DJJ10033-WORKSHOP TECHNOLOGY
CASE STUDY
TOPIC 7
ABDUL AZIZ BIN HUSEN (14DKM23F1801)
AHMAD SYAHMI BIN MUHAMMAD (14DKM23F2003)
MUHAMMAD HAZIQ BIN KAMARUDDIN (14DKM23F2805)
When repairing a cracked hull on a ship, especially one made of
12mm thick mild steel, it is crucial to select the appropriate
welding process to ensure a durable and leak proof fix. The crack
spans approximately 3 meters, necessitating a method that offers
strength, reliability and efficiency within 14 day time frame. This
document outlines the required welding type, detailed work steps
and justification criteria to ensure the repair meets the necessary
standards and time frame.
Type of welding:1)MIG WELDING
2)SMAW WELDING
1)Characteristic of weld
a)Equipment: -MIG welding typically requires a welding machine,
a wire feeder, a welding gun, a shielding gas cylinder and a power
source.
-SMAW welding requires a welding machine, welding
electrodes and a power source. Its generally simpler in terms of
equipment compared to MIG welding
b)Heat source: -MIG welding heat is generated by an electric arc
between the workpiece and the consumable wire electrode.
-SMAW welding the heat is generated by an electric
arc between the workpiece and the flux coated electrode.
c)Strength and Durability: -MIG welds tend to have higher strength
and durability due to the continuous and consistent feeding of the
electrode wire, resulting in better control over weld bead and
fusion.
-SMAW welds are strong and durable but
may have slightly lower strength compared to MIG welds due to
the manual nature of the process, which can lead to variations in
weld quality.
d)Welding Speed: - MIG welding is generally faster than SMAW
welding due to its semi-automatic or automatic nature and the
ability to continuously feed the electrode wire.
-SMAW welding is typically slower than MIG
welding because each electrode must be replaced manually after
it is consumed during welding
2)Welding Work Step:
a)MIG WELDING
1)Preparations: - Clean the surface to be welded by using a wire
brush, grinder or solvent. Choose appropriate filler wire and
shielding gas. Prepare the joint by selecting the appropriate joint
configuration.
2)Welding: Setup the MIG welding machine , adjust voltage , wire
feed speed and gas flow rate. Hold the welding gun at the correct
angle and distance. Control the welding arc to achieve proper
fusion and penetration.
3)Inspection: Visually inspect the weld for defects such as
undercut or incomplete fusion after welding
b)SMAW WELDING
1)Preparations: -Clean the surface using wire brush to remove any
rust or scale.Choose the appropriate electrode based on the
material being welded.Selecting the appropriate joint
configuration based on the welding technique and material
thickness.
2)Welding: Setup the SMAW welding machine include selecting
appropriate electrode , electrode polarity and adjust voltage. Hold
the electrode at the correct angle and distance. Control the arc
length, electrode manipulation and welding speed to achieve
proper penetration and fill.
3)Inspection: Visually inspect the weld for defect such as slag
inclusion , incomplete fusion or undercut.
3)Estimate time and cost of welding
MIG Welding : On a 3 meter crack it will take about 3-5 days
depending on the damage and the expertise of the technician. The
cost of welding materials and inert gas, along with labor wages
may reach several thousands to tens of thousands depending on
factors such as location and scale of work.
SMAW Welding: The SMAW process takes longer than MIG
welding, it may take 5-7 days to handle a 3 meter crack. The cost
of electrode welding materials, insulation, and labor may be quite
similar to MIG welding depending on the specific needs of the
project and job site conditions.
4) Result:
a) MIG Welding: By using MIG welding, it is expected that the
welding will have sufficient strength to maintain the integrity of
the ship's hull, prevent leakage and ensure the safety of
navigation.
b)SMAW Welding: SMAW welds typically offer high strength and
good resistance to stress and impact, making them the ideal
choice for handling large cracks in hulls. The quality of welding
depends on the skill of the technician who performs it
