15FMCE212 – Mechanical Engineering Workshop II: “Wind Turbine” Project
Question 1: Physical Project: (45 Marks)
In this task you need construct a turbine using the different welding techniques you have learned during the course. Pick up 10 pieces of metal sheets/pieces from the scrap yard to construct your project. The tree should include at least the following: 2 perfect clean welds (butt and fillet) (10 each total 20) a) The weld should be straight line; b) The weld should be along the work piece – edge to edge; c) The weld thickness should be between 8-10mm only; d) You should produce clean slags; e) The weld should be consistent wavy weld; 5 Weld Defects (5 each total 25) f) Excess penetration g) Inclusions/Porosity h) Undercut/Incompletely filled join i) Overroll j) Misalignment
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Based on the physical model that you have constructed, you need to write a full report discussing the project you have constructed and it should reflect your understanding of the theory. The report should include a research on the following:
1. Safety aspects and considerations of the welding process 2. Mention the types of welding & types of electrodes 3. Mention the welding process and equipment needed 4. Welding defects and the causes of each defect: For each defect you should address the causes and the defects you practise during welding. You should include a clear close picture showing each of the previous defects. 5. Report style and format
