1 Experiment No.

8
Objective: To investigate the effects of varying voltage and current on MIG welded
specimen.

Apparatus:
 MIG welding Set-Up
 Work pieces of MS
 MS wire
 Personal Protective Equipment (PPE)

Theory:

Introduction:
Figure 1: MIG welding apparatus
Metal Inert Gas welding (MIG welding) is a type of Gas
Metal Arc welding in which the arc is produced between the workpiece and the consumable MIG
wire electrode which causes to melt the metal and to join them. Along with the wire electrode,
from the gun shielding gases also provided which protects the specimen from the atmosphere air.
This process can be Semi-automatic and may be fully automatic. This process provides a better
coalescence than the manual arc welding or stick welding and give a high strength joint. This
welding process was developed in 1940 for the welding of Ferrous and Non-ferrous metals.
Nowadays, MIG welding finds in every manufacturing and industries due to its high speed than
other welding processes, easily automated qualities and easy to operate.

MIG welding:
MIG/MAG welding is a versatile technique suitable for both thin sheet and thick section
components, as shown in Fig. An arc is struck between the end of a wire electrode and the
workpiece, melting both of them to form a weld pool. The wire serves as both heat source (via
the arc at the wire tip) and filler metal for the welding joint.

The wire is fed through a copper contact tube (contact tip) which conducts welding current into
the wire, as shown in Fig. The weld pool is protected from the surrounding atmosphere by a
shielding gas fed through a nozzle surrounding the wire. Shielding gas selection depends on the
material being welded and the application. The wire is fed from a reel by a motor drive, and the
welder moves the welding torch along the joint line. Wires may be solid or cored. A typical but
welded joint is shown in Fig.

Figure 2: MIG welding

Application of MIG Welding:

1. The automobile industry has a huge use of MIG welding.

2. Heavy constructions like bridges and building materials are welded using this process.
3. Pipe welding can be done efficiently with MIG. There are different types of welding
apparatus to weld the pipelines using MIG.
4. MIG welding, if incorporated with robotics can be used in amazing automotive repairs.
5. Before MIG, it was very difficult to weld automotive repairing parts.
6. Heavy, medium to light all types of automotive vehicles can be repaired with ease.
7. The weld is strong even if the thickness is limited to 0.5 mm.
8. Worn-out railways tracks are easily repaired with MIG.
9. Rebuilding is an important property of MIG that is used frequently.

Procedure:

 Firstly, we turn on the welding plant.

 Then we adjust the voltage and current according to the thickness of work piece and the
material of the work piece.
 After the adjustment we adjust the torch of the plant and the pressure of the gas.
 We bring the torch near the workpiece an arc is produced which generates heat at this
welded area and causes the coalescence of the metals.
Figure 3: MIG welded sample

Advantages:
1. Higher welding
2. Greater deposition rates.
3. Less post welding cleaning.
4. Better weld pool visibility.

Disadvantages:
1. Welded joints are more brittle and therefore their fatigue strength is less than the
members joined.
2. Due to uneven heating & cooling of the members during the welding, the members may
distort resulting in additional stresses.
3. Skilled labor are required for this kind o

Observation and Calculation:

Table 1 : Variable Voltage vs. Constant Current

Sr. No. Variable Voltage Constant Current

(15 to 40 volts)
1 17 60
2 19 99
3 22 120
6
7
Graph:

Variable Voltage vs. Constant Current

180

160

140

120

100

80

60

40

20

0
Variable Voltage Constant Current

Series 1 Series 2 Series 3

Comments:
This process is semi- automated.
This is very fast process than the other welding processes.
This causes the instance melting of the metal.
It is very easy process.
 2 Experiment No # 09

Objective:

Investigate the effects of varying voltage and current on TIG welded specimen.

Apparatus:
 TIG welding Set up
 Work pieces of MS
 MS filler Rod
 Tungsten Rod
 Personal Protective Equipment (PPE)

Theory:
2.1.1 TIG welding
Also known as Gas Tungsten Arc Welding (GTAW) is an arc welding process that produces the
weld with a non-consumable tungsten electrode, as shown in Figs. 1&2. Tungsten inert gas
(TIG) welding became an overnight success in the 1940s for joining magnesium and aluminum.
TIG welders can be used to weld steel, stainless steel, aluminum, nickel alloys, magnesium,
copper, brass, bronze, and even gold. TIG is a useful welding process for welding wagons, bike
frames, lawn mowers, door handles, fenders, and so on. A butt welded joint from TIG welding
process is shown in Fig. 12.

Figure 4: MIG Welded Samples

 Figure 5: Apparatus for TIG welding

Principle:
The TIG process uses the heat generated by an electric arc between the metals to be joined and
an infusible tungsten-based electrode, located in the welding torch. The arc area is shrouded in
an inert or reducing gas shield to protect the weld pool and the tungsten electrode.

Procedure:

1: It's working procedure is Same like TIG welding but different in using wire system.

2: In this we use a constant specific non consumable tip element and a consumable wire.

3: Set the work piece on process and make liquid by making with electrode holder.

4: In this welding the wire is also used and make fed into pour and dip.

5: Finally, we make the required joint on the work piece.

6: There two types of procedure used one in which wire is consumed and for other wire is not
consumed. It is according to meet requirements of the working.

7: We finally make the joint as shown in figure 13. a welded work piece sample.
Advantages:
 TIG welding uses non-consumable tungsten electrode.
 Filler metal, when required, is added by hand.
 Shielding gas, usually argon protects the weld and tungsten.
 Produces high quality and clean welds.
 Welds more metals than any other process.

Disadvantages:
o TIG is a time-consuming process. They are slower than any other welding process.
o Highly skilled and professional workers are needed to perform TIG welding.
o Welders are exposed to high intensity of light which can cause eye damage.
o High initial cost.

Applications:
 Aerospace
 Repairing
 Automotive

Results:
Table 2: Observations and Calculations for TIG welding process

Sr. Constant Voltage Variable Current

No.
(5 to 300 amp)
1
2
3
4
5
6
7
Figure 6: TIG welding sample

Graph:

Constant Voltage vs. Variable Current

160 60

140
50
120
40
100

80 30

60
20
40
10
20

0 0
Constant Voltage Variable Current

Volume Close
Comments:

 The discussion section serves as an opportunity to interpret the experimental results and
compare them with theoretical expectations. Referencing "Welding and Welding
Technology" by Richard L. Little, the discussion could delve into the factors influencing
TIG weld quality and the effects of varying voltage and current settings.
 Comparison with Theory: Evaluate how the observed weld quality correlates with
theoretical expectations based on the principles outlined in the reference book. Discuss
any deviations and potential reasons behind them, such as variations in material
composition or welding parameters.
 Optimization Strategies: Utilize insights from the reference material to propose
optimization strategies for enhancing TIG weld quality. This could involve adjusting
voltage, current, and shielding gas flow rates to achieve desired weld characteristics and
minimize defects.
 Applications: Discuss the practical implications of the experimental findings for real-
world welding applications. Consider how the insights gained from this experiment could
inform decision-making in industries such as aerospace, automotive, and repair, where
TIG welding is commonly utilized.
 By integrating these elements into the discussion, you can provide a comprehensive
analysis of the experimental results while drawing meaningful connections to established
welding principles and practices outlined in the reference material.

3 Experiment No. 10
Objective:
To investigate the effects of varying gas pressure on gas welded specimens.

Apparatus:
 Acetylene cylinder.
 Oxygen cylinder.
 Torch.
 Flux.
 Work piece.
 Filler material.
 Personal Protective Equipment (PPE)

Figure 7: Oxy fuel welding apparatus

Theory:

Introduction:
It is a type of welding in which heat is produced by burning the oxy-acetylene fuel along with the
correct proportion of the oxygen. This burning produces the flame whose temperature ranges
from 5500 to 5800oF which is enough temperature to melt any industrial metal and cause fusion
of two metal pieces and weld them together in such a way that the point of fusion come close to
the strength of base metal. We can also accomplish the cutting purpose with the gas welding by
increasing the supply of oxygen. For cutting we firstly, preheat the metal up to the melting point
at that temperature metal melt then high speed of the flame due to the high pressure of oxygen
from the cylinder causes the removal of the melted metal in this way cutting has been done.
Oxy fuel gas welding is a type of fusion welding process, as shown in Figure 1. Oxy fuel gas
welding refers to a group of welding processes that use, as their heat source, the flame produced
by the combustion of a fuel gas and oxygen.

The combustion of oxygen and acetylene (C2H2) by means of a welding torch produces a
temperature of about 5850oF in a two stage reaction [1].

In first stage, the oxygen and acetylene react to produce carbon monoxide and hydrogen.

2C2H2 + O2 → 2CO + 2H2

This reaction occurs near the tip of the torch.
The second stage of reaction involves the combustion of the CO and H2 and occurs just beyond
the first combustion zone. The specific reactions of stage two are:
4CO + 2O2 → 4CO2
2H2 + O2 → 2H2O
The oxygen for these secondary reactions is generally obtained from the surrounding
atmosphere.
The complete combustion equation is [1]:
2C2H2 + 5O2→ 4CO2 + 2H2 O
Types of flames:

Three different types of flames can be obtained by varying the oxygen/acetylene (or oxygen/
fuel gas) ratio, as shown in Figure. If the ratio is about 1:1 to 1.15:1, all reactions are carried
to completion and a neutral flame is produced. A higher ratio, such as 1.5:1, produces an
oxidizing flame, hotter than the neutral flame (about 6000 oF) but similar in appearance.
Excess fuel, on the other hand, produces a carburizing flame. The excess fuel decomposes to
carbon and hydrogen, and the flame temperature is not as great (5550 oF). A but joint obtained
from oxy fuel welding is shown in Fig.
Figure 8: Types of flames

Carburizing:

1. Oxygen is less than C2H2.

2. Less heat is produced as compared to others
3. Used for high carbon steel and Nickel alloy.

Figure 9: carburizing flame

Neutral:

1. Equal ratio of oxygen and C2H2.

2. Less chemically effective.
 3. Heat produced is less than oxidizing but greater than carburizing.

Figure 10: Neutral Flame

Oxidizing:
1. Oxygen is greater than C2H2.
2. Not suitable for steel (greater oxygen can cause oxidation).
3. Used for high melting point alloys and metals.

4.
Figure 11: Oxidizing flame

Advantages of Gas Welding:

1. Welder has a good control over the oxidizing and reducing potential of flame,
temperature of flame and on the rate of heat input.
2. Since source heat and filler material are separate so good accuracy of deposition of filler
material on weld joint can be accomplished.
3. It is portable to any location.
4. Its initial equipment cost is less as compared to other welding plants.
5. Weld bead size its shape and weld puddle viscosity can also be controlled because the
filler metal is supplied separately.
6. It is perfectly suitable for thin metal sheets, tube and small diameter pipes.

Disadvantages of Gas Welding:

1. It is not suitable for the welding of thick metal sheets because it has not good penetration
ability.
2. It is slow process that’s why it is not suitable for mass production.
3. Its maintenance cost is high because its fuel gases are very expensive.
4. Highly skilled worker is required.
 5. It proves very dangerous in case of any misshape.

Procedure:
 First of all we setup the acetylene cylinder and oxygen cylinder using key.
 Then we setup the regulator to control pressure from the tanks to the required pressure
in the hose.
 Now we setup the torch to produce the flame starting from acetylene valve and then to
the oxygen valve with ratio (1:1).
 Now we prepare the metal (clean from dust, rust, oil, and grease, etc.) for welding.
 Now we make weld joints with gas welding apparatus.

Figure 12: Gass welded sample

Figure: Gas welded sample
Observation and Calculation:
Table 3: oxygen pressure vs. Acetylene pressure

Sr. No. Oxygen Pressure Acetylene Pressure

1
4
3
2
 Graph:

Oxygen vs. Acetylene

70

60

50

40

30

20

10

0
Oxygen Pressure Acetylene Pressure

Series 1 Series 2 Series 3 Series 4

Comments:
 It is very slow process.
 It requires very high precision.
 Pressure adjustment is of very great importance which requires a skill full .We
conclude that:  There are three main components needed to create a weld. These are:
A heat source such as an electric arc, a flame, pressure, or friction.
 Acetylene is the only fuel gas suitable for gas welding because of its favorable flame
characteristics of both high temperature and high propagation rates.
 It relies on combustion of oxygen and acetylene. When mixed together in correct
proportions within a hand-held torch or blowpipe, a relatively hot flame is produced
with a temperature of about 3,200 deg