Directorate: Curriculum FET

SUBJECT AGRICULTURAL TECHNOLOGY GRADE 10

TERM 2 WEEK 7
TOPIC Construction Processes: Arc Welding Electrode
LESSON At the end of the lesson the learners should understand the following concepts:
OBJECTIVES
Arc welding:
 Arc welding electrodes
 Basic arc welding principles
 Welding defects

SOURCES  Handbook - based sources:

 Agricultural Technology grade 10 learner's book.

INTRODUCTION  The purpose of this lesson is to expose the learner to the basics of arc welding.

CONCEPTS AND  Arc welding electrode

SKILLS  Briefly describe an electrode / welding rod.
 An electrode is a filling rod with which the load is made.
 Consists of a metal rod covered with an insulating material called casing / flux.

 The purpose of the coating is to:

 Stabilize the current.
 Melt impurities.
 Helps to form slag.
 Helps speed up the welding process.

 What is the purpose of the slag formed on the weld?

 Protect the molten metal from air pollution.
 Prevent the metal from cooling too quickly.
 Causes an even weld. (Slag must be removed after welding with a hammer)

 Briefly describe each of the following terms:

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Arc. Flame or spark formed between the tip of the electrode and the metal to be welded

Shielded arc. Blue gas forming around the welding arc.

Welding pool Place / pool of molten metal that forms directly under the electrode when an arc is struck.
or welding
bead.
Penetration. When the metal being welded melts and the welding rod penetrates the welded object.

Slag. Cover formed over the welded area during welding.

Flux. Cover the welding rod.

Tack weld Weld the ends of two pieces to be welded to prevent the parts from shifting when you start welding.

Welding run. A series of welding pools is called a welding run.

Welding Hammer used to remove slag from a welding area.

chipping
hammer.

 Tabulate the different defects that can occur on electrodes and give the effect of each defect.

Defect Effect

A. Point of electrode covered with insulating material No arc can be struck.

B. Color code absent or unclear Difficult to choose the correct rod for a specific metal

C. Welding rod coating absent  Current cannot be stabilized.

 Impurities on the surface of the

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metal cannot be melted away.

 Slag cannot be formed.
 Melting time delayed.
 An even weld is not possible.
 Protected arch cannot be obtained

 Name TWO consequences that poor storage / storage conditions can have on electrodes.
 Electrodes rust.
 Damage to the coating.

 Briefly explain the welding term “Tack welding”

Preliminary welding on the ends of the welded workpiece to ensure that the workpieces do not move apart due to
the high welding temperature when welding.

 Briefly describe the process of how a “welding arc” is strike.

 Make sure that the earth cable clamp makes good contact with the welding table and workpiece.
 Use an electrode with the correct diameter that corresponds to the thickness of the workpiece.
 Adjust the amperes of the welding machine according to the table.
 Put on a welding helmet to protect your eyes.
 Start the welding by making a tight motion with the welding rod.
 A crackling noise is a sign that the welding is running smoothly.
 Make a zigzag motion with the electrode.
 When the electrode is stuck, bend the electrode back and pick it up.
 At the end of the weld, the snail must be removed with a hammer.

 Make a sketch of the welding arc.

o Cover.
o Core of the electrode.
o Molten metal.
o Melted flux.

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o Shielding gas.
o Solidified flux.
o Electric arc.
o Melted pool.

 Describe the arc welding process.

Electric arc welding is a process of fusion where electrical energy in the form of an arc is used to provide the
necessary heat for the metals to melt.

 The different welding defects and the causes of each.

Name of welding defect Causes Sketch

Insufficient penetration  Welding torch flame too

small or amperes too low
 Incorrect welding technique
 Insufficient load preparation
Welding crater  Too large flame or too high
arc current
 Incorrect welding technique
 Too thin electrode or rod
Undercutting  Too high amperage / current
or too high flame
 An incorrect electrode angle
 An incorrect welding torch
angle

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 Directorate: Curriculum FET

Slag inclusion  The arc current is too low

 Slag is not removed after
each weld
 An incorrect electrode angle
 Improper preparation of
welds
 Insufficient penetration
Insufficient penetration  Too small root gap
 Arc current too low or
welding torch flame too small
 Electrode or rod too heavy
Gas holes  Dirty metal
 Base metal melts too fast
 Welding metal cooled too
quickly

Porosity  Too high arc current or too

large flame
 Too sudden removal of the
arc or burner causes the
molten metal to be polluted
by atmospheric gases
 Wrong electrode or rod
Adhesion  Incorrect welding technique
 Wrong electrode or rod

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Concave welding  Too little welding material

deposited
 Too large flame or too high
arc current

Unequal leg lengths  Wrong electrode angle

 Wrong burner nozzle angle

ACTIVITY/ Teacher must work out activities on the given content and provide them to the learners
ASSESSMENT
CONSOLODATIO  The lesson covered all the content as required by the CAPS.
N  The learners understand all the concepts and concepts and content.