Workshop Practice Manual (Sem-3&4)

MECHANICAL WORKSHOP MANUAL

WELDING

COURSE CODE : C207&C217

SEMESTER : 3&4
REVISION : 2021
COURSE NAME : MECHANICAL WORKSHOP III/IV

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 SAFETY PRECAUTIONS

PERSONAL SAFETY

 Wear tight clothes; beware of hanging hair, ties, clothing, scarves or belts
getting caught.
 Never enter the workshop without safety shoes.
 Do not use rings, watches etc. while working.
 Keep the workshop clean and tidy. The floor should be free from oil and
grease; the slippery floor is always dangerous.
 Wear goggles whenever there is danger of flying matter.
 Never attempt to measure the job in running.
 Always stand in respectful distance from moving and hanging parts.
 Practice cleanliness and orderliness in the shop.
 Do not run or play on the shop floor.
 Keep your body behind the sharp edges of cutting tools.
 Do not attempt to lift heavy articles without assistance.
 Never handle chips or shavings with bare hands; use special hooks,
brushes etc.
 Never place sharp tools on the floor or at the edges of the workbench;
keep them in proper place assigned for them.
 Be aware the cause of electrical hazards such as bare wires, poor earthing,
return connections, wet floors etc.

MACHINE SAFETY
 Never operate the machine unless you have been properly instructed.
 Never work on the machine having unguarded moving parts.
 Stop the machine immediately, if it produces any unusual sounds.
 Before starting an operation, always check whether the work and cutting
tools are secured fast.
 Never leave a machine when it is running.
 Never mount or remove the work, replace tools, clean or lubricate the
machine, or remove the swarf, while the machine is running.
 Do not run the machine in an incorrect speed.
 Workshop Practice Manual (Sem-3&4)
 Do not talk or disturb others while they are operating a machine.

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JOB SAFETY
 Use right tools for right job.
 Use metal strips to hold work pieces like Brass or Aluminum, to avoid
gripping marks on the finished surface.
 Put oil lightly on finished jobs to avoid rust.
 Tools with loose fitting or broken handles shall not be used.
 To save the time and material, frequent checking has to be made.
 Do not mix the precision measuring instruments with other tools and
equipment.
 Store inflammable materials like kerosene, turpentine etc. away from the
shop.
 Be aware of the details and location of firefighting devices like firebuckets,
fire extinguishers etc. and first aid box in the workshop.

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 Workshop Practice Manual (Sem-3&4) - Welding

WELDING SAFETY PRECAUTIONS

To prevent injury to personnel, extreme caution should be exercised when

using any types of welding equipment. Injury can twill from fire, explosions,
electric shock, or harmful agents. Both the general and specific safety
precautions listed below must be strictly observed by workers, who weld or cut
metals,
 Do not permit unauthorized persons to use welding or cutting,
equipment.
 Do not weld in a building with wooden floors, unless the floor', are
protected from hot metal by means of fire, resistant fabric, and, or other
fireproof material. Be sure that hot sparks or hot metal will not fall on
the operator or on any welding equipment components.
 Remove all flammable material, such as cotton, oil, gasoline, etc from
the vicinity of welding.
 Before welding or cutting, warn those in close proximity who are not
protected to wear proper clothing or goggles.
 Remove any assembled parts from the component being welded that
may become warped or otherwise damaged by the welding process.
 Do not leave hot rejected electrode stubs, steel scrap, or tools on the
floor or around the welding equipment. Accidents and/or fires may occur.
 Keep a suitable fire extinguisher nearby at all times. Ensure the fire
extinguisher is in operable condition.

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 WELDING

Electric Welding Process Gas Welding Process Other Welding Processes

Oxy- Oxy- Oxy- Oxy- Air-

acetylene hydrogen coal liquefied acetylene
gas gas gas gas gas
welding welding welding welding welding

Electric Induction Laser Electron Electric Thermit Forge Plastic Friction Ultrasonic Explosive Cold
Arc Welding welding Beam Resistance Welding Welding welding welding welding welding Pressure
Welding welding welding welding

Workshop Practice Manual (Sem-3&4) - Weldin

Spot Seam Butt Flash Projection
Welding Welding welding Butt
welding
 Workshop Practice Manual (Sem-3&4) - Welding

WELDING
INTRODUCTION
Welding is a process of joining similar or dissimilar metal pieces. Welding is
metal joining method in which the joining edges are heated and fused together
to form a permanent bond. Riveting, assembling with bolt, seaming, soldering
and brazing all result in temporary joints. Welding is the only method to join
metals permanently. It is the strongest joints and type of metal any thickness
can be joined. Welding joints cannot b separated like soldering and brazing
because it is made homogeneous by heating and fusing the joining edges
together. Even though there is draw back in welding joints because of the
twisting due to shrinkage of joints while the solidification of molten material in
the joints. Welding is superior to other metal joining methods because it.
- It is a permanent pressure tight joint.
- Occupies less space
- Gives more economy of material
- Has less weight
- Withstands high temperature and pressure equal to joint material
- Can be done quickly
- Gives no color change to joints
Welding methods are classified in to:
1. Fusion method without pressure/with pressure
2. Non fusion method
FUSION WELDING WITHOUT PRESSURE
A method of welding in which similar and dissimilar methods are jointed
together by melting and fusing their joining edges with or without the addition
of filler metal but without the application of any kind of pressure os known as
fusion welding. The joint made is permanent.
PRESSURE WELDING
This is a method of welding in which similar metals are joined together by
heating them to plastic or partially molten state and then joined by pressure
or hammering without the use of filler metal. This is fusion method joining with
pressure. The joint is made permanent. Heat source may be black smiths forge
(forge welding) or electric resistance (resistance welding) or friction.

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ARC WELDING PROCESS

TYPES OF WELDED JOINTS

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NON FUSION WELDING

This is a method of welding in which similar or dissimilar metals are joined
together without melting the edges of the base meal by using a low melting
point filler rod but without the application of pressure.
Eg: soldering, brazing and bronze welding.
ARC WELDING
PRINCIPLE
Electric arc is formed when both the terminals of an electric circuit are brought
together and then separated by a small gap. When high current passes through
an air gap from one conductor to another, it produces very intense and
concentrated heat in the form of a spark. The temperature of this spark (or
arc) is approximately 3600°C, which can melt and fuse the metal very quickly
to produce a homogeneous weld.
ARC LENGTH
It is the straight distance between the electrode tip and the job surface when
the arc is formed. There are three types of arc lengths,
1. Medium and normal
2. Long
3. Short
1. Medium or Normal Arc
The correct act length or normal arc length is approximately equal to the
diameter of the core wire of the electrode. It is used to weld mild steel using a
medium coated electrode.
2 .Long Arc
If the distance between the tip of the electrode and the base metal is more
than the diameter of the core wire it is called a long arc. It is used in plug and
slot welding, for restarting the arc and while withdrawing the electrode at the
end of a bead after filling the crater. Generally long arc is to be avoided as it
will give a defective weld.
3. Short Arc
If the distance between the tip of the electrode and the base metal is less than
the diameter of the core wire, it is called a short arc. It s used for root runs to
get good root penetration for positional welding and while using a heavy coated
electrode, low hydrogen, iron, power and deep penetration electrode.

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POLARITY IN ARC WELDING

Polarity indicates the direction of current flow in the welding circuit. Direct
current always flows from, the positive (higher potential) terminal to the
negative (lower potential) terminal, as per the conventional theory. Negative
terminal to positive terminal, as per electronic theory. In the latest machines
a polarity switch is used to change the polarity.
In AC, we cannot utilize the polarity as the power source changes its poles
frequently.
In DC welding, 2/3rd of the heat is liberated from the positive end and 1/3rd
from the negative end. To have this advantage of unegual heat distribution in
the electrode end base metal, the polarity is an important factor of successful
welding.
TYPES OF POLARITY
Straight polarity: In straight polarity, the electrode is connected to the negative
and the work to the positive terminal of the power source.
Reverse Polarity: In reverse polarity the electrode is connected to the positive
and the work to the negative terminal of the power source.
ELECTRODE SIZES
The electrode size refers to the diameter of its core wire. Each electrode has a
certain current range. The welding current increases with the electrode sizes.
Electrode Sizes:-
1.6mm, 2.0mm, 2.5mm, 3.15mm, 4.0mm, 5.0mm, 6.0mm, 6.3mm, 8.0mm,
10.mm. the electrodes are manufactured in two different lengths, 350mm or
450mm.
TYPES OF ELECTRODE
Electric arc welding electrodes are of three general types. They are carbon
electrodes, bare electrodes, flux coated electrodes.
ARC WELDING MACHINES
In arc welding process, the sources of het is electricity (high ampere-low
voltage). The required electrical energy for welding is obtained from an arc
welding machine, a power source.

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LAYOUT OF ARC WELDING EQUIPMENT

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The equipment is used to,

- Provide AC or DC welding supply for arc welding.
- Change the high voltage of the main supply to low voltage and
heavy current supply (AC or DC) suitable for arc welding.
- Establish a relationship between arc voltage and welding current.
- Control and adjust the required welding current during arc welding.
- Weld with all gauges of electrode.
- Weld with all gauges of electrode.
- Weld thin and thick plates, both ferrous and non ferrous metals.

Basically, power sources are:

1. Alternate current welding machine
2. Direct current welding machine

DC MACHINES: 1. Motor generator set

2. Engine generator set
3. Rectifier set
AC MACHINES: 1. Transformer set

AC WELDING TRANSFORMER
This is a type if AC welding machine which converts AC main supply into AC
welding supply. AC main supply has high voltage-low ampere. AC welding
supply has high ampere-low voltage. It is a step down transformer, which:
- Reduces the main supply voltage (220v or 440v) to welding supply
open circuit voltage (ocv) between 40 and 100 volts.
- Increases the main supply low current to the required high output
welding current in hundreds of amperes.
The main AC supply (220-440v) is connected to the primary winding which
produces a magnetic line of force in the iron core. The magnetic lines of force
affect the secondary winding and induce high ampere-low voltage welding
supply in it. This action is called the principle of mutual induction.

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DC WELDING GENERATOR
DC welding generator are used to,
- Generate DC welding supply with the help of AC main supply
- Generate welding supply where electricity (main supply) is not
available, with the help of engine driven sets.
- Get relative advantages of polarity, heat distribution between the
electrode and the base metal and welding non ferrous metals.
COMPARISON BETWEEN AC AND DC ARC WELDING
AC ARC WELDING DC ARC WELDING
1. The AC welding transformer has no 1. The DC welding generator has
moving parts and is simpler. rotating parts and is more
complicated.
2. The transformer costs less and its 2. The generator cost more and its
maintenance cost is low maintenance cost is high
3. Since the distribution of heat is 3. Heat distribution is different in two
equal, therefore there is no need for poles by changing the polarity, all
changing. Hence only ferrous metals types of metals can be welded by DC
are usually welded by AC
4. All types if electrodes cannot be 4. All types of electrodes bare or
used in AC arc welding, because the coated can be used in DC arc welding,
current constantly reverses with every because the polarity can be changed to
cycle. Only coated electrodes can be suit the electrode.
used.
5. The problem of arc blow does not 5. In DC the arc blow is severe and
arise as it is very easy to control. cannot be controlled easily.
6. The arc is never stable 6. The arc is more stable.
7. It can be used only when AC 7. In the absence of AC main supply,
supply from the main is available. an engine driven DC generator set can
be used.
8. AC is more dangerous. 8. DC is comparatively less
dangerous.

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WELDING DEFETCS
Always a defective welded joint will have the following bad effects:
- The effective thickness of the base metal is reduced
- The strength of the weld is reduced
- The joint will break, when loaded, causing accident.
- The effective throat thickness is reduced.
- The properties of base metal will change
- More electrodes are required which will also increase the cost of
welding
- Waste of labour and materials
- The weld appearance will be poor

Weld defects may be considered under two heads. External defects

and internal defects.
EXTERNAL DEFECTS INTERNAL DEFECTS
1. Under cut 1. Cracks
2. Cracks 2. Blow hole and porosity
3. Blow hole and porosity 3. Slag inclusions
4. Slag inclusions 4. Lack of fusion
5. Edge of plate melted off 5. Lack of root penetration
6. Excessive convexity 6. Internal stresses
7. Excessive concavity
8. Overlap
9. Mismatch
10. Uneven/irregular bead appearance
11. Spatters

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GAS TUNGSTEN ARC WELDING

GAS METAL ARC WELDING

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GAS TUNGSTEN ARC WELDING (TIG)

The gas tungsten arc welding process fused melts by heating them between a
non consumable tungsten electrode and work piece. The heat necessary for
fusion is provided by an arcing electric current between the tungsten electrode
and the base metal. The tungsten electrode and the weld zone are shielded
from the atmosphere by an inert has, such as argon or helium. Filler metal may
be or may not be used, this process is also called TIG (Tungsten Inert Gas)
welding. This welding is used for stainless steel, aluminium, titanium and many
other non ferrous metals. Tig welding process produces sound weld because
there is very little smoke, fumes or sparks.
Advantages:
- Highly suitable for joining reactive metals like stainless steel,
aluminum, magnesium etc.
- More economical use of filler wire and higher welding speed
- It is always clean and without any oxidation
- It produces high quality weld in non-ferrous metals
- The arc and weld pool are clearly visible to the welder
GAS METAL ARC WELDING (MIG)
Gas metal arc welding is a gas shielded metal arc welding process which uses
the high hear of an electric arc between a continuously fed, consumable
electrode wire and the material to be welded. In this process the wire is fed
continuously from a reel through a gun to constant surface which imparts a
current upon the wire. A fixed relationship exists between the rate of wire burn
off and the welding current. The current ranges from 100 to 400A depending
upon the diameter of wire and the speed of melting of the wire may be up to
5m/min. In this welding, the welding area is flooded with a gas (an inert gas)
which will not combine with the metal. The rate of flow of this gas is sufficient
to keep oxygen of the air away from the hot metal surface while welding is
being done. Carbon dioxide (CO2), Argon helium mixtures, argon-oxygen
mixtures are used as inert gases for this welding.

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SPOT WELDING

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Advantages:
- No flux required
- High welding speed
- Increased corrosion resistance
- Easily automated welding
- Welds all metals including aluminum and stainless steel
- High economy
SPOT WELDING
This type of resistance welding machine is most commonly used for resistance
welding. The material to be joined is placed between two electrodes. Pressure
is applied after a quick shot of electricity is sent from one electrode through
the job to the other electrode. Spot welding is made in three steps. The first
step is when the parts to be joined are clamped between the electrodes. In the
second step a high current is allowed to pass through the clamped members
and is raised to the welding temperature. The third step sees the current being
cut off and high pressure being applied to the joint and the joint completed.
The pressure may be developed by afoot lever or by air pressure or by hydraulic
cylinders. This may be used to weld steel and other metal parts up to a total
thickness of 12 mm. A special copper alloy material has been developed for
use as electrodes. It can be used for steel, aluminium, copper, stainless steel,
galvanized metals etc.
GAS WELDING
Gas welding is a process o joining similar metal by a gas flame with the
application of pressure and with or without use of filler metal. Oxy-acetylene
flame and oxy-hydrogen flame are generally used in this process.
EQUIPMENTS AND ACCESSORIES FOR GAS WELDING
1. Cylinders
2. Regulators
3. Low pressure gas generator
4. Hose pipes
5. Hose clips
6. Hose protector

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7. Blow pipe
a). high pressure blow pipe
b). low pressure blow pipe
8. Gas cutting torch and railing
9. Spanners
10. Cylinder key
11. Welding goggles and helmet
12. Spark lighter
13. Protective clothing
14. Tongs
15. Tip cleaner
16. Chipping hammer
17. Carbon steel wire brush
In a gas welding the direction of travel and the tilt of the torch and the welding
rod have appreciable effects on the speed and quality of welding. Three typical
procedures that may be employed are,
1. Leftward or forward
2. Rightward or backward
3. Vertical
The temperature of the oxy-acetylene flame in its hottest region is about
3200°C.
The functions of a pressure regulator are, to reduce the cylinder pressure to
the required working pressure and also to produce a steady flow of gas
regardless of the pressure variations at the source.
REGULATOR PRESSURE FOR GAS WELDING
The pressure required for gas welding depends on the thickness of the plates
to be welded. For plates of thickness of about 1 to 25mm, the regulator
pressure in oxygen and acetylene varies from 0.15 to 0.75kg/cm2 (15 to
70kN/m2) and for plate thickness over 25mm, the pressure of each gas is about
0.98 kg/cm2 (98 kN/m2).
The cutting torch differs from the regular welding blowpipe in most cases; it
has an addition lever for the control of cutting oxygen used to cut the metal.

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CUTTING TORCH

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Usually different tip sizes are provided for cutting metals of different thickness.
Pieces of wires or rods of standard diameter and length used as filler metal in
the joint during gas welding process are called filler rods or welding rods. The
size of the filler rod is determined from the diameter as 1.0, 1.2, 1.6, 2.0, 2.5,
3.15, 4.0, 5.0 and 6.3mm. length of filler rod 500mm or 1000mm.
Oxygen cylinders painted in black colour. Oxygen cylinders can store gas to a
capacity of 7 m3 with the pressure ranging between 120 to 150 kg/cm2. Oxygen
has cylinder valves are right hand threaded. Acetylene cylinders are painted in
maroon colour. The normal storing capacity of storing acetylene in dissolved
state us 6 m3 with the pressure ranging between 15-16 kg/cm2. Acetylene gas
cylinder valves are right hand threaded.
Blowpipes are used to control and mix the oxygen and acetylene gases to the
required proportion. The size of the nozzle varies according to the thickness of
the plates to be welded.
TYPES OF FLAME
There are three types if flame producing in the oxy-acetylene process.
NEUTRAL FLAME
Oxygen and acetylene are mixed in equal proportion in the blowpipe. It is used
to weld most of the common metals ie. Mild steel, cast iron stainless steel,
copper and aluminium.
OXIDISING FLAME
It contains an excess of oxygen over acetylene as the gases come out of the
nozzle. It is used for welding of brass and for brazing of ferrous metals.
CARBURISING FLAME
It receives an excess of acetylene over the oxygen from the blowpipe. It is
used for welding of aluminum.
OXY-ACETYLENE CUTTING PROCEDURE
Fix a suitable size cutting nozzle in the cutting blow pipe. Ignite the torch in
same way as was done in the case of the welding pipe. Set the neutral flame
for preheating. To start the cut, hold the cutting nozzle at angle 90° with the
plate surface, and the inner cone of the heating flame 3mm above the metal.

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TONGS

EARTHING CLAMP

EARTHING CLAMP
CHIPPING HAMMER

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WIRE BRUSH

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Preheat the metal to bright red before pressing the cutting oxygen lever. If the
cut is proceeding correctly, a shower of sparks will be seen to fall from the
underside of the plate. Move the torch steadily on the punched line. If the edge
of the cut appears to be too ragged, the torch is being moved too slowly. For
a bevel cut, hold the cutting torch at the desired angle and proceed as is done
in making a straight line cut. At the end of the cut, release the cutting oxygen
lever and close the control valves of the oxygen and acetylene. Clean the cut
and inspect.
TOOLS
1. CHIPPING HAMMER
A special type of hammer having one end sharpened and the other end
flattened. It is used for chipping the slag after welding and it is made with mild
steel or high carbon steel.
2. EARTHING CLAMP OR GROUND CLAMP
The ground clamp that completes the circuit between the electrode and the
welding machine is generally fastened to the metal being welded either with a
clamp, a bolt or some other means depending on the size of the metal
3. WIRE BRUSH
The wire brush, which removes small particles of slag, is generally made of
stiff steel wire embedded in wood.
4. ELECTRODE HOLDER
It is fitted at the end of the electrode cable. It should be light in weight and
well insulated the holder should have sufficient current carrying capacity.
5. CABLES AND CABLE CONNECTORS
Cables or leads are intended to carry the electric energy from welding
machine to work. The cables are flexible and well insulated. the cables are
generally made up of copper or aluminum wire. Welding cables are connected
by mechanical connectors soldering, welding or brazing. the mechanical
connectors are the connection leads that are probably most used because they
can be more easily assembled and dismantled.
6. CABLE LUGS
Cable lugs are used for connecting the cables to the welding machine. One
of the cables fastened to the c able lug by means of soldering or pressing

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FACE SHIELD HAND GLOVES

ELECTRODE HOLDER CABLE LUG

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7. FACE SHIELD
Face shield must be used to protect the operators face and eyes from flying
particles of spatters and burning action of the ultraviolet and infra red rays
given off by the arc. There are two types of lenses used in the protective shield
known as colour lenses and cover glass. The other lens is designed to absorb
the infra red rays and ultraviolet rays. Cover glasses are used in front of the
colour lens to prevent weld spatters from making or clouding the colour lens
chemically treated non spatters cover glasses to provide the best protection.
8. HAND GLOVES
Hand gloves are used to protect the hands from the ultra violet and infra red
radiations as well as the heat that is given off by the arc column. Hand gloves
also protect the hand from minor burns during the chipping operations. The
gloves should be worn at all times during the welding process.
9. APRONS
Aprons are two types, asbestos apron and lead limed leather aprons. Apron
is also protective clothing used to prevent the hot metal and harmful hot rays
attack on the body.
10. SAFETY GOGGLES
Goggles made of plastic frame and plane protective glasses are used while
chipping, so that any particles of slag may not strike on the eyes.

*****

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STRAIGHT LINE VELDING PRACTICE-

VERTICAL

Exercise No.1 Date:

AIM
To make a rectangle MS piece as per given dimensions and arc striking
practice.

MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 1 No.
MS Electrode – ∅3.15mm x 350 mm – 1 No.

TOOLS AND EQUIPMENTS REQUIRED

Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield,
apron, gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen
hammer.

OPERATIONS TO BE CARRIED OUT

Measuring, marking, cutting, holding, filing, checking, setting, arc striking
and maintaining, chipping and cleaning.

PROCEDURE
- Measure and mark the MS flat in required dimension with steel rule, try
square, scriber
- Cut it with the help of hack saw and bench vice
- Hold the work in bench vice and file the adjacent edges and check the
straightness and 90° angle
- Place the work piece on the welding table and switch on the welding
machine and set the required current.
- Hold the electrode in the electrode holder and touch the electrode tip
on the work piece either scratching or hitting method.
- Strike the arc and maintain it with proper arc length, slow speed and
electrode angle.
- Hold the hot work with tongs and allow to cool slowly.
- Chip out the slag and spatters with chipping hammer, chisel and ball
peen hammer
- Clean the work by wire brush and subject to visual inspection.
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Exercise No.2 Date:

SINGLE SQUARE BUTT JOINT-VERTICAL

AIM
To make a straight-line welding in down hand position by arc welding
process MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 1 No.

MS Electrode – ∅3.15mm x 350 mm – 1 No.

TOOLS AND EQUIPMENTS REQUIRED
Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield, apron,
gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen hammer.
OPERATIONS TO BE CARRIED OUT
Measuring, marking, cutting, holding, filing, checking, setting, arc striking and
maintaining, welding, chipping and cleaning.
PROCEDURE
- Mark the required length using a steel rule and a scriber cut the work
piece with a hacksaw.
- Hold the work piece in the bench vice and file the length side. Check the
level with steel rule.
- File the adjacent side and check the angle with try square. Mark the
required width and length then file that side.
- Check the angle with try square and Mark the center and punch through
the center line using dot punch and ball peen hammer.
- Put the work piece on the work table and connect the phase cable to the
electrode holder and neutral cable to the work.
- Start the AC transformer or DC generator set then Check the ampere
before striking the arc according to the diameter of the electrode and
Insert the electrode into electrode holder.
- Touch the electrode on the work piece. Then create Arc and maintain that
arc up to required length. Remove the slag using a chipping hammer.
- Clean the work with wire brush. Cool the work piece

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Exercise No.3 Date:

SINGLE V BUTT JOINT-VERTICAL POSITION
AIM
To make a square butt joint welding in down hand position by arc welding
process
MATERIALS REQUIRED
MS flat 102 x 40 x 6 mm - 2 No.
MS Electrode – ∅3.15mm x 350 mm – 1 No.
TOOLS AND EQUIPMENTS REQUIRED
Steel rule, Try square, scriber, hacksaw, bench vice, flat file, face shield, apron,
gloves, tongs, chipping hammer, wire brush, flat chisel and ball peen hammer.
OPERATIONS TO BE CARRIED OUT
Measuring, marking, cutting, holding, filing, checking, setting, tacking,
welding, chipping and cleaning.
PROCEDURE
- Mark the required length using a steel rule and a scriber and Cut the
work piece with a hacksaw.
- Hold the work piece in the bench vice and file the length side and Check
the level with steel rule.
- File the adjacent side and check the angle with try square and Mark the
required width and length then file that sides and check the angle with
try square.
- The gap between two work piece are 2 mm. Put the work piece on the
work table and connect the phase cable to the electrode holder and
neutral cable to the work.
- Start the AC transformer or DC generator set. Then Check the ampere
before striking the arc according to the diameter of the electrode and

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Insert the electrode into electrode holder .

- Tack the work piece and check the levels, Touch the electrode on the
work piece. Then create Arc and maintain that arc up to required length.
Remove the using a chipping hammer.
- Clean the work with wire brush. Cool the work piece.

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