2008 Fabrication & Welding

Higher

Finalised Marking Instructions

 Scottish Qualifications Authority 2008

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These Marking Instructions have been prepared by Examination Teams for use by SQA Appointed
Markers when marking External Course Assessments. This publication must not be reproduced for
commercial or trade purposes.
2008 Higher Fabrication and Welding

Solutions and Marking Instructions

Question Solution Marks Notes

1
1 (a) • Protect the weld pool. 2
• Be ionized to provide arc medium.

1 (b) Flat characteristic (constant voltage). 1

Required to provide self-adjusting arc to 3

control arc length by increasing and
decreasing electrode burn off.

1 (c) Sketch to include:

• Power source 6
• Wire drive unit
• Torch assembly
• Cable arrangement
• Weld return lead and clamp
• Gas supply

• Clarity of sketch. 1

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 Question Solution Marks Notes
2
2 (a) • Single bevel butt weld. 2
• On the arrow side.

2 (b) • Fillet weld 5

• Both sides
• Leg length 17mm
• Intermittent weld
• 5x welds of 75, miss 75

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 Question Solution Marks Notes
3
3 (a) 0.62 5 • Locating formula – 1 mark.
• Correct substitution – 2
marks.
• Final solution – 2 marks.

3 (b) 50 degrees C 6 • 1 mark for locating correct

hydrogen scale table (c.2.3.3)
(scale D).
• 1 mark for correct use of
carbon equivalent.
• 1 mark for selecting correct
table (table c2i) from resource
pack.
• 1 mark for combined thickness
calculation
(12+12).
• 1 mark for correct use of arc
energy (1.1 kj/mm).
• 1 mark for correct answer.

3 (c) Candidates should complete the following

information marked with an asterisk in the
worksheet:

Range of approval:

• welding process 1
• single/multi pass 1
• gas flux 1
• type of current 1
• sketch test joint details 5
(angle, root face, root gap, metal
thickness, sketch)

Weld and Filler metal details:

• joint type (butt) 1

• gas composition 1
• sketch of bead sequence detail (multi- 3
run, single V, sketch)
• preheat and interpass temperature 1
(method) and control (0 degrees)

Procedure details section

for each run:

• process 1
• size of filler 1
• polarity. 1

Total 18 marks

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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 processes Details of cutting and forming Assembly methods Joining processes Inspection
No processes
1 Mark out base plate to size and Dimensional check
mark fold lines
2 Cut base plate to size (guillotine)
3 Fold base plate flanges (press Dimensional check
brake)
4 Mark out end plates to size and Dimensional check
mark radius
5 Cut end plates to size (guillotine Dimensional check
for straight cuts, oxy-fuel for
radius)
6 Mark out stiffener to size and Dimensional check
mark radius
7 Cut stiffener to size (guillotine for Dimensional check
straight cuts, oxy-fuel for radius)
8 Mark out side plates to size Dimensional check
9 Cut side plates to size (guillotine) Dimensional check
10 Prep end plates
11 Flame cut or nibble
12 Grind cut edge if flame cut
13 Tack end plates to base
plate in position
14 Mark out position of side Check
plates on end plates
15 Tack side plates in Check using stiffener
position

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16 Mark out stiffener position on Check
side plates
17 Tack stiffener in position Check for square and
dimensions
18 Weld single bevels on
end plate to base plate
19 Mark approximate positions of
intermittent welds
20 Weld side plates to base
plate
21 Weld side plates to end
plate
22 Weld stiffener to base
plates and side plates
23 Carry out NDT
24 Remove excess spatter and grind
flame cut edges
25 Final dimensional
check

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 Question Solution Marks Notes
4
4 • layout of operations sheet. 5
• correct sequence of operations. 3

The sequence of operations and

manufacturing instructions should make
reference to the following:

• Marking out (op nos. 1, 4, 6, 8, 10, 14, 8

16, 19)

• Cutting & forming (op nos. 2, 3, 5, 7, 8

9, 11, 12, 24)

• Assembly and Joining (op nos. 13, 15, 7

17, 18, 20, 21, 22)

• Inspection (op no. 1, 3, 4, 5, 6, 7, 8, 9, 5

14, 15, 16, 17, 23, 25).

Total 36 marks

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 Question Solution Marks Notes
5
5 (a) Heat the component to 20 to 50 degrees C 3 • Correct temperature − 1 mark
above the upper critical temperature and • Correct soak time − 1 mark
soak for one hour for each 25mm thickness • Method of cooling − 1 mark
and cool in the furnace or by a method of
maintaining a slow cooling rate.

5 (b) • Degrease 8
• Apply penetrant
• Soak time
• Remove excess penetrant
• Apply developer
• Wait time
• View
• Complete report

5 (c) • Degrease 4
• Pickle
• Hot dip in zinc
• Cool

[END OF MARKING INSTRUCTIONS]

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