Fabrication and Welding Practice s1
FABRICATION AND WELDING PRACTICE
ABC Level 2 Award in Fabrication and Welding Practice 60051310
ABC Level 2 Certificate in Fabrication and Welding Practice 60051905
Work Book
for
Unit A/503/9494 Science and Calculations for
Fabrication and Welding
Level 2
Version 2 – August 2014
This booklet provides questions and tasks for learners linked to the Assessment Criteria for Unit A/503/9494 Science and Calculations for Fabrication and Welding Level Two. This unit appears in the following qualifications
60051410 ABC Level 2 Award in Fabrication and Welding Practice
60051905 ABC Level 2 Certificate in Fabrication and Welding Practice
In this unit, learners develop an understanding of the states and structures of matter. Learners explore the relationship between the chemistry, mechanical and physical properties of materials. Basic principles and effects of heat and electrical energy are also explored. This unit is also designed to develop the learner’s understanding of basic mathematics, welding symbols, quality control and technology within an industrial context.
This unit is assessed in two ways.
· Learners need to complete this workbook which provides evidence of achievement of all Learning Outcomes and Assessment Criteria. This is to be internally assessed and must be available for Internal Quality Assurance Processes and for ABC’s External Quality Assurance process.
· Learners are also required to complete an externally set and marked multiple choice test confirming knowledge and understanding. This test provides the grade for this unit at Pass/Merit/Distinction.
N.B. the overall grade for the qualification is Pass/Fail.
All questions and tasks identify the Assessment Criteria they link to and appear in brackets e.g. (AC 2.1)
Learners could complete them at their own pace, at a pace directed by the centre or under test conditions. It is up to the centre to decide on this.
Whichever method is selected, it is important that learners are given information and support prior to being given assessment tasks.
Assessors will need to make a judgement as to whether a learner has successfully completed each task.
All evidence must be the learner’s own work
With reference to the basic structure of matter. Explain the following terms:Atoms:
......
......
......
......
......
Molecules:
......
......
......
......
...... / The sketch shows three features of an atom. Identify on the sketch which is the nucleus, proton and electron.
AC 1:2 For each of the following examples, give the definition and one example of how these may occur in fabrication and welding practice
Definition / Example
An element
A compound
A mixture of a solution
Solid
Liquid
Gas
AC 1:3 Name the FOUR main gases occurring in the atmosphere
1) ...... 2) ......
3) ...... 4) ......
AC 1:4 Describe the characteristics of combustion
a) The drawing shows a flame produced when oxygen and acetylene is mixed together in equal amounts. Identify on the flame the following: outer envelope, inner cone and the hottest part of the flame.
b) When equal amounts of oxygen and acetylene are used to produce a flame it is referred to as a ...... flame
c) Identify one typical application of using this type of flame in welding practice......
AC 1:4 Complete the table below with the flame temperatures of the listed gases when mixed with oxygen
Gases / Flame temperature °C
Acetylene
Propane
Methane
Butane
AC 1:5 Describe the properties of the following materials
Ferrous metals:
L.C.S. (Low Carbon Steel)
Non-ferrous metals:
Copper
Aluminium
Non-metals:
Plastics
Ceramics
AC 1:6 Give a simple definition of the property detailed and one example of this property that may be found in an engineering application
Property / Simple definition of the property / Example of this property found in an engineering application
Tensile Strength
Elasticity
Plasticity
Ductility
Malleability
Brittleness
Hardness
Toughness
AC 3:1 Define the unit of heat
Define the term JOULE ......
......
AC 3:2 Define the modes of heat transfer
Heat can be transferred in THREE different ways; these are radiation, conduction and convection.
Complete the text boxes below by placing the correct type of heat transfer for each example shown.
Generation: State the type of current/s(AC/DC) that can be found when using the listed welding machines:
Generator ......
Transformer ......
Rectifier ......
Control:
In order to alter the welding current, various devices are used. A tapped reactor is one method. State ONE other method and give ONE advantage of using that particular device.
Name of device......
Advantage......
Application:
State ONE advantage and ONE limitation of using:
AC (Alternating current) DC (Direct current)
Advantage...... Advantage......
Limitation...... Limitation......
AC 4:2a. Perform calculations relevant to Ohm’s Law
Given the information: To find resistance To find voltage To find current
Where I - Current
V- Voltage V V
V R- Resistance R = ----- V = I x R I = ------
Formula I = ----- I R
R
Calculate the resistance in a welding circuit if a current of 180 amps is used with an arc voltage of 24 volts. Show ALL working out.
AC 4:2b. Perform calculations relevant to power in a circuit
The power developed in a welding arc is 2.6 kw. Calculate the current used if the welding voltage is 22 volts. Show ALL working out
AC 4:2c. Perform calculations relevant to energy in a circuit
A welding unit has a voltage output of 80 volts with 250 amperes. Calculate the output in Kilowatts. Show ALL working out
AC 4:2d. Perform calculations relevant to the kilowatt hour.
How many joules are there in a Kilowatt hour? Show ALL working out
AC 5:1 a. Perform calculations relevant to industrial situations to include length
Calculate the total length of material used if the following sections are used for a particular fabrication. Show ALL working out
Two lengths of 40x40 RSA at 2.83 m
Four lengths of 100x50 RSC at 3.27 m
Three lengths of 50x50 SHS at 2.95 m
Two lengths of 110 mm diameter pipe at 2.75 m
AC 5:1 b. Perform calculations relevant to industrial situations to include area
A circular disc having a diameter of 1.35 m is to be cut from a rectangular plate measuring 1.75 m x 2.25 m. Calculate the area of plate remaining. Show ALL working out.
AC 5:1 c. Perform calculations relevant to industrial situations to include volume
An open top cylindrical tank has a diameter of 850 mm and a depth of 925 mm. Calculate the volume of the tank. Show ALL working out
AC 5:1 d. Perform calculations relevant to industrial situations to include time
A welder completes the welding on a fabrication in an average time of 11½ minutes. Calculate how long it will take to fully weld
23 fabrications. Show ALL working out
AC 5:1 e. Perform calculations relevant to industrial situations to include mass
Calculate the mass of a full plate measuring 2.5 m x 1.75 m with a thickness of 12 mm. Given the mass of steel is 7850 Kg/m³.
Show ALL working out
AC 5:1 f. Perform calculations relevant to industrial situations to include force
Calculate the minimum and maximum forces required to break a low carbon steel specimen having a diameter of 10 mm if the tensile strength equates to between 380 – 450 N/mm². State the difference. Show ALL working out
AC 5:2 a. Perform calculations related to welding problems to include fractions
If a length of channel section is 2.45 m long and ⅔ (two thirds) of this is removed, what will be the new length of the channel section?
Show ALL working ou
AC 5:2 b. Perform calculations related to welding problems to include percentages
A 3.5 m length of rolled steel channel section is used on a fabrication, if only 2.8 m is used, what is the percentage wasted?
Show ALL working out
AC 5:2 c. Perform calculations related to welding problems to include averages
Eight welders are timed to complete a welded fabrication; the times recorded are 11, 10, 13, 9, 12, 10, 11 and 14 minutes. Find the average time of welding. Show ALL working out
AC 5:2 d. Perform calculations related to welding problems to include proportions
A 4.00 mm electrode is 235 mm in length, after welding a 55 mm stub end is left. Calculate the proportion of the welded section of the electrode to the stub end. Show ALL working out
AC 5:2 e. Perform calculations related to welding problems to include decimals
A length of 50 mm x 50 mm angle section 1.85 m long has 0.75 of this length is cut off. Calculate the length of section removed.
Show ALL working out
AC 5:3 Perform calculations related to welding costs
The total length of welding in a fabricated tank is measured at 3.750 m. Calculate the following:
a) The overall cost of welding is calculated at £8.40 per 300 mm of completed welding. What will be the cost of welding the tank?
b) If welded by the MMA process. One electrode deposits 170 mm of weld. Calculate how many electrodes will be required to weld the tank.
c) If one box of electrodes costs £49.50 and contains 35 electrodes. Calculate the cost of total electrodes used to fully weld the tank
Show all working out.
AC 6:1 Identify supplementary welding symbols
Welding requirement / Welding symbol
Shape of weld surface / Flat
Convex
Concave
Weld all round
Weld on site
State FOUR pieces of information that can be obtained from the welding symbol shown.
1)......
2)......
3)......
4)......
AC 6:3 Define the terms associated with a single vee butt weld
Identify the three features at A, B and C on the drawing of the single vee butt weld preparation.
AC 6:4 Define the types of joint preparation recommended for different thicknesses of low carbon steel
Sketch and name the appropriate welding joint to be used when welding the listed thicknesses of material.
3mm Thick (low carbon steel) 6mm Thick (low carbon steel)
Sketch Sketch
Name of joint...... Name of joint......
WELDING POSITIONS (AC 6) – Complete the chart
Symbol / Butt welds / Symbol / Fillet welds
PA / Flat
PG / Vertical-down / PG / Vertical-down
Overhead / PD
PC / Horizontal-vertical / Horizontal-vertical
Vertical-up / PF / Vertical-up
AC 7:1 Identify the main factors in controlling the quality of welded joints and fabrication processes
Quality of welded joints:
Using the correct welding preparation is one factor. 1......
Name TWO other important factors to ensure the
quality of welded joint 2......
Quality of the fabrication process:
Using material that is not twisted or distorted 1......
is one factor. Name TWO other important factors
to ensure the quality of fabrications. 2......
AC 7:2 Identify weld inspection techniques
Destructive and non-destructive testing are methods used to examine welds. List TWO types of test used in EACH method.
Destructive testing Non-destructive testing (NDT)
1)...... 1)......
2)...... 2)......
AC 7:3 Identify typical defects and their causes which may affect quality
Description of welding defect / Name of welding defect / One possible cause of the welding defect
A cluster of small air/gas holes found in the weld deposit
Slag trapped in the weld deposit
A groove or hollow cut in the surface face of the parent material and the toe of the weld.
The weld metal does not extend to the root of the weld
A hollow at the end of a weld if the correct finishing procedure is not carried out correctly
AC 7:4 State the remedial action required to eliminate the occurrence of a weld defect
Using the correct welding parameters is one action that could be taken to eliminate the occurrence of a weld defect. State TWO other possible measures that may be taken:
1)......
2)......
AC 7:5.Summarise the importance of maintaining records of the checks made and their consequences
State why it is important to maintain records of inspections carried out on completed welds......
......
......
Name TWO important aspects of a weld inspection that should be recorded.
1)......
2)......
A/503/9494 L2 Science and Calculations for Fabrication and Welding Work Book Issue 2
Fabrication and Welding Practice Aug 14
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