Acknowledgement

We express our deep gratitude to Mr. RAJINDER SINGH for helping us all through the project. The project was impossible without his help. It was only under his able guidance that we learnt the minutest of the techniques. He guided us with patience and we tried our best to learn maximum from him. He led us through different ways of doing things to achieve best quality job. We are very grateful to work under his able supervision. We thank him for urging us to constantly work with dedication. We thank Mr. MALKIAT SINGH and Mr. GURNAAM SINGH as our Assistant Mentors for their guidance, support and always keeping the work environment lively.

We also thank the Superintendant, Mr. RAJESH KANDA and the Lab Foreman, Mr. HARBANS LAL for giving us the opportunity to do this project and being the source of encouragement and support. We are now aware of the different workshops, tools and processes. We appreciate the idea of summer workshops very deeply. These workshops are highly important for forging good quality engineers. It has been a wonderful experience. Thank You.

OUR GROUP
S.NO 1 2 3 4 5 6 NAME EESHAANEE ARYA KAMALPREET KAUR JASMEET KAUR TARUN GOYAL MANCHITWAN JAUHAL SIDDHARTH THAKKAR ROLL NO. 09102012 09102019 09102017 09107058 09107057 09107072

introduction
Welding is the most common way of permanently joining
metal parts. In this process, heat is applied to metal pieces, melting and fusing them to form a permanent bond. Because of its strength, welding is used in shipbuilding, automobile manufacturing and repair, aerospace applications, and thousands of other manufacturing activities. Welding also is used to join beams in the construction of buildings, bridges, and other structures and to join pipes in pipelines, power plants, and refineries. Welders may work in a wide variety of industries, from car racing to manufacturing. The work done in the different industries and the equipment used may vary greatly. The most common and simplest type of welding today is arc welding, which uses electrical currents to create heat and bond metals together, but there are over 100 different processes that a welder can employ. The type of weld used is normally determined by the types of metals being joined and the conditions under which the welding is to take place. Steel, for instance, can be welded more easily than titanium. Some of these processes involve manually using a rod and heat to join metals, while others are semiautomatic, with a welding machine feeding wire to bond materials. Automated welding, done completely by robots, is increasingly being used in the manufacturing industry

History of welding
The growth of welding during the last century is outstanding and today welding is one of the most important and reliable tool in the Production Technology. Welding Processes are universally used for Air Crafts, Missiles and rocket fabrication. Today 3erlding is advancing towards new metals and alloys to meet the need of Space Technology, Nuclear Devices and under water operations.

What is welding?
Welding is a fabrication or sculpture process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with Soldering and Brazing, which involve melting a lowermelting-point material 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 industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, however, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.

List of welding processes

There are many different types of welding that you can use to join materials together. Arc welding Oxyfuel welding Resistance welding Energy beam welding Solid state welding

Arc welding
These 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 current (DC) or alternating current (AC) current, and consumable or non-consumable electrode. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and filler material is sometimes used as well.

WELDING MACHINES
1. Welding transformer: it is a special kind of power transmission with a very low voltage and a very high current on the output side. 2. Welding generator: It is a low voltage, high current DC generator. It is used for arc welding. An IC engine or an induction motor is used as a prime mover to run this generator. 3. Rectifier: It is a device to convert an AC to DC to be used for arc welding.

Types of arc welding

smaw(shielded metal arc welding)
One of the most common types of arc welding is SHIELDED METAL ARC WELDING (SMAW), which is also known as MANUAL METAL ARC WELDING (MMA) or stick welding.

Electric current is used to strike an arc between the base material and consumable electrode rod, which is made of steel and is covered with a flux that protects the weld area from oxidation and contamination by producing carbon dioxide gas during the welding process. The electrode core itself acts as filler material, making a separate filler unnecessary.

Gas metal arc welding

GAS METAL ARC WELDING (GMAW), also known as metal inert gas or MIG welding, is a semi-automatic or automatic process that uses a continuous wire feed as an electrode and an inert or semi-inert gas mixture to protect the weld from contamination. As with SMAW, reasonable operator proficiency can be achieved with modest training. Since the electrode is continuous, welding speeds are greater for GMAW than for SMAW. Also, the smaller arc size compared to the shielded metal arc welding process makes it easier

to make out-of-position welds (e.g., overhead joints, as would be welded underneath a structure).

The equipment required to perform the GMAW process is more complex and expensive than that required for SMAW, and requires a more complex setup procedure. Therefore, GMAW is less portable and versatile, and due to the use of a separate shielding gas, is not particularly suitable for outdoor work. However, owing to the higher average rate at which welds can be completed, GMAW is well suited to production welding. The process can be applied to a wide variety of metals, both ferrous and non-ferrous.

Gas tungsten arc welding

GAS TUNGSTEN ARC WELDING (GTAW), or tungsten inert gas (TIG) welding (also sometimes erroneously referred to as heliarc welding), is a manual welding process that uses a nonconsumable tungsten electrode, an 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. GTAW 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 bicycles, aircraft and naval applications

Submerged arc welding

SUBMERGED ARC WELDING (SAW) is a high-productivity welding method in which the 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 almost no smoke is produced. The process is commonly used in industry, especially for large products and in the manufacture of welded pressure vessels.

Other arc welding processes

ATOMIC HYDROGEN WELDING CARBON ARC WELDING

ELECTROSLAG WELDING

ELECTROGAS WELDING

 STUD ARC WELDING

OXYFUEL GAS WELDING

The most common gas welding process is OXY FUEL WELDING, also known as 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. It is also frequently wellsuited, and favored, for fabricating some types of metalbased artwork. Oxyfuel equipment is versatile not only because it is preferred for some sorts of iron or steel welding but also because it lends itself to brazing, brazewelding, metal heating (for bending and forming), the loosening of corroded nuts and bolts, and also is the ubiquitous means for oxy-fuel cutting of ferrous metals.

The equipment is relatively inexpensive and simple, generally employing the combustion of acetylene in oxygen to produce a welding flame temperature of about 3100 C. 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 small 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
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 (1000100,000 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 equipment cost can be high. SPOT WELDING is a popular resistance welding meused to join overlapping metal sheets of up to 3 mm thick. Two electrodes are simultaneously used to clamp 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.

SPOT WELDING Like spot welding, SEAM WELDING relies on two electrodes to apply pressure and current to join metal sheets. However, instead of pointed electrodes, wheelshaped 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 FLASH WELDING, PROJECTION WELDING, and UPSET WELDING.

ENERGY BEAM
Energy beam welding methods, namely LASER WELDING and ELECTRON BEAM 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) and a susceptibility to thermal cracking. Developments in this area include Laser hybrid welding, which uses principles from both laser beam welding and arc welding for even better weld properties, and X-ray welding

Solid state welding

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, ULTRASONIC WELDING, is used to connect thin sheets or wires made of metal or 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 are introduced vertically. Ultrasonic welding is commonly used for making electrical connections out of aluminum or copper, and it is also a very common polymer welding process.

WELDING TOOLS
Hand screen Colored Glasses White Glasses

Pair of hand gloves of leather Apron of leather Wire brushes Cables of leads Chipping Screen on Chipping goggles Chipping hammer Files, Hammers, Tongs, Chisels etc. Electrode holder Earth clamp

WELDING ELECTRODES AND RANGE OF CURRENT

SWG NO 4 6 8 10 12 14 16 THICKNESS 6 mm 5 mm 4 mm 3.25 mm 2.5 mm 2 mm 1.5 mm CURRENT IN AMP 230-280 approx 180-220 approx 140-170 approx 100-130 approx 70-90 approx 50-60 approx 30-50 approx

TYPES OF JOINTS
Welded joints are primarily of two kinds a) Lap or fillet joint: obtained by overlapping the plates and welding their edges. The fillet joints may be single transverse fillet, double transverse fillet or parallel fillet joints. b) Butt joints: formed by placing the plates edge to edge and welding them. Grooves are sometimes cut (for thick plates) on the edges before welding. c)Corner joint . d)Edge or seal joint e)T-joint

APPLICATIONS
1. Production and Fabrication 2. Repair and maintenance

Faults in welding
1. 2. 3. 4. 5. 6. 7. 8. Incorrect penetration Lack of fusion Undercut Edge of a plate melted off. Over lapping Slag inclusion Porosity Crack in the weld

Safety issues
Welding, without the proper precautions, can be a dangerous and unhealthy practice. However, with the use of new technology and proper protection, 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 and fire is significant; this is why it is classified as a hot work process. To prevent them, welders wear personal protective equipment 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 inflammation of the cornea and can burn the retina of the eyes. Goggles and welding 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 high amounts of UV light. To protect bystanders, translucent welding curtains often surround the welding area.

(Arc welding with welding helmet ,gloves and other protective clothing)

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.

PROJECT WORK-BARRICADE

TOOLS USED
Hand screen Pair of hand gloves of leather Apron of leather Wire brushes Cables of leads Chipping Screen on Chipping goggles Chipping hammer Files, Hammers, Tongs, Chisels etc. Electrode holder Earth clamp

MATERIALS USED
M.S. Sheet (18 Gauge) M.S. Square pipe (1.5X 1.5X14 Gauge) M.S. Square Rod (1.25X1.25) Split pin (3/16) Hand hack-saw blade Rubber wheel (6X 2 X 1dia) M.S. Square rod (10 mm) M.S. Washer (1 dia) Amery paper (60 mm) White paint Red paint Turpentine oil Red oxide

DAILY DIARY
Day I (24 May 2010: Monday) Brief discussion about the workshop groups and the job to be undertaken was done. Four groups were divided to make the project, and timings were allotted to each group. Day II (25 May 2010: Tuesday) Today the job was actually started. Introduction about the project was given in detail. Dimensions of the actual barricade were taken. Sketches were drawn properly. Welding practice was done side by side.

WELDING MACHINE

Day III (26 May 2010: Wednesday) Welding practice was done side by side.

Dimensions were discussed.

Day IV (27 May 2010: Thursday) Cutting of the MS Square pipes (1.5inch X1.5inch X14G). Two rods were cut each of length 45 inch.

 Filing was also done where required.

Day V (28 May 2010: Friday) MS Square rods were cut on the cutting machine (power hack-saw). Two rods of 53 inch and 50 inch each were cut. MS Square pipes were also cut.

Power Hacksaw Machine Day VI (31 May 2010: Monday)

 3 MS Square pipes were tapered on cutting machine at 45Welding practice was done side by side.

Day VII (1 June 2010: Tuesday) Cylindrical turning operation of MS Square rods was done on lathe machine.

Day VIII (2 June 2010: Wednesday) Three sided frame was gas welded. Sheet was straightened. Focus was more on accurate measurements and intricate designing.

 Gas welding was explained by the instructor. Day IX (3 June 2010: Thursday) A square pipe was cut and welded with the frame to complete the four sided frame. Eight square rods (four of length 20 and four of 43) were cut and straightened.

Day X (4 June 2010: Friday) Four small square rods were welded on one side inside the frame.

Day XI (7 June 2010: Monday) Sheet was welded with the square rods and the frame. The square rods on the other side were also welded with the sheet and the frame.

Day XII (8 June 2010: Tuesday) The frame was welded with the cylindrically turned rods.

Washers were welded on the cylindrically turned rods.

Day XIII (9 June 2010: Wednesday)

A square pipe was cut with length 45 was cut and welded with the frame and in between the cylindrically turned rods.

Day XIV (10 June 2010: Thursday)

The wheels were filed and counter-bored so as to fit them in the cylindrically turned rods.

 Then washers were fitted on all four sides and split pins were fitted to fix the wheels.

Day XV (11 June 2010: Friday)

Two small square pipes were cut and welded in between two pipes to give sufficient support to the barricade. Four square pipes were also cut, tapered at both ends and welded in between the frame and the cylindrically turned rods to provide support.

Day XVI (14 June 2010: Monday)

 The rust (oxide layer) from the frame was removed with the help of sand paper.

Day XVII (15 June 2010: Tuesday)

Grinding and finishing operations were performed on the frame.

Day XVIII (16 June 2010: Wednesday) Primer was applied on the barricade.

Day XIX (17 June 2010: Thursday)

Two coats of white paint were applied on the barricade.

Day XX (18 June 2010: Friday The barricade is ready.