Lab Report No.

Welding (Lab Work)

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Welding and Joining Processes Lab

Group#6
Muhammad Luqman Hashmi
Awais Ahmad
Muhammad Razwan
Mr. Bilal Ghafoor
19-03-2014

Welding:
Welding is process of joining similar metals by
application of heat with or without application of
pressure and addition of filler material. Modern methods
of welding may be classified under two broad
categories.
Pressure Welding
Fusion or non-fusion welding
Figure 1: Process of welding

Pressure Welding:
In pressure welding process the pieces of metals to be joined are heated to plastic
state and then forced together by external pressure by hammering, rolling or
pressing to effect the weld. It includes following types of welding.
Forge Welding
Resistance Welding
Thermit Welding

Fusion Welding:
In the fusion welding process the material at the joint is heated to fusion
temperature and a filler metal is added externally. The weld is the allowed to cool
down. Following types of welding come under fusion welding:

Electric Arc Welding

Electric Resistance Welding
Gas Welding
Induction Welding

Gas Welding:
Gas welding (commonly called oxyacetylene welding or oxy welding,) and oxyfuel cutting are processes that use fuel gases and oxygen to weld and cut metals,
respectively. Pure oxygen, instead of air, is used to increase the flame temperature

to allow localized melting of the workpiece material (e.g. steel) in a room

environment. A common propane/air flame burns at about 2,000 C (3,630 F), a
propane/oxygen flame burns at about 2,500 C (4,530 F), and an
acetylene/oxygen flame burns at about 3,500 C (6,330 F).
Oxy-fuel is one of the oldest welding processes, besides forge welding. Still used
in industry, in recent decades it has been less widely utilized in industrial
applications as other specifically devised technologies have been adopted. It is still
widely used for welding pipes and tubes, as well as repair work. It is also
frequently well-suited, and favored, for fabricating some types of metal-based
artwork.
In oxy-fuel welding, a welding torch is used to weld metals. Welding of metal
results when two pieces are heated to a temperature that produces a shared pool of
molten metal. The molten pool is generally supplied with additional metal called
filler. Filler material depends upon the metals to be welded.
In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A
stream of oxygen is then trained on the metal, burning it into a metal oxide that
flows out of the kerf as slag.
Types of Flame:
The welder can adjust the oxy-acetylene flame to be carbonizing (aka reducing),
neutral, or oxidizing. Adjustment is made by adding more or less oxygen to the
acetylene flame. The neutral flame is the flame most generally used when welding
or cutting.

Types of Welds:
Bead type: These are used for making edge joints in thin materials.
Fillet Type: These are used for tee, lap and corner joints.
Groove Type: V, U and J type grooves are made to join two pieces of
metals.
Plug Type: These are used to connect two parts by welding through a round
hole or a slot in either one of the parts.

Figure 2: Bead weld, fillet weld and groove weld (types of welds)

Figure 3: Plug Weld (type of weld)

Types of Welded Joints:

Following are different types of welded joints:

Butt Joint
Lap Joint
Edge Joint
Corner Joint
Tee Joint
Plug Joint

Lap and butt joints are most commonly used in resistance welding, gas welding
and electric arc welding.

Figure 4: Types of welded joints

Lab Work:
In previous two labs following tasks were practiced:
1) The bead weld was deposited over the thin sheet of iron metal through gas
welding. The neutral flame was used by adjusting 1:1 ratio of acetylene and
oxygen. First of all, a puddle was made by flame over the substrate metal.
The angle of the filler rod with the base metal was kept low. Bead formation

was started from the puddle. Forward movement of the filler rod and the
flame with intermediate speed resulted in the formation of beads along the
straight line.
2) The cutting of metal sheet by using gas welding. The oxidizing flame was
used by increasing amount of oxygen.

Figure 5: Bead welds, practice by students

Precautions:

Use gloves and glasses for welding

Clean the surface of metal before welding
Angle of filler rod with the substrate metal should be small
Inner core of the flame should not touch the substrate metal
Movement of the filler rod and flame neither should be too fast nor too slow