Construction Of A 10Kva Arc-Welding Machine

Project and Seminar Material For Electrical Electronics Engineering EEE

Project and Seminar Material For Electrical Electronics Engineering EEE


The sole aim of this project is construction of a 10KVA arc welding machine. With the increase in the use of arc welding machines by industries, designers, fabricators and other uses of welding product. It therefore becomes apparently necessary to produce the machine using local materials.

The work explains the fundamental principles principle characteristics of welding processes, indicating the relationship process variables and functions of particular techniques. There are also numerous sources of information on the practical use of specific processes of welding using the arc welding machine

In this construction, we assumed the reader is familiar with the E.M.F equation of a transformer which is the major component of the system. Only those factors which are extremely important for the operation of this project were discussed.

The project furthermore, explains the operation and construction of the transformer designed construction structured steps taken and perform once characteristics of the entire system.

Table Of Contents

Preliminary Page(s)

  • Title page
  • Approval page
  • Dedication
  • Acknowledgment
  • Abstract
  • Table of contents

Chapter One

  • 1.0 Introduction
  • 1.1 Gas welding

Chapter Two

  • 2.0 Literature review

Chapter Three

  • 3.0 Mode of operation of the arc-welding machine
  • 3.1 An ideal transformer
  • 3.2 E.M.F. equation of a transformer
  • 3.3 The arc welding circuit

Chapter Four

  • 4.0 Construction analysis
  • 4.1 Transformer construction
  • 4.2 Specifications
  • 4.3 Size of conductor
  • 4.4 Construction
  • 4.5 Steps in construction
  • 4.6 Performance
  • 4.7 Arc-welding safety practices

Chapter Five

  • 5.0 Summary, Conclusion and Recommendation
  • 5.1 Summary
  • 5.2 Conclusion
  • 5.3 Recommendation
  • 5.4 Appendix
  • References

Chapter One

1.0 Introduction

In every fabrication process involving metals and non-metals, there is always a need to join two metal parts which gives rise to welding machine.

Actually, welding is a metal-joining process. It may be defined as the art of joining two metal parts by means of heat or pressure or both in such away that the resultant joint is equivalent in composition and characteristics to the metals used.

Welding machines has two sides the electrical side (primary side) and the welding side (secondary side).

Generally, welding processes fall into two categories namely:

  • – Fusion welding
  • – Non-fusion welding.

Fusion welding involves melting the parent metal while non-fusion welding does not involve melting of the parent metal. Examples of fusion welding include; carbon arc welding, metal arc welding electron beam welding, electro slag welding which utilizes electric energy.

Examples of non-fusion welding includes forge welding and gas non-fusion welding which use chemical energy, explosive welding, friction welding and ultrasonic etc.

This uses mechanical energy resistance welding which uses electrical energy. Proper selection of the welding process depends on the kind of metals to be joined. Cost involves nature of products to be fabricated and the production techniques adopted.

Electricity plays a vital role in welding process as it is used for generating heat at the point to welding in order to melt the material which will subsequently fuse and form the actual weld joint.
There are many ways of producing this heat but the two most common methods are;

  • – Resistance welding and arc welding.

Resistance welding is fundamentally heat and squeeze process. The term resistance welding denotes a group processes in which welding heat is produced by the resistance offered to the passage of electric current through the two metal pieces being welded. These processes differ from the fusion processes in the sense that no extra metal by H = 12Rt/s

Obviously, amount of heat produced depends on;

  • – Square of the current
  • – The time of current
  • – The resistance offered.

As seen, in simple resistance welding, high-amperage is necessary for adequate weld. Usually, R is contact resistance between the two metals being welded together.

The current is passed for a suitable length of time controlled by a timer. In arc welding, electricity is conducted in the form of an arc which is established between the two metallic surfaces. It is the most used welding process because it can be used in all welding positions with mild alloy, heat and corrosion resistance steels and with some copper nickels base alloys.

The process is used in ship building, structural and general engineering.

It is a low capital cost process, which uses portable equipment and can be supplied to a wide range of joint and type.
In arc welding, two forms of electrical energy are used; these are Alternating Current (A.C) and Direct Current (D.C).

Chapter Five

5.0 Summary, Conclusion And Recommendation

5.1 Summary

Most of the activities done in the field of engineering technology involve the joining of two or more metals together. This reveals the importance of an arc welding machine in this technologically driven world, as one of the equipment used in metal joining.

The objective of this project which has been achieved is to produce heat used in melting metals which fuse together after cooling. The heat is produced by an arc. The arc is formed when current passes between two metallic electrodes separated by a short distance, hence the name arc-welding machine.

5.2 Conclusion

The electric arc welding machine is vital equipment in the today as many items in the modern world depend on joints. Hence attempts were made to produce a functional project. Due to high sufficient current, it becomes very essential that sufficient insulation was provided beef-up the durability, reliability and safety of the equipment.

Hence, the project is considered a successful development in the department, as the equipment produced is very easy to operate.

Furthermore, the equipment performs its desired objective as long as arc production is concerned. This project like other project carried out by students is aimed at reducing cost by modifying the design, changing material specification, better processing, finding alternative source of supply and more importantly developing new innovations.

5.3 Recommendation

The importance of electric arc welding machine in today’s life cannot be over emphasized. The arc welding machine does virtually everything that concerns joining.

With regards to this project, it has been designed to suit all working condition as far as arc welding is concerned, hence the development with ease of operation. The importance, success and viability of this project to the development of the department have been considered thoroughly.

We therefore, recommend that more emphasis should be laid in schools and the contemporary world on the development of this topic and project for the comfort of man.

Construction Of A 10Kva Arc-Welding Machine

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