2005 Fabrication and Welding

Higher

Finalised Marking Instructions

These Marking Instructions have been prepared by Examination Teams

for use by SQA Appointed Markers when marking External Course
Assessments.
2005 Higher Fabrication and Welding

Solutions and marking instructions

Question Solution Marks Notes

1 (a) Any three from: 3

• speed of travel
• arc length
• wire feed speed
• angle of torch
• arc voltage
• deposition technique (weave
pattern)
• selection of filler diameter
• selection of shielding gas.

1 (b) • Argon/CO2 max or Argoshield (or 2

similar trade name).
• CO2.

1 (c) • Dip transfer. 1

1 (d) Any three from: 3

• use correct grade of lens

• protect skin from welding rays
• ensure protection from heat
• ensure there are no gas leaks
• ensure adequate ventilation
• keep work area free of flammable
materials
• use eye protection when cleaning
weld
• ensure electrical safety
• be aware of the safety of others in
the work area.

1 (e) • described as filler. 3

• melts.
• becomes part of weld.

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 Question Solution Marks Notes
2 (a)

2 (b)

------------ 3

2 (c)

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 Question Solution Marks Notes
3 (a) 0.64 5 • Locating formula – 1
mark
• Correct substitution – 2
marks
Final solution – 2
marks

3 (b) 0 degrees c 6 Information from EN1011

marked (*)
• 1 mark for locating
correct hydrogen scale
table (scale d, table
C2) *
• 1 mark for correct use
of carbon equivalent
(0.64)
• 1 mark for selecting
correct table (Graph
C2.j) from resource
pack *
• 1 mark for combined
thickness calculation
(10 + 12 + 12) = 34 *
• 1 mark for correct use
of arc energy (1.8
kj/mm)
• 1 mark for correct
answer

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3 (c) Candidates should complete the
following information in the
worksheet:

• welding process to be used 1

• joint type 1

• shielding gas type 1

• welding position 1

• welding pass details 1

• type of welding current 1

• test piece position 1

• joint type 1

• shielding gas composition 1

• pre-heat temperature 1

Procedure details section – for each

run:
• process 1
• size of filler material 1
• polarity 1

Sketches:
• test joint details of weld
preparation 2
• bead sequence detail 2

(Total 17)

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4. The planning operations sheet for the manufacture of the component is detailed below. While the answer below is a suggested response other
sequences or methods of manufacture should be considered on their merit.

Op Marking out Details of cutting & forming Joining processes Assembly Inspection and testing
No processes processes methods
1 Mark out base plate Check size for accuracy
including hole
centres
2 Cut base plate to size-
Shearing Drill holes and
debur
3 Draw layout of Check for accuracy
web plate A to
produce template
4 Manufacture web plate A.
Thermal cut radius, shear
plate
5 Dress edges where required

6 Mark out plate

stiffeners
7 Manufacture stiffeners
using shearing process
8 Tack weld assembly using Assemble base Check accuracy and
MAGS process plate, web and squareness
stiffeners using
magnetic
clamps

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Op No Marking out Details of cutting & forming Joining processes Assembly Inspection and testing
(cont) processes processes methods
9 Calculate
approximate size of
clamp straps
10 Cut straps to finished size
by shearing
11 *Manufacture forming jig
(preferred option)
12 Heat and form main radius

13 Heat and form tabs

14 Mark out hole Drill holes on clamps and *Assemble

positions on debur clamps in pairs
clamps prior to drilling
15 Tack weld clamp to web Position bottom Check for accuracy
plate using MAGS process clamp on web
plate
16 Fully weld assembly using Check for distortion and
MAGS process carry out full visual
inspection
17 Carry out Dye Penetrant
testing of welds

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 Question Solution Marks Notes
4. • layout of operations sheet 5
• correct sequence of operations 5

The sequence of operations and

manufacturing instructions should
make reference to the following:

• marking out (op no. 1, 3, 6, 9,

14)
• cutting & forming (op no. 2, 4,
5, 7, 10, 11, 12, 13, 14)
• joining and assembly (op no. 8,
14, 15, 16)
• inspection (op no. 1, 3, 8, 15,
16, 17)
5
11 *Candidates who specify
the use of a jig for
operation 11 gain an
extra 2 marks
5 *Candidates specifying
the pairing up of clamps
gain an extra 2 marks
6

(Total – 37)

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 Question Solution Marks Notes
5. Clean assembly by pickling in an 4 Solution should include
acid bath or by sand or shot the following points:
blasting. Neutralise the acid by hot • method of cleaning –
washing. If shot or sand blasted 1 mark
then degrease. Ensure assembly is • neutralising or
dry and submerge in molten zinc degreasing – 1 mark
bath. Remove and allow to cool. • use of molten zinc –
1 mark
• finishing (cooling) –
1 mark

6.
• de – grease specimen 1 The description of the
procedure should contain
• dry specimen 1 the main points listed

• apply penetrant 1

• soak time 1

• remove surplus dye 1

• apply developer 1

• allow drying time 1

• carry out inspection 1

• record results 1

• clean specimen 1

(Total 10)

7. (a) Tensile Strength 2

The ability of a material to resist

being pulled apart.

7. (b) Malleability 2

The ability of a metal to be

hammered, shaped and worked

[END OF MARKING INSTRUCTIONS]

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