index year 4 term 1 week 1 - pro-practicum

1

PRO-PRACTICUM SCHOOL

WELDING CENTRE

Index

Year 4 Term 1

Week 1

1) Topic 1-1: Safety procedures 2) Topic 1-2: Housekeeping. 3) Topic 1-3: Workshop safety. 4) Topic 1-4: Firstaid box.

Week 2

1) Topic 2-1: PPE. 2) Topic 2-2: Signs and coulers. 3) Topic 2-3: How to clean and dress a wound. 4) Topic 2-4: HIV AND AIDS.

Week 3-4

1) Topic 3-1: Measuring tools. 2) Topic 3-2: Measuring tools. 3) Topic 4-1: Measuring tools.

Week 5

1) Topic 5-1: Materials.

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WELDING CENTRE

Week 6

1) Topic 6-1: Ferrous and none ferrous materials. 2) Topic 6-2: Materials.

Week 7

1) Topic 7-1: Arc welding.

Week 8

1) Topic 8-1: Arc welding.

Always

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WELDING CENTRE

YEAR 4 TERM 1 WEEK 1-2 DATE: ____________

TOPIC 1:1

SAFETY PROCEDURES

CENTRUM

a) Always make sure the work area are clean. b) Welding cables and machines must be in a good working condition. c) No oil, water, grease or any flammable materials near welding. d) No playing in work place. e) Always wear the right PPE. f) Report any injuries immediately. g) Do not leave any cylinders open. h) Use the right tools for the kind of job that’s going to be done. i) No swearing and fighting in the work place. j) No alcohol or any kind of drugs in work place. k) Always line up infront of the centre.

TASK

1) Describe 4 safety rules in the centrum? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________

YEAR 4 TERM 1 WEEK 1-2 DATE:_____________

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WELDING CENTRE TOPIC 1-2

GOOD HOUSE-KEEPING

1) House-keeping. What is the purpose of good house-keeping?

A) Poor house-keeping can be the cause of accidents, such as:

a) Tripping over loose objects on floors, stairs and platforms. b) Being hit by falling objects. c) Slipping on greasy, wet or dirty surfaces. d) Striking against projecting, poorly stacked items or misplaced materials. e) Cutting, puncturing or tearing the skin of hands or other parts of the

body on projecting nails, wire or steel strapping.

To avoid these hazards, workplace must maintain order throughout a workday. Although this effort requires a great deal of management and planning, the benefits are many.

2) Effective house-keeping results in:

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WELDING CENTRE a) Reduced handeling to ease the flow of materials. b) Fewer tripping and slipping accidents in clutter- free and spill-

free work areas. c) Decrease fire hazards. d) Lower work exposure to hazardous substances (e.g. dust, vapours). e) Better control of tools and materials, including inventory and supplies. f) More efficient equipment clean up and maintenance. g) Better hygienic conditions leading to improve health. h) More effective use of space. i) Reduced property damage by improving preventive maintenance. j) Less janitorial work. Improve morale. Improved productivity (tools and

machines will be easy to find).

TASK

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WELDING CENTRE

1) Name 3 poor house- keeping elements that can be a cause of accident.

a) ______________________________________________________________________________________________________________________

b) ______________________________________________________________________________________________________________________

c) ______________________________________________________________________________________________________________________

2) Name 4 effective house- keeping elements that can be a cause of accidents.

a) ______________________________________________________________________________________________________________________

b) ______________________________________________________________________________________________________________________

c) ______________________________________________________________________________________________________________________

d) ______________________________________________________________________________________________________________________

YEAR 4 TERM 1 WEEK 1-2 DATE: _____________

TOPIC 1-3

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WELDING CENTRE WORKSHOP SAFETY

1) What is an accident? An accident is an unplanned and uncontrolled event by unsafe acts or unsafe conditions.

A) Unsafe acts. a) Work at unsafe speed. b) Work without permission. c) Leave machine unsafe. d) Place material at unsafe position. e) Horse play (playing in the workshop). f) Adjust on moving parts.

B) Unsafe conditions. a) Walking paths are opstructed. b) Bad planning, bad ventilation and bad lightning. c) Dirty works area. d) Not wearing PPE. e) Open and loose wires. f) Material laying around.

C) Cause of an accident. a) Bad house-keeping. b) Loose clothing. c) Wrong use of tools. d) Machines wrongly adjusted.

D) General safety. a) Always wear PPE. b) Safety comes first. c) No playing in centre. d) Always make sure the work area is clean.

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WELDING CENTRE e) No water, oil, grease or any flammable materials near welding.

f) No alcohol or drugs or any kind of drugs in the workplace. g) Use the right tool for the right job.

TASK

1) What is an accident?

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WELDING CENTRE a) ___________________________________________________________________________________________________________

______________________________________________________________________

2) Write down 4 unsafe acts. a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________ 3) Write down 5 unsafe conditions. a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________ e) ___________________________________________________________ 4) What can cause an accident? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ 5) How can we prevent an accident? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________


TOPIC 1:4

FIRST AID BOXES

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WELDING CENTRE

1) First aid box. a) The box is white with a red cross on it.

2) What in a first aid box must be. a) Tweesers b) Scissors c) , d) Sterilised water e) Triangle bandage f) Gauze g) Plaster h) Record book

3) Procedures with an injury. a) Do not panic keep calm. b) Determine how serious the injury is. c) Call the teacher. d) If the person is bleeding, do not touch the wound with your bare hands.

TASK

1) What must be in a first aid box? a) ___________________________

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WELDING CENTRE b) ___________________________ c) ___________________________

d) ___________________________ e) ___________________________ f) ___________________________ g) ___________________________ h) ___________________________

2) What must you do incase of an injury? a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________ e) ___________________________________________________________

___________________________________________________________ f) ___________________________________________________________

___________________________________________________________ g) ___________________________________________________________

___________________________________________________________ h) ___________________________________________________________

___________________________________________________________ i) ___________________________________________________________

___________________________________________________________ j) ___________________________________________________________

___________________________________________________________ k) ___________________________________________________________

___________________________________________________________


TOPIC 2:1

PROTECTIVE CLOTHES (PPE)

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WELDING CENTRE 1) The following protective clothes must be worn in a welding centre.

a) Cloves: To protect your hands from burning and hot particals and working with sharp materials or picking up or moving plates.

b) APRON: To protect your body and clothes from burning and it is made out of leather.

c) Overal: To protect our body from burning.

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WELDING CENTRE

d) Welding helmet: To protect your eyes from arc eyes.

e) Safety shoes: The shoes got a steel point in to protect your feet.

e) Safety glasses: To protect your eyes from grinding sparks.

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WELDING CENTRE

TASK

1) Write down the PPE what the boy has got on.


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WELDING CENTRE TOPIC 2:2

COULERS AND SIGNS

1) Mandatory signs: It is regulary signs which indicates that an instruction must be carried out and the colours is white and blue.

2) Warning signs: Signs that warns you of a hazard that is not likely to be life threatening.

3) Danger signs: Used to indicate an imminently hazardous situation which, if avoided, will result in death or serious injury.

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WELDING CENTRE

4) Causion signs: Used to indicate a potensially hazardous situation which, if not avoided, may be the result of a minor or moderate injury.

5) Fire sign: It advices the location of fire alarms and firefighting equipment, it has a red back round with a white symbol.

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WELDING CENTRE

TASK

1) What is the use of a mandory sign? a) ___________________________________________________________

______________________________________________________________________________________________________________________

2) What is the use of a warning sign? a) ___________________________________________________________

______________________________________________________________________________________________________________________

3) What do fire signs indicate? a) ___________________________________________________________

______________________________________________________________________________________________________________________

4) Draw a no smoking sign.

YEAR 4 TERM 1 WEEK 1-2 DATE: ___________

TOPIC 2-3

HOW TO CLEAN AND DRESS A WOUND

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WELDING CENTRE

1) STEP ONE: If possible wash your hands before dealing with the wound. Then if the wound is dirty, lightly rinse it with water.

2) STEP TWO: Temporarily protect protect the wound with a sterile swap. Carefully clean the surrounding skin with water and soap. Gently wipe away from the wound using each swap once only.

3) STEP THREE: If bleeding persists apply direct pressure.

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WELDING CENTRE

4) STEP FOUR: Dress small wound with an adhesive dressing.

5) STEP FIVE: If the wound is lager, apply a sterile medicated dressing or gauze and clean pad and bandage firmly in position.

TASK

1) How will you deal with a deap wound?

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WELDING CENTRE a) ___________________________________________________________________________________________________________

______________________________________________________________________

2) Why do you need to wash your hands before you dress a wound? a) ___________________________________________________________

______________________________________________________________________________________________________________________

3) What do you do with running water? a) ___________________________________________________________

______________________________________________________________________________________________________________________

4) How do you dress a small wound? a) ___________________________________________________________

______________________________________________________________________________________________________________________

5) How many steps are there that you must follow to dress a wound? a) _______________________________________________________

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WELDING CENTRE TEAR 4 TERM 1 WEEK 1-2 DATE:___________

TOPIC 2-4

HIV & AIDS

1) What is HIV? a) HIV is a very small organism, called a vires, wich can infect people. It can

not be seen with the naked eye, but only under the microscope. b) HIV only survives and multiplies in boddy fluits such as sperm, vaginal

fluits, breast milk, blood and saliva. We can only get infected through contact with infected body fluids.

2) What is AIDS? a) Aids is the final stage of infection with HIV, and this is what cause a

person to get very ill. b) People with AIDS usually have several different illnesses at the same

time.

3) Redusing the risk to get HIV & AIDS. a) Be alert to open wounds, cuts and sores. Always wear latex cloves when

you attend to someones injury. b) Cover all bloody material, for example cotton, in a plastic bag and throw

away in a save container.

TASK

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WELDING CENTRE 1) Describe the difference between HIV & AIDS. a) ___________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________________

2) If someone is bleeding what must you do? a) ___________________________________________________________

YEAR 4 TERM 1 WEEK 3-4 DATE:____________

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WELDING CENTRE TOPIC 3:1

IDENTIFY MEASURING TOOLS

1) Measuring tools. a) Tape measure: Tape measure are used to measure different sizes. It is

made out if spring steel and comes in different lenths. (1m, 3m, 5m,8m, 30m)

2) Steel ruler. a) Steel ruler: Steel rulers are used to measure and draw lines on work

pieces. Steel rulers are made out of spring steel.

3) Meter stick (ruler). a) To draw longer lines, usualy used with drawings.

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WELDING CENTRE

TASK

1) Measure the following lines and write down the sizes in mm.

YEAR 4 TERM 1 WEEK 3-4 DATE:___________

TOPIC 3-2

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WELDING CENTRE MEASURING TOOLS

1) Veneer calliper. a) To measure presision work pieces, in and outside sizes. Some are

electronic and give the measurement on it. A veneer must be clean at all times. Do not use as a hammer or any other tool.

2) 90 deg square. a) To measure inside and outside corners that forms a 90 deg. It is made

out of spring steel. Do not use as a hammer or any other tool. Do not weld near a square.

TASK

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WELDING CENTRE 1) For what do u use a veneer? a) _____________________________________________

___________________________________________________________________________________________________________________________

2) Draw a 90 deg square?

YEAR 4 TERM 1 WEEK 3-4 DATE:___________

TOPIC 4-1

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WELDING CENTRE MEASURING AND HAND TOOLS

1) Combination square. a) A combination square are used to measure different angles, levels, and

can also be used to draw different degrees on material.

2) Height gage with marble top. a) To measure hights and thicknesses of materials.

TASK

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WELDING CENTRE 1) Mark if the following statements are true or false regarding general safety and tools.

TRUE FALSE

Safety comes second.

You may not run in the centre.

Always wear an overall.

We use a steel ruler to draw lines.

90 deg corners are measured with a square.

You use a welding helmet to look in the sun.

You don’t have to wear PPE.

Tools must always be packed away.

With a veneer we measure thickness of material.

Make sure machine guards are tighten.

Use the right tool for the right job.

Leave floors dirty.

There must not be oil or water on the floors.

It is important to report any injury.


TOPIC 5:1

MATERIALS

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WELDING CENTRE

1) Identify ferrous and none ferrous materials. a) Ferrous metals:

Ferrous metals has got a high carbon content, wich generally makes them vulnerable to rust when exposed to moisture. Most ferrous metals are magnetic, wich makes them very use full for motor and electrical applications.

2) None ferrous metals. The main advantage over none ferrous metals is their malleability (material

that you can shape without breaking) and they don’t content iron, that’s giving it a higher resistance to rust and electronic and wireing applications.

TASK

1) What is ferrous metals? a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________

2) What is none ferrous metals? a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________


TOPIC 6:1

FERROUS AND NONE FERROUS METALS

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WELDING CENTRE 1) None ferrous metals. a) Brass:

Brass is red of colour, and and it is not highly ductile, we use brass pipes in our houses for water.

b) Bronze: Bronze is copper of couler, bronze are used for medals and decorations.

c) Hardened steel: It is steel that has less carbon and a much harder steel than normal steel. We

use hardened steel for tools, anvils, hammers and machines. d) Copper:

Copper is red of couler, highly ductile, malleable and has high conductivity for electricity and heat. We use copper for electrical cables.

e) Aluminium: Aluminium is light weight, soft and low strength. Aluminium is used for

aircrafts and food cans.

TASK

1) For what can brass be used for? a) ___________________________________________________________

___________________________________________________________ 2) What kind of tools do u make of hardened steel? a) ___________________________________________________________

___________________________________________________________ 3) What do people build with aluminium? a) ___________________________________________________________

___________________________________________________________


TOPIC 6:2

MATERIALS

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WELDING CENTRE 1) Mild steel: Mild steel is a dark colourand containing a lot of carbon, we use mild

steel for buildings, roofs, cars and factories.

2) Stainless steel: Stainless steel is a important alloy steel made of chromium. Stainless steel are

used for pots and pans, airplanes and are none magnetic.

3) Cast iron: Cast iron is an alloy made from iron, carbon and silicon. It is used for water

pipes, machine tools and car engines.

TASK

1) Where do u use mild steel? a) ___________________________________________________________

___________________________________________________________ 2) From what are stainless steel made of and where do u use it? a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________

3) From what are cast iron made of? a) ___________________________________________________________

______________________________________________________________________________________________________________________


TOPIC 7:1

ARC WELDING

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WELDING CENTRE 1) What is shield metal arc welding? a) Arc welding is a fusion of two metals that are joint with arc

welding. b) An additional material in the form of an electrode do the melting and

jointing process.

2) Safety. a) Make sure the work area is clean. b) The welding machine and cables are in a good working condition. c) No oil, grease or water near machine. d) Work piece must be well prepared. e) Make sure your welding glasses are clean and there are no open or

broken cables.

3) Welding equipment. a) Welding machine, cables and material. b) Cloves, apron, overall, safety shoes, welding helmet. c) Welding equipment must be stored in a dust free and water free area

and must be packed nicely away.

TASK

1) Describe shield metal arc welding? a) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE ________________________________________________________________________________________________________________

_________________________________________________________________

2) Write down the welding equipment that u use? a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________ e) ___________________________________________________________


TOPIC 8:1

ARC WELDING

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WELDING CENTRE 1) Suitable power, welding settings and welding rods.

Welding rod (mm) Lenth (mm) Machine settings

2 mm 300 mm 40-80

2,5 mm 350 mm 60-95

3,15 mm 350 mm 110-130

4 mm 350 mm 140-165

5 mm 450 mm 170-260

6 mm 450 mm 270-340

2) Welding holders. a) Positive clamps is where the current flows through and to hold the

welding rod. b) Negative clamp, clamp on to work piece to get an earth through to the

work piece.

TASK

1) Fill in the missing items in the collum.

Welding rod (mm) Lenth (mm) Machine settings

2 mm

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WELDING CENTRE

350 mm

3,15 mm 110-130

350 mm

350 mm

6,3 mm

WELDING

YEAR 4

TERM 2

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WELDING CENTRE INDEX

WEEK 1-2

1) TOPIC 1-1: (Revision) Safety, first aid and HIV & AIDS. 2) TOPIC 1-2: (Revision) PPE, unsafe acts and conditions. 3) TOPIC 2-1: (Revision) Good house-keeping, safety signs, safe evacuation.

WEEK 3-4

1) TOPIC 3-1: Dividers and G-Clamps. 2) TOPIC 3-2: Cold chisels and various files. 3) TOPIC 3-3: Scroll bender, ball peen hammer, anvil and a bench vice. 4) TOPIC 3-4: Spanners and socets, compressor, pneumatic hand tools. 5) TOPIC 3-5: Hand drill and angle grinder. 6) TOPIC 3-6: Finishing grider, jig saw and SDS rotary drill.

WEEK 3-4 ( FLOOR MOUNTED EQUIPMENT)

1) TOPIC 4-1: Folder and bender. 2) TOPIC 4-2: Bench grinder and guillotine. 3) TOPIC 4-3: Pedestal drill and 300mm disc sander. 4) TOPIC 4-4: Repair a faulty 3 core cable, 3 pin plug and store and clean

hand power tools.

WEEK 5-6

1) TOPIC 5-1: Materials. 2) TOPIC 6-1: Joints.


TOPIC 1:1

REVISION OF SAFETY, FIRST AID AND HIV & AIDS

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WELDING CENTRE 1) What is an accident? An accident is an unplanned and uncontrolled event by unsafe acts

or unsafe conditions.

A) Safety. a) Always wear PPE. b) Safety comes first. c) No playing in the centre. d) Always make sure the work area is clean. e) No water, oil, grease or any flammable material near welding. f) No alcohol or drugs or any kind of drugs in the workplace.

2) First aid boxes. a) Make sure the first aid box are marked properly. b) The first aid box must be cheked regulary. c) There must be a record book of all the equipment in the box. d) Only one person must be in chached of the first aid box.

3) Procedures with an injury. a) Do not panic keep calm. b) Determine how serious the injury is. c) Call the teacher. d) If the person is bleeding, do not touch the wound with your bare hands.

4) HIV & AIDS. a) HIV is a small organism, called a vires, wich can infect people. b) AIDS is the final stage of infection with HIV, and this is what causes a

person to get very ill.

TASK

1) What is an accident? a) ___________________________________________________________

______________________________________________________________________________________________________________________

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WELDING CENTRE

2) Write down 4 safety rules. a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________

3) Describe the procedures incase of an injury. a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________

___________________________________________________________

4) Explain what you understand under the following terms: A) HIV a) ___________________________________________________________

___________________________________________________________

B) AIDS a) ___________________________________________________________

___________________________________________________________

YEAR 4 TERM 2 WEEK 1-2 DATE: _________

TOPIC 1-2

REVISION OF PROTECTIVE CLOTHES (PPE), UNSAFE ACTS AND CONDITIONS.

1) PPE. a) Leather cloves is to protect hands from burning and sharp edges of

material.

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WELDING CENTRE b) Apron is to protect your clothing (overall) and body from burning.

c) Overall to protect your hole body from burning, injuries and open heat. d) Welding helmet is to protect your eyes from arc eyes that is caused by

the sharp lightning of the welding. e) Safety shoes to protect your feet, the shoe has got a steel point in.

2) Unsafe acts. a) Work at unsafe speed. b) Work without permission. c) Leave machine unsafe. d) Place material at at unsafe position. e) Horse play (playing in the centre). f) Adjusting on moving parts.

3) Unsafe condition. a) Walking paths are obstructed. b) Bad planning, bad ventilation and bad lightning. c) Dirty works area. d) Not wearing PPE. e) Open and loose wires. f) Material laying around.

TASK

1) What are the names of the following safety items that are used in the welding centre?

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WELDING CENTRE

2) Explain why safety boots has got a steel point. a) ___________________________________________________________

___________________________________________________________ 3) What do a overall protect. a) ___________________________________________________________


TOPIC 2:1

REVISION OF GOOD HOUSE-KEEPING AND SAFETY SIGNS.

1) Poor house-keeping. a) Tripping over loose objects on floors.

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WELDING CENTRE b) Being hit by falling objects. c) Slipping on greasy, wet or dirty floors.

d) Poorly stacked items.

2) Effective house-keeping. a) Reduce handeling to ease the flow of materials. b) Decrease fire hazards. c) Better control of tools and materials. d) More effective use of space.

3) Safety signs. a) A mandory sign is a sign wich indicates that an instruction must be

carried out. b) A warning sign warns you of a hazard that is not likely to be life

threatening. c) Danger signs are use to indicate an imminently hazardous situasion. d) Caution signs indicate a potensial hazardous situation, may be the result

of a minor or moderate injury. e) Fire signs advices the locations of fire alarms and firefighting equipment.

4) Safe evacuation. a) Evacuate the centre. b) Move to a safe area. c) Do raw call (register). d) Phone the fire department.

TASK

1) What do you understand under poor house-keeping. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE d) ___________________________________________________________________________________________________________

___________

2) What is effective house-keeping? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________

3) Write down 4 safety signs and their meaning. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________


TOPIC 3:1

HAND TOOLS

1) Dividers. a) Dividers are used to measure and draw circels. b) Dividers got a sharp one end and the other end has got a pensil.

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WELDING CENTRE c) Do not use the dividers to stab some one els. d) It has got a settings screw weel in the centre of the legs to set

it on the right size you need.

2) G-Clamps a) The purpose of a g-clamp is to clamp work pieces together. b) To clamp work pieces that must get drilled. c) Do not weld near the screw of the clamp or use as a hammer.

TASK

1) What are the uses of a divider? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE

2) Draw a G-CLAMP.


TOPIC 3:2

HAND TOOLS (COLD CHISELS & VARIOUS FILES)

1) What are cold chisels used for? a) A cold chisel is a tool made of tempered steel used for cutting cold

metals.

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WELDING CENTRE b) The name cold chisel comes from its use by black smiths to cut metal while it was cold.

2) Safety of cold chisels. a) Wear safety glasses, or goggles or a face shield. b) Use the right size of chisel for the right job. c) Choose smooth rectangular handles that have no sharp edges and are

attached firmly to the chisel.

3) Files. a) Files are used when a small amount of metal needs to be removed or to

form metal in the crafters design. This tool is very important when precision is needed.

4) The following files are commonly used in the welding workshop.

A) Flat file. a) The flat file gets its name from its shape and is mostly used to file flat

surfaces.

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WELDING CENTRE

B) Half-round file. a) The half-round file is flat on the one side and round on the other side.

This file helps us to file big curves or holes. It can also file flat surfaces and sharp corners.

C) Round file. a) This file is made to file round holes.

D) Square files. a) This file helps us to file 90 deg angles and square holes.

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WELDING CENTRE

TASK

1) What are cold chisels used for? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________

2) Write down the names of the files we use in a welding centre. a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________ d) ___________________________________________________________

YEAR 4 TERM 2 WEEK 3-4 DATE: __________

TOPIC 3:3

HAND TOOLS (SCROLL BENDER; BALL PEEN HAMMER; ANVIL, BENCH VICE)

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WELDING CENTRE

1) Scroll bender. a) This tool helps you bend metal into scrolls. b) You can bend different sizes and types of scrolls. c) Keep clear of any clamp or moving parts.

2) Ball peen hammer. a) Can be used to drive nails. b) Can form metal. c) Keep your hands away when you strike with the hammer.

3) Anvil. a) Used to bend metal on. b) To form metal on. c) Do not try to move this tool alone it is very heavy.

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WELDING CENTRE

4) Bench vice. a) It is always mounted on a table. b) To clamp work pieces together. c) To clamp material for drilling or assembling.

TASK

1) What are the uses of a scroll bender?

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WELDING CENTRE a) ___________________________________________________________________________________________________________

___________ b) ___________________________________________________________

___________________________________________________________

2) For what can we use a ball peen hammer? a) ___________________________________________________________

___________________________________________________________

3) For what do we use a bench vice for. a) ___________________________________________________________

___________________________________________________________

4) Draw a anvil.


TOPIC 3:4

HAND TOOLS (SPANNERS & SOCETS: JIGS: UNIVERSAL SCROLL BENDER)

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WELDING CENTRE

1) Spanners and socets. a) Can be used to loosen and tighten bolts and nuts. b) Spanners has got a ring side and a open end side. c) Socets are beter to use because it has got a better grip and do not strip

the bolts or nuts. d) Do not pull the spanners or socets towards you, this will cause a slip and

injure you.

2) The uses and safety of a compressor. a) A compressor is a machine that generates air for spray work. b) It can be used for air tools. c) Make sure there are no air in the tank after use. d) The gage must work correctly. e) Make sure there are no leaks, do not weld on tank while it is under

pressure.

3) Pneumatic hand tools. a) These tools are driven by compressed air. b) There are any type of pneumatic hand tools. (grinders, drills, sanders) c) Do not use comprest air on your skin, air can cut through your skin.

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WELDING CENTRE

TASK

1) What are the uses and safety of a compressor? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ e) ___________________________________________________________

___________________________________________________________

2) Name 3 types of pneumatic hand tools? a) ___________________________________________________________ b) ___________________________________________________________ c) ___________________________________________________________


TOPIC 3:5

POWER HAND TOOLS (HAND DRILL & ANGLE GRINDER)

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WELDING CENTRE 1) Hand drill machine. a) The main use of a drill is to cut holes in material.

b) It also can house a series of different types of drill bits. c) It can also be used to clean holes, brus off paint and rust in narrow

corners. d) Do not leave the chuck key in the chuck. e) Keep body parts away from moving parts. f) Make sure the drill bit is tight. g) Do not stop the drill with your hand.

2) Angle grinder. a) This is a very dangerous tool and needs to be handled with care. b) This tool is used for cutting metal and also to clean and form metal. c) Keep hands and body parts away from blade and grinding disk. d) Do not adjust on grinder while the disc is turning. e) Make sure the disc is on properly. f) Make sure the grinder guard is in place.

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WELDING CENTRE

TASK

1) What are the uses of a drilling machine? a) ___________________________________________________________

___________________________________________________________

2) Write down 4 safety rules of the drilling machine? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________

3) For what do you use a angle grinder for. a) ___________________________________________________________

___________________________________________________________ ______________________________________________________________________________________________________________________

4) What makes an angle grinder dangerous. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE d) ___________________________________________________________________________________________________________

___________


TOPIC 3:6

HAND TOOLS (FINISHING GRINDER & JIG SAW).

1) Finishing grinders. a) This tool is use for polishing rought material smooth.

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WELDING CENTRE b) It can be used on metal and wood. c) It does not contain a grinding disc, it has a sanding disc or

weel on. d) Do not stop the weel by hand. e) Always clean the machine after each use. f) Make sure it is in a good working condition. g) Always wear safety glasses.

2) Jig saw. a) A jig saw can cut wood or metal. b) Are usualy used to cut curves and small metals. c) Make sure the blade is tight. d) Make sure the guard is on and the machine is in good working condition.

3) SDS rotary drill. a) A SDS rotary drill is for heavy duty work. b) Normaly they use it to drill concrete and brick wals. c) Make sure the drill bit is right for the tipe of job that’s goingto be done. d) Always make sure the machine is clean.

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WELDING CENTRE

TASK

1) What are the uses and safety of the finishing grinder? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ e) ___________________________________________________________

___________________________________________________________

2) Describe in your own words the uses of a jig saw. a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________


TOPIC 4:1

FLOOR MOUNTED EQUIPMENT (FOLDER & BENDER)

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WELDING CENTRE 1) Folder. a) Folders are used to bend thin material less than 2mm.

b) It can bend different of degrees. c) Keep hands away from clamps and moving parts. d) Do not put fingers in any clamping parts. e) Do not bend bars on the machine.

2) Bending machine. a) These machines are doing different types of work but their main use is

to bend metal. b) It can bend any degree. c) Keep hands away from any roling, clamping or moving parts. d) Do not put fingers in any clamping parts.

TASK

1) What are the uses and safety of the folder machine? a) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE b) ___________________________________________________________________________________________________________

___________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ e) ___________________________________________________________

___________________________________________________________

2) What do we use a bender for? a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________


TOPIC 4:2

FLOOR MOUNTED EQUIPMENT (BENCH GRINDER & GUILOTINE)

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WELDING CENTRE 1) Bench grinder. a) The bench grinder is mostly used to sharpen tools mostly.

b) This grinder can also be used for polishing, forming metal, cleaning metal and removing rust or paint.

c) Always wear safety glasses and gloves. d) Do not use a cracked disc. e) Make sure the grinder gard is in place.

2) Guilotine machine. a) To cut sheets of metal. b) Do not keep your foot on the trigger pedestal. c) Keep fingers away from clamps and blade. d) Cut with the right thickness plate, each machine can cut different

thicknesses.

TASK

1) Give 4 safety rules of a bench grinder. a) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE b) ___________________________________________________________________________________________________________

___________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________

2) Write down any 5 safety rules of the quilotine machine. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ e) ___________________________________________________________

___________________________________________________________


TOPIC 4:3

FLOOR MOUNTED EQUIPMENT (PEDESTAL DRILL & 300MM DISC SANDER)

1) Pedestal drill. a) The drill is a more precise way of drilling.

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WELDING CENTRE b) The drill is used to drill holes in materials at a 90 degree angle. c) Do not stop drill with your hand.

d) Wear safety glasses and cloves. e) Make sure the piece of material is properly clamped. f) Do not force the machine and make sure the drill bits are sharp.

2) 300mm disc sander. a) Used for finishing of materials. b) Shape and form of materials. c) To polish work pieces. d) Do not adjust on moving parts. e) Wear safety glasses and gloves. f) Do not use force when working with machine.

TASK

1) What is the purpose of a pedestal drill? a) ___________________________________________________________

___________________________________________________________

2) Write down 3 safety rules of the pedestal drill?

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WELDING CENTRE a) ___________________________________________________________________________________________________________

___________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

3) What are the uses of a 300mm disc sander? a) ___________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________


TOPIC 4:4

REPAIR AND REPLACE A 3 CORE CABLE AND 3 PIN PLUG & STORE AND CLEAN HAND POWER TOOLS

1) How to repair 3 core cables. a) Find the damaged part of the cable.

64


WELDING CENTRE b) Cut the damaged part out of the cable. c) Bind or solder the same coloured wires together.

d) Isolate the wires with tape to prevent electrical shock.

2) How to repair a 3 pin plug.

3) Store and storage of clean hand power tools. a) Keep tools clean. b) Store tools neat in a safe place. c) Don’t bend wires but roll the wires up neatly. d) Change bushes when needed. e) Check for any cracks in the hullnof the power tool. f) Keep the electrical wires in good condition.

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WELDING CENTRE

TASK

1) How must a 3 core wire be replaced. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE c) ___________________________________________________________________________________________________________

___________ d) ___________________________________________________________

___________________________________________________________

2) Give the colours of the following wires. a) Earth wire: ________________________ b) Neutral wire: ______________________ c) Live wire: _________________________


TOPIC 5-1

MATERIALS

1) MATERIALS.

Materials Composition % Carbon Quality Uses

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WELDING CENTRE

Cast iron Alloy of iron and carbon with small amounts of manganese, silicone, sulphur and phosphorus.

Contains more than 1.7% carbon

About 6 times stronger under compressive stress.

Machine beds, hand weels, and levers

Ferrous metals

Low carbon steel

Iron and carbon

0.15% 0.30%

It is soft, stretchable and has high tensile strength.

It is used for cold bending and riveting.

Medium carbon steel

Crude iron,steel scrap and mild steel

0.3% 0.75%

It is less stretchable, harder and has a higher tensile strength than low carbon steel.

It is used for axles, cross bars, drive shafts, motor shafts

High carbon steel

Crute iron, steel scrap and mild steel.

0.75% 1.7%

Has a higher tensile strength and hardness than the other. It reacts readily to heat treatment.

Used at most cutting tools.

Ferrous alloys

Stainless steel

Composition of iron and chromium.

0.1%- 1.5%

The steel has a 12% content of chromium which gives the steel a characteristic that is corrosion resistant.

It is commonly used in kitchens, knifes

TASK

1) Complete the following table by filling in the quality and use for each metal.

Metal Quality Use

Low carbon steel

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WELDING CENTRE

Medium carbon steel

High carbon steel

Cast iron

Stainless steel


TOPIC 6:1

WELDING JOINTS

1) Different types of welding joints.

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WELDING CENTRE

TASK

1) Draw a butt joint.

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WELDING CENTRE

2) Draw a corner joint.

3) Draw a tee joint.

WELDING

YEAR 4

TERM 3

INDEX

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WELDING CENTRE Week 1

Topic 1:1 ; Safety; first aid; HIV& AIDS; good house keeping; emergency escape; fire drill.

Week 2:3

Topic 2:1 ; Shield metal arc welding. (safety; arc welding)

Topic 2:2 ; Shield metal arc weld. (setup; prepare workpiece; weldingrod)

YEAR 4 TERM 3 WEEK 1 DATE: _____________

TOPIC 1:1

SAFETY; FIRST AID; HIV & AIDS; GOOD HOUSE KEEPING; EMERGRNCY DRILL; FIRE ESCAPE

RECAP OF PROCEDURES

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WELDING CENTRE Safety

a) Always wear your PPE in the workplace. b) Do not fool around with tools and machines. c) Make sure the work area are always clean and tools are packed away. d) No material must lay around. e) Do not play in the centre.

First aid

a) The area where the first aid box is must be clearly marked. b) The first aid kid must be checked regulary. c) It must be available for treatment. d) Before treating some one wear surgical cloves. e) If it is a slight wound you can treat it, but if the wound is deap you must

get professional treat ment.

HIV & AIDS

a) This vires can only be infected through unsafe sex, blood transvers, drugs and people misusing alcohol.

b) There is treatment for people that are infected with HIV. c) Always wear surgical cloves when helping some one with a open wound.

Good house keeping

a) Always make sure the workplace are clean. b) All the tools must be packed away after use. c) Machines must be kept clean at all times. d) Material must be packed away and not lay on the floors.

Emergency escape and assemble point

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WELDING CENTRE a) Emergency escape routes must be marked and area must be shown.

b) All learners and teachers must go to the rugby field as fast as possible. c) All learners must fall in according their class groups. d) Register must be taken to make sure every one is there, if some one is

not there it must be reported emediatly. e) Futher instructions will be given there by the one that’s in charge.

Fire drill

a) Incase of a fire, evacuate the building and make sure no one is left behind.

b) Move to the assembly point and report where the fire is. c) Priorety things to know when you report a fire: where the fire is:

dirctions: how serrios it is and a contact number. d) Register must be taken.

TASK

1) Give 3 reasons why safety must be carried out in a work inviroment? a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE 2) How must the first aid area be. a) ___________________________________________________

______________________________________________________________________________________________________________________________

3) What can be the cause of HIV & AIDS. a) ___________________________________________________________

______________________________________________________________________________________________________________________

4) If there is a fire what are the procedures that has to be followed. a) ___________________________________________________________

______________________________________________________________________________________________________________________

b) _________________________________________________________________________________________________________________________________________________________________________________

YEAR 4 TERM 3 WEEK 2:3 DATE: ___________

TOPIC 2:1

SHIELD METAL ARC WELDING

1) Safety of shield metal arc welding. a) Always operate in a well-ventilated area. b) Be sure the welder is properly installed and grounded. c) Take proper precautions to prevent fires. d) Wear eye protection at all times.

75


WELDING CENTRE e) Weld only in a fire safe area. f) No water or oil near welding equipment.

g) Always wear the right PPE.

2) What is shield metal arc welding. a) An electric currend in the form of either alternating currend or direct

currend from a welding power supply. b) It is used to form an electric arc between the electrode and the metals

to be joint. c) The workpiece and the electrode melts forming a pool of molten metal

(weld pool) that cools to form a weld. d) As the weld is laid, the flux coating of the electrode disintergrates, giving

a vapors that serve as a shielding gas and providing a layer of slag.

TASK

1) Write down 4 safety rules of arc welding. a) ___________________________________________________________

______________________________________________________________________________________________________________________

b) _________________________________________________________________________________________________________________________________________________________________________________

c) _________________________________________________________________________________________________________________________________________________________________________________

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WELDING CENTRE d) ___________________________________________________________________________________________________________

______________________________________________________________________

2) Explain shield metal arc welding. a) ___________________________________________________________

______________________________________________________________________________________________________________________

b) _________________________________________________________________________________________________________________________________________________________________________________

c) _________________________________________________________________________________________________________________________________________________________________________________

d) _________________________________________________________________________________________________________________________________________________________________________________

YEAR 4 TERM 3 WEEK 2-4 DATE: ____________

TOPIC 2:2

SHIELD METAL ARC WELDING

1) Welding machine setup. a) Make sure the welding connections are correct. b) No loose or open wires at all. c) Setup the equipment in a safe place and organize items that you are

using. d) Secure the piece you must weld, and connect the ground clamp to it.

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WELDING CENTRE e) Turn on the welder and set the amperage to just past the half-way point of the suggested range listed on the machine.

f) With the rod holder well away from the work pieces, insert the rod and locket into one of the grooves (usually the angled one).

g) Place the rod tip a couple mm from where you are going to weld. h) Lower your helmet and you are ready to weld.

2) How to prepare a work piece. a) The weld edges must be cleaned of oil, wax layers, paint or scale. b) Tack weld the ends of work piece together. c) Make sure the work piece is stable and that the welding connections are

correct. d) The welding gaps must not exceed 3mm. e) Clamp or tag weld work piece you make sure it aint going to move

around while welding process are in process.

3) Settings and welding rod sizes.

Welding rod (mm) Lenth of welding rod Machine settings

2 mm 300 mm 40-80

2,5 mm 350 mm 60-95

3,15 mm 350 mm 110-130

4 mm 350 mm 140-165

5 mm 450 mm 170-260

6 mm 450 mm 270-340

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WELDING CENTRE

TASK

1) Describe the set up of an welding machine. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________ d) ___________________________________________________________

___________________________________________________________ e) ___________________________________________________________

___________________________________________________________ f) ___________________________________________________________

___________________________________________________________ g) ___________________________________________________________

___________________________________________________________ h) ___________________________________________________________

YEAR 4 TERM 3 WEEK 2-4 DATE: ________________ TOPIC 3:1

CARE AND STORE OF WELDING EQUIPMENT

1) Care of welding machines. a) Machines must be clean. b) Good working condition. c) Must be regulary tested and service. d) No oil, water or dust by or near machines.

79


WELDING CENTRE e) Check for any loose or open cables or connections.

2) Store of welding equipment. a) Machines must be stored where it is dust, water, oil and flammable

equipment free. b) Cables must be rolled up and packed away. c) Make sure the machine is clean after each use. d) Welding rods must be packed away in a dry place. e) Overals and welding helmets must be hanged up.

TASK

1) Describe 3 caring methods of welding machines. a) ___________________________________________________________

___________________________________________________________ b) ___________________________________________________________

___________________________________________________________ c) ___________________________________________________________

___________________________________________________________

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WELDING CENTRE 2) How must a welding store be at all times. a) ___________________________________________________

___________________________________________________________________

b) ______________________________________________________________________________________________________________________

c) ______________________________________________________________________________________________________________________

d) ______________________________________________________________________________________________________________________

e) ______________________________________________________________________________________________________________________


TOPIC 3:2

WELDING MACHINES

1) Transformer welder. a) It is either 220 or 380 volt, and it is a AC machine.

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WELDING CENTRE b) The machine deffers from small to large machines and has a high amperage current.

c) It is either air cooled or oil cooled. d) The machine works by means of a trans former. e) Transformer machines are much cheaper than generator machines.

2) Direct currend welding machine. a) It is either 220 or 380 volt. b) It is a big heavy machine. c) The machine is air cooled. d) The machine are driven by a generator.

3) Inverter welding machine. a) It is a 220 volt machine. b) Easy to carry around. c) Turn direct currend into direct currend. d) Welding effect is fine, equal and smooth. e) The machine works by means of modern electronics components.

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WELDING CENTRE

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index year 4 term 1 week 1 - pro-practicum

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