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APPLIED WELDING
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Experiment 1
SMAW
PLATE 1
GTAW
PLATE 2
Cut 1 for Group 1
Cut 2 for Group 2
Cut 3 for Group 3
Cut 4 for Group 4
Cut 5 for Group 5
Cut 6 for Group 6
D
C
R
P
A
C
D
C
S
P
Pulsed TIG
A
C
Weld on plate
Weld on plate
Same current
Same current
D
C
S
P
Instruction to students:
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
M
I
G
M
A
G
FCAW
Shielded
Unshielded
Weld on Plate
Same current
Same weld travel speed
Instruction to students:
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.
MIG
MAG
Unshielded
B H W H B
M A M A M
Z
Z
Shielded
FCAW
Experiment 3
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
SEAM welded
Metal rod
Experiment 4
Title: Study the Science and System operation of thermal cutting using Gas Cutting, Plasma Cutting, and Air
Arc Gouging process.
Plasma Cutting
1. How plasma is produced in Plasma Cutting Process.
2. Draw the system operation in Plasma Cutting and describe briefly.
3. Which type of Arc (Transferred Arc or Non Transferred Arc) suitable for Plasma Cutting?
4. Do plasma cutting in AL & SS.
5. What contributes to quality cuts?
6. What metals normally cut by Plasma Cutting.
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
Weld root
Ground flush
40mm
Weld Face
FBT
RBT
T-Joint
Leg length
Leg length
Direction to cause fracture
Saw cut,
depth 1.5 -2.0 mm
General Question
Experiment 6
Title : Destructive Test - Strength Test & Toughness Test to evaluate quality of weld for Butt Welded Joint
Strength Test : Tensile Strength Test
1. Get sample of standard such as ASTM or BS to be used as reference to prepare specimen for Tensile
Strength Test.
R
D
C
D
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
L = Length of specimen (to suit machine)
B = Width of specimen (to suit machine)
C = Traverse length of weld
G = Gauge Length
T = Thickness of plate
W
D
L
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)
T
L
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
1. When do we need to do Charpy Impact Test or Izod Test?
2. Give the meaning of the impact toughness values obtained in both cases.
Experiment 7
Carbon steel
AL/SS
Weld padding (WM)
Base metal
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?