Workshop 13
Workshop 13
Workshop 13
LAB MANUAL
INSTRUCTOR NAME
M-TAHIR MAHMOOD
It is your responsibilities to ensure that at all times you work in such a way
as to ensureyour own safety and that of other persons in the laboratory.
If you are uncertain about any safety matter for any of the experiments,
you MUSTconsult a demonstrator.
You should take care of all lab equipment and do not practice any
experiment withoutinstructor permission.
Submit your ID card to lab assistant before issuing any equipment in the lab
18 WELDING(A)
OBJECTIVES
a. To get familiar with basic electronic components such as Resistor, capacitors, Inductor,
diodes, transistors, integrated circuits (IC), light emitter diode (LED), switches, fuses,
batteries, power plugs, connectors, wires and cables.
b. To test and understand the function of various electronic components.
RESISTORS
A resistor is a passive two-terminal electrical component that implements electrical resistance as a
circuit element. The current through a resistor is in direct proportion to the voltage across the resistor's
terminals. This relationship is represented by Ohm's law. A device used in electrical circuits to maintain
a constant relation between current flow and voltage. Resistors are used to step up or lower the voltage
at different points in a circuit and to transform a current signal into a voltage signal or vice versa, among
other uses. The electrical behavior of a resistor obeys Ohm's law for a constant resistance; however,
some resistors are sensitive to heat, light, or other variables.
Resistors are one of the most used components in a circuit. Most are color coded, but some have their
value in Ohms and their tolerance printed on them. A multimeter that can check resistance can also be
helpful, providing the resistor is already removed from the board (measuring it while still soldered in
can give inaccurate results, due to connections with the rest of the circuit). They are typically marked
with an “R” on a circuit board.
POTENTIOMETERS
Potentiometers are variable resistors. They normally have their value marked with the maximum value
in Ohms. Smaller trim pots may use a 3-digit code where the first 2 digits are significant, and the 3rd is
the multiplier (basically the number of 0′s after the first 2 digits). For example, code 104 = 10 followed
by four 0′s = 100000 Ohms = 100K Ohms. They may also have a letter code on them indicating the
taper (which is how resistance changes in relation to how far the potentiometer is turned). They are
typically marked with an “VR” on a circuit board.
Capacitors are also very commonly used. A lot have their values printed on them, some are marked with
3-digit codes, and a few are color coded. The same resources listed above for resistors can also help you
identify capacitor values. They are typically marked with an “C” on a circuit board.
INDUCTORS
An inductor, also called a coil or reactor, is a passive two-terminal electrical component which resists
changes in electric current passing through it. It consists of a conductor such as a wire, usually wound
into a coil. When a current flows through it, energy is stored in a magnetic field in the coil. When the
current flowing through an inductor changes, the time-varying magnetic field induces a voltage in
the conductor, according to Faraday’s, which by Lenz's law opposes the change in current that created
it. Inductors, also called coils, can be a bit harder to figure out their values. If they are color coded, the
resources listed for resistors can help, otherwise a good meter that can measure inductance will be
needed. They are typically marked with an “L” on a circuit board.
FUSES
In electronics and electrical engineering, a fuse is a type of low resistance resistor that acts as a sacrificial
device to provide overcurrent protection, of either the load or source circuit. Its essential component is
a metal wire or strip that melts when too much current flows, which interrupts the circuit in which it is
connected. Short circuit, overloading, mismatched loads or device failure are the prime reasons for
excessive current. A fuse interrupts excessive current (blows) so that further damage by overheating or
fire is prevented. Fuses can be easy to identify, and typically have their voltage and ampere rating
marked on them.
DIODES
In electronics, a diode is a two-terminal electronic component with asymmetric conductance, it has low
(ideally zero) resistance to current flow in one direction, and high (ideally infinite) resistance in the
other.
Semiconductors, such as Diodes (typically marked with an “D” on a circuit board).
TRANSISTORS
A transistor is a semiconductor device used to amplify and switch electronic signals and electrical
power. It is composed of semiconductor material with at least three terminals for connection to an
external circuit. A voltage or current applied to one pair of the transistor's terminals changes the current
through another pair of terminals. Because the controlled (output) power can be higher than the
controlling (input) power, a transistor can amplify a signal. Today, some transistors are packaged
individually, but many more are found embedded in integrated circuits.
Transistors (typically marked with an “Q” on a circuit board).
A diode bridge is an arrangement of four (or more) diodes in a bridge circuit configuration that provides
the same polarity of output for either polarity of input. When used in its most common application, for
conversion of an alternating current (AC) input into a direct current (DC) output, it is known as a bridge
rectifier. A bridge rectifier provides full- wave rectification from a two-wire AC input, resulting in
lower cost and weight as compared to a rectifier with a 3-wire input from a transformer with a center-
tapped secondary winding.
Bridge Rectifiers (typically marked with an “BR” on a circuit board)
INTEGRATED CIRCUITS
An integrated circuit or monolithic integrated circuit (also referred to as an IC, a chip, or a microchip)
is a set of electronic circuits on one small plate ("chip") of semiconductor material, normally silicon.
This can be made much smaller than a discrete circuit made from independent components. Integrated
circuits are used in virtually all electronic equipment today and have revolutionized the world of
electronics. Computers, mobile phones, and other digital home appliances are now inextricable parts of
the structure of modern societies, made possible by the low cost of producing integrated circuits.
Integrated Circuits (typically marked with an “U” or “IC” on a circuit board)
SWITCHES
In electrical engineering, a switch is an electrical component that can break an electrical circuit,
interrupting the current or diverting it from one conductor to another. The most familiar form of switch
is a manually operated electromechanical device with one or more sets of electrical contacts, which are
connected to external circuits. Each set of contacts can be in one of two states: either "closed" meaning
the contacts are touching and electricity can flow between them, or "open", meaning the contacts are
separated and the switch is non-conducting.
BATTERIES
In electricity, a battery is a device consisting of one or more electrochemical cells that convert stored
chemical energy into electrical energy.
Batteries are also pretty easy to identify, and are well marked with their specification.
Digital multimeter
1st digit
Tolerance
2nd digit
Multiplier (no. of zeros,
following 2nd digit)
Yellow 4 4 ×10000 –
White 9 9 – –
Gold – – ×0.1 5%
Silver – – ×0.01 10%
Procedure
1. Connect probes: black probe to COM terminal and red probe to terminal marked with ‘
2. Set function to resistance measurement
3. Set to the appropriate range (refer to above)
4. Connect the two probes’ crocodile clips to the resistor (or to the resistor circuit via jumper wires)
to make measurement
5. Note the reading, adjust range if necessary
6. Take the more accurate reading.
Measured Value
No. Colour code Actual Value
(DMM)
1 Red, red, black
Code Tolerance
C ±0.25pF
J ±5%
K ±10%
M ±20%
D ±0.5pF
Z 80% / -20%
2 223
3 68
DIODE TESTING
Draw the schematic symbol of a 1N4001 diode and identify the leads (Anode and Cathode) in
the box below.
b. Measure the forward and reverse bias voltages of the given diodes and record them
i. Forward bias voltage:
Place the RED probe on the Anode. Touch the BLACK probe to the Cathode and
record the reading
ii. Reverse bias voltage:
Place the RED probe on the Cathode. Touch the BLACK probe to the Anode and
record the reading
1N4001
1N914
CONCLUTION:
Marks Awarded:
AC Source DC Source
Motor
Ammeter
Circuit Breaker
Tube Light
CONCLUTIONS:
Marks Awarded:
OBJECTIVE:
a. To get familiar with basic electronic instrument and Equipment handling and usage
procedure for Digital Multimeter, DC power supply, Function Generator and CRO.
b. To study the self-test / calibration procedure of CRO.
INTRODUCTION:
MULTIMETER:
A Multimeter is an electronic device that is used to make various electrical measurements such as
AC and DC voltage, AC and DC current, and resistance. It is called a Multimeter because it combines the
functions of a voltmeter, ammeter, and ohmmeter Multimeter may also have other functions such as diode test,
continuity test, transistor test, TTL logic test and frequency test.
OSCILLOSCOPE:
An oscilloscope is a laboratory instrument commonly used to display and analyze the waveform of
electronic signals. In effect, the device draws a graph of the instantaneous signal voltage as a function of
time.
Fig 1. Cathode Ray tube Oscilloscope Fig 2. Out Line Diagram of CRO
POWER SUPPLY:
A power supply is an electrical device that supplies electric power to an electrical load.
The primary function of a power supply is to convert electric current from a source to the
correct voltage, current, and frequency to power the load. As a result, power supplies are sometimes
referred to as electric power converters.
ELECTRONICS ELEMENTS:
RESISITOR:
In electronic circuits, resistors are used to reduce current flow, adjust signal levels, to divide voltages, bias active
elements, and terminate transmission lines, among other uses.
A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit
PROCEDURE:
Electronic Circuit Overview. An electronic circuit is a structure that directs and controls electric current
to perform various functions including signal amplification, computation, and data transfer. It comprises
several different components such as resistor, transistor capacitor, inductors and Diodes
CONCLUTIONS:
Marks Awarded:
OBJECTIVE:
Used the Proteus Design Suite for PCB making audio amplifier TDA2030 amplifier circuit
THEORY:
The Proteus Design Suite is a proprietary software tool suite used primarily for electronic design
automation. The software is used mainly by electronic design engineers and technicians to
create schematics and electronic prints for manufacturing printed circuit boards.
TDA2030 Amplifier Circuit Use a pair of TDA2030 integrated. This monolithic integrated circuit is a
class AB, which comes to providing up to 15W of output power with an 8 Ohm load. The TDA
2030provides high output current and low harmonic distortion
CONCLUTION:
Marks Awarded:
OBJECTIVE:
Copper laminated sheet
Soldering Iron
Soldering Wire
Soldering Sucker
AC Supply
\
THEORY:
Copper Sheet & Plate. Copper sheet and copper plate find use in a huge array of applications one of few
metals that doesn’t need to be extracted from ore (i.e., it is directly usable in its natural state).Copper
exhibits excellent thermal and electrical Conductivity, good ductility
And a natural resistance to corrosion.
SOLDERING IRON:
A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow
into the joint between two work pieces. A soldering iron is composed of a heated metal tip and an
insulated handle.
SOLDERING SUCKER:
A quality solder sucker is a quintessential part of any home soldering setup. These small, inexpensive
tools are used to remove unwanted solder. They’re also essential for the process of desoldering a joint.
Most solder suckers consist of a plunger or vacuum
A printed circuit board, or PCB, is used to mechanically support and electrically connect electronic
components using conductive pathways, tracks or signal traces etched from copper sheets laminated
onto a nonconductive substrate ,After prototyping a circuit on a breadboard or dot board it is always
better to make PCB for added stability and compactness
CONCLUTION:
Marks Awarded:
OBJECTIVE:
Ferric chloride
Copper sheet
CAN
ETCHING:
Etching is the process of using strong acid to cut into the unprotected parts of a metal surface to create a
design in intaglio (image is created by cutting, carving or engraving into a flat surface) in the metal. As
an intaglio method of printmaking it is, along with engraving, the most important technique for old
master prints and remains widely used today.
CAN
Copper Sheet & Plate, is widely known for its architectural applications whereas the familiar green
patina appearance is achieved when exposed to the elements. Copper sheets / plates are also noted for
their high electrical and thermal conductivity, and good corrosion resistance.
Procedure:
Place some newspaper on the bottom so the etching solution does not spoil your floor. Take a plastic box
and fill it up with some water. Dissolve 2-3 teaspoons of ferric chloride power in the water. Dip
the PCB into the etching solution (Ferric chloride solution) for approximately 30 minutes.
CONCLUSION:
Marks Awarded:
OBJECTIVE:
Sand paper
Copper Sheet
Iron
THEORY:
Sand paper:
Sand paper and glass paper are names used for a type of coated abrasive that consists of sheet of paper
or cloth with abrasive material glued to one face.
IRON:
Firstly, Iron the side of PCB. After 30 seconds, you will find the Matte Paper will stick to Copper firmly.
It means it is successful. Then Iron the whole PCB.
Marks Awarded:
OBJECTIVE:
To make of manual drilling on PCB for automatically maintain a constant voltage level Voltage input 12v
and output 5v, 9v CIRCUIT.
THEORY: When using a conventional drill press, hole placement accuracy can be improved and
drill breakage minimized through the use of a "sensitive drilling" or "finger" chuck. Small formats,
precision high-speed drill presses, ideal for PCB fabrication, are also available from a number of
sources.
Regardless of the type of drill press being used, a pressure foot should be employed if available.
If available, position a work lamp on a flexible mount as close to the work surface as possible.
Although more brittle than conventional high speed steel (HSS) drills, tungsten carbide bits
designed specifically for PCB drilling will yield far superior hole wall quality. Minimize burr
formation, and outlast HSS bits almost 10 to 1. The downside is that, with smaller diameters
[0.018"(0.46mm) and less], the carbide drills are easier to break and must be handled carefully.
Always use drill bits that have been fitted with depth setting rings. This will allow you to set the
plunge depth stop on your drill press to a single value that will work for all bit diameters.
Prepare a chart that links the various diameter bits with the symbols used in the drillmaster
CONCLUSION:
Marks Awarded:
THEORY:
Introduction: Soldering is the act of unifying two pieces of similar or dissimilar metals by an alloy
called Solder, the melting point of which is lower than that of the metal to be united. When two
surfaces of the metal are soldered together, the solder penetrate pores of the metal and it makes firm
grip with permanent electrical continuity and strength.
Solder: The soldering material or solder usually employed for the purpose of joining together two
or more metals at temperature below their melting point and is a fusible alloy consisting essentially
of lead and tin. Solder is an alloy (mixture) of tin and lead, typically 60% tin and 40% lead. It melts
at a temperature of about 200°C. Coating a surface with solder is called 'tinning' because of the tin
content of solder. Solder for electronics use contains tiny cores of flux, like the wires inside a mains
flex.
Flux: When a metal is heated in free air, it is immediately affected by oxygen. A layer of oxide is
formed over the surface which is a hindrance during soldering. This layer of oxide can be removed
using chemical compounds called fluxes. They are deoxidizes agents and are used to keep the
surface clean from oxide, increase the fluidity of the solder and help the joints to adhere perfectly.
The melting temperature of the flux is always less than that of the solder used.
DESOLDERING:
To de-solder means to remove a joint or re-position a wire or component. There are two ways to remove
the solder:
1. Set the pump by pushing the spring-loaded plunger down until it locks.
2. Apply both the pump nozzle and the tip of your soldering iron to the joint.
3. Wait a second or two for the solder to melt.
4. Then press the button on the pump to release the plunger and suck the molten solder into
the tool.
5. Repeat if necessary to remove as much solder as possible.
6. The pump will need emptying occasionally by unscrewing the nozzle.
1. Apply both the end of the wick and the tip of your soldering iron to the joint.
2. As the solder melts most of it will flow onto the wick, away from the joint.
3. Remove the wick first, then the soldering iron.
4. Cut off and discard the end of the wick coated with solder.
After removing most of the solder from the joint(s) we can remove the wire or component lead
straight away (allow a few seconds for it to cool). If the joint will not come apart easily apply
your soldering iron to melt the remaining traces of solder at the same time as pulling the joint
apart.
Marks Awardeded:
Introduction:
There are four electrical cables according to its core
1-Single core cable
2-Two core cable
3-Three core cable
4-Four core cable
Special cables:
1. R.G cable
2. Co-Axial cable
3. Telephone cable
2. Coaxial cable:
It is used as transmission line for radio frequency signals its application includes feeds line connecting transmitter
and receiver with their antenna and for distributing signals this cable also provides the protection of the signals
from external electromagnetic interference it is also used for video distribution in home offices and restaurants it
is also used in dish antennas.
3. Telephone Cable:
It is used in in wiring of telephone lines for indoor and outdoor purposes in residential and commercial area.
4. Intercom Cable:
It is used in intercom wiring for indoor purposes in the same building or building to building.
5. Fiber Optic Cable:
The fiber optic cables are used mainly for internet and digital audio connection between devices an optical fiber
cable contains one or more optical fiber .Fiber optic lines are laying for long distance s for phone calls and for
internet .fiber optic cable consist of bundles of glass threads each of which is cable of fiber .optical fiber has a
greater signal band width than metal cable.
2. Multimedia Cable.
Marks Awardeded:
APPARATUS:
Voltmeter, ammeter tester bulb holder tape, wires circuit board
DAIGRAM:
PROCEDURE:
1. Philled the ends of wire.
RESULT:
Marks Awardeded:
APPARATUS:
Voltmeter, Ammeter, Phase tester, Screw driver, Pliers &cutter, Crimping tool ,Circuit board, Bulb holder,
Insulation tape, Wire, Single pole switch.
Circuit diagram:
Procedure:
1. Take wires according to the measurements.
2. Remove the insulation of wire from both ends.
RESULT:
Marks Awardeded:
REQUIRED:
WIRING TOOLS & INSTRUMENTS:-
(i) Electrician plier (ii) Side cutting plier (ii) Electrician knife (iv) Connector screw driver (v) Phase tester (vi)
Drill Machine with drill bit (vii) Bradawl / Pocker (viil) Multi meter.
WIRING MATERIAL:-
(i) Single-way switch (ii) Two pin socket (ii) Bulb holder (iv) Bulb (v) Fuse with fuse wire (vi) Wooden Board
(suitable in size) (vii) Wooden screws 1/2" 8Nos. (viii) Used sand paper (ix)Wiring cable 3/0.029" (colored) as
required (x) Ac supply source
CIRCUIT DIAGRAM
2. Now you have two pieces of wire. Fix the bulb holder using one end of the two pieces of wires and install a
light bulb on to the holder.
3. You have other two ends of the wire free. Fix a two-pin plug on that free pairs of wires. It means you can light
up the bulb if you put two-pin plug in a live two-pin socket.
4. Check the continuity of the test lamp by an multi meter be sure that bulb turns on when the plug is inserted in a
live two-pin socket.
6. Finally, you need to slice one of the wires in the middle and remove insulation from each of the cut-ends for
half an inch so that the bare copper is clearly visible.
7. Your test lamp is ready for experimental test. Always use a cap to cover the bare copper wire to avoid any
accidental electrification.
Marks Awardeded:
APPRATUS:
Multi meter, Single way switch, Circuit board, Fan regulator, Peeler, Cutter, Screw driver, Wire as required,
Phase tester, Crimping tool.
CIRCUIT DIAGRAM:
PROCEDURE:
1. Take wires according the measurement.
3. Connect the phase wire with the one terminal of single way switch.
7. Switch on the circuit and regulate the speed of fan using regulator.
PRECAUTIONS:
1. Make all connection carefully.
Marks Awardeded:
APPARATUS:
Multi meter, Phase tester, two way switch, Bulb and Bulb holders, Cutter, Plier, Screw driver, Crimping tool,
Wires as required, Circuit board.
CIRCUIT DIAGRAM:
PROCEDURE:
1. Take wires according to the measurements and a circuit board.
4. Connect the upper and lower terminal of s/w 1 and s/w 2with each other.
5. Connect the central terminal of s/w 2 with positive terminal of bulb holder.
6. Connect the negative terminal bulb holder with the negative terminal of source.
PRECAUTIONS:
1. Make all connections carefully.
Marks Awardeded:
OBJECTIVE:
Identify the measure the Two terminal active devices
APPARATUS:
SC Diode
Zener Diode
DIAC
Integrated Circuit
Multimeter
THEORY:
A-SEMI CONDUCTOR DIODE
TWO TERMINAL DIODE:
A diode is an electrical device allowing current to move through it in one direction with far greater
ease than in the other. The most common type of diode in modern circuit design is the semiconductor
diode, although other diode technologies exist. Semiconductor diodes are symbolized in schematic
diagrams as such
When the polarity of the battery is such that electrons are allowed to flow through the diode, the
diode is said to be forward-biased.
Conversely, when the battery is "backward" and the diode blocks current, the diode is said to be
reverse-biased. A diode may be thought of as a kind of switch: "closed" when forward-biased and
"open" when reverse-biased.
ZENER DIODE:
Zener diode is basically like an ordinary PN junction diode but normally operated in reverse
biased condition. But ordinary PN junction diode connected in reverse biased condition is not
used as Zener diode practically.
A Zener diode is a specially designed, highly doped PN junction diode. The name Zener diode
was named after the American physicist Clarence Melvin Zener who discovered the Zener effect.
Zener diodes are the basic building blocks of electronic circuits. They are widely used in all kinds
of electronic equipment. Zener diodes are mainly used to protect electronic circuits from over
voltage.
The term DIAC stands for the Diode for Alternating Current (DIAC), it is a bidirectional semiconductor switch
that can be turned ON in both forward and reverse direction.
The device is a member of the Thyristor family and it is mostly used in triggering TRIAC
And other Thyristor based circuits.
The DIAC starts conducting electric current if the applied voltage goes beyond its break-over voltage.
DIACs are available in different types of DIAC packages such as discrete components in small leaded
packages, surface-mount packages, large packages that are bolted to chassis and various other packages.
Most of the time the DIAC and TRIAC are used together, so they are available in integrated packages also.
Being able to determine the polarity (cathode versus anode) and basic functionality of a diode is a
very important skill for the electronics hobbyist or technician to have
Since we know that a diode is essentially nothing more than a one-way valve for electricity, it
makes sense we should be able to verify its one-way nature using a DC (battery-powered)
ohmmeter. Connected one way across the diode, the meter should show a very low resistance.
Connected the other way across the diode, it should show a very high resistance.
In order to determine which end of the diode is the cathode and which is the anode, you must know with
certainty which test lead of the meter is positive (+) and which is negative (-) when set to the "resistance"
or "Ω" function.
An integrated circuit is electronic circuit or device that has electronic components on a small
semiconductor chip. It has functionality of logic AND or amplifying of a signal. These are mainly
two types of circuits: Digital or Analog. Analog ICs handle continuous signals such as audio signals
and Digital ICs handle discrete signals such as binary values.
Linear ICs (Linear Integrated Circuits) are Digital ICs (Digital Integrated
called as analog IC. Circuits) are also called as nonlinear
IC.
The design requirements are more drastic The design requirement as less
as compared to digital ICs. drastic as compare To linear ICs.
CONCLUTION:
Marks Awardeded:
ENERGY METER:
An electricity or energy meter is a device that measures the amount of electric energy consume by residence,
Business, Or an electrically power device, Electricity meters are typically calibrated in billing units, The most
common one being the kilowatt hour. Periodic readings of electric meters establish billing cycles and energy used
during a cycle.
In settings when energy saving during certain periods is desired, Meters may measure demand, the maximum use
of power in sum interval. “Time of day” metering allows electric rates to be changed
During a day, to record usage during peak high-cost periods and off-peak, Lower-cost, periods. Also, in some
areas meters have relays for demand response shedding of loads during peak loads periods. The most common
unit of measurement on the electricity meter is the kilowatt hour, which is an equal to the amount of energy used
by a load one kilowatt over period of one hour, or 3,600,000 joules. Some electricity companies use the SI mega
joule instead.
CONCLUTION:
Marks Awardeded:
INTRODUCTION
Welding is the process of joining similar metals by the application of heat, with or without
application of pressure or filler metal, in such a way that the joint is equivalent in composition
and characteristics of the metals joined. In the beginning, welding was mainly used for
repairing all kinds of worn or damaged parts. Now, it is extensively used in manufacturing
industry, construction industry (construction of ships, tanks, locomotives and automobiles) and
maintenance work, replacing riveting and bolting, to a greater extent.
The various welding processes are:
1. Electric arc welding,
2. Gas welding
3. Thermal welding
4. Electrical Resistance welding and
5. Friction welding
However, only electric arc welding process is discussed in the subject point of view.
Any arc welding method is based on an electric circuit consisting of the following parts:
a. Power supply (AC or DC);
b. Welding electrode;
c. Work piece;
(d)Welding leads (electric cables) connecting the electrode and work piece to the power supply
Motor generators
These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as pert the requirement for welding. These are designed to produce
D.C current in either straight or reversed polarity. The polarity selected for welding depend
upon the kind of electrode used and the material to be welded.
Rectifiers
These are essentially transformers, containing an electrical device which changes A.C into
D.C by virtue of which the operator can use both types of power (A.C or D.C, but only one
at a time).In addition to the welding machine, certain accessories are needed for carrying out
the welding work.
Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the
case of using and coiling the cables. Cables are specified by their current carrying capacity, say
300 A, 400 A, etc.
Electrodes in the mild steel group. Various constituents like titanium oxide, potassium oxide,
cellulose, iron or manganese, Ferro silicates, carbonates, gums, clays, asbestos, etc., are used
as coatings on electrodes. While welding, the coating or flux vaporizes and provides a gaseous
shield to prevent atmospheric attack. The size of electrode is measured and designated by the
diameter of the core wire in SWG and length, apart from the brand and code names; indicating
the purpose for which there are most suitable
Electrodes may be classified on the basis of thickness of the coated flux. As
1. Dust coated or light coated
2. Semi or medium coated and
3. Heavily coated or shielded
Electrodes are also classified on the basis of materials, as
1. Metallic and
2. Non‐metallic or carbon
Metallic arc electrodes are further sub‐divided into
1. Ferrous metal arc electrode (mild steel, low/medium/high carbon steel, cast iron, etc.
2. Non‐ferrous metal arc electrodes (copper, brass, bronze, aluminum, etc. In case of non‐metallic
arc electrodes, mainly carbon and graphite are used to make the electrodes
Carbon and graphite are used to make the electrodes
7- WELD POSITION
Electrode holder
The electrode holder is connected to the end of the welding cable and holds the electrode. It
should be light, strong and easy to handle and should not become hot while in operation. Figure
shows one type of electrode holder. The jaws of the holder are insulated, offering protection
from electric shock.
Ground clamp
It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance
connection.
Face shield
A face shield is used to protect the eyes and face from the rays of the arc and from spatter or
flying particles of hot metal. It is available either in hand or helmet type. The hand type
is convenient to use wherever the work can be done with one hand. The helmet type though
not comfortable to wear, leaves both hands free for the work.
Shields are made of light weight non‐reflecting fiber and fitted with dark glasses to filter out
the Harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to
protect it from spatter.
Hand gloves
These are used to protect the hands from electric shocks and hot spatters
WELDING POSITIONS
Depending upon the location of the welding joints, appropriate position of the electrode
and hand movement is selected. The figure shows different welding positions.
Flat position welding
In this position, the welding is performed from the upper side of the joint, and the face of the
weld is approximately horizontal. Flat welding is the preferred term; however, the same
position is sometimes called down hand.
Horizontal position welding
In this position, welding is performed on the upper side of an approximately horizontal
surface and against an approximately vertical surface.
Vertical position welding
In this position, the axis of the weld is approximately vertical as shown in figure.
Overhead position welding
In this welding position, the welding is performed from the underside of a joint
Marks Awardeded:
LAP JOINT
Aims: To make a double lap joint, using the given mild steel pieces and by arc welding.
Material used:
Two mild steel pieces of 100X40X6 mm
1. Take the two mild steel pieces of given dimensions and clean the
surfaces thoroughly from rust, dust particles, oil and grease.
2. Remove the sharp corners and burrs by filing or grinding and
prepare the work pieces.
3. The work pieces are positioned on the welding table, to form a lap
joint with the required over lapping.
4. The electrode is fitted in to the electrode holder and the welding
current is set to a proper value.
5. The ground clamp is fastened to the welding table.
6. Wearing the apron, hand gloves, using the face shield and holding
the over lapped pieces the arc is struck and the work pieces are
tack‐welded at the ends of both the sides
7. The alignment of the lap joint is checked and the tack‐welded pieces
are reset, if required.
8. Welding is then carried out throughout the length of the lap joint, on
both the sides.
9. Remove the slag, spatters and clean the joint.
Precautions:
1. Use goggles, gloves in order to protect the human body.
2. Maintain the constant arc length.
Result The lap joint is thus made, using the tools and equipment as mentioned above.
Marks Awardeded:
Tools required:
1. welding transformer,
2. connecting cables,
3. electrode holder,
4. ground clamp,
5. Electrode
6. hipping hammer,
7. Welding shield etc.
Aim: preparation of butt joint as shown in figure using shielded metal arc welding process.
BUTT JOINT
Marks Awardeded: