The drum set shown is fabricated from sheet stainless steel which is rolled and welded - Leaving Cert Engineering - Question a) - 2016

TIG welding involves an arc formed between a non-consumable electrode and the metal being welded. The workpiece is protected by an inert gas shield, which is typically argon, preventing oxidation at the joint area. Here is a simplified diagram illustrating the setup:

      +----------+  
      |          |  
      |   TIG    |  
      |   Torch   |  
      |          |  
      +----------+  
         /|
          |  (Arc)  
         /|
        +---------+  
        |  Workpiece |
        +---------+

The high-frequency generator provides a path for the welding current.

1. The flux coating helps to start the arc during the welding process.
2. It provides a gas which prevents oxidation of the weld area, thereby enhancing the quality of the weld.

Resistance spot welding is a process where two workpieces are welded together by applying heat generated by an electric current that flows through the contact area. The heat produced is sufficient for local melting, forming a small weld nugget at the joint.

1. Arc eye or flash burn: A common risk that can cause damage to the eyes due to exposure to the bright welding arc.
2. Inhalation of fumes: Welding generates harmful fumes that can be detrimental to health if inhaled.
3. Electrical shock: The equipment operates at high voltages, posing a risk of electrical shock if proper precautions are not taken.

SAW is suitable for welding steel girders as it provides a continuous and automated operation, allowing for heavy sections to be welded efficiently. The process ensures a strong and uniform weld joint from beginning to end.

1. A superior weld is produced as each weld run has a positive heating effect on the previous one, resulting in better fusion.
2. The finished weld is stronger and has a more refined structure compared to single run welds.

Oxy-acetylene welding equipment includes:

• Acetylene cylinder
• Oxygen cylinder
• Oxygen and acetylene hoses
• Welding torch
• Pressure regulators
• Flashback arrestors

Here’s a basic diagram:

     +------------------+   +------------------+
     |  Acetylene      |   |  Oxygen         |
     |   Cylinder      |   |  Cylinder       |
     +------------------+   +------------------+
            |                          |
         Red Hose                 Blue Hose
            |                          |
          +--------------------------+
          |        Pressure Regulator    |
          +--------------------------+
                     |
                     v
              +------------------+
              |    Welding Torch   |
              +------------------+

Oxy-acetylene welding features three flame types:

1. Neutral flame: Equal proportions of both gases, ideal for most welding.
2. Oxidising flame: Excess oxygen gas, used for welding bronze.
3. Carburising flame: Excess acetylene gas, suitable for aluminum alloys and soft steels.

Integrated safety features include:

• Use of flashback arrestors to prevent flame reversal into the hoses.
• Color coding of the cylinders and hoses to identify gases easily.
• Pressure regulators designed to control and visualize gas pressure accurately.

Oxy-acetylene welding is commonly used for:

• Joining ferrous and non-ferrous materials such as steel and aluminum.
• Cutting metals, commonly known as gas cutting, due to its high temperature and versatility.