1. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Manufacturing Processes Lab I MET 1321

2. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri MET 1321 – Course Introduction This is a lecture and laboratory course. Students familiarize themselves with industrial manufacturing techniques from a mechanical technology perspective. Co-requisite: MET 1311 or concurrently. If you do not meet the co-requisite requirement, then you are expected to withdraw from this course.

3. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Course texts The texts for the course are: Miller R.T. Welding Skills, 3rd edition. American Technical Publishers. Walker, J. R. Machining Fundamentals. The Goodheart-Willcox Co., Inc. The text is meant as a reference and for supplemental assigned reading, lecture notes will deviate in both content and approach.

4. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Course Objectives The objective of the course is to Students familiarize themselves with industrial manufacturing techniques from a mechanical technology perspective. The processes covered will introduce fundamental machine tool operations, basic metal joining techniques, Terminology (American Welding Society or AWS), and current safety practices.

5. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Course content- Topic coverage Part 1: Welding safety, Shielded metal arc welding, Gas metal arc welding, Gas Tungsten arc welding, Oxyacetylene welding, Fundamental of welding design, Precision measurement and inspection, Part 2: Machine tool safety, Cutting tool selection, Machine tool workholding, Speed and feedrate calculations, Materials properties.

6. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Part 1: What is Welding? The process of joining two members by the addition of heat and filler metal. Welding is the most economical and efficient way to join metals permanently. A large amount of welding is done by manual techniques where an electric arc or a gas flame is used to melt the metal in the joint.

7. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Welding Processes There are four main manual processes. They are called: 1.Manual Metal Arc welding (MMA or stick welding), 2.Tungsten Inert Gas welding (TIG), 3.Metal Inert Gas welding (MIG) and 4.Oxyfuel Welding (OFW)

8. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Welding Processes ARC Welding (AW) 1.Shielded Metal Arc Welding (Stick welding) 2.Gas Metal Arc Welding (MIG) 3.Gas Tungsten Arc Welding (TIG) 4.Flux Cored Arc Welding 5.Submerged Arc Welding 6.Plasma Arc Welding Oxyfuel Welding OFW Oxyacetylene Welding (OAW) Resistance Welding RW

9. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc (MMA) welding or informally as Stick Welding Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld.

10. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Fact 1: The world's most popular welding process, Fact 2: The process is used primarily to weld iron and steels (including stainless steel) but aluminum, nickel and copper alloys can also be welded with this method. Fact 3: The main advantages of shielded metal arc welding are that high-quality welds are made rapidly at a low cost. Shielded Metal Arc Welding (SMAW), or Manual Metal Arc (MMA) welding or Stick Welding

11. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Shielded Metal Arc Welding (SMAW), or Manual Metal Arc (MMA) welding or Stick Welding Shielded metal arc welding is performed by striking an arc ( electronic current AC or DC) between a coated-metal electrode and the base metal. Once the arc has been established (the weld is laid), the molten metal from the tip of the electrode flows together with the molten metal from the edges of the base metal to form a sound joint. This process is known as fusion.

12. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Shielded Metal Arc Welding (SMAW), or Manual Metal Arc (MMA) welding or Stick Welding The coating from the electrode forms a covering over the weld deposit, shielding it from contamination; therefore the process is called shielded metal arc welding.

13. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Shielded Metal Arc Welding (SMAW), or Manual Metal Arc (MMA) welding or Stick Welding The SMAW welding process typically is capable of producing three types of welded joints. They are:

14. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri MIG is an arc welding process that uses an arc between a continuous wire electrode and the weld pool. Wire is continuously fed from a spool. Argon is used as a shielding gas for nonferrous metals such as aluminum, and Carbon dioxide/carbon dioxide mixtures ( such as 75/25, 98/2) with argon are used as a shielding gas for steels. MIG welding is a commonly used high deposition rate welding process. MIG welding is therefore referred to as a semi-automatic welding process. Gas Metal Arc Welding (GMAW) or Metal Inert Gas (MIG) Welding Metal Active Gas (MAG) Welding

15. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Gas Tungsten Arc Welding (GTAW) Tungsten Inert Gas (TIG) GTAW or TIG is an arc welding process in which a shielding gas protects the arc between a non consumable tungsten electrode and the weld area. The shielding gas is helium or argon. It runs with or without filler metal. Usage: Joining thin-wall tubing and depositing the root pass in pipe joints. GTAW Produces high quality weldment.

16. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri A high temperature flame (normally made using acetylene gas and oxygen) is used to melt the edges of the parts that is welded together. Sometimes additional welding material needs to be added.  Can be used for most types of sheet metal welding.  The welding equipment is easy to transport and does not require external power supply.  It is typically slower than the electrical arc-welding processes.  The equipment is often found in small workshops and automobile workshops since it is also used for heating parts and for soldering. Oxyfuel Welding (OFW)

17. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Summary ARC Welding (AW) 1.Shielded Metal Arc Welding (Stick welding) 2.Gas Metal Arc Welding (MIG) 3.Gas Tungsten Arc Welding (TIG) Oxyfuel Welding OFW 4. Oxyacetylene Welding (OAW)

18. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is used here? It can be anything, but mainly by SMAW (MMA or stick welding)

19. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is this? Oxy-fuel welding

20. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is this? Gas Metal Arc Welding or MIG

21. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is this? SMAW (MMA or stick welding)

22. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is this? Gas Tungsten Arc Welding or TIG

23. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Test yourself What type of welding is this? Gas Metal Arc Welding or MIG

24. Manufacturing Processes lab 1 (MET 1321) Prof S. Nasseri Which one is which? Gas Metal Arc Welding or MIG SMAW (MMA or stick welding) Stick welding, Gas metal arc welding (MIG)