🏆 MEQ444 Welding Challenge
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1.0 Introduction
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. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Diagram of the SMAW process, showing the core components like the electrode, shielding gas, weld pool, and slag layer.
2.0 Objective
- To demonstrate some mostly used welding processes.
- To build a welded bead technique on a mild steel plate.
3.0 Apparatus
Equipment List:
- ⚡ Power Supply (17-40V, 120A) - AC, DCRP, or DCSP
- 🔧 Arc Welding Machine
- 🔩 Thin plates of mild steel (workpiece)
- 🔌 Electrode holder with leads
- 📎 Ground Clamp with leads
- 📏 Welding Electrodes (various diameters)
- 🔨 Chipping Hammer
- 🧹 Wire Brush
- 🦺 Personal Protective Equipment (PPE)
A typical welding setup including the power supply, electrode holder, and ground clamp.
4.0 Method of Approach
Follow these steps carefully. Mark each step as complete as you finish it.
Safety Instructions
Welding is a potentially hazardous process.
To minimize injury risk, be aware of the hazards and use all required Personal Protective Equipment (PPE). The three major injury cases are:
1. Eye Damage
Caused by the intensely bright arc. Always use a welding face mask.
2. Molten Metal Burns
Hot slag and metal can cause severe burns. Wear safety gloves and protective clothing.
3. Conductive Burns
Direct contact with a freshly welded (and hot) workpiece can cause burns.
🦺 Required Personal Protective Equipment (PPE)
Welding Helmet
Auto-darkening lens protects eyes from UV/IR radiation and bright arc flash.
Safety Goggles
Additional eye protection during grinding and slag removal.
Welding Gloves
Heat-resistant leather gloves protect hands from sparks and hot metal.
Safety Boots
Steel-toe boots with metatarsal guards protect feet from falling objects.
Welding Jacket
Flame-resistant jacket or apron protects body from sparks and spatter.
Safety Trousers
Fire-resistant trousers without cuffs to prevent spark collection.
🎮 Interactive Practice Zone
Complete all 4 games to test your welding knowledge and skills. Each game is timed for competitive scoring!
🔥 Game 1: Master the Welding Bead
Draw a straight welding bead along the guideline. Stay accurate for combo bonuses!
⚡ Game 2: Arc Striking Blitz
Tap/click on targets to strike the arc! Chain hits for massive combo bonuses!
🦺 Game 3: PPE Safety Quiz
Tap the correct PPE for each body part! Test your safety knowledge!
Click "Start Quiz" to begin!
Answer 6 PPE safety questions
📐 Game 4: Torch Angle Master
Tap/drag to match the target angle! Keep your torch steady for higher scores!
5.0 Grading Rubric
The lab report will be graded based on the following criteria. Please review them carefully to understand the expectations for a high-quality report. Total marks: 100.
Report Question
Address the following question in your discussion section:
"What are the factor considerations in producing good quality joints?"
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