The document describes the development of a welding machine that uses salt water. It works by using salt water as a variable resistance to control amperage for arc welding. The process involves setting up electrodes in a salt water solution connected to a power supply. An electric arc is created between the electrode and workpiece when submerged in the solution, generating enough heat to melt and join the metals. Key advantages are low cost and ability to perform emergency welding at home, though safety equipment is required and efficiency is lower than traditional welding.
2. In salt water welding machine , the salt water work as a variable resistance
or ballast to control the amperage. In this operation a electrode of 6601 or 6603
will be held in electrode holder and it is connected to the main phase of AC
power supply of 230/110v. The two iron rods are dipped into the salt water
solution.
One of the rod which is connected to the work piece(neutral phase) that to be
taken for weld and another connected to the phase ( AC power supply ).
The ratio of the solution (solute is half of the solvent) {ex: For a solvent of 10
litres of water the solute will be 5kg of salt} .
After closing the circuit(switch ON),When the electrode placed near to the
work piece ,at a small distance there is an arc produced due to high current and
low voltage by means of salt water
The heat generated by the arc melts the work piece and electrode at the
joining portion . The joining possible through the salt water welding
Abstract
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DEVELOPMENT OF WELDING MACHINE USING SALT WATER
3. CONTENTS
Arc welding.
Arc welding working.
Salt water welding principle.
Working steps of S.S.W.
Advantages.
Limitations.
Conclusion.
Reference.
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4. ARC WELDING
Welding is a joining process of two or more
similar or dissimilar with or without application of
heat, pressure & filler material.
Arc welding is a welding process that is used to
join metal to metal by using electricity to create
enough heat to melt metal, and the melted metals
when cool result in a binding of metals.
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5. ARC WELDING WORKING
It is a type of welding that uses a
welding power supply to create an
electric arc between a metal.
The stick(electrode) and the base
material to melt the metals at the point
of contact arc welders can use either
DC or AC current and consumable or
non consumable electrodes.
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6. SALT WATER ARC WELDING
The welding in which Arc produced with the help of salt water called
salt water welding.
Salt water solution act as an electrolyte solution.
The salt water work as a variable resistance or ballast to control the
amperage.
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7. SALT WATER WELDING PRINCIPLE
Salt water welding based on the principle of electrolyte solution
behaviour of salt water.
The salt water work as a variable resistance or ballast to control the
amperage.
The salt water cuts voltage at a greater rate than current. The resistance
will be decrease.
NaCl→Na+ CL-
The electrons moves towards anode at high velocity and ions move
towards cathode.
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8. WORKING STEPS
Step 1: This project uses High Amperage and
High Voltage and its mostly lethal if not handed
carefully, always wear gloves and shoes, don't
operate exposed parts or not securely insulated
components, if you need to change the
positions of the cables inside the water, unplug
it first.
Use all the recommended welding equipment
when working on this project including: Welding
Glasses or Mask, Leather Gloves, Leather
clothes and an insulated surface. Don't forget to
be dry (always dry your hands if you change
anything on the water).So Its done carefully.
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DEVELOPMENT OF WELDING MACHINE USING SALT WATER
9. STEP 2: MATERIALS
5mm diameter of Copper
10L of water
5kg of Salt
Electrode holder
Earth clamp
6013 or 6011 welding rods or electrode
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10. STEP 3.PREPARATION OF WIRE
CABLES
First we are going to need 3 pieces of wire, Take
the 10m piece and cut it in half,
next take one of these half's and cut in half again.
Now we got 3 pieces of wire:
1st piece=5m 2nd & 3rd pieces are 2.5m each
Take the 5m piece, scrape about 1.5cm on each
side of the cable, it will be used as the ground
wire.
Take the 2.5m cable and scrape 1.5cm on one
end and 20cm on the other end, these will be our
positive wire. 15-04-2023 10
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11. STEP4: ATTACHEMENT OF HOLDER AND EARTH
CLAMP
Now install the electrode holder
on the 1.5 cm end of the 2.5m
cable
and the earth clamp on one of
the 1.5cm end of 5m cable.
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12. STEP5 :PREPARATION OF SALT WATER
Fill the 20ltr gallon with around 151tr of water,
Keep the 20cm end of the 2.5m cables in the water
and put something on the bottom to hold them
submerged and straight.
Pour around 1 kg of salt on the water.
The salty water will work as a variable resistor,
powering the AMPs up based on Electrolysis.
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13. STEP 6: ELECTRICAL POWER SUPPLY
To turn the power on, Attach the 5m cable on the neutral line of your
wall plug and the 2.5cm cable on the Positive line,
"DON'T PUT THEM AS YOU WISH, YOU MUST KNOW WHICH ONE
IS THE HOT WIRE AND WHICH ONE IS THE GROUND WIRE".
Put the 6013 electrode on the electrodes holder and try striking an arc,
if the amps are too low, put the two cables nearer inside the water,
if the amps are too high, space them from one another.
"DON'T FORGET TO UNPLUG THE WIRES BEFORE ADJUSTING
THE CABLES". 15-04-2023 13
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15. ADVANTAGES:
Easily made.
Low cost.
In Emergency, it can made at home easily.
It works on general line voltage like 230/110V.
Heat generation equal on both cathode and anode
Work on medium penetration depth.
Works on dirty metal
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16. LIMITATIONS:
Safety equipment required.
It may be short circuit.
As high current it will be more dangerous.
Lower efficiency.
High skill level - operators.
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19. CONCLUSION
Finally we can weld through salt water.
Some time at home, we can weld in emergency.
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