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

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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

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 LEARNING OUTCOME No.1 - UNDERSTAND THE BASIC STRUCTURE OF MATTER

AC 1:1 Identify the basic structure of matter in terms of atoms and molecules

With reference to the basic structure of matter. Explain the following terms: The sketch shows three features of an atom. Identify on the sketch which is
the nucleus, proton and electron.
Atoms:

................................................................................................................................

...............................................................................................................................

................................................................................................................................
Hydrogen atom

................................................................................................................................
Identify the parts of the hydrogen
atom

A ...........................................
B
B ...........................................

C ..........................................

................................................................................................................................
C

Molecules:

................................................................................................................................

................................................................................................................................

................................................................................................................................

................................................................................................................................

...............................................................................................................................

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 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

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 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

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 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

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 Acetylene
Example of this property found in an
Property Propane Simple definition of the property
engineering application
Methane of the following materials
AC 1:5 Describe the properties
Tensile Strength
Butane
Ferrous metals:
L.C.S. Elasticity
(Low Carbon Steel)

Non-ferrous metals:
Plasticity
Copper
Aluminium

Ductility
Non-metals:
Plastics
Ceramics
Malleability

Brittleness

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Hardness
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Toughness
 LEARNING OUTCOME No.2 - UNDERSTAND THE DIFFERENT TEMPERATURE SCALES

Celsius temperature scale

AC 2:1.Identify temperature scales and their units
150°

125° Using the Kelvin temperature scale.

100° State:

75° Freezing point of water .................

A/503/9494 L2 Science and Calculations for Fabrication
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.................
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25°

0°
 LEARNING OTUCOME No.3 - UNDERSTAND THE EFFECTS OF HEAT

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.

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 Hot metal
Hot metal Hot metal

The transfer of heat which The transfer of heat that The transfer of heat which
travels through a metal is rises from a metal is can be emitted is referred
referred to as referred to as to as

________________________ _______________________ ________________________

_________________________

AC 3:3 The effects of heat on the mechanical properties of low carbon steel

If a section of low carbon steel was heated to 950°C what would be the effect on the listed mechanical properties? Would they increase or
decrease?

malleability..........increase or decrease ductility.............increase or decrease

hardness ............increase or decrease toughness.........increase or decrease

brittleness..........increase or decrease plasticity...........increase or decrease

elasticity............increase or decrease tensile strength.........increase or decrease

Indicate the correct answer by underlining the appropriate effect.

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 LEARNING OUTCOME No.4 - UNDERSTAND ELECTRICAL PRINCIPLES

AC 4:1 Describe basic electrical principles

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

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 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=IxR 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.

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 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

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 LEARNING OUTCOME No.5 - BE ABLE TO CARRY OUT CALCULATIONS

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.

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 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

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 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

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 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

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 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

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 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.

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 LEARNING OUTCOME No.6 - UNDERSTAND WELDING TERMS AND SYMBOLS

AC 6:1 Identify the type of joint preparation and weld required from the welding symbols shown

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 Type of weld Welding symbol Joint preparation

AC 6:1 Identify supplementary welding symbols

Welding requirement Welding symbol

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 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)..................................................................................................... 6

3).....................................................................................................

4).....................................................................................................

AC 6:2 Define the term slope and tilt angles associated with the angle of torch and filler material

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 The drawing shows an electrode being used to weld
A the joint.
The angle at A is the .......................angle
B
The angles at B is the .........................angle
B

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.

A
D
B

B C

A D

AC 6:4 Define the types of joint preparation recommended for different thicknesses of low carbon steel

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 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

LEARNING OUTCOME No.7 - UNDERSTAND QUALITY CONTROL MEASURES

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 AC 7:1 Identify the main factors in controlling the quality of welded joints and fabrication processes
AC 7:3 Identify typical defects and their causes which may affect quality
Quality of welded joints:
Description of welding defect Name of welding defect One possible cause of the welding defect
Using the correct welding preparation is one factor. 1..............................................................................................................
Name TWO other important factors to ensure the
quality of
A cluster of small
welded joint holes found in the weld
air/gas 2..............................................................................................................
deposit
Quality of the fabrication process:
Slag trapped in the weld deposit
Using material that is not twisted or distorted 1...............................................................................................................
is one factor. Name TWO other important factors
to ensure
A groove the quality
or hollow cut inofthe
fabrications.
surface face of the 2...............................................................................................................
parent material and the toe of the weld.

The weld metal does not extend to the root of the

weld
AC 7:2 Identify weld inspection techniques
A hollow at theand
Destructive endnon-destructive
of a weld if the testing
correctare methods used to examine welds. List TWO types of test used in EACH method.
finishing procedure is not carried
Destructive out correctly
testing Non-destructive testing (NDT)

1)................................................................................. 1).......................................................................................

2)................................................................................. 2).......................................................................................

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 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:
AC 7:5.Summarise the importance of maintaining records of the checks made and their consequences
1).............................................................................................................................................................................................................

State why it is important to maintain records of inspections carried out on completed welds. .................................................................
2)............................................................................................................................................................................................................

...................................................................................................................................................................................................................

..................................................................................................................................................................................................................

Name TWO important aspects of a weld inspection that should be recorded.

1)...............................................................................................................................................................................................................
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2)...............................................................................................................................................................................................................
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