FOUNDRY AND WELDING WORKSHOP

PRACTICALMANUAL

Prepared By
[Link], Lecturer

DEPARTMENT OF MECHATRONICS
PSG POLYTECHNIC COLLEGE (AUTONOMOUS)
Coimbatore-641 004
WORKSHOP FOUNDRY AND WELDING MANUAL
DEPARTMENT OF MECHATRONICS

Subject code : L21253

Name of subject : FOUNDRY WELDING WORKSHOP

Name : ………………………………..

Reg no : ………………………………..

Branch : ………………………………..

Year& Semester : ………………………………..

Vision of the Institution:

PSG Polytechnic College aspires to be recognized as one of the leaders in the development
of technical education and application of the knowledge and skills for the benefit of the society.

Mission of the Institution:

 Provide world-class engineering education, foster research and development.

 Evolve innovative applications of technology.
 Encourage entrepreneurship.
 Ultimately mould young men and women capable of assuming leadership
of the society for the betterment of the country.

Vision of the Department:

Department of Mechatronics aspires to be a pioneer in imparting technical knowledge and

multi disciplinary skills in the young minds to develop and implement applied automation
solutions in the industries and contribute to the development of the society.

Mission of the Department:

M1: Provide fundamental knowledge in multi disciplinary fields of Engineering an

instigate skills to develop innovative Mechatronics systems.
M2: Expose the students to latest technologies through continual improvement in the
curriculum.
M3: Encourage Entrepreneurship and nurture quest for knowledge.

Programme Educational Objectives (PEOs)

PEO1: The Diploma in Mechatronics Engineer will be able to apply the concepts of
Mechatronics to design, develop and maintain automation systems in industries.
PEO2: The Diploma in Mechatronics Engineer will be able to develop professional
competency by exploring latest technologies in industrial automation and attain skills for
sustainable growth.
PEO3: The Diploma in Mechatronics Engineer will be able to lead a team or contribute as
a part of the team with ethics and aptitude for continuous learning for the betterment of
society.
Program Outcomes (PO)
PO 1: Basic and Discipline specific knowledge:
Apply knowledge of basic mathematics, science and engineering fundamentals and engineering
specialization to solve the engineering problems.
PO2: Problem analysis
Identify and analyse well-defined engineering problems using codified standard methods.
PO3: Design/development of solutions
Design solutions for well-defined technical problems and assist with the design of systems
components or processes to meet specified needs.
PO4: Engineering Tools, Experimentation and Testing:
Apply modern engineering tools and appropriate technique to conduct standard tests and
measurements.
PO5: Engineering practices for society, sustainability and environment:
Apply appropriate technology in context of society, sustainability, environment and ethical
practices.
PO6: Project Management:
Use engineering management principles individually, as a team member or a leader to manage
projects and effectively communicate about well-defined engineering activities
PO7: Life-long learning:
Ability to analyse individual needs and engage in updating in the context of technological changes.
Program Specific Outcome (PSO)
PSO1: Demonstrate technical competency in the selection, production, testing and configuration
of components in Mechatronic systems.

PSO2: Develop and implement mechatronic systems by integrating mechanical, electronics and
control systems.
Course objectives:
 To provide an insight into different sand preparation and foundry equipment’s.
 To provide an insight into different welding tools and equipment’s.
 To provide training to students to enhance their practical skills.
 To practically demonstrate precautions to be taken during casting and welding.

Course outcomes

CO1:
Describe the various functions of tools and equipments used in foundry and welding process
CO2:
Demonstrate various skills of sand preparation, molding and welding

COs-POs Mapping
CO/PO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PSO1 PSO2

CO1 3 1 - 2 - - 1 3 - 3 1

CO2 3 1 - 2 - - 1 3 - 3 1
 LIST OF EXPERIMENTS

FOUNDRY
Introduction of tools and equipment. Types of patterns, Types of sands,
Preparation of sand moulds, core sands, preparation of core
1. Solid pattern
2. Pipe with flange-using split patterns
3. T-Pipe with flange- using split patterns
4. Bend pipe with flange- using split patterns
5. Stuffing Box- using split patterns
6. Tumbles- using split patterns

WELDING
7. Bead on plate
8. Square butt joint
9. T-joint
10. Lap-joint
11. Corner Joint
12. Edge joint
 FOUNDRY
Introduction: -
Foundry practice deals with the process of making casting in moulds,
formed in either sand or other material. This is found to be the cheapest method of
metal shaping. The process involves the operations of pattern making, sand preparation,
molding, melting of metals, pouring in moulds, cooling, shake out, fettling, heat
treatment, finishing, and inspection.
Mould is a cavity in a molding core, formed by a pattern. It is similar in
shape and size that of the actual casting plus some allowance for shrinkage, machining
etc., molding is the process of making molds.
Moulds are classified as: -
 Temporary moulds
 Permanent moulds

Temporary mould are made of sand and other binding materials and may be produced
either through hand molding (or) machine molding.

Permanent moulds are made of ferrous materials and alloys i.e., cast iron, steel etc.,
Molding Sand: -
Sand is the principle material used in foundry. The principle ingredients of molding sands are

1) Silicon sand 2) Clay 3) Sand

Clay imparts the necessary bonding strength to the molding sand, moisture when added
to correct preparation provides the bonding action to the clay sand can withstand high
temperature and doesn’t react with molten metal.
Natural molding sand is either available in river beds are dug from pits. It
possesses and appreciable amount of clay and are used as received with the addition
of water. Synthetic sands are prepared by adding clay. Water and other materials to
silica sand so that the desirable strength and banding properties are achieved.
Most of molding is done with green sand i.e.; sand containing 6 to 8%, moisture and
10% clay content to give it sufficient bond. Green sand moulds are used for pouring the
molten metal
– immediately after preparing the moulds. Green sand moulds are cheaper and take
less time to prepare. These are used for small and medium size casting.
Parting sand, which is clay tree, fence grained silica sand, is used to keep the
green sand from sticking to the pattern and also to prevent the cope and drug from
cleaning. Core sand is used for making cores. This is silica missed with core oil and
other oddities.
Pattern; -
A pattern is the replica of the desired coasting, which when packed in a
suitable materials produces a cavity called mould. This cavity when filled with
molten metals, produces their desired coasting of the solidification.
Types of pattern; -
Wood are metal patterns are used in foundry practice, single piece, split
loose piece and cored patterns are some of the common types.

Tools and equipment; -

The tools are equipment needed for molding are; -
Molding board: -
It is wooden board with smooth surfaces. It supports the flasks and the
pattern, while the mould is being made.
Molding Flask: -
It is a base, made of wood or metal, open at both ends. The sand is
rammed in after placing the pattern to produce a mould it is made of 2 parts;
cope is the top half of the flask, having guides for the aligning paints to enter.
Drag is the bottom half of the flask having aligning pins.
Shovel: -
It is used for mixing and tempering molding sand and for transferring the
sand in to the flask. It is made of steel blade with a wooden handle.
Rammer: -
It is used for pocking or ramming the sand, around the pattern one of its
ends called the peen end, is wedge shaped and is used for packing sand in
spaces, pockets and corners in the early stages of ramming. The other end
called the But – end has a surface and is used for computing the sand towards
the end of molding.
Strike of edge / strike of bar: -
It is a piece of metal or wood with straight edge. It is used remove the
excess sand from the mould after ramming to provide a level surface.
Spruce pin: -
It is tapered wooden pin used to make a hole in the cope sand through
which the molten metal is poured into the mould.
Riser pin: -
It is tapered wooden pin used to make a hole in the cope sand over the
mould cavity for the molten metal to rise and feed the casting to compassable
the shrinkage that take place during solidification.
Trowel: -
It is used to smoothen the surface of the mould. It may also be used for
reproducing the damaged portion of the mould. A trowel is made in many
different styles and sizes each one recallable for a particular hole.
 SOLID PATTERN
(SINGLE PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using Solid Pattern

Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sandmixing
3. Pouring
4. Finishing
All dimensions are in ‘mm’
Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit
it is covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of the
flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer,
using first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen
the upper surface.
[Link] the cope on to the drag in position. Locate riser pin on the highest
point of the pattern.
[Link] the sprue pin at about 5 to 6 cm from the pattern on the other
side of the riser pin.
[Link] the upper surface with parting sand.
[Link] steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
[Link] the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouring cup.
[Link] the cope and place it aside on its edge.
[Link] the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
[Link] and repair the mold by adding bits of sand, if necessary.
[Link] gate in the drag from the sprue to the mold. Blow off any loose
sand particles in the mold.
[Link] the mold by replacing the cope and placing weights on it.
Result:
A sand mold cavity is prepared by using Solid Pattern
 PIPE WITH FLANGE
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using Pipe with flange (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
PIPE WITH FLANGE

All dimensions are in ‘mm’

Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of the
flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer, using
first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest point
of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side of
the riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel shaped
hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Result:
A sand mold cavity is prepared by using Pipe with flange pattern.
 T-PIPE WITH FLANGE
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using T-Pipe with flange (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
T-PIPE WITH FLANGE

All dimensions are in ‘mm’

Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of
the flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer,
using first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest
point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side
of the riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Result:
A sand mold cavity is prepared by using T-Pipe with flange pattern.
 BEND-PIPE WITH FLANGE
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using Bend-Pipe with flange (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
BEND PIPE WITH FLANGE

All dimensions are in ‘mm’

\\\\
Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of
the flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer,
using first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest
point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side
of the riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Result:
A sand mold cavity is prepared by using Bend-Pipe with flange pattern.
 STUFFING BOX
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using Stuffing Box (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
STUFFING BOX

All dimensions are in ‘mm’

Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of
the flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer,
using first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest
point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side
of the riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Result:
A sand mold cavity is prepared by using Stuffing Box pattern.
 TUMBLES
(SPLIT PIECE PATTERN)
EXPERIMENT No: DATE:

Aim: - To prepare a sand mould cavity using Tumbles (split piece pattern).
Tools required: -
1. Molding board
2. Molding flask
3. Shovel
4. Riddle
5. Rammer
6. Strike-off bar or Strike Edge
7. Sprue pin
8. Riser pin
9. Trowel
[Link] or Draw pin
[Link]
[Link]
[Link] cutter
[Link]
[Link] rod
Material required: -
1. Molding sand
2. Parting sand
3. Dum-Bell
Sequence of operation: -
1. Sand preparation
2. Sand mixing
3. Pouring
4. Finishing
THUMBLES

All dimensions are in ‘mm’

Procedure: -
1. Place the pattern on the molding board, with its flat side on the board.
2. Place the drag over the board, after giving a clay wash inside.
3. Sprinkle the pattern and molding board, with parting sand.
4. Allow loose sand, preferably through a riddle over the pattern, unit it is
covered to a depth of 2 to 3 cm.
5. Pack the molding sand around the pattern and into the corners of
the flask, with fingers.
6. Place some more sand in the flask and pack the pattern with a rammer,
using first the peen end and then butt end.
7. Strike-off the excess sand from the top surface of the drag with the strike-off bar.
8. Turn the drag upside down.
9. Blow-off the loose sand particles with the bellows and smoothen the upper
surface.
10. Place the cope on to the drag in position. Locate riser pin on the highest
point of the pattern.
11. Place the sprue pin at about 5 to 6 cm from the pattern on the other side
of the riser pin.
12. Sprinkle the upper surface with parting sand.
13. Repeat steps 3 to 7, approximately.
14. Make holes with the vent rod to about 1 cm from the pattern.
15. Remove the sprue and riser pins by carefully drawing them out. Funnel
shaped hole is made at the top of the sprue hole, called the pouring cup.
16. Lift the cope and place it aside on its edge.
17. Insert the draw pin into the pattern. Wet the edges around the pattern.
Loosen the pattern by rapping. Then draw the pattern straight up.
18. Adjust and repair the mold by adding bits of sand, if necessary.
19. Cut gate in the drag from the sprue to the mold. Blow off any loose sand
particles in the mold.
20. Close the mold by replacing the cope and placing weights on it.

Result:
A sand mold cavity is prepared by using Tumbles pattern.
WELDING

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 andcharacteristics of the metals joined. In the beginning,
welding was mainly used for repairing all kinds ofworn or damaged parts. Now, it is
extensively used in manufacturing industry, construction industry(construction of ships,
tanks, locomotives and automobiles) and maintenance work, replacing rivetingand
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.

Electric arc welding

Arc welding is the welding process, in which heat is generated by an electric arc struck
between an electrode and the work piece. Electric arc is luminous electrical discharge
between two electrodes
through ionized gas.

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.
Fig:1 Arc welding set up

Fig :2 parts of an electrode

 Electric arc between the electrode and work piece closes the electric circuit. The
arc temperature may reach 10000°F (5500°C), which is sufficient for fusion the work
piece edges and joining them. When a long joint is required the arc is moved along the
joint line. The front edge of the weld pool melts the welded surfaces when the rear
edge of the weld pool solidifies forming the joint.
Transformers, motor generators and rectifiers’ sets are used as arc welding machines.
These machines supply high electric currents at low voltage and an electrode is used
to produce the necessary arc. The electrode serves as the filler rod and the arc melts
the surface so that, the metals to be joined are actually fixed together.
Sizes of welding machines are rated according to their approximate amperage
capacity at 60% duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This
amperage is the rated current output at the working terminal.
Transformers
The transformers type of welding machine produces A.C current and is considered
to be the least expensive. It takes power directly from power supply line and transforms
it to the voltage required for welding. Transformers are available in single phase and
three phases in the market. 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
depends 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 usingand coiling the cables. Cables are specified by their current carrying
capacity, say 300 A, 400 A, etc.
Electrodes
Filler rods are used in arc welding are called electrodes. These are made of
metallic wire called core wire, having approximately the same composition as the
metal to be welded. These are coated uniformly with a protective coating called flux.
While fluxing an electrode; about 20mm of length is left at one end for holding it with
the electrode holder. It helps in transmitting full current from electrode holder to the
front end of the electrode coating. Flux acts as an insulator of electricity. In general,
electrodes are classified into five main groups; mild steel, carbon steel, special alloy
steel, cast iron and non‐ferrous. The greatest range of arc welding is done with
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 andlength, 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,
stainless steel, 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.
Fig :3 Electrode holder Fig :4 Ground Clamp

Fig :5Wire brush Fig :6Chipping hammer

Fig :7Hand gloves Fig :8Face shield

WELDING TOOLS
Electrode holder
The electrode holder is connected to the end of the welding cable and holds the
electrode. Itshould 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.
Wire brush and chipping hammer
A wire brush is used for cleaning and preparing the work for welding. A chipping
hammer is used for removing slag formation on welds. One end of the head is
sharpened like a cold chisel and the other, to a blunt, round point. It is generally made of
tool steel. Molten metal dispersed around the welding heads, in the form of small drops,
is known as spatter. When a flux coated electrode is used in welding process, then a
layer of flux material is formed over the welding bead which contains the impurities of
weld material. This layer is known as slag. Removing the spatter and slag formed on
and around the welding beads on the metal surface is known as chipping.
Welding table and cabin
It is made of steel plate and pipes. It is used for positioning the parts to be welded
properly. Welding cabin is made‐up by any suitable thermal resistance material,
which can isolate the surrounding by the heat and light emitted during the welding
process. A suitable draught should also be provided for exhausting the gas produced
during welding.
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
TECHNIQUES OF WELDING
Preparation of work
Before welding, the work pieces must be thoroughly cleaned of rust, scale and
other foreign material. The piece for metal generally welded without beveling the edges,
however, thick work pieceshould be beveled or veed out to ensure adequate penetration
and fusion of all parts of the weld.
a) Ensure that the welding cables are connected to proper power source.
b) Set the electrode, as per the thickness of the plate to be welded.
c) Set the welding current, as per the size of the electrode to be used.

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
 BEAD ON PLATE

EXPERIMENT No: DATE:

Aim
To make a bead on plate using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X25X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
BEAD ON PLATE

All dimensions are in ‘mm’

Procedure
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 bead on plate has made, using the tools and equipment as mentioned above.
 BUTT JOINT

EXPERIMENT No: DATE:

Aim
To make a butt joint using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X50X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
BUTT JOINT

All dimensions are in ‘mm’

Procedure
10. Take the two mild steel pieces of given dimensions and clean the surfaces
thoroughly from rust, dust particles, oil and grease.
11. Remove the sharp corners and burrs by filing or grinding and prepare the work pieces.
12. The work pieces are positioned on the welding table, to form a lap joint with the
required over lapping.
13. The electrode is fitted in to the electrode holder and the welding current is set
to a proper value.
14. The ground clamp is fastened to the welding table.
15. 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
16. The alignment of the lap joint is checked and the tack‐welded pieces are reset, if required.
17. Welding is then carried out throughout the length of the lap joint, on both the sides.
18. Remove the slag, spatters and clean the joint.

Precautions:
3. Use goggles, gloves in order to protect the human body.
4. Maintain the constant arc length.

Result:
Butt joint is prepared as shown in figure by using arc-welding process
 T-JOINT

EXPERIMENT No: DATE:

Aim
To make a T joint using the given mild steel pieces and by arc welding.

Material used: Two mild steel pieces of 100X50X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
T JOINT

All dimensions are in ‘mm’

Procedure
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:
T-joint is prepared as shown in figure by using arc-welding process
 CORNER JOINT

EXPERIMENT No: DATE:

Aim
To make a Corner joint using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X25X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
CORNER JOINT

All dimensions are in ‘mm’

Procedure
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 corner 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 corner 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:
Corner joint is prepared as shown in figure by using arc-welding process
 EDGE JOINT

EXPERIMENT No: DATE:

Aim
To make a Edge joint using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X25X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
EDGE JOINT

All dimensions are in ‘mm’

Procedure
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 edge 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 edge 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:
Edge joint is prepared as shown in figure by using arc-welding process
 LAP JOINT

EXPERIMENT No: DATE:

Aim
To make a lap joint using the given mild steel pieces and by arc welding.

Material used: Two mild steelpieces of 100X25X6 mm.

Tools and equipment used
1. Arc welding machine,
2. Mild steel electrodes,
3. Electrode holder,
4. Ground clamp,
5. flat nose Tong,
6. Face shield,
7. Apron,
8. Hand gloves,
9. Metallic work Table,
10. Bench vice,
11. Rough flat file,
12. Try square,
13. Steel rule,
14. Wire brush,
15. Ball peen hammer,
16. Chipping hammer.
Operations to be carried out
1. Cleaning the work pieces
2. Tack welding
3. Full welding
4. Cooling
5. Chipping
6. Finishing
LAP JOINT

All dimensions are in ‘mm’

Procedure
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:
Lap joint is prepared as shown in figure by using arc-welding proces
VIVA VOCE QUESTIONS

FOUNDRY

1. What are the different types of manufacturing processes?

2. Define the term Casing?
3. Define the term Foundry?
4. What are the basic steps involved in manufacturing process?
5. Why is testing of Foundry Sands necessary?
6. What are the common tests performed on foundry sand?
7. Discuss how the grain size and shape affects the performance of foundry sand.
8. Name different tools and equipments used in foundries.
9. What is a pattern? 10. Name the different types of patterns used in the laboratory
11. Distinguish between split pattern and solid pattern.
12. What are the different additives used in moulding sand?
13. Differentiate between moulding sand and core sand.
14. What is base sand? 15. What are the functions of clay and water in moulding sand?
16. Define Permeability or porosity 17. Discuss the function of dowel pins in moulding
18. What is a core and state its function?
19. What are the purpose of runner and riser in castings?
20. What is a gating system?
21. Name the different materials used for pattern making?
22. How does green strength of moulding sand vary grain size, shape, clay content etc?

WELDING

Define welding. List out its uses.

Explain why shielding of weld area during welding is required
Point out the different types of Oxyacetylene flame by sketches
List out the various types of welding.
List out the flame characteristics.
5Define the role flux in welding operation
Explain the principle of manual metal arc welding
Define spelter and give the composition of some commonly used sp
List the advantages of AC equipment over DC equipment in arc Weld
Explain the difference between soldering and brazing.
Define Brazing process.
Define Soldering Process.
Define Friction welding.
Formulate the process parameters in FSW.
Explain thermit welding briefly.
Differentiate between transferred and non transferred plasma arc w
automotive bodies and in large appliances.
Show that the seam welding is an application of spot welding.
Give the meaning of Nugget in Electric Resistance Welding.
List any four welding defects.
Examine the causes of Welding defects.