Arc Welding Basics Quiz

Arc Welding Experiment

• The aim of the experiment is to study arc welding and weld mild steel plates with various joints.
• Arc welding is a process that fuses two or more metal pieces together using heat from an electric arc welding machine.
• The arc is created between the electrode and the metal, then heats the metal to its melting point.
• The electrode is then removed, allowing the molten metal to cool and solidify.

Basics of Arc Welding

• The arc welding process involves the use of electrodes and a welding machine.
• Consumable and non-consumable electrodes are used.

Fusion Welding Processes

• Consumable electrode processes include SMAW (Shielded Metal Arc Welding), GMAW (Gas Metal Arc Welding), SAW (Submerged Arc Welding), and Oxygen/Fuel Welding.
• Non-consumable electrode processes include GTAW (Gas Tungsten Arc Welding), PAW (Plasma Arc Welding), Electron Beam Welding, and Laser Beam Welding.

Shielded Metal Arc Welding (SMAW)

• Common name is "stick" or manual arc welding
• Widely used in various welding applications
• Used on most common metals and alloys
• Employes alternating current (AC) or direct current (DC).
• Current flows through the electrode cable to the holder and through the electrode to the arc.
• Current flows through the base metal to the work clamp, then to the welding machine.

Core Rod (Metal Filler)

• A consumable part of the welding process.
• Carries the welding current.
• Becomes part of the weld.

Flux Coating

• Produces a shielding gas to protect the weld area from contamination.
• Provides additional filler material.
• Forms a slag (protective layer).

SMAW Equipment

• Uses a step-down transformer to reduce voltage and increase current, resulting in a constant current output.
• Constant current output ensures consistent heat, even with fluctuating arc distance and voltage changes

SMAW - DC Polarity

• Straight Polarity ( + to electrode, - to work piece): shallow penetration (thin metal)
• Reverse Polarity ( - to electrode, + to work piece): deeper penetration (thicker metal)
• AC(Alternating Current): produces pulsing arc beneficial for welding thick sections.

AWS Classification of SMAW Electrodes

• E70XX: A common designation of electrodes, with tensile strength and welding position characteristics. Specific examples are included in the presentation.

Welding Equipment

• Key components of welding equipment are described with diagrams and numbered labels for easy identification and understanding for the students.

Welding Joints

• Butt, Corner, Lap, Tee, and Edge are the main welding joint types. Diagrams illustrate each type.

• For example, butt joints connect members in the same plane.

Welding Procedure (General Steps)

• Clean the metal surfaces prior to welding.
• Mark lines on the work pieces using a steel rule and scriber.
• Keep the work pieces together according to the marking on the metal table.
• Clamp the work pieces on the metal table for rigidity.
• Set the current as required

Weld Procedure

• Insert the correct electrode in the electrode holder
• Bring the electrode straight down to the work piece and lift slightly to initiate the arc.
• Hold the electrode perpendicular to the work piece and move at a uniform speed.
• Use a chipping hammer and a wire brush to remove the slag.

Arc Welding Safety Rules

• Never allow any part of the body to touch electrical circuits.
• Do not harm wiring/clamp/machine elements
• Weld on a dry surface
• Use appropriate eye protection.
• Use appropriate personal safety equipment (gloves, apron, clothing).
• Ensure the working area is free of flammable materials.
• Always guard your face and eyes when chipping slag.

Test your knowledge of arc welding processes and techniques with this informative quiz. Covering essential topics like Shielded Metal Arc Welding (SMAW) and various welding joints, it helps reinforce your understanding of welding principles. Perfect for anyone studying welding or looking to enhance their skills!