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APPLIED WELDING
ENGINEERING
LAB GUIDELINE
Prepared by:
prof
SMAW GTAW
PLATE 1 PLATE 2
D A D Pulsed TIG A D
C C C C C
R S S
P P P
1. Observe performance
2. Cut, polish, etch, observe, and redraw the macrostructure of the weld bead i.e. WM & HAZ.
3. Measure the depth of weld penetration due to polarity changes both in SMAW & GTAW.
4. Analyze & make comparison within SMAW, GTAW, and between SMAW & GTAW.
5. Discuss the findings.
6. Conclude the experiment.
Experiment 2
Title: Effect of different welding processes on hardness and depth of weld penetrations in GMAW
(MIG & MAG) & FCAW (shielded & unshielded)
GMAW FCAW
M M Shielded Unshielded
I A
G G
Weld on Plate
Same current
1. Observe performance
2. Cut, polish, etch, observe, and redraw the macrostructure of the weld bead i.e. WM & HAZ.
3. Measure the depth of weld penetration due to changes in welding process both is GMAW & FCAW.
4. Measure the hardness on WM, HAZ and BM using Vickers method at points shown below.
B H W H B
M A M A M
Z Z
Title: Study the system operation and performance for SAW, SPOT/SEAM, & Friction welding.
SAW
1. Prepare 2 similar plates.
2. Weigh both plates
3. Run SAW on plate 1 using DCRP, record current and weld travel speed.
4. Run SAW on plate 2 using DCSP, use same current & weld speed as plate 1
5. Observe performance.
6. Analyze and make comparison in performance.
7. Calculate the Rate of Deposition in both polarities.
8. Analyze & make comparison in Rate of Deposition
9. Discuss the findings.
10. Conclude the experiment.
Plate 1 Plate 2
DCRP DCSP
Weld On Plate
Metal rod
Plasma Cutting
1. Draw the system operation in Air arc gouging & describe briefly.
2. What is the difference between gouging and cutting?
3. When Air Arc gouging applied.
4. Describe the correct procedure in Air Arc Gouging
5. Do Air Arc gouging in DCRP & DCSP, compare & analyze their performance.
Experiment 5
Title: Destructive Tests - Bend Test & Nick Break Test / Fracture Test to evaluate quality of weld on
Butt & Fillet welds.
Preparation
Weld face Ground flush
X 2 plates
FBT
RBT
Nick Break Test (NBT) for Butt Weld
Throat
Leg length
Saw cut,
Title : Destructive Test - Strength Test & Toughness Test to evaluate quality of weld for Butt Welded Joint
R W R
B G C
A A
L = Length of Specimen
2. Configure the test specimen above in detail as according to the selected applicable standard.
W = Weld width
D = Reduced section
A = Straight portion
R = Radius
G = Gauge Length
T = Thickness of plate
1. Get sample of standard such as ASTM or BS to be used as reference to prepare specimen for Charpy
Impact Test.
1. Configure in detail the above specimen for Charpy Impact Test as according to the requirement of the
applicable standard.
2. Do Charpy Impact Test and record the impact toughness value (I charpy)
Toughness Test : Izod Test
1. Get sample of standard such as ASTM or BS to be used as reference to prepare specimen for Izod
Test.
W S
2. Configure in detail the above specimen for Izod Test as according to the requirement of the applicable
standard code.
3. Do Izod test & record the impact toughness value (Iizod)
General Question
Base metal
Grind/machine
flat for spectrometer test
4. On carbon steel
I. Obtain the composition of BM
II. Obtain the composition on WM
III. Calculate the Carbon Equivalent (CE) of Base Metal and give meaning.
IV. Compare the composition on Weld Metal (WM) with the composition found on Base Metal
(BM) and give meaning.
5. On AL/SS
I. Find the composition of both Base Metal and Weld Metal and give comment
II. Which category the AL belongs?
III. Which category the SS belongs?