Translated from Afrikaans to English - www.onlinedoctranslator.

com

Agricultural technology Grade 12 Date:______________

CHAPTER 4
SKILLS AND CONSTRUCTION PROCESSES
MIG / MAG WELDING (MIG = Metal Inert Gas) (MAG = Metal Activation Gas) p 54
1. Name 10 General advantages of MIG / MAG welding.
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
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 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 _______________________________________________________________________

2. Name 6 General disadvantages of MIG / MAG welding.

 _________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

3. MIG / MAG welding most common welding defects. (Table p. 54/55).

Complete the table in full by filling in the Probable cause against the defect.

DEFECTIVE PROBABLE CAUSE

Porosity
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________

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Agricultural technology Grade 12 Date:______________

DEFECTIVE PROBABLE CAUSE

Lack of penetration
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________

Splash
 ___________________________________________
 ___________________________________________
 ___________________________________________

Cutting / incision  ___________________________________________

 ___________________________________________
 ___________________________________________
 ___________________________________________

Lack of merger  ___________________________________________

 ___________________________________________
 ___________________________________________
 ___________________________________________

Krake
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________
 ___________________________________________

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Agricultural technology Grade 12 Date:______________

4. What does the abbreviation MIG commonly used in welding stand for?
 __________________________________________________________________________
5. Explain the process of MIG welding.
 MIG welding uses an arc of
__________________________________________________________________________
__________________________________________________________________________
 The heat that _______________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________
 Once heat is removed, ______________________________________________________
__________________________________________________________________________
__________________________________________________________________________

6. Name 5 Specific benefits of MIG welding.

 _________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

7. Name 3 Specific disadvantages of MIG welding.

 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

8. Photo of welding nozzle and parts. Name the parts and give a brief description of purpose.

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Agricultural technology Grade 12 Date:______________

9. Name and discuss the parts inside the machine (p 56 at the bottom / 57 at the top)

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Agricultural technology Grade 12 Date:______________

10. Explain fully the 9 points in the gas supply process of the MIG (p 57)
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 _______________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

11. Now explain the 7 points of the welding nozzle on the next page. (p 57)
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________

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Agricultural technology Grade 12 Date:______________

 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________

12. Explain the purpose and operation of the earth clamp in full. (3pt)

 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________

13. MIG welding is only safe when safety precautions are followed. MIG welding produces a lot of
harmful heat and light. Name the steps you will take / take to protect yourself from the above. (p.
59)

 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________________________________________________________________________

14. a. Why should galvanized steel not be welded?

__________________________________________________________________________
__________________________________________________________________________
b. What type of fire extinguisher should be in Welding Workshop and why?
__________________________________________________________________________
__________________________________________________________________________
15. Before you start welding, make sure that both the welding machine and the welding piece are set
up properly.
Explain the setup of the welding machine.

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Agricultural technology Grade 12 Date:______________

 __________________________________________________________________________
__________________________________________________________________________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________________________________________________________________________

Briefly explain the set-up of the Metal.

 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________

16. Explain step by step the 13 points when laying a weld bead. (p. 61)

 __________________________________________________________________________
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 __________________________________________________________________________
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 __________________________________________________________________________
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 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________

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Agricultural technology Grade 12 Date:______________

 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
 __________________________________________________________________________
__________

17. Describe the wrong / correct machine settings according to the photos below as well as how the
errors can be corrected. (p. 62/63)

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Agricultural technology Grade 12 Date:______________

18. Welding of metal

Identify the welding defects in the square tube steel suture above.
 __________________________________________________________________________
 __________________________________________________________________________
 _________________________________________________________________________
 __________________________________________________________________________
 _________________________________________________________________________

Also identify the welding defects in the second photo.

 __________________________________________________________________________
__________

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Agricultural technology Grade 12 Date:______________

 __________________________________________________________________________
__________
 __________________________________________________________________________
__________
18. Describe the process of Welding of metal (p. 63) in full.
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

19. Explain the grinding / sanding process of a load. (p. 65)

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 __________________________________________________________________________
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 __________________________________________________________________________
 __________________________________________________________________________
 __________________________________________________________________________

20. Explain the following Common problems as well as how you would correct them: (p 65/66)
a. Welding splashes (metal balls) _______________________________________________
_______________________________________________________________________
b. Weld does not penetrate
_______________________________________________________
_______________________________________________________________________
c. Poor welding penetration
_______________________________________________________
_______________________________________________________________________

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Agricultural technology Grade 12 Date:______________

d. Welding arc burns hole through metal

____________________________________________
_______________________________________________________________________
e. Too much metal in your welding bead
_______________________________________________
_______________________________________________________________________
f. Nozzle spits and does not provide a constant load .______________________________
_______________________________________________________________________

21. Photographs of welding wire stuck to tip as well as the exchange of the tip. Make a brief
description of each photo to explain steps.

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Agricultural technology Grade 12 Date:______________

22. Explain the following features found on advanced MIG welding machines.
a. Arc force _______________________________________________________________
_______________________________________________________________________
b. Strangle
__________________________________________________________________
_______________________________________________________________________
c. Low setting
_______________________________________________________________
_______________________________________________________________________
d. High setting
_______________________________________________________________
_______________________________________________________________________
e. Point / carbon welding
_______________________________________________________
_______________________________________________________________________
f. Push-pull nozzle
_______________________________________________________________________
_______________________________________________________________
g. Soft start _______________________________________________________________
_______________________________________________________________________

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Agricultural technology Grade 12 Date:______________

23. Explain the difference between the 2-roll feed system and the 4-roll feed systems and where it
occurs in wire spinning feed mechanisms.
Two-roll feed
mechanisms__________________________________________________________________
____
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
________
Four-roll feeding mechanisms
_______________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________

24. SHORT QUESTIONS:

1. Give a brief description of what MIG welding is.
This is an arc welding process where
________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
______
2. Name the three types of gas used in MIG welding?
 ____________________
 ____________________

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Agricultural technology Grade 12 Date:______________

 ____________________
3. What type of current is used in the MIG welding process?
____________________________
4. Name the advantages of MIG welding over those of ordinary arc welding. (14)
 ____________________________________________________________________
________
 ____________________________________________________________________
________
 ____________________________________________________________________
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 ____________________________________________________________________
________
 ____________________________________________________________________
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________
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 ____________________________________________________________________
________
5. Make a neatly labeled sketch of the MIG welding process (p. 68)

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Agricultural technology Grade 12 Date:______________

6. In what direction should one work with MIG welding?

__________________________________________________________________________
__________________________________________________________________________
7. The photo below shows the nozzle of a MIG welding machine.

7.1 Give the name of part A and give its function.

____________________________________________________________________
____________________________________________________________________
____________
7.2 Which provides the screen that protects the welding area from oxygen during the
welding process.
____________________________________________________________________
________
7.3 Part A sometimes melts against part B. Give a reason for this and provide a possible
solution to it.
____________________________________________________________________
____________________________________________________________________
____________
7.4 Give the name of part B.
____________________________________________________________________
________
7.5 Provide any two Safety Rules when welding with MIG welding equipment.
a) ______________________________________________________________

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Agricultural technology Grade 12 Date:______________

b) ______________________________________________________________
7.6 Identify the energy source for this type of welding.
______________________________.
7.7 Give three types of metal that can be successfully welded with this welding machine.
 ____________________
 ____________________
 ____________________

8.1 The figure shows the tip of a MIG welding nozzle / gun.

WELDING PRINCIPLES. (P. 71)

8.1.1 Describe the process of overhead welding at Gassweis.
 ___________________________________________________________________
____
 ___________________________________________________________________
____
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____
 ___________________________________________________________________
____
8.1.2 Describe the process of overhead welding at Arc Welding.
 ___________________________________________________________________
____
 ___________________________________________________________________
____

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Agricultural technology Grade 12 Date:______________

 ___________________________________________________________________
____
 ___________________________________________________________________
____
8.2 Make a small neat sketch of the process of Vertical upward arc welding and explain the 5
steps in sequence. (vertical up) (Page 71)

 Special electrodes
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__
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__
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__
 __________________________________________________________________
__________________________________________________________________
__

8.3 Name the 4 different types of welding movements used for vertical welding runs.
 ______________________
 ______________________
 ______________________
 ______________________

8.4 When is the horizontal square butt weld used.

________________________________________________________________________
______________________________________________________________________

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Agricultural technology Grade 12 Date:______________

8.5 Make a neat sketch of the process of the horizontal square butt weld and explain the 5
steps in sequence. (p. 72)

 __________________________________________________________________
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__
 __________________________________________________________________
__________________________________________________________________
__
 __________________________________________________________________
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__
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__
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8.6 What to keep in mind when welding pipes.

________________________________________________________________________
______________________________________________________________________
8.7 Name the three pipe welding positions.
 __________________________________________________________________
_____
 __________________________________________________________________
_____
 __________________________________________________________________
_____

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Agricultural technology Grade 12 Date:______________

8.8 What should be kept in mind when welding galvanized metals?

________________________________________________________________________
______________________________________________________________________
8.9 Name the 4 different pipe welds.
 _______________________________________________
 _______________________________________________
 _______________________________________________
 _______________________________________________
8.10 Describe the 12 procedures to be followed when welding a cast-iron pot
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8.11 Name 6 common points to remember when welding. (p. 73)
 ______________________________________________________________
 ______________________________________________________________
 ______________________________________________________________

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Agricultural technology Grade 12 Date:______________

 ______________________________________________________________
 ______________________________________________________________
 ______________________________________________________________
8.12 Describe what is meant by Hardcasting
 __________________________________________________________________
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__
 __________________________________________________________________
__________________________________________________________________
__

8.13 Name 4 types of wear and tear to which parts can be subjected.
 ____________________________________________________________________
___
 ____________________________________________________________________
___
 ____________________________________________________________________
___
 ____________________________________________________________________
___

8.14 Describe the Hard Leveling process.

 ____________________________________________________________________
___
 ____________________________________________________________________
___
 ____________________________________________________________________
___

8.15 Define Weld Shrinkage.

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
____

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Agricultural technology Grade 12 Date:______________

8.16 Make a neatly labeled sketch in which the 4 types of DISTORTION that occur in welds are
indicated.

8.17 Name the 5 factors on which the amount of distortion depends on a weld.
(p. 74)
a) ____________________________________________________________________
___
b) ____________________________________________________________________
___
c) ____________________________________________________________________
___
d) ____________________________________________________________________
___
e) ____________________________________________________________________
___
8.18 Name four methods that can be used to prevent distortion of a weld.
 __________________________________________________________________
_____
 __________________________________________________________________
_____
 __________________________________________________________________
_____
 __________________________________________________________________
_____

OXI-ACETILENE CUT AND HEAT (Oxy gas burner)

1. Describe the cutting process. 5 points (p. 76)

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Agricultural technology Grade 12 Date:______________

 ____________________________________________________________________
________
 ____________________________________________________________________
________
 ____________________________________________________________________
________
 ____________________________________________________________________
________
 ____________________________________________________________________
________
2. Name 3 types of metals that can be cut using Oksi gas burner.
 ___________________________
 ___________________________
 ___________________________
3. Name the gates / holes of the intersection. (p. 76)

4. Name the sketch of the welding nozzle / cutting torch.

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Agricultural technology Grade 12 Date:______________

5. Label photo of the oxy-acetylene apparatus. (add the Afrikaans captions.) p 77

USE OF OXI-ACETYLENE HEATING / CUTTING SAFETY APPLIANCE

1. Why should a leather apron or similar protective clothing and welding gloves be used in oxy-
acetylene welding? Pg 79
__________________________________________________________________________
__________________________________________________________________________
__
2. Which PPE should you use when doing oxy-acetylene welding. Bl 78
 ____________________________________________________________________
___

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Agricultural technology Grade 12 Date:______________

 ____________________________________________________________________
___
 ____________________________________________________________________
___
 ____________________________________________________________________
___
 ____________________________________________________________________
___

3. Name 5 safety tips when using the oxy-acetylene welding device. Bl 78

 _____________________________________________________________________
__
 _____________________________________________________________________
__
 _____________________________________________________________________
__
 _____________________________________________________________________
__
 _____________________________________________________________________
__
4. What to look for when using the oxy-acetylene welding device. Pg 79
 _____________________________________________________________________
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_____________________________________________________________________
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 _____________________________________________________________________
_____________________________________________________________________
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 _____________________________________________________________________
_____________________________________________________________________
____

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Agricultural technology Grade 12 Date:______________

 _____________________________________________________________________
_____________________________________________________________________
____
 _____________________________________________________________________
_____________________________________________________________________
____

STEP BY STEP INSTRUCTIONS:

IGNITION AND EXHAUST OF OXI-ACETYLENE WELDING
1. Light the cutting nozzle and adjust a neutral flame; light the cutting nozzle and adjust the gas
flow until you have a neutral flame.
2. Describe “Heat for
removal”___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
___________

3. Accidents happen easily in the workshop with gas welding equipment. Extinguishing or
Turning Off is very important. Explain steps for complete extinguishing / switching off
completely.

PLASMASNY bl 80
General:
1. What is High pressure plasma.
_______________________________________________________
__________________________________________________________________________
_____
Which involves the Plasma cutting process.
_______________________________________________
__________________________________________________________________________
__________________________________________________________________________
__
What part of the process does the cutting work.
____________________________________

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Agricultural technology Grade 12 Date:______________

__________________________________________________________________________
__________________________________________________________________________
__

2. Fully explain the operation of plasma cutter with respect to low voltage, high current. Bl 80.
 Plasma cutter converts 220v 15Amp AC to low voltage and high current
 Voltage can be between 20-50 volts
 The current can now be up to 100 amps.
 _______________________________________________________________________
 _______________________________________________________________________
 _______________________________________________________________________
 _______________________________________________________________________
 _______________________________________________________________________
3. Discuss the operation of compressed air when using a plasma cutter. This is also known as
the final force. (Bl 81)
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
4. Fully discuss the angle at which the cut is made with plasma cutter.
 The final angle at which the plasma cutter cuts is not 90 degrees.
 _______________________________________________________________________
 _______________________________________________________________________
 _______________________________________________________________________
5. What temperatures can be obtained with the plasma cutter.
 _______________________________________________________________________
6. Which gases are used by plasma cutter to generate plasma.
 _______________

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Agricultural technology Grade 12 Date:______________

 _______________
 _______________
 _______________
7. Name the different electrodes and their various uses in the plasma cutter.
 _______________________________________________________________
 _______________________________________________________________
8. What voltages are required for plasma cutting
 ____________________________________________________
9. What is the purpose of calibration in plasma
cutting .______________________________________
__________________________________________________________________________
_____
10. What criteria should be used when choosing the correct plasma cutting machine.
 _______________________________________________________________________
 _______________________________________________________________________
 _______________________________________________________________________
11. Name and discuss the different gases available for plasma cutting.
 Lug
________________________________________________________________________
____
 Oxygen
________________________________________________________________________
____
 Nitrogen_________________________________________________________________
______
 Argon / hydrogen
________________________________________________________________________
____________________________________________________________________
12. Which determines the flame size with respect to Watts and cutting nozzle.
 Power is determined by power (Watts), not____________________________
 Power = voltage x current
 Cutting nozzle size is not necessarily determined by the office rating.
13. How are speeds and cutting thicknesses determined?
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________

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Agricultural technology Grade 12 Date:______________

14. Discuss plasma cutting safety in full. 6 points p 82

 Refractory gloves and a face shield must be worn at all times.
 Flame-retardant clothing should always be worn because possible hot metal and
sparks pose a potential hazard.
 Any flammable material must
______________________________________________
_______________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
15. Discuss fire hazard in plasma cutting in detail. Bl 83
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
 ____________________________________________________________________
__________________________________________________________________
16. What is important regarding eye protection in plasma cutting and why.
 Plasma radiation causes a large amount of visible, ultraviolet radiation which can be
harmful to the eyes.
 Wear proper _______________________________________________________
 ____________________________________________________________________
___
17. What procedures should be followed in plasma cutting to protect yourself from respiratory
danger. 6 points
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________

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Agricultural technology Grade 12 Date:______________

 ______________________________________________________________________
 ______________________________________________________________________
18. Explain electrical hazards when using the plasma cutter. 6 points.
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________
 ______________________________________________________________________
19. Why consultation and training for the use of plasma cutters is so essential.
These machines are extremely dangerous improper use can cause injuries or even death.
20. Discuss benefits of plasma side work
a. Fast cutting speed: - _______________________________________________
____________________________________________________________________
___
b. Wide range of materials and thicknesses: - thicknesses of up to 75mm can be cut
effectively.
c. Easy to use: - requires only minimal operator training.
d. Economic: - _______________________________________________________
____________________________________________________________________
___

21. There are six common problems with the use and maintenance of plasma cutters.
Discuss in full. Bl 85.
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________
 ________________________________________________________________________
______________________________________________________________________

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