Leaving cert Engineering HL Q5
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| show | >Flux coated consumable electrode
>Joint protected by gas from melting flux
>Slag produced on top of weld
>Electrode has to be changed often
>Versatile process
>Equipment light and portable
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| show | >Semi automatic process
>Bare wire electrode fed to gun from a spool
>Joint protected by inert gas (argon)
>Very easy to do
>Equipment big and bulky
>No slag produced
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| Describe the main features of TIG welding | show 🗑
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| show | >Fully automatic process set up on guide rail
>Wire electrode fed from spool
>Powder flux fed from hopper completely submerges the arc
>excess flux sucked back into the hopper
>used for straight lines eg bridges, ships, factory roofs
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| Describe the main features of Spot welding | show 🗑
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| show | >Non-consumable copper motorised electrode rollers
>Series of overlapping weld nuggets form air tight seal
>No filler added
>Quick and easy to use
>Used to seal the edges of radiators
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| show | >Fully automatic process
>Used to weld very thick plate
>Must be done vertically
>Water cooled copper shoes enclose the weld pool
>wire electrode and flux powder fed in
>Weld pool rises until the whole gap is filled in
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| show | • MMA welding machines are protected from electrical surges.
• Welding stations need to be free from dampness.
• Cables and electrode holders are covered with plastic insulators.
• Welding machines are earthed.
• Power supplied can be adjusted to an a
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| Why is tungsten inert gas welding suitable for welding aluminium? | show 🗑
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| show | If acetylene is compressed into a cylinder, it would explode under high pressure. Acetylene cylinders are packed with a porous material that is filled with acetone. The acetylene is dissolved into the acetone under pressure to prevent it from exploding.
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| show | It's important so the gasses don't get mixed up. Oxygen cylinder is black and acetylene is maroon, hoses and regulators are colour coded with oxygen as blue and acetylene as red.
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| Outline three safety precautions that should be observed in the preparation of equipment and materials for oxyacetylene welding; | show 🗑
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| Describe multi-run welds; | show 🗑
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| show | • Make sure the gas tank is not empty
• Clean the material surfaces removing oil and grease
• Eliminate moisture – the prime cause of weld porosity
• Make sure gas flow is at correct pressure
• Eliminate drafts and air
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| show | • Contains excess acetylene.
• It has a working temperature of 3150oC.
• Used to weld aluminium and alloy steel where it gives
protection against oxidation.
• Flame is bigger with the distinctive acetylene feather.
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| show | • Contains excess oxygen.
• Has a working temperature of up to 3500°C.
• Used to weld copper and brass, it would oxidise steel.
• Flame appears smaller.
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| show | • A balanced proportion of oxygen and acetylene.
• Maximum combustion as all carbon from the acetylene
is used.
• Has a working temperature of up to 3300°C.
• The most extensively used flame for oxy-acetylene welding.
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| show | >Flux coating on the electrode in MMA welding
>Inert gas pumped out of the gun in MIG/TIG welding
>Arc submerged under flux powder in SAW welding
>Acetylene flame
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| show | >Other students might look at the arc and damage their eyes
>Someone could trip on the wires
>Appropriate ventilation
>A welding apron should be worm to protect uniform
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| Outline the functions of the transformer, capacitor and rectifier in manual metal arc welding. | show 🗑
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| show | • To generate a gas shield to protect welded joints from contamination by oxygen and nitrogen in the air.
• To form a slag coating which protects the weld from oxidation and
ensures a slow cooling rate for the weld
• Helps to maintain the arc
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| show | The flux coating in Manual Metal arc welding:
• Helps to start the arc
• Burns to give off a gas which prevents oxidation
• Helps the formation of a slag on the weld
• Additional alloy material can be part of the coating to improve weld strength
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| Explain why submerged arc welding (SAW) is suitable for welding steel girders. | show 🗑
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| show | Advantages of multi-run welds:
• A superior weld is produced as each weld has a post heating effect on the previous
run.
• The finished weld is stronger and more refined in structure than single run welds.
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| show | Oxy-acetylene equipment include:
• Acetylene cylinder
• Oxygen cylinder
• Oxygen and acetylene hoses
• Welding torch
• Pressure gauges
• Flashback arrestors
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| Describe, with the aid of a suitable diagram(s), oxy-acetylene welding with reference to flame types | show 🗑
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| show | • The colour coding helps prevent any mix-up
• The oxygen cylinder is usually thinner and taller.
• The connections for the different gases have either left or right hand threads
• The flashback arrestors prevent the flame returning to the cylinders.
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| Describe, with the aid of a suitable diagram(s), oxy-acetylene welding with reference to applications. | show 🗑
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| Outline the reasons for porosity in welding | show 🗑
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| show | • If a diver surfaces too fast, he can get the bends
• Sharks ,
•run out of oxygen
• The ocean current can actually carry a welder off,
• Nitrogen can build up in the diver's blood and create deposits.
• drowning
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| Give two benefits of using resistance seam welding in the production of house radiators. | show 🗑
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| Describe, with the aid of a suitable diagram The essential differences between Metal Inert Gas (MIG) welding and Tungsten Inert Gas (TIG) welding | show 🗑
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| show | Multi-run welds:
• Multi-runs produce a superior quality weld which is more refined than a single run
weld.
• Multi-run welds have a post heating effect on the previous weld which will improve
its quality.
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| Give two benefits of the formation of slag in manual metal arc welding | show 🗑
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| Describe two safety hazards associated with resistance spot welding | show 🗑
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| Outline three ways in which oxidation may be prevented during welding. | show 🗑
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| State two reasons for the use of tungsten inert gas (TIG) welding for securing the stainless steel slide. | show 🗑
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| Describe how an acetylene cylinder is filled under low pressure. | show 🗑
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| Describe, with the aid of a diagram, the process of friction stir welding FSW | show 🗑
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| Describe, with the aid of a diagram, the process of Linear Friction Welding (LFW) | show 🗑
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| show | Rotary Friction Welding (RFW) is similar to
LFW except that the workpieces are often
round and are rotated relative to each other
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Created by:
todd.ciaran
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