INTRODUCTION

Arc welding is a type of welding that uses a welding power supply to create and
electric arc between an electrode and the base material to melt the metals at the welding
point. They can use either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes. The welding region is usually protected by some type of shielding
gas, vapor, or slag. Are welding processes may ne manual, semi-automatic, or fully
automated. First developed in the late part of the 19th century, are welding because became
commercially important in shipbuilding during the Second World War. Today it remains
an important process for the fabrication of steel structures and vehicles. Arc welding is one
of the alternatives for joining process in manufacturing. Arc welding process had done by
create an electric arc between electrode and the base material to melt the metal at the
welding point using welding power supply. The welding region is sometimes protected by
some type of inert or semi-inert gas, known as a shielding gas and sometime adds by an
evaporating filler material. Shielded metal arc welding (SMAW), also known as manual
metal arc (MMA) welding or informally as stick welding, is a manual arc welding process
that uses a consumable electrode coated in flux to lay the weld. They can use either direct
current (DC) or alternating current (AC) from a welding power supply, used to form an
electric arc between the electrode and the metal to be joined. As the weld is laid, the flux
coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and
providing a layer of slag, both of which protect the weld area from atmospheric
contamination. Gas metal arc welding (GMAW), sometimes referred to by its sub types
metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or
automatic arc welding process in which a continuous and consumable wire electrode and a
shielding gas are fed through a welding gun. A constant voltage, direct current power
source is mist commonly used with GMAW, but constant current systems, as well as
alternating current, can be used. There are four primary methods of metal transfer in
GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which.

OBJECTIVES
 1. To know main function of welding.
2. Learn the basic techniques of welding.
3. Give a real-life experience of metal arc welding to engineering students.

THEORY

Arc welding is one of several fusion processes for joining metals. By applying
intense heat, metal at the joint between two parts is melted and caused to intermix - directly,
or more commonly, with an intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created. Since the joining is an intermixture of
metals, the final weldment potentially has the same strength properties as the metal of the
parts. This is in sharp contrast to non-fusion processes of joining (i.e. soldering, brazing
etc.) in which the mechanical and physical properties of the base materials cannot be
duplicated at the joint.

Fig. 1 The basic arc-welding circuit

In arc welding, the intense heat needed to melt metal is produced by an electric arc. The
arc is formed between the actual work and an electrode (stick or wire) that is manually or
mechanically guided along the joint. The electrode can either be a rod with the purpose of
simply carrying the current between the tip and the work. Or, it may be a specially prepared
rod or wire that not only conducts the current but also melts and supplies filler metal to the
joint. Most welding in the manufacture of steel products uses the second type of electrode.
 The basic arc-welding circuit is illustrated in Fig. 1. An AC or DC power source,
fitted with whatever controls may be needed, is connected by a work cable to the workpiece
and by a "hot" cable to an electrode holder of some type, which makes an electrical contact
with the welding electrode. An arc is created across the gap when the energized circuit and
the electrode tip touches the workpiece and is withdrawn, yet still with in close contact.
The arc produces a temperature of about 6500ºF at the tip. This heat melts both the base
metal and the electrode, producing a pool of molten metal sometimes called a "crater." The
crater solidifies behind the electrode as it is moved along the joint. The result is a fusion
bond.

However, joining metals requires more than moving an electrode along a joint.
Metals at high temperatures tend to react chemically with elements in the air - oxygen and
nitrogen. When metal in the molten pool comes into contact with air, oxides and nitrides
form which destroy the strength and toughness of the weld joint. Therefore, many arc-
welding processes provide some means of covering the arc and the molten pool with a
protective shield of gas, vapor, or slag. This is called arc shielding. This shielding prevents
or minimizes contact of the molten metal with air. Shielding also may improve the weld.
An example is a granular flux, which actually adds deoxidizers to the weld.

Fig. 2 This shows how the coating on a

coated (stick) electrode provides a gaseous
shield around the arc and a slag covering on
the hot weld deposit.
APPARATUS

APPARATUS
NO. DESCRIPTION

1. Arc Welding Machine It is a type of welding that uses a welding

power supply to create and electric arc
between a metal stick (electrode) and the
base material to melt the metals at the point
of contact.

2. Face Shield It is made from inflammable material. In

the middle of the shield there is a bright
rectangular glass coated with dark colored
glass. It is used to protect the user from
fire-bolt and harmful rays during welding
work. There are two types of shield, one is
the helmet type and the other one is the
hand-held type.

4. Leather Hand Gloves It made from high quality leather. Use to

protect your hand from fire bolt and hot
metal welding.
5. Plier Used for hold hot workpiece

6. Chipping Hammer It is made from and old punch. Chisel or

spring metal. Shape like a chisel at one and
has a sharpened end at the other one. Its
holder is made from welded soft metal. It
is used commonly to remove the slag
excess stringer from the surface of the
work metal.

7. Wire Brush Used to clean the surface of the stringer

bed after the slag is chipped away and to
remove dirt from the surface of metal work
before welding can be done.
 8. Apron To protect the body from the spark and
flame that produce while welding process.

PROCEDURE

1. Prepare two pieces of mild steel plates 3.0mm thick.

2. Clean the surface of both plates with wire brush.
3. Use an electrode code MS6013 or E6013 with diameter 2.6mm or 3.2mm.
4. Adjust the ampere around 60-100 for electrode diameter 2.6mm.
5. Put an electrode at the electrode holder and make sure that there are no movement of
electrode at the holder.
6. Hold the electrode 70 or 80 degrees work angle and 2mm-3mm above the base metal.
7. Make tack weld on both sides to prevent the plates from bending during the welding process
occur.
8. Scratch the front end of the electrode onto the work metal to start the burning. After the
electrode has started burning, hold it at 3mm above the work metal. Try to avoid the
electrode from being in contact with the surface of work because the electrode might be
stick onto the workpiece.
9. Welding then proceeds from left to right (for the right hand).
10. Stop the process at the end of the work piece.
11. The correct technique is holding an electrode at the start position for 1s or 2s and continue
until the end of the process.
12. The frequency of this action will be determined by the size of the weld being deposited, and
the correct action improve with practice.
13. When finish the welding process, use the chipping hammer to chipped off the slag and brush
it off using a wire brush.

RESULT

Fig. 3 The result of arc welding

DISCUSSION

There are some problems that happened in arc welding process. The first problem
that happened in arc welding process is the thicknesses of arc line on mild steel plate. We
can overcome it such as we can improve our skill with reduce the movement of speed when
doing arc welding. Second problem is the work of arc welding is not good enough. It may
cause from the wrong angle and wrong position on plate when doing welding. This problem
can be solved if we use 70-80 angle and at least 3mm between electrode and plate when
welding. After we make some work of welding, we can know the main factor why the work
in our welding is not too good. The main factor is lack of skill from student. So that we
need to improve ourselves by do the weld properly and use the right method in welding.

CONCLUSION

In conclusion, we can conclude that welding is an important thing that can apply in
manufacturing and construction. Arc welding is capable of welding the thickest kinds of
metal such as cold rolled steel. Oxygen and acetylene are used for thinner metals. It’s good
to apply this welding knowledge to everyone to produce more skillful welder in this
country.

REFERENCES

1. The Lincoln Electric Company (2001). Arc Welding Fundamentals. Retrieved from
https://www.lincolnelectric.com/en-us/support/process-and-theory/Pages/arc-
welding-detail.aspx
2. Raymond J. and Edward R. (2004). Welding Principles & Practices. McGraw-Hill
Higher Education; 3 editions.
3. Griffin, Ivan H. (1984). Basic Arc Welding. Delmar Cengage Learning; 4 editions.