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A roll cage is a specially engineered tubular steel frame built into the passenger cabin of vehicles to protect the occupants - Leaving Cert Engineering - Question a - 2020
Question a
A roll cage is a specially engineered tubular steel frame built into the passenger cabin of vehicles to protect the occupants. (i) Describe, with the aid of a diagr... show full transcript
Worked Solution & Example Answer:A roll cage is a specially engineered tubular steel frame built into the passenger cabin of vehicles to protect the occupants - Leaving Cert Engineering - Question a - 2020
Step 1
Describe, with the aid of a diagram(s), a suitable welding process to manufacture the tubular steel roll cage shown.
Answer
The suitable welding process for manufacturing the tubular steel roll cage is MIG (Metal Inert Gas) Welding. This process is semi-automatic, using a consumable bare wire electrode fed continuously into the weld pool through a welding torch.
Diagram
(Insert the MIG welding diagram here)
Process Description
- Welding Equipment: The main components include the wire reel, gas cylinder (typically containing Argon or a mix), power supply, and the welding gun.
- Inert Gas Shielding: An inert gas (like Argon) flows around the weld pool to protect it from atmospheric contamination, ensuring high-quality welds without slag.
- Arc Generation: The operator brings the welding gun close to the workpiece, creating an electric arc which heats the electrode and the base material.
- Filling the Weld Pool: As the wire electrode melts, it fills the joint, forming a strong bond. The operator controls the feed rate and the flow of gas to ensure optimal welding conditions.
Step 2
Outline three safety precautions to be observed when operating a welding unit.
Answer
- Wear a welding mask to prevent "arc-eye" and facial burning, which can occur due to intense light and heat from the welding arc.
- Have proper ventilation to prevent inhaling toxic fumes which can be harmful to your health while welding.
- Ensure all electrical units are grounded and connections are properly insulated to prevent electrical hazards.