Grade 11 Welding Simulation Lesson COURSE CODE: WELDS1002 (STSENGS873) Objectives (PC 1.5, 1.6, 2.1) To identify MIG welding equipment and describe the welding procedure To identify TIG welding equipment and describe the welding procedure To demonstrate welding machine setup and produce practice welds

ARC Welding Arc welding is a processes where metals are melted and joined together using intense heat produced by an electric arc. (about 1400oc for steel) There are 3 main types of ARC Welding that you will be looking at in this course : MMA Manual Metal Arc (also called Stick welding or Shielded Metal Arc Welding - SMAW) MIG - Metal Inert Gas welding (also called Gas Metal Arc Welding – GMAW) TIG – Tungsten Inert Gas welding (also called Gas tungsten Arc Welding -GTAW) (Today we will look at MIG and TIG welding)

Metal Inert Gas Welding - MIG (also called Gas Metal Arc Welding – GMAW) Mig Welding is the most common electric ARC welding process used today. It is cheap, easy to use and is used both by professional and amateur welders. In MIG Welding the electrode is a thin metal wire that feeds through the welding gun and melts onto the base metal due to the electric arc between the wire and the base metal. A flow of an inert gas passes through the welding gun at the same time as the wire electrode. This inert gas (ARGON, CO2 or a mixture of these) acts as a shield to protect the weld process.

MIG Welding Equipment

Task Set up the simulator up to weld a flat plate using MIG. MIG Simulation Task Set up the simulator up to weld a flat plate using MIG. Step 1 Input Your Name or Initials

Step 2 Select the Practice Plate (coupon)

Step 3 GMAW Short Arc (MIG process)

Step 4 Set your welding position as shown (check that this is the position for your equipment)

Step 5 Select the Weld Booth for welding

MIG Settings for the practice plate (all of the following settings will affect the quality of your weld) Step 6 Choose 75%Argon 25%CO2 Set the gas flow at 16 L/min (or 30 CFH)

Step 8 Check that the machine is set as follows : GMAW (mig welding) Wire Speed: 6.3 m/min (250ipm) Power 18V, DC + You are now ready to start welding

Step 9 Put your mask on Press the gun to allow the wire and gas to come out and strike an arc.

Step 10 Hold the trigger and continue to weld at a steady pace in a straight line across the plate. (Check the quality of your work – it should be better than this)

Step 11 Set the Actions and continue welding Use the guides in GREEN for The best torch Angles The best torch distance Repeat the weld as often as you need with a ‘New coupon’.

Assessment Task 1: Check the quality and accuracy of your finished weld Repeat the weld as often as you need with a ‘New coupon’. Once you achieve a score greater than 60% Show your teacher. (You will be assessed as competent / Not yet competent)

Task 2: Label parts of the MIG welding equipment shown

Tungsten Inert Gas Welding - TIG (also called Gas tungsten Arc Welding -GTAW) TIG Welding is becoming more common in welding but is still mostly used by professional welders. TIG is a more controlled welding process and is better than MIG for non-steel welding e.g. Aluminium. In TIG Welding the electrode made of Tungsten. It makes an arc with the base metal and produces a molten pool of metal. Additional metal (filler rod) is usually added into the molten metal pool The tungsten electrode does not melt in this process. A flow of an inert gas passes out of the welding torch during welding. This inert gas (usually ARGON) acts as a shield to protect the weld process. TIG welding is not available on the simulator so we will look at real TIG welding

TIG Welding Equipment (filler rod not shown)

Task 3: Follow your teachers instructions and demonstrate a simple TIG weld on Aluminium flat plate.

Task 4: Record the machine settings for TIG welding aluminium and complete the diagram shown below. TIG Settings for Aluminium Aluminium Thickness:____________________ Voltage:________________________________ Current:__________________ Is this DC or AC ?______________