25
include Turnitin report)
● Original maximum 30%

Compulsory to include/attach this lab

report assessment form in your report
Please note: submission. NO MARK be given if
Total Marks
failure to do so.
INTRODUCTION

Shielded metal arc welding (SMAW) also known as manual metal arc (MMA) or informally
known as stick welding, is a manual arc welding process for joining metals. Arc welding is a
process that uses flux coated electrodes to join itself with base metal. 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. In arc welding, the intense heat needed to melt metal is produced by an electric arc
with the help of a power supply. The arc is formed between the actual work and an electrode
(stick or wire) that is manually or mechanically guided along the joint creating a weld pool in
between the weld metal and the core wire of the electrode. When cooled, this results in a binding
of metals.
During the process, the heat would also disperse flux coating from the electrode, which produces
shielding gas that solidifies as a slag above the weld metal, protecting it from atmospheric
contamination. Since the joining is an inter-mixture of metals, the final weld joint potentially has
the same strength properties as the metal of the parts. This is in sharp contrast to non-fusion
processes of joining in which the mechanical and physical properties of the base materials cannot
be duplicated at the joint.

OBJECTIVE

● To demonstrate some mostly used welding processes.

● To build a welded bead technique on a mild steel plate.
APPARATUS

● Flat bars are the basis of building

support materials. They are generally
used for support braces,gate latches,
duct work, overhead doors and
heaters.
● During the welding lab, mild steel flat
bar are used as a base to try the
welding process.

Mild Steel Flat Bar

● Electrodes are used in different battery

types, electroplating and electrolysis,
welding, cathodic protection ,
membrane electrode assembly and
taser electroshock weapons.
● In welding, electrodes are used to
assemble both mild steel flat bar or
used to welding on top of the mild
Electrodes steel flat bar.

● Current uses for mild steel arc welding

are between 90 – 130 amp. The best
current use for this arc welding is 110
amp.

DC Arc Welding Machine

 ● It is made from inflammable material.
In the middle of the shield there is a
bright rectangular glass coated with
dark coloured glass.
● It is used to protect the user from
fire-bolt and harmful rays during
welding work.
● There are two types of shield, one is
the helmet type and the other one is
Face Shield the hand held type

● It must be made from high quality

leather. Use to protect your hand from
firebolt and hot metal welding.

Leather Hand Gloves

● Its main use is for gripping and

holding. In welding, it been used to
gripping and holding mild steel flat
bar

Plier

● Chipping hammers are used to clean

● and remove the slag after welding and
can also be used for boiler scaling
applications.

Chipping Hammer
 ● Wire brush is primarily an abrasive
implement. In welding, it used to clean
the rust and removing the slag after
using the chipping hammer

Wire Brush

● Leather jackets are used to warn and

protect our body from having an
accident during the workshop.

Leather Jacket

EXPERIMENTAL AND SAFETY PROCEDURE

Experimental Procedure

1. Make sure to wear protective clothing

2. Make sure workpiece is clean before welding
3. The workpiece was clamped to the weld as closed as possible
4. Suitable electrodes were selected and inserted in the electrode holder. A small
diameter electrode requires less current than large one
5. The weld bead was examined to determine if the arc length is correct. Arc length
for 1/16 and 3/32 in diameter electrodes should be about 1/16 in (1.6mm); arc
length for 1/8 and 5/32 in electrodes should be about 1/8 in (3 mm).
6. Chipping hammer and wire brush were used to remove slag. Slag was removed
and the weld bead was checked before making another weld pass.
7. The welder was switched on.
 8. Be careful not to touch the electrode to the workpiece or worktable until ready to
strike an arc.
9. Scratch or tap an electrode on the plate ; immediately lift the electrode slightly
after touching work. If the arc goes out, the electrode was lifted too high. If the
electrode sticks to the workpiece, use a quick twist to free it.
10. The arc was striked with a long scratching motion of the electrode across the
workpiece The electrode was lifted away from the workpiece after the weld was
done.
11. The electrode was dropped from the holder and put down the electrode holder

Safety Precautions

1. Wear Approved Eye Protection.

2. Wear Flame Resistant Clothing.
3. Wear Long Sleeves, Pocket Flaps and No Cuffs.
4. Wear Approved safety boot.
5. Wear Approved Hand Protection.
6. Always protect the eyes from arc rays.
7. Protect face and body from heat radiation and molten metal.
8. Move all the flammable material off the working place or cover it up using
fireproof material.
9. Make sure that the welding machine is earthen.
10. Make sure that all line holders, earth clip and connection are placed in a good
place.
11. Make sure that the working place is clean and tidy.
12. Make sure that all electric connections are tight, clean and dry.
13. Avoid pulling the cable on top or near sharp things.
14. Do not ever scratch the arc on top of the gas cylinder.
15. Turn off the welding machine when not in use.
16. Avoid welding cable from being in contact with hot metal, water, oil and grease.
17. All equipment such as hammer, chisel, brush and others must be well maintained.
RESULT AND DISCUSSION

Drawing part Final product

Based on the result obtained, there are several factors that affected the welding
beads size and shape. For this experiment, the main three factors that contribute to the
results of the welding beads are the angle, the travel speed and the arc length. For the
angle, the tip of the welding gun is supposed to be 60° to 80° to the specimen and the drag
technique is used for this practice. If the drag technique used is correct, it will result in
deeper penetration and a narrow bead. Besides that, the travel speed also plays an
important role to gain good welding beads. When the travel speeds are too slow, the bead
will become wider and build up higher. If it has too fast welding speed, the welding bead
will become thin with elongated semicircles and the penetration quality is also poor. The
third factor is the arc length. If the arc length is too long, the welding will become uneven
and some splatter will show. Besides that, the arc and sound will be inconsistent when the
welding process is conducted.
Other than that, the penetration into the base metal is also poor. Next, if the arc
length is too short, the weld also shows poor penetration into the base metal. The welding
bead may rise above the base metal. During the welding process, the electrode may attach
to the base metal.
 There are some defects that occur on our specimen that have been welded. One of
them is porosity. There is a small cavity or holes resulting from gas pockets in weld metal.
The possible cause of the porosity is the workpiece is dirty before the welding process is
carried out. We must remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt
from the work surface before welding. Other than that, we can see the incomplete fusion
at the end of our joining specimen. The failure of welded metal to fuse completely with
base metal. The possible cause occurs because of improper welding techniques . We must
place the stringer bead in proper locations at the joint during welding. Other than that, we
must adjust the work angle or widen the groove to access the bottom during welding. The
momentarily hold arc on groove side walls when using weaving technique. We also must
keep arcs on the leading edge of the weld puddle.
REFERENCE

1. “Shielded metal arc welding (SMAW): Equipment and applications,” Your Article
Library,06-Feb-2017.[Online].Available:https://www.yourarticlelibrary.com/metallurgy/a
rc-welding/shielded-metal-arc-welding-smaw-equipment-and-applications/96604.
[Accessed: 20-Jun-2022].

2. J. D. on, “Shielded Metal Arc Welding Basics,” FABTECH, 04-Jan-2018. [Online].

Available:
https://www.fabtechexpo.com/blog/2018/01/04/shielded-metal-arc-welding-basics.
[Accessed: 20-Jun-2022].

3. “Welding procedure specification,” Wikipedia, 29-Oct-2019. [Online]. Available:

https://en.wikipedia.org/wiki/Welding_Procedure_Specification#:~:text=A%20Welding%
20Procedure%20Specification. [Accessed: 20-Jun-2022]

4. “Shielded metal arc welding (SMAW): Equipment and applications,” Your Article
Library,06-Feb-2017.[Online].Available:https://www.yourarticlelibrary.com/metallurgy/a
rc-welding/shielded-metal-arc-welding-smaw-equipment-and-applications/96604.
[Accessed: 20-Jun-2022].