Group No: 05

Module Name: ME2024

Semester: 3

Familiarization with metal welding II

By

Index No. Name Marks

200107M De Silva H.G.A.E.

Date of submission 18/12/2022

Due date of submission 19/12/2022

Advisors’/Instructors’ names, associations and signature

Department of Mechanical Engineering,

Mr. M.R.S Perera
University of Moratuwa

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
Summary
This practical session is a continuation of the practical titled “Familiarization with metal
welding I”. Effect of welding, parameters on the welding process is analyzed in a systematic
manner and associated weld defects for different working conditions is identified separately.
Thereby, we are required to develop our skills and knowledge to select proper welding
parameters for a given application.

Table of Contents

Summary ................................................................................................................................ 1

Table of Contents ................................................................................................................... 1

1 Introduction ......................................................................................................................... 2

2 Material and methods .......................................................................................................... 3

3 Discussion and conclusions ................................................................................................ 5

4 References ............................................................................................................................. 10

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1. INTRODUCTION

Welding is a production that joins materials by applying heat, often metals or

thermoplastics. This is frequently accomplished by melting the workpieces and adding a
filler material to create a pool of molten metal (the weld pool), which then cools to form a
sturdy bond. Pressure may also be used to create the weld, either alone or in combination
with heat. This is in contrast to soldering and brazing, which entail bonding two
workpieces together without melting them by melting a material having a lower melting
point.
We use welding in many engineering constructions and fabrications due to they have high
permanent strong bonds. But the thing is to ensure the safety and to estimate the
durability of the construction, we must have a clear understanding about the defects of
welding. Hence during this practical we study about weld parameters, defects and their
root causes in oxy-fuel, arc and spot-welding.

❖ Learning objectives of the lab session.

• To develop an awareness of weld parameters of oxy-fuel, arc and spot-welding
processes.
• To identify types of weld defects and their root causes.
• To understand the influences of weld parameters on the quality of the weld and
welding process.

❖ Learning outcomes of the lab session.

On successful completion of this lab session, the student should be able to:

• Explain types of weld parameters and their significance in controlling the process.
• Identify weld defects, their root causes and precautions / corrective actions to
obtain a quality weld.
• Select appropriate weld settings for a given welding application.

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 2. MATERIAL AND METHODS
First our instructor gave us a clear explanation about welding parameters , welding defect and
their root causes. Then we got a hands on experience in oxy fuel and arc welding.

Oxy fuel welding

Required tools and equipment :-

• Welding torch
• Oxygen and Acetylene gas cylinders
• PPE (goggles) and safety suit
• pressure regulators
• pressure gauges
• hoses
• filler rod

The oxygen cylinder was recognized as the dark-colored (or black) cylinder. First, the valve
on the oxygen cylinder was opened. It rotates to the right. The right side meter gauge was
used to measure the nozzle pressure and other used to measure the nozzle pressure for both
cylinder. The valve was rotated leftward in order to open the acetylene cylinder.

The table of nozzle notation vs metal thickness graph was used to select the welding nozzle.
The other valve was just slightly opened after opening the torch acetylene valve by half a

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turn. For safety, the nozzle could only be fired using a spark lighter. In order to the weld the
metals the flame was adjusted in to the neutral flame.

The given work pieces were mild steel so, the filler metal was chosen as mild steel. Then two
edges of the workpieces were weld while the filler rod was laying on the join, after that the
join was weld completely. While the welding proceeds, we didn’t move the filler rod. We
moved the welding torch from appropriate speed. Once the weld was complete first the
acetylene valve was closed and then oxygen.

Arc welding

Arc welding is a method of joining two metals together, by utilizing electricity to generate
enough heat to melt metal and then allowing the molten metal to cool.

Required tools and equipment :-

• welding transformer
• electrode holder
• welding table
• safety suit
• chipping hammer
• Wire brush
• electrodes

Three metal components were used to build the square joint and lap joint. First, we adjust the
ampere range of the transformer to the appropriate range. Electrode was selected by
considering about the workpiece metal material and the thickness of that. Then the electrode
was inserted to the electrode holder the two edges of work pieces were properly aligned for

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the square butt joint. Then the electrode tip was touched with the welding table and by the
produced arc two ends were weld first and after that welded the joint from one end to the
other by slowly moving the electrode holder. (While welding eye area was shielded by a hand
shield.) We maintained the arc length as same as the diameter of the electrodes. After
finishing the welding, the slag was removed completely. As same as we welded the lap joint,
in that we used hammer to support the vertical plate. After completing the welding the
transformer was turned off.

3. DISCUSSION AND CONCLUSIONS

❖ The common welding issues/defects and reasons for their occurrences

Weakness in the joint that is over the permitted level because of an improper welding
procedure or technique can be used to describe weld defects. A high-quality weld must
properly fuse the filler metal to the edge and have adequate penetration. Here is a few
welding defects.

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Inclusions

Non-metallic substances like slag and oxides that are entrapped in the weld metal, in the
space between the weld beads, or between the weld and the workpiece metal are known
as inclusions.

Causes :-
• Incorrect angle and feeding rate
• Poor cleaning of welding area

In complete Penetration

When the depth of the weld's penetration into the joint is less than what is required to fuse
through the plate or through the weld that came before it, this is known as incomplete
penetration.
Causes :-
• When there is too much gap between the workpieces.
• When bead moving speed is too high.
• Improper joint.
• amperage can be too low, which results in the current not being strong enough
to properly melt the metal.
• Large electrode diameter.

Weld Cracks

cracks are highly undesirable as they will rapidly propagate to larger cracks and eventually
leads to failure.

Causes :-
• Due to of residual stress.
• Joints that constrain the expansion and contraction.
• higher levels of Sulphur and carbon.
• Base metal contamination.
• Poor joint design.
• High welding speed and low ampere range.

Porosity

This occurs when holes develop in the weld pool due to gas bubbles that didn’t escape.
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 Causes :-
• Uncleaned surfaces.
• incorrect electrode selection.
• Lack of shielding gas.
• Either too low or too high welding current.
• Fast feeding

Arc strikes
Small, areas known as arc strikes where surface melting has taken place away from a joint.

Causes :-
• poor ground connections.
• accidental striking the arc in the wrong location.

Undercut

A joint face that has metal removed by the arc force but not replaced by weld metal develops
an undercut.
Causes :-

• High arc voltage

• Incorrect electrode angle.
• Higher feeding rate

Spatter

This occurs when material droplets get ejected on the metal surface.
Causes :-
• High arc length.
• weld current.
• Improper shielding.
• Incorrect polarity may cause excessive spatter.

Underfill
When the amount of deposited weld metal is insufficient to raise the weld's face or root
surfaces to the same level as the original plane or plate surface, underfill develops on a
groove weld.

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 Causes :-
• Low welding current.
• Incorrect weld bead placement.
• High feeding rate

❖ The influence of each of the weld parameters

Arc Welding

• Amperage - has an impact on the size and penetration of the weld bead. Low
current will start the uncomfortable and cause the arc to perhaps wander to one side.
The electrode rod's diameter must be taken into consideration while setting the
current.
• Feeding speed - a greater rate will result in excessive spatter and have an impact on
the form of the bead.
• Feeding angle - Welds of lower quality can be produced by narrower travel angles.
• Arc length – Normally take as same as the electrode diameter. By keeping the proper
arc length, the proper heat and control may be produced. Additionally, the splatter can
be reduced.
• Electrode diameter - select based on the thickness of the workpiece.
• Electrode material - The right materials must be utilized to achieve effective fusion.

Oxy- Acetylene Welding

• Gas pressure - Cylinder pressure must be regulated in accordance with the welding
torch tip.
• Feeding speed - a slower feed may generate too much heat, which might result in a
large bead or even burn through.
• Oxy-fuel mix ratio - must be adjusted appropriately since various flames have varied
uses.
• Nozzle size - must be selected appropriately nozzle on the thickness of the workpiece
material.
• Welding rod - must select based on the workpiece material.
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Spot Welding

• Weld time -The thickness of the workpieces and thermal conductivity must also be
taken into consideration when selecting the weld time. Longer periods select for thick,
poorly thermally conductive sheets
• Weld current - because heat generation depends on thermal conductivity and current.
• Pressure -The thickness of the workpieces must be taken into consideration when
adjusting the pressure.
• thicker, more insulative metals require higher weld currents.
• Workpiece thickness - A larger workpiece thickness requires a higher weld current.

❖ important design considerations in welding to improve weld quality

and performance of the welding process.

• Thorough proper cleaning of the workpiece before welding can prevent any weld
weakening.
• Calculating mathematically the necessary welding strength For safety.
• Determine where the proper location for the weld. The choice of the ideal position for
the welded junction involves two factors. The location of the welded junction should be
away from critical loads and deflection. Additionally, it should be placed such that the
welder and welding equipment have unhindered access to that area. At the location of the
weld, it should be feasible to do pre-weld machining, post-weld heat treatment, and
ultimately weld inspection.

• Use of appropriate techniques and procedures depending on the work items and the
demand, the right welding process must be selected. To get a high-quality weld after
choosing a welding technique, the right procedures must be performed.

• Choose a material that has good weldability. Low carbon steel is typically easier to weld
than high carbon steel. Higher carbon concentration tends to harden the welded joint,
making the weld more brittle and prone to cracking. Maximum carbon concentration is
typically restricted to 0.22 per centimeter square for ease of welding.

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• Checking the weld quality while it is being made and taking remedial action if
necessary.
• Using robotic welding equipment to increase efficiency and precision.
• Use standard components. The nonstandard portion required extra welding and plate
flame cutting. To counteract torsional forces, employ regular tubular sections. The designer
should aim to use plates with an equivalent thickness for a butt joint.

4. REFERENCES

• A. one, O. mwiti 3 S. 2019, shb 3 S. 2019, F. mbaka 3 S. 2019,

and L. Y. A. K. O. T. A. E. D. W. A. R. D. 3 S. 2019, “7 most common welding defects, causes
and remedies,” SLV, 27-Jul-2022. [Online]. Available: https://slv.co.id/7-common-welding-
defects-causes-remedies/. [Accessed: 16-Dec-2022].

• E. Staff, “Design considerations of Welded Assemblies: Machine Design,” Engineering Arena,

01-Jan-2022. [Online]. Available: https://www.enggarena.net/design-considerations-of-
welded-assemblies/. [Accessed: 15-Dec-2022].

• Gerald J SmithI am a welder professional and Since, “Different types of welding and what
they are used for [new updated],” WelderPoint, 08-Aug-2021. [Online]. Available:
https://welderpoint.com/types-of-welders/. [Accessed: 18-Dec-2022].

• T. E. P. team, I. Joe, S. M, M. Rizwan, V. kumar, and Shivaji, “16 common types of welding
defects [causes, remedies] pdf,” The Engineers Post, 03-Jul-2022. [Online]. Available:
https://www.theengineerspost.com/welding-defects/. [Accessed: 16-Dec-2022].

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