Welding

CHAPTER 1
ARC WELDER
1.1 INTRODUCTION
This is a transformer type arc welder that will transform incoming high voltage, low amperage
electricity into high amperage, low voltage welding current. An arc welder should be on a separate
circuit of its own with a 50 amp. Breaker and in our welding transformer it will take from power
supply 220volt and 3 amps no load current and it give output of 200 amp range current and 40 volt
at output terminals. And it melts the 8 no. rod to weld any metallic surface. The diagram of the
transformer is shown as below.
FIGURE1.1: ARC WELDING MACHINE
ACERC/DOEE/2014-15/PROJECT/1
CHAPTER 2
MATERIAL REQUIRED
MATERIAL
QUANTITY
1. TRANSFORMER CORE
SIZE (9 X 2 & 5 X 2)
2. WINDING CONDUCTOR
SWG (10 & 4)
3. INSULATING PAPER
CLASS B
4. COTTON TAPE
1 INCH
5. PVC TAPE
6. SLIP
7. NUTS AND BOLTS
16
8. VARNISH
500 ML
9. BAKELITE SHEET
12 INCHES
10. LUX
11. INDICATOR
12. HOLDER
13. HOLDER LEAD
10 MM (2 METERS)
14. PVC CABLE
6 MM (3 METERS)
15. WELDING RODS
8, 10&12 NUMBERS
16. CLAMPS
4(12 X 2)
17. PLIER
18. CUTTER
19. SCREW DRIVER
20. WRIENCH
2(10-12, 14-15)
21. HAMMER
1( 200 GRAMS)
22. SCISSOR
23. CLAMP METER
CHAPTER 3
CONSTRUCTION AND DESIGN OF WELDING

TRANSFORMER
3.1. CORE
The performance of a transformer mainly depends upon the flux linkages between the
windings. For efficient flux linking between the windings, one low reluctance magnetic
path common to all windings should be provided in the transformer. This low reluctance
magnetic path in transformer is known as core of transformer.
We used an insulated metal strip (CRGO) of size 92 and 52 for a construction of a core
of a transformer. The size of the core of transformer is 9 of length and 9 inches of
breadth. The weight of a whole transformer core is 14.5 kg. The construction of core is
shown in the figure 2.1 below.
FIGURE 3.1: CORE OF TRANSFORMER (TOP VIEW)
In this we made a core type construction for a transformer, in which we placed two coils in
each of the vertical leg of the core. When these lamination stampings is connected together
form the required core shape as shown in above figure2.1 and their side view of core also
shown in the figure2.2.
FIGURE 3.2: FRONT VEW OF CORE
3.2 COILS CONSTRUCTION

The conducting material used for the windings depends upon the application, but in all
cases the individual turns must be electrically insulated from each other to ensure that the
current travels throughout every turn. The coils used for this transformer are form-wound
and are of cylindrical type. The cylindrical coils will have different layers and each layer
will be insulated from the other with the help of materials like paper, cloth, etc.
2.2.1. Primary winding:
The transformer's primary winding creates a varying magnetic flux in the core and a
varying magnetic field affect on the secondary winding. This varying magnetic field at the
secondary induces a varying electromotive force (EMF) or voltage in the
secondary winding.
For the construction of primary winding coil DCC conductor is used, which come in
different size. For the primary coil we use 2.4 kilograms of 10 SWG aluminium DCC
conductors. The coil made by wrapping the conductors in a cylindrical form layer by layer.
Paper is used to insulate the different layers of the coil.
In the primary winding coil there is 125 numbers of turns in each coil.there are fours
tapping is available in primary coil in every 24 turns.
No. of turns in primary coil each, N1 =125
FIGURE 3.3. PRIMARY COIL FIXED ON A CORE
3.2.2. Secondary Winding

The secondary winding that provides the output to the load or loads. The flux, produced by
primary winding, passes through the core, will link with the secondary winding. The same
aluminium DCC conductor used in primary winding coil Is also used in secondary winding
coil. But size of the conductor for secondary winding is different. We use 2.4 kilograms of
4 SWG alluminium DCC conductors for secondary side coil. We made two coils for
secondary side of transformer. The each coil having a 38 number of turns.
No. of turns in secondary coil each, N2=38
FIGURE 3.4 SECONDARY WINDING FIXED ON A CORE
CHAPTER 4
CONNECTIONS
The connection of the welding transformer done in series connection. The coil is arranged
over the core in alternate form. In the first leg placed primary coil, then the secondary coil.
Similarly on the another leg put secondary coil first then primary coil over the secondary.
These coil insulated from each by using a insulated paper.
FIGURE 4.1: SERIES CONNECTION OF TRANSFORMER
FIGURE 4.2: FINAL VIEW OF CONNECTION
CHAPTER 5
SPECIFICATIONS AND COST

5.1DESCRIPTION:
180 amp air cooled arc welder.
1) Input voltage / phase: 220 volt / 1
2) Current input: 3 amps 27 amps
3) Current output: 70 amps 180 amps
4) Voltage output: 20.8 volt 25.2 volt
5) Welding rods recommended: 1 mm 3 mm
6) Dimensions (Length X Breadth X Height) : 14 X 12 X 14.
7) Weight: 20KG.
5.2 COST
MATERIAL
COST (RS.)
CORE
1200
CONDUCTOR
1500
ELECTRODE HOLDER
200
HOLDER LEAD
260
PVC CABLE
50
BAKELITE SHEET
60
VARNISH AND PAPER
250
COTTON TAPE
140
LUX
40
OTHERS
500
TOTAL COST
4200
CHAPTER 6
SURVEY
6.1. TRANSFORMER INDUSTRIES IN JAIPUR
1. Uttam Bharat Electricals Private Limited
Road no. 9F, V.K.I Industrial Area Jaipur Rajasthan
2. Indian Transformer Electrical

Road no. 17, V.K.I Industrial Area, Jaipur, Rajasthan.
3.Shree Transformers
V.K.I Area, Jaipur, Rajasthan
4. Swastik Copper Private Limited

Sitapura Jaipur,Rajasthan
6.2. WELDING TRANSFORMER DEALER IN JAIPUR

1. Anil Electrical,
M.I Road, Jaipur ,Rajasthan.
2. Maheshwari Electrical
Mi Road, Jaipur, Rajasthan
3. Avishkar Traders
Shansar Chand Road, Jaipur, Rajasthan.
6.3. RATE LIST
s. no.
Brand name
Type
rating
Cost(Rs.)
1.
Primeir
4 coil
50-200amp
5500
2.
Hi-tech
4 coil
70-250amp
6200
3.
Vulcan
4 coil
55-200amp
5800
6.4. COMPARATIVE ANALYSIS

Brand
Primeir
Hi-tech
Vulcan
Our welding
machine
Type
4-coil
4-coil
4-coil
4-coil
Rating(amps)
50-200
70-250
55-200
70-200
Cost(Rs.)
5500
6200
5800
4200
CHAPTER 7
ADVANTAGE AND DISADVANTAGE

7.1. ADVANTAGES
Versatility - readily applied to a variety of applications and a wide choice of

electrodes
Relative simplicity and portability of equipment
Low cost
Adaptable to confined spaces and remote locations
Suitable for out-of-position welding
7.2. DISADVANTAGES
Not as productive as continuous wire processes
Likely to be more costly to deposit a given quantity of metal
Frequent stop/starts to change electrode
Relatively high metal wastage (electrode stubs)
Current limits are lower than for continuous or automatic processes (reduces
deposition rate)
CONCLUSION
Welding is a fabrication process that joins materials; usually metals. This is often done by
melting the work-piece and adding a filler material to form a pool of molten material (the
weld pool) that cools become a strong joint. The melting is achieved with pressure
sometimes used in conjunction with heat, to produce the weld. Different power supply can
be used for welding. Arc welding machine transform low voltage low amperage primary
power into the low voltage, high amperage power used for welding at high frequency. This
high frequency transformation helps to reduce the weight and size of the transformer.
The samples were characterized by means of tensile strength, hardness and elongation.
From the investigation it is found that an increase in welding speed increases the tensile
strength and increase in tool rotation speed, decreases the tensile strength.
Welding means the permanent joining together of components by means of heat or
pressure, with or without welding additives. It has specialized in arc welding, one of the
oldest electrical welding processes for metallic materials. This arc between a consumable
electrode as additive material and the work piece, functions as a heat source when welding.

Welding

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Welding

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CHAPTER 1

FIGURE1.1: ARC WELDING MACHINE

SWG (10 & 4)

7. NUTS AND BOLTS

13. HOLDER LEAD

14. PVC CABLE

15. WELDING RODS

19. SCREW DRIVER

23. CLAMP METER

CONSTRUCTION AND DESIGN OF WELDING

FIGURE 3.1: CORE OF TRANSFORMER (TOP VIEW)

FIGURE 3.2: FRONT VEW OF CORE

3.2 COILS CONSTRUCTION

No. of turns in primary coil each, N1 =125

FIGURE 3.3. PRIMARY COIL FIXED ON A CORE

3.2.2. Secondary Winding

No. of turns in secondary coil each, N2=38

FIGURE 3.4 SECONDARY WINDING FIXED ON A CORE

FIGURE 4.1: SERIES CONNECTION OF TRANSFORMER

FIGURE 4.2: FINAL VIEW OF CONNECTION

SPECIFICATIONS AND COST

VARNISH AND PAPER

2. Indian Transformer Electrical

4. Swastik Copper Private Limited

6.2. WELDING TRANSFORMER DEALER IN JAIPUR

6.3. RATE LIST

6.4. COMPARATIVE ANALYSIS

ADVANTAGE AND DISADVANTAGE

Versatility - readily applied to a variety of applications and a wide choice of

Relative simplicity and portability of equipment

Adaptable to confined spaces and remote locations

Suitable for out-of-position welding

Not as productive as continuous wire processes

Likely to be more costly to deposit a given quantity of metal

Frequent stop/starts to change electrode

Relatively high metal wastage (electrode stubs)

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