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The process of submerged arc welding (SAW) is illustrated - Leaving Cert Engineering - Question Question 1 - 2012
Question Question 1
The process of submerged arc welding (SAW) is illustrated. (i) Describe the principles of operation of submerged arc welding (SAW). (ii) Identify one application o... show full transcript
Worked Solution & Example Answer:The process of submerged arc welding (SAW) is illustrated - Leaving Cert Engineering - Question Question 1 - 2012
Step 1
Describe the principles of operation of submerged arc welding (SAW).
Answer
Submerged Arc Welding (SAW) utilizes a bare wire electrode that is fed from a spool into the welding arc. The process requires the use of a granular flux that is fed automatically from a hopper, completely covering the weld joint and providing a protective layer. This flux protects the molten metal from contamination and reduces spatter, enabling a high-quality weld. The heat generated forms a molten pool that fuses the workpiece material. SAW is highly automated, making it suitable for large-scale industrial applications.
Step 2
Step 3
Describe, with examples, the importance of colour coding in oxyacetylene equipment.
Answer
Colour coding in oxyacetylene equipment is crucial for safety and proper handling of gases. For example, oxygen cylinders are typically painted green or black, while acetylene cylinders are marked in red or maroon. This visual distinction helps prevent dangerous mistakes, such as connecting the wrong gas supply, ensuring that personnel use the correct equipment and follow safe practices.
Step 4
Outline three safety precautions that should be observed in the preparation of equipment and materials for oxyacetylene welding.
Answer
- Remove oil and grease: It is essential to clean all fittings and hoses with a suitable solvent to eliminate any flammable substances that could ignite.
- Check flashback arrestors: Ensure that these devices are correctly positioned on both the oxygen and acetylene lines to prevent dangerous backfire incidents.
- Proper storage of cylinders: Store gas cylinders upright in a well-ventilated area, secured to prevent tipping, and always in separate locations for oxygen and acetylene.
Step 5
Describe multi-run welds.
Answer
Multi-run welds consist of several overlapping passes of the welding tool across the joint between two materials. This method enhances the strength of the weld due to the cumulative heating effect from each pass, effectively addressing any imperfections from the previous runs. As each layer is added and cools, the material has a chance to fuse better than a single pass, leading to a more robust joint, which is especially advantageous in thick materials.
Step 6
Describe one type of welding suitable for the automated welding of steel panels in motorcar manufacture.
Answer
Resistance spot welding is a common choice for the automated welding of steel panels in motorcar manufacture. This process uses electric resistance to generate heat and fuse overlapping sheets of metal together at specific points, creating strong, precise welds quickly and efficiently, which is essential in high-volume automotive production.
Step 7
Describe, with the aid of suitable diagrams, the main features of Tungsten Inert Gas (TIG) welding.
Answer
Tungsten Inert Gas (TIG) welding is a process that uses a non-consumable tungsten electrode to produce the weld. The inert gas (usually argon) provides a shielding layer to protect the weld area from atmospheric contamination. A filler material may be added manually to the weld pool. A diagram illustrating the setup would show the tungsten electrode, the inert gas flow, and the workpiece being welded, emphasizing the precise and clean weld created by this method.
Step 8
Identify two other industrial processes where robotic control is widely used.
Answer
- Painting: Robotic systems are extensively employed for consistent and efficient application of paint in automotive and manufacturing industries.
- Component assembly: Robots are utilized to assemble intricate parts in electronics and machinery, ensuring accuracy and reducing production time.