gas welding report.docx
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[Nama]| 01DKP13F1030 | 18 Oktober 2013
KM 104GAS WELDING REPORT
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PAGE 1
DEFINITION OF WELDING
Welding is a materials joining process which produces coalescence
of materials by heating them to suitable temperatures with or without the
application of pressure or by the application of pressure alone, and with or
without the use of filler material.
Welding is used for making permanent joints. It is used in the
manufacture of automobile bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks, furniture, boilers, general repair
work and ship building.
DEFINITION OF GAS WELDING
It is a fusion welding in which strong gas flame is used to generate
heat and raise temperature of metal pieces localized at the place where
joint is to be made. In this welding metal pieces to be joined are heated.
The metal thus melted starts flowing along the edges where joint is to be
made.
A filler metal may also be added to the flowing molten metal to fill
up the cavity at the edges. The cavity filed with molten metal is allowed to
solidify to get the strong joint. Different combinations of gases can be
used to obtain a heating flame. The popular gas combinations are oxy-
hydrogen mixture, oxygen-acetylene, and etc. different mixing proportion
of two gases in a mixture can generate different types of flames with
different characteristics.
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PAGE 2
GAS WELDING EQUIPMENT
GAS WELDING SAFETY EQUIPMENT
GOOGLE
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PAGE 3
GAS WELDING EQUIPMENT
TORCH
APRON
GLOVE
SAFETY SHOES
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PAGE 4
HOSE
FLASHBACK ARRESTOR
OXYGEN PRESSURE
REGULATOR
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PAGE 5
ACYTELENE PRESSURE
REGULATOR
CYLINDER
SPARK LIGHTER
FILLER ROD
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PAGE 6
PLIERS
WIRE BRUSH
TYPE AND PROPERTIES OF FLAMES, WORKING
FLAME
There are three basic flame types:
i. Neutral (or balanced)ii. Reducing or carburizing (excess acetylene)
iii. Oxidizing (excess oxygen)
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An oxidizing flame should not be used for welding steelbecause the deposited metal will be porous, oxidized, and
brittle.
A slightly oxidizing flame is used weld brass and bronze
iii. Carburizing flame: which has excess acetylene The inner cone has a feathery edge extending beyond it If the acetylene feather is twice as long as the inner cone it is
known as a 2x flame, which is a way of expressing the amount
of excess acetylene
The carburizing flame may add carbon to the weld metal It has a temperature of approximately 5700F (3149C) at the
inner cone tips
A carburizing flame is advantageous to weld monel metal(certain alloy steels and hard facing such as nonferrous alloys
as nickel.
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WELDING OPERATION
I. PRESSURE SETTINGII. LIGHTTING UPIII. CLOSING DOWN
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PAGE 10
SAFETY PRECAUTIONS
GENERAL SAFETY PRACTICES
Some hazards are common to both electric arc and oxygen-fuel gas
welding. If you work with or near a welding operation, the following
general precautions should help you to work more safely.
Weld only in designated areas Only operate welding equipment you have been trained to use Know what the substance is thats being welded and any coating on
it
Wear protective clothing to cover all exposed areas of the body forprotection sparks, hot spatter, and radiation
Protective clothing should be dry and free of holes, grease, oil, andother substance which may burn
Wear flameproof gauntlet gloves , a leather apron, and high-topshoes to provide good protection against sparks and spatter
Wear specifically designed, leak-proof helmets equipped with filterplates to protect against ultraviolet, infrared, and visible radiation.
Never look at a flash, even for an instant Keep your head away from the plume by staying back and to the
side of the work.
Use your helmet and head position to minimize fume inhalation inyour breathing zone
Make sure there is good local exhaust ventilation to keep the air inyour breathing zone clear
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Don weld in a confined space without adequate ventilation and aNIOSH-approved respirator
Dont weld in wet areas, wear wet or damp clothing or weld withwet hands
Dont coil the electrode cablearound your body Keep a fire watch in the area during and after welding to be sure
there are no smouldering materials, hot slag or live sparks which
could start a fire
Locate the nearest fire extinguisher before welding Provide enough ventilation wherever gas welding, cutting, and
heating operations are performed. Proper ventilation will protect the
operator from the evolving noxious fumes and gases.
SAFETY PRACTICES OF GAS WELDING
GENERAL SAFETY PRACTICE
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Some hazards are common to both electric arc and oxygen-fuel
gas welding. If you work with or near a welding operation, the
following general precautions should help you to work more safely.
Weld only in designated areas Only operate welding equipment you have been trained to use Know what the substance is thats being welded and any
coating on it
Wear protective clothing to cover all exposed areas of the bodyfor protection sparks, hot spatter, and radiation
Protective clothing should be dry and free of holes, grease, oil,and other substance which may burn
Wear flameproof gauntlet gloves , a leather apron, and high-top shoes to provide good protection against sparks and
spatterWear specifically designed, leak-proof helmets equipped with
filter plates to protect against ultraviolet, infared, and visible
radiation.
Never look at a flash, even for an instant Keep your head away from the plume by staying back and to
the side of the work.
Use your helmet and head position to minimize fumeinhalation in your breathing zone
Make sure there is good local exhaust ventilation to keep theair in your breathing zone clear
Don weld in a confined space without adequate ventilationand a NIOSH-approved respirator
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Dont weld in wet areas, wear wet or damp clothing or weldwith wet hands
Dont coil the electrode cable around your body Keep a fire watch in the area during and after welding to be
sure there are no smouldering materials, hot slag or live sparks
which could start a fire
Locate the nearest fire extinguisher before welding Provide enough ventilation wherever gas welding, cutting, and
heating operations are performed. Proper ventilation will
protect the operator from the evolving noxious fumes and
gases.
SAFETY PRACTICE OF GAS WELDING WORK
Use correct shaded lens when welding.
Wear heat-resistant, non-flammable gloves.
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Keep area and clothes free from grease or oil. Do not oil or grease cylinder screws. Report defective material or tools to instructorWelding and cutting should be done in well ventilated areas Use soap and water to check for gas leaks
PERSONAL PROTECTIVE EQUIPMENT
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HOUSEKEEPING WORKS
GLOVES
PRON
GOGGLES
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A good housekeeping program plans and manages the orderly
storage and movement of materials from point of entry to exit. It includes
a material flow plan to ensure minimal handling. The plan also ensures
that work areas are not used as storage areas by having workers move
materials to and from work areas as needed. Part of the plan could include
investing in extra bins and more frequent disposal.
The costs of this investment could be offset by the elimination of
repeated handling of the same material and more effective use of the
workers' time. Often, ineffective or insufficient storage planning results in
materials being handled and stored in hazardous ways. Knowing the plant
layout and the movement of materials throughout the workplace can help
plan work procedures.
Worker training is an essential part of any good housekeeping
program. Workers need to know how to work safely with the products
they use. They also need to know how to protect other workers such as by
posting signs (e.g., "Wet - Slippery Floor") and reporting any unusual
conditions.
Housekeeping order is "maintained" not "achieved." Cleaning and
organization must be done regularly, not just at the end of the shift.
Integrating housekeeping into jobs can help ensure this is done. A good
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housekeeping program identifies and assigns responsibilities for the
following:
clean up during the shift
Day-to-day cleanup
Waste disposal
Removal of unused materials
Inspection to ensure cleanup is complete
Do not forget out-of-the-way places such as shelves, basements,
sheds, and boiler rooms that would otherwise be overlooked. The orderly
arrangement of operations, tools, equipment and supplies is an important
part of a good housekeeping program.
The final addition to any housekeeping program is inspection. It is
the only way to check for deficiencies in the program so that changes can
be made. The documents on workplace inspection checklists provide a
general guide and examples of checklists for inspecting offices and
manufacturing facilities.
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