Amadi Welding Mme Report
Amadi Welding Mme Report
1.1 Introduction
The Student Industrial Work Experience Scheme (SIWES) was initiated in October
8, 1973 by the Industrial Training Fund (ITF), the Student Industrial Work
Work Experience program in an Industry that relate to their field of study in order
Colleges of Technology. It was aimed at bridging the gap between the theoretical
The Industrial Training Fund’s Policy Document No. 1 of 1973 which established
SIWES outlined the objectives of the scheme. The objectives of the Students
Prepare students for industrial work situations that they are likely to meet
after graduation;
Expose students to work methods and techniques in handling equipment and
Make the transition from school to the world of work easier and enhance
in real work situations, thereby bridging the gap between theory and
practice;
through SIWES.
The objective for which the Fund was established has been pursued vigorously and
efficaciously. In the four decades of its existence, the ITF has not only raised
training consciousness in the economy, but has also helped in generating a corps of
skilled indigenous manpower which has been manning and managing various
Over the years, pursuant to its statutory responsibility, the ITF has expanded its
services in order to meet the expanding, and changing demands for skilled
50% Levy paid by employers of labour registered with it, and administers the
effort.
CHAPTER TWO
and fabrication of pipes, equipment and machines using various types of materials
such as carbon steel, stainless steel, duplex, super duplex and titanium.
large welding and fabrication works in both the onshore and offshore industries.
Our workers strive to keep the highest standards in welding and fabrication within
Our Welding and Fabrication department would move your project through the
fabrication and welding processes smoothly and efficiently. All of the companies
we service demand fast, reliable fabrication and erection services and they receive
Our services include, but are not limited to, full service fabrication and installation
of process piping, oil and gas fabrication, and structural steel. We also offer in-
in the industrial environment. We draw our strength from our experience, integrity,
demonstrate our leadership position with great passion, rigour and total
always meeting and exceeding, where possible, customer’s need and expectations.
Building and developing well trained professionals that are proud of their
Ensure that all employees are treated well, working as an “intelligent army”
3.1 Introduction
workpieces and adding a filler material to form a pool of molten material (the weld
puddle) that cools to become a strong joint, but sometimes pressure is used in
conjunction with heat, or by itself, to produce the weld. This is in contrast with
between the workpieces to form a bond between them, without melting the
workpieces.
Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an
remains dangerous, and precautions must be taken to avoid burns, electric shock,
Until the end of the 19th century, the only welding process was forge welding,
which blacksmiths had used for centuries to join metals by heating and pounding
them. Arc welding and oxyfuel welding were among the first processes to develop
during the 1800s, and resistance welding followed soon after. Welding technology
advanced quickly during the early 20th century as World War I and World War II
drove the demand for reliable and inexpensive joining methods. Following the
methods like shielded metal arc welding; now one of the most popular welding
methods, as well as semi-automatic and automatic processes such as gas metal arc
the latter half of the century. Today, the science continues to advance. Robot
continue to develop new welding methods and gain greater understanding of weld
Arc welding processes use a welding power supply to create and maintain an
electric arc between an electrode and the base material to melt metals at the
welding point. They can use either direct (DC) or alternating (AC) current, and
protected by some type of inert or semi-inert gas, known as a shielding gas, and
3.2.2 Step by Step Free Guide to Make the Right Weld using Arc Welding
Machine
Given below are step-by-step instructions to get the perfect weld with the help of
metals of unwanted grease, dust and rust and filing a slanting edge out of the metal
sides. The latter process allows an increased room for penetration, forming an even
Any process that involves electricity and produces sparks calls for strict adherence
to safety guidelines. Welding gear primarily includes welding robes, safety shoes,
safety gloves and safety glasses. Welding robes are made of fire-resistant materials
to prevent potential fires or holes from being burnt into your clothes; safety shoes
provide protection against welding sparks; safety gloves protect your hands from
burns and safety glasses protect your eyes from being damaged by the fierce glare
emanated from the metal whilst welding. Welding blankets are often used to
smother small fires, preventing them from turning into infernos. Firetex is famous
It is equally important to set up a safe workspace. The table or platform you are
fireproof material. Often sparks from welding fall on the ground; thus it is
imperative to clear the workshop floor of any flammable substances such as grease
and oil.
Clasp the metal pieces to be joined until they are welded. You could make use of
An arc is established by touching the workpiece with the electrode for a few
seconds and lifting it back. When the electrode is in contact with the metal
workpieces, the electric circuit gets completed, producing heat which melts and
While welding, it is good practice to keep the rods tilted at an angle of ten degrees
or twenty degrees from the vertical. The rod motion should be such that it traverses
a straight line. Arc length, which is defined as the distance of the electrode from
the pool of weld, must be kept neither too small, nor too long. The characteristic to
look for in the perfect arc length is that it would cover up a large portion of the
light emanating from the weld and keep the rod from being shoved into the slag
molten consumable electrode and molten base metal, a bead formation is said to
have taken place. For getting a bead of the envisaged shape, it is best practice to
Clearing your weld of any slag will help you examine it better for any defects and
faults that may have happened whilst welding; an angle grinder can be used to
perform the job. Painting your newly welded workpiece will ensure it has a longer,
corrosion-free life.
3.3 Gas metal arc welding (GMAW
Gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, is
an electrode and an inert or semi-inert gas mixture to protect the weld from
contamination. Since the electrode is continuous, welding speeds are greater for
GMAW than for SMAW. However, because of the additional equipment, the
process is less portable and versatile, but still useful for industrial applications. The
process can be applied to a wide variety of metals, both ferrous and non-ferrous. A
related process, flux-cored arc welding (FCAW), uses similar equipment but uses
wire consisting of a steel electrode surrounding a powder fill material. This cored
wire is more expensive than the standard solid wire and can generate fumes and/or
slag, but it permits higher welding speed and greater metal penetration.
3.4 Gas tungsten arc welding
Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, is a
inert or semi-inert gas mixture, and a separate filler material. Especially useful for
welding thin materials, this method is characterized by a stable arc and high quality
welds, but it requires significant operator skill and can only be accomplished at
relatively low speeds. It can be used on nearly all weldable metals, though it is
most often applied to stainless steel and light metals. It is often used when quality
welds are extremely important, such as in bicycle, aircraft and naval applications.
A related process, plasma arc welding, also uses a tungsten electrode but uses
plasma gas to make the arc. The arc is more concentrated than the GTAW arc,
making transverse control more critical and thus generally restricting the technique
to a mechanized process. Because of its stable current, the method can be used on a
wider range of material thicknesses than can the GTAW process, and furthermore,
it is much faster. It can be applied to all of the same materials as GTAW except
cutting process.
arc is struck beneath a covering layer of flux. This increases arc quality, since
contaminants in the atmosphere are blocked by the flux. The slag that forms on the
weld generally comes off by itself, and combined with the use of a continuous wire
feed, the weld deposition rate is high. Working conditions are much improved over
other arc welding processes, since the flux hides the arc and no smoke is produced.
The process is commonly used in industry, especially for large products. Other arc
oxyacetylene welding. It is one of the oldest and most versatile welding processes,
but in recent years it has become less popular in industrial applications. It is still
widely used for welding pipes and tubes, as well as repair work. The equipment is
The flame, since it is less concentrated than an electric arc, causes slower weld
cooling, which can lead to greater residual stresses and weld distortion, though it
eases the welding of high alloy steels. A similar process, generally called oxyfuel
cutting, is used to cut metals. Other gas welding methods, such as air acetylene
welding, oxygen hydrogen welding, and pressure gas welding are quite similar,
generally differing only in the type of gases used. A water torch is sometimes used
for precision welding of items such as jewelry. Gas welding is also used in plastic
welding, though the heated substance is air, and the temperatures are much lower.
Resistance welding involves the generation of heat by passing current through the
resistance caused by the contact between two or more metal surfaces. Small pools
of molten metal are formed at the weld area as high current (1000–100,000 A) is
passed through the metal. In general, resistance welding methods are efficient and
cause little pollution, but their applications are somewhat limited and the
the metal sheets together and to pass current through the sheets. The advantages of
the method include efficient energy use, limited workpiece deformation, high
production rates, easy automation, and no required filler materials. Weld strength
is significantly lower than with other welding methods, making the process
process, called shot welding, can be used to spot weld stainless steel.
Like spot welding, seam welding relies on two electrodes to apply pressure and
electrodes roll along and often feed the workpiece, making it possible to make long
continuous welds. In the past, this process was used in the manufacture of beverage
cans, but now its uses are more limited. Other resistance welding methods include
welding, are relatively new processes that have become quite popular in high
production applications. The two processes are quite similar, differing most
notably in their source of power. Laser beam welding employs a highly focused
laser beam, while electron beam welding is done in a vacuum and uses an electron
beam. Both have a very high energy density, making deep weld penetration
possible and minimizing the size of the weld area. Both processes are extremely
fast, and are easily automated, making them highly productive. The primary
disadvantages are their very high equipment costs (though these are decreasing)
hybrid welding, which uses principles from both laser beam welding and arc
Like the first welding process, forge welding, some modern welding methods do
not involve the melting of the materials being joined. One of the most popular,
thermoplastic by vibrating them at high frequency and under high pressure. The
equipment and methods involved are similar to that of resistance welding, but
instead of electric current, vibration provides energy input. Welding metals with
this process does not involve melting the materials; instead, the weld is formed by
introducing mechanical vibrations horizontally under pressure. When welding
plastics, the materials should have similar melting temperatures, and the vibrations
pushing them together under extremely high pressure. The energy from the impact
plasticizes the materials, forming a weld, even though only a limited amount of
heat is generated. The process is commonly used for welding dissimilar materials,
such as the welding of aluminum with steel in ship hulls or compound plates. Other
welding, friction welding (including friction stir welding), high frequency welding,
3.10.1 Geometry
Common welding joint types – (1) Square butt joint, (2) Single-V preparation joint,
Welds can be geometrically prepared in many different ways. The five basic types
of weld joints are the butt joint, lap joint, corner joint, edge joint, and T-joint.
characterized by the two pieces of material each tapering to a single center point at
one-half their height. Single-U and double-U preparation joints are also fairly
preparation joints, they are curved, forming the shape of a U. Lap joints are also
commonly more than two pieces thick—depending on the process used and the
thickness of the material, many pieces can be welded together in a lap joint
geometry.
Often, particular joint designs are used exclusively or almost exclusively by certain
welding processes. For example, resistance spot welding, laser beam welding, and
electron beam welding are most frequently performed on lap joints. However,
some welding methods, like shielded metal arc welding, are extremely versatile
and can weld virtually any type of joint. Additionally, some processes can be used
to make multipass welds, in which one weld is allowed to cool, and then another
weld is performed on top of it. This allows for the welding of thick sections
After welding, a number of distinct regions can be identified in the weld area. The
weld itself is called the fusion zone—more specifically, it is where the filler metal
was laid during the welding process. The properties of the fusion zone depend
primarily on the filler metal used, and its compatibility with the base materials. It is
surrounded by the heat-affected zone, the area that had its microstructure and
properties altered by the weld. These properties depend on the base material’s
behavior when subjected to heat. The metal in this area is often weaker than both
the base material and the fusion zone, and is also where residual stresses are found.
3.10.2 Quality
Most often, the major metric used for judging the quality of a weld is its strength
and the strength of the material around it. Many distinct factors influence this,
including the welding method, the amount and concentration of heat input, the base
material, the filler material, the flux material, the design of the joint, and the
interactions between all these factors. To test the quality of a weld, either
welds are defect-free, have acceptable levels of residual stresses and distortion, and
The effects of welding on the material surrounding the weld can be detrimental—
depending on the materials used and the heat input of the welding process used, the
HAZ can be of varying size and strength. The thermal diffusivity of the base
material plays a large role—if the diffusivity is high, the material cooling rate is
high and the HAZ is relatively small. Conversely, a low diffusivity leads to slower
cooling and a larger HAZ. The amount of heat injected by the welding process
plays an important role as well, as processes like oxyacetylene welding have an
unconcentrated heat input and increase the size of the HAZ. Processes like laser
small HAZ. Arc welding falls between these two extremes, with the individual
processes varying somewhat in heat input. To calculate the heat input for arc
Where Q = heat input (kJ/mm), V = voltage (V), I = current (A), and S = welding
speed (mm/min). The efficiency is dependent on the welding process used, with
shielded metal arc welding having a value of 0.75, gas metal arc welding and
submerged arc welding, 0.9, and gas tungsten arc welding, 0.8.
Welding methods that involve the melting of metal at the site of the joint
necessarily are prone to shrinkage as the heated metal cools. Shrinkage, in turn,
can introduce residual stresses and both longitudinal and rotational distortion.
Distortion can pose a major problem, since the final product is not the desired
shape. To alleviate rotational distortion, the workpieces can be offset, so that the
such as clamping the workpieces in place, cause the buildup of residual stress in
the heat-affected zone of the base material. These stresses can reduce the strength
of the base material, and can lead to catastrophic failure through cold cracking, as
in the case of several of the Liberty ships. Cold cracking is limited to steels, and is
associated with the formation of martensite as the weld cools. The cracking occurs
in the heat-affected zone of the base material. To reduce the amount of distortion
and residual stresses, the amount of heat input should be limited, and the welding
sequence used should not be from one end directly to the other, but rather in
segments. The other type of cracking, hot cracking or solidification cracking, can
occur in all metals, and happens in the fusion zone of a weld. To diminish the
3.10.4 Weldability
The quality of a weld is also dependent on the combination of materials used for
the base material and the filler material. Not all metals are suitable for welding,
and not all filler metals work well with acceptable base materials.
3.10.5 Steels
hardenability of the steel, which measures the ease of forming martensite during
with greater quantities of carbon and other alloying elements resulting in a higher
hardenability and thus a lower weldability. In order to be able to judge alloys made
chromium and vanadium, while not as great as carbon, is more significant than that
of copper and nickel, for example. As the equivalent carbon content rises, the
weldability of the alloy decreases. The disadvantage to using plain carbon and low-
and weldability. High strength, low-alloy steels were developed especially for
welding applications during the 1970s, and these generally easy to weld materials
have good strength, making them ideal for many welding applications.
Stainless steels, because of their high chromium content, tend to behave differently
with respect to weldability than other steels. Austenitic grades of stainless steels
tend to be the most weldable, but they are especially susceptible to distortion due
to their high coefficient of thermal expansion. Some alloys of this type are prone to
cracking and reduced corrosion resistance as well. Hot cracking is possible if the
electrode is used that deposits a weld metal containing a small amount of ferrite.
Other types of stainless steels, such as ferritic and martensitic stainless steels, are
not as easily welded, and must often be preheated and welded with special
electrodes.
practice. However, with the use of new technology and proper protection, the risks
of injury and death associated with welding can be greatly reduced. Because many
common welding procedures involve an open electric arc or flame, the risk of
burns is significant. To prevent them, welders wear protective clothing in the form
of heavy leather gloves and protective long sleeve jackets to avoid exposure to
extreme heat and flames. Additionally, the brightness of the weld area leads to a
condition called arc eye in which ultraviolet light causes the inflammation of the
cornea and can burn the retinas of the eyes. Goggles and helmets with dark face
plates are worn to prevent this exposure, and in recent years, new helmet models
have been produced that feature a face plate that self-darkens upon exposure to
often surround the welding area. These curtains, made of a polyvinyl chloride
plastic film, shield nearby workers from exposure to the UV light from the electric
arc, but should not be used to replace the filter glass used in helmets.
Welders are also often exposed to dangerous gases and particulate matter.
Processes like flux-cored arc welding and shielded metal arc welding produce
smoke containing particles of various types of oxides, which in some cases can
lead to medical conditions like metal fume fever. The size of the particles in
question tends to influence the toxicity of the fumes, with smaller particles
presenting a greater danger. Additionally, many processes produce fumes and
various gases, most commonly carbon dioxide and ozone, that can prove dangerous
flames in many welding processes pose an explosion and fire risk, some common
precautions include limiting the amount of oxygen in the air and keeping
CHAPTER FOUR
During my Industrial training I acquired new skills in different skill such as:
4. Tool maintenance
Safety (HSE) Skills: this include how to use a fire extinguisher, where a formal
such system, it is recommended that a responsible person should know what work
hazards.
Piping fabrication and Installation skills: I can now tack weld, bolt flange Joint,
Project management and Supervision Skills: The main function of the project
makes sure that things happen on time and keeping the project on schedule.
limited to tools such as grinding machine welding machine cutting machine etc. To
maintain proper working condition of tools, Good House Keeping is required by:
b. I also faced a major challenge in transporting myself to and fro office, I had
to travel over eighty kilometers and beat heavy gridlock which was stressful
but I was supported by the company which lessen the financial problem.
c. I was forced to stop work during the pandemic lockdown and I was home for
Six months.
CHAPTER FIVE
5.1 Conclusion
Integrated Services Ltd where I engaged in industrial activities that help shape my
industrial work environment, acquired both working and professional ethics and
socialization.
Integrated Services Ltd is the best place for industrial training, especially for
realized that I learnt lot new things that one would never be able to learn at our
Testing and bubble leakage testing of threaded joints and commissioning of piping
5.2 Recommendation
of the workshop practices courses where student will be allowed to use all