MERU UNIVERSITY OF SCEINCE AND

TECHNOLOGY
SCHOOL : ENGINEERING AND ARCHITECTURE

DEPARTMENT : ELECTRICAL ENGINEERING

UNIT NAME : INDUSTRIAL ATTACHMENT

NAME : JOSEPH JUMA

REG NO : EG209/109691/22

TASK : REPORT ON WELDING

TABLE OF CONTENT
1. Introduction

2. Types of Welding

3. Laboratory experiment
 CHAPTER 1- INTRODUCTION

a. Definition of Welding
Welding is a process where by two or several metal or non-metal parts are fused together by use of pressure or heat. This result to
formation of a joint normally referred to as a weldment. The materials that are used to make the weldment are called fillers.
Welding can be used to make several types of joints. The five major types of joint that can be made by use of welding are; tee joint,
edge joint, butt joint, corner joint and lap joint.

For welding to be done, four components are required. These components are a heat source, a filler metal, the metals to be welded
and a form of shield from the air. A form of shield from the air is mainly for protection of the filler from being oxidized. The heats
source for welding can be get from several different energy sources such as gas flames, an electric arc, friction, ultra sound or a laser.
The metals are heated to their melting point and the filler metal is added to the heated area to produce a single metal.

b. Safety rules for welding

Welding is an important practice but it can be a very dangerous when wrongly approached. For this reasons, there are safety rules
that have been placed so as to minimize or to completely avoid accidents during welding practice. Some of the safety rules are
aligned below;

i. Welding should be conducted in a designated safe location, mostly in legal workshops.

ii. Welders should wear appropriate Personal Protective Equipment (PPEs) at all times which include long-sleeved shirts,
welding helmets or goggles, ear muffs, boots, gloves and long trousers with no cuffs.
iii. Warning labels should be read and be adhered to accordingly.

c. Basic Conditions of Welding

Since welding is an important process, it is required to be done at its best. This is also highlighted by the fact that the welded joints
are required to stay intact for long enough. Furthermore, some joints must be made in such a way that they can remain intact even
after subjection to immense pressure depending on the duties they will perform. These joint are able to result very much quality
products. Therefore for a welding joint to be termed or categorized as a quality joint, it must meet the following conditions;

i. The weld joint should not have any crack or holes.

ii. It should have uniform waves, width and height.
iii. The joint must meet the standards of the required strength.
iv. The filler should fully penetrate the materials to be fused together to join the entire interface between them.

d. The Purpose of Welding.

Welding is done due to very many reasons. Welding can be done to increase the productivity of a material. When a matron or
broken material is welded back, it can regain its worth thus its economic demand will rise again. Welding can also be done for one to
be able to know parts of welding arc or gas. Welding can also be done to equip the students with actual welding skills. While
students perform the actual welding skills they can be able to acquire the skills.

Through welding, one can learn its dangers and ways of preventing themselves from welding accidents. One can also know the
functions of welding while welding.

CHAPTER 2- TYPES OF WELDING

There are several types of welding that are used in the modern workshops today. These types of welding includes gas welding,
resistance welding, arc welding, newer welding and solid state welding.

Arc Welding
Arc welding is a type of welding where metal to be welded together are fused using the heat generated by an electrical arc. Arc
welding can categorized as follows Gas Metal Arc Welding, Gas Tungsten Arc Welding, Shielded Metal Arc Welding, Metal Arc,
Carbon Arc and Flux-coated Arc Welding. Arc welding is done by applying intense heat on the metal at the joint between two parts.
A molten filler is applied at the joint. Upon cooling and solidification the joint is intact the two metals are tightly held together.

Gas Welding
Gas welding is the process whereby two metals are joined together by melting and cooling part of both metals by creating a hot
flame by use of oxygen gas and a fuel. Gas welding is of different types which include Oxy-acetylene, Oxy-gasoline, butane, propane
and Hydrogen Gas Welding. Gas welding works by feeding both oxygen and fuel gas out of the end of a torch to produce a highly
concentrated flame that can melt a metal. The material is melted to produce a weld pool. When the weld pool cools, it bonds the
pieces of the materials to form a strong joint. Metals that can be gas welded include aluminum, stainless steel, brass and copper.

1. Advantages of Gas Welding

Gas welding has several advantages which some are;

i. Gas welding does not require electricity and therefore it can be used in isolated areas.
ii. Gas welding does not require high rated skills
iii. Gas welding can join parts made of both ferrous and non-ferrous metals.
iv. Gas welding equipment is portable.
2. Disadvantages of Gas Welding
i. The heat from gas welding affects the mechanical properties of high-strength steel
ii. Its lack of flux can cause wild effect
iii. It is slower than other methods since it does not get as hot.

Applications of welding
Welding has very vast application in this technological world. Some of the places where welding is applied include in shipbuilding
industries, in automobile industries, when building railway lines, for fabrication of pressure vessels, on space crafts, when laying pipe
lines, when building bridges, buildings and in electrical industries.
 CHAPTER 3- LABORATORY EXPERIMENT.
The experiment done was majorly on Metal Arc Welding.

a. Objective
To prepare a mud chucker by use of the knowledge of welding.
b. Apparatus
i. An electrode holder
ii. A long piece of metal probably 10 meters
iii. An electrode
iv. A metal plate
v. A socket outlet.
vi. Welding googles
vii. gloves
c. Procedure
i. The piece of metal was cut into two 20cm pieces and eight 40cm pieces
ii. The metals that were cut to be welded were placed together.
iii. The electrode was placed in the electrode holder at an angle bigger than 90 degrees.
iv. The electrode was melted by rubbing it on the metal plate.
v. Each joint was then welded.
vi. The joints were then left to cool.
vii. The joints were tested and confirmed qualitative.
d. Discussion
 Welding is one of the best ways of making metal joints. When welding is done, it melts both metals to be fused together and
also melts the electrode. Upon cooling, the two metals and the electrode become a single part and therefore the joint is
intact and firm. These results to a long lasting joint.

e. Conclusion
From the laboratory experiment that was done, it concluded that welding has a large variety of applications, importance to the day
to day life businesses. It was also concluded that when welding is done, the welder wellbeing should be taken into account.
Protection of eyes by wearing welding goggles and wearing of gloves and long pair of trousers and long sleeved shirts, or an overall
was highly encouraged.

f. References
i. https://www.xometry.com/resources/sheet/what-is-gas-welding/
ii. https://www.uti.edu/blog/welding/gas-welding
iii. https://interestingengineering.com/innovation/gas-welding-basics-advantages-disadvantages-and-applications