REPORT OF THE MANUFACTURING PROCESSES LABORATORY I

ELKIN JOSE DE AVILA

LUIS ALBERTO DE LEON MONTES
Sebastian Andres Olmos Salcedo

ATLANTIC UNIVERSITY
FACULTY OF ENGINEERING
MECHANICAL ENGINEERING PROGRAM
Barranquilla
2020
WELDING SPEED VARIABLES IN THE SMAW WELDING PROCESS
(ARC WELDING WITH COATED ELECTRODE)

ELKIN JOSE DE AVILA

 LUIS ALBERTO DE LEON MONTES
SEBASTIAN ANDRES OLMOS SALCEDO

REPORT OF THE MANUFACTURING PROCESSES I LABORATORY

ALFREDO WILLIAN BARRIOS GALVEZ

UNIVERSITY OF THE ATLANTIC

FACULTY OF ENGINEERING
MECHANICAL ENGINEERING PROGRAM
BARRANQUILLA
2020

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 CONTENT

Page.

GLOSSARY....................................................................................4

SUMMARY………………………………………………………………………………………5

1.
INTRODUCTION. 6

2. OBJECTIVES.7
2.1 GENERAL OBJECTIVE...............................................................................................7
2.2 SPECIFIC OBJECTIVES......................................................................................7

3. MACHINES, TOOLS, AND MATERIALS TO USE…………………………… 8

4. EXPERIMENTAL PROCEDURE…………………………………………………………9

5. COLLECTED DATA AND CALCULATIONS ………………………………………………9,11

6. THEORETICAL FRAMEWORK…………………………………………………………………………….11

7.CONCLUSIONS.12

8.BIBLIOGRAPHY. 13

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 GLOSSARY

ELECTRODE: An electrode is a pole of the circuit which generates an arc at its tip.
electric.

WELDING BEAD: We call a bead the continuous deposit of metal from

welding formed on the surface of the base metal.

MANUFACTURING PROCESSES: It is the grouping of precise tasks to transform

the original characteristics of raw materials.

Welding: Process used for the joining of ferrous and non-ferrous metals.

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 SUMMARY

One of the first advances in electric arc welding processes with

manual electrode, it was to use metallic electrodes in such a way that the heat from the
it would fuse both the base metal and the electrode metal and consequently obtain
automatically the necessary contribution material. This procedure, although
it solved the contribution problem, ultimately it turned out to be inconvenient, due to the difficulty
to maintain the arc and due to the severe oxidation of the melted metal, which is why it was chosen
to coat the electrodes in order to solve the previously mentioned problems
mentioned.

Welding, coated electrode, welding, bead.

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 1. INTRODUCTION

Currently, one of the most important methods for joining pieces and assemblies
metallics in general in the industries that contribute to the gross domestic product and advancement in
infrastructure of developed and developing countries is welding and its
technologies, therefore it is the responsibility of the manufacturing companies of products
soldiers check that the quality of their products complies with the
customer requirements and what is established in welding codes and specifications, and
a first step to ensure the quality of your products and the suitability and skill of
its welders are developing welding procedures that ensure
compatibility of the deposited welding metal with the base metal used and qualification
the welders and tackers according to the qualified welding procedure, this
evaluation of welders is very important for the company, as it allows
ensure the development of high-quality welded joints and also provides a guarantee, good
name and reliability to the company as well as to the welder, responsible for the application of
welding. It is also important that within the context of research, innovation
and development of mixed and hybrid processes in welding, of new base materials and of
contribution, and mechanical characterization and microstructure of welds and coatings
superficial studies conducted by technological institutions, universities, and centers of
research; the welding applications should be supported in addition to personnel
qualified, certified, and trained for that purpose must also be supported by
manufacturing, assembly, and welding procedures that ensure reliability of
the obtained results and therefore of the welded joints.
Hence, this work presents a teaching proposal within the context
of competency-based training in welding technologies that integrates the student
from the university with the industry based on project-based learning and
related strategies, while also presenting a methodology for the development and
qualification of welding procedures and qualification of welders from the
perspective of control and quality assurance resulting from the process itself of
teaching in the classroom.

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 2. OBJECTIVES

2.1 GENERAL OBJECTIVE

• Identify the different variables involved in a welding process

SMAW
• Recognize the basic elements necessary for security in the process

2.2 SPECIFIC OBJECTIVES

• Calculate the filler material needed for each weld bead

• Determine the heat provided in the process for the different types of cord.

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3. MACHINES, TOOLS, AND MATERIALS TO BE USED

• Welding helmet
• Protective glasses
• Hood to protect the head and neck
• Cutting disc, polishing disc
• Ball peen hammer
• Industrial piece squad
• Measuring tape
• Long sleeve leather protective gloves
• Engineering gloves
• Chisel
• Caliper
• Polisher
• Steel bristle brush
• Electrodes,
• Inverter type equipment
• Platinum 21x16 (material A36 steel)

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4. PROCEDURE

The procedure for the collection of the data analyzed in this report
it consisted of the presentation of a video recorded by engineer Alfredo Barrios, in the
time assigned for the development of the experience, during which several pauses were made
for its collection and subsequent analysis.

5. COLLECTED DATA AND CALCULATIONS

The procedure consisted of taking the times of the different cords in the process.
of welding, to then calculate the speed of this and the filler material.

ELECTRODE USED E6011, LENGTH OF 34.8 cm, DIAMETER OF 1/8 in

PARAMETERS Cordon 1 CORDON 2 CORDON 3
TENSION (V) 17 17 17
INTENSITY (A) 90 90 90
SPEED 0.316 0.117 O,133
SOLDEO (cm/seg)
LONGITUDE OF 20.6 10,9 13.5
CORD (mm)
T. PERFORMANCE 1 1 1
THERMAL CONTRIBUTION 4841.77 13076.92 11503.75
(julios/min)
TIME OF 65 93 101
FUSION OF
ELECTRODE (seg)
MATERIAL OF 1.30 0.597 O,514
CONTRIBUTION (cm3)

DISCRIMINATION OF VARIABLES

VSWelding speed ……………………………………………………..[cm/s]

LcCord length……………………………………………………... [mm]
TfElectrode melting time …………………………………………[s]
AsThermal contribution…………………………………………………………. [joules/min]
ɳ tThermal performance………………………………………………….. [Dimensionless]
Tension ………………………………………………………………….[Volts]

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I = Intensity ………………………………………………………………..[Amperes]

V t∗(T ∗I)
s =¿
Lc
¿ ; At =ɳ
tf VS

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 6. THEORETICAL FRAMEWORK

Welding can be considered a heat input process, through which it

join two metal pieces, possibly with the intervention of another substance or foreign material.
pieces or of its own nature. In metal cutting, the flame can be used.
coming from the combustion of a gas or the electric arc, therefore, the protocols for
Welding can be applied to metal cuts.
The risk factors that can occur in welding operations,
they come from both the base material to be welded and the filler material, as well as from the possible
reactions in the air. Its in-depth knowledge allows one to understand the
contaminants that may appear in the work atmosphere in each case, being of
great utility when its analysis and evaluation are carried out.

The base material is usually a metal piece. As the welding operations are
they develop at very high temperatures, favoring their disaggregation into particles of
colloidal size that oxidize easily in contact with the oxygen in the air, being able to
to affirm that, in the fumes generated during a welding operation, one can find
always the oxides of the metals that make up the base metal. Examples:

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 CONCLUSIONS

The methodology used for the development of welding procedures and

welders' certification under the code becomes a working tool in the
quality assurance of the welded joint that facilitates the preparation and interpretation
of the specifications of the procedure, the record of its qualification and the
welding qualifications for supervisors, technicians, engineers, and related personnel with the
welding technology.

BIBLIOGRAPHY

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Altube Basterrtxea, Iñigo (2015). Work in Confined Spaces. Training Institute
occupational risk practice. Registration number: 01/2015/429. Recovered the
March 18, 2016
Invalid input. Please provide text to translate.
s/confined_space_work.pdf

2. Safety recommendations for cutting and welding work, prevention services

from Valencia. Available at:
The provided text is a URL and does not contain translatable content.
CUTTING AND WELDING.pdf

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