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ED 401 436

TITLE

INSTITUTIONSPONS AGENCY

PUB DATECONTRACTNOTE

AVAILABLE FROMPUB TYPE

EDRS PRICEDESCRIPTORS

ABSTRACT

DOCUMENT RESUME

CE 072 929

Machine Tool Advanced Skills Technology (MAST).Common Ground: Toward a Standards-Based TrainingSystem for the U.S. Machine Tool and Metal RelatedIndustries. Volume 6: Welding, of a 15-Volume Set ofSkill Standards and Curriculum Training Materials forthe Precision Manufacturing Industry.Texas State Technical Coll., Waco.Office of Vocational and Adult Education (ED),Washington, DC.Sep 96V199J40008209p.; For other volumes in this set, see CE 072924-938.World Wide Web: http://machinetool.tstc.eduGuides Classroom Use Teaching Guides (ForTeacher) (052)

MF01/PC09 Plus Postage.Blueprints; Computer Assisted Manufacturing; CourseContent; Curriculum Development; *Entry Workers; HandTools; *Job Skills; Job Training; Learning Modules;Machinery Industry; *Machine Tools; ManufacturingIndustry; Metal Working; Postsecondary Education;Secondary Education; *Standards; Teaching Methods;*Welding

This document is intended to help education andtraining institutions deliver the Machine Tool Advanced SkillsTechnology (MAST) curriculum to a variety of individuals andorganizations. MAST consists of industry-specific skill standards andmodel curricula for 15 occupational specialty areas within the U.S.machine tool and metals-related industries. This volume provides theMAST standards and curriculum for the welding specialty area. (Awelder is a person who uses arc and gas, shielded metal arc welding(SMAW), gas metal arc welding, gas tungsten arc welding, brazing,metallurgy, and print interpretation to perform welding operations-necessary to produce a workpiece to required standards.) This volumeis organized in the following sections: (1) a profile of MoraineValley Community College (Illinois), the development center thatproduced these standards and curriculum; (2) a welder competencyprofile of job duties and tasks; (3) a welder duty, task, and subtaskoutline; (4) a course curriculum outline and course descriptions; (5)a technical workplace competencies and course crosswalk; and (6) aSecretary's Commission on Achieving Necessary Skills (SCANS)proficiencies course crosswalk. Individual syllabi for the followingcourses are provided: Basic Arc/Gas Welding I-II; Electrical WeldingCircuits; Reading Welding Blueprints; Advanced SMAW and Cutting I-II;Metal Inert Gas (MIG), Tungsten Inert Gas (TIG), and Brazing I-II;Basic Welding Metallurgy; Individual Welding Problems I-II; BasicPipe Welding I-II; and Visual Inspection of Welds. Each coursesyllabus includes the following: course hours, course descriptions,prerequisites, required course materials, teaching and evaluationmethods, lecture and laboratory outlines, course objectives fortechnical and SCANS competencies, and suggested references. Twoappendixes contain industry competency profiles and the pilot programnarrative. (KC)

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S. DEPARTMENT OF EDUCATIONOR< of Educational Research ano ImprovementE CATIONAL RESOURCES INFORMATION

CENTER (ERICI

This ISOCurnen1 has been reorocluced asreceived from the person or OrganizabonOngenaleng iI

O Minor changes have been made to improvereproduction Quality

Points of new or opinions stated on INS clOCu.went do not neCeSSanly rearesera officialOERI posttion or poiicv

COMMON GROUND:TOWARD A STANDARDS-BASED TRAINING

SYSTEM FOR THE U.S. MACHINE TOOLAND METAL RELATED INDUSTRIES

VOLUME 6

WELDING

ofa 15 volume set of Skills Standards

andCurriculum Training Materials for the

PRECISION MANUFACTURING INDUSTRY

2=err rnpv AI/All ADI C

Supported bythe Office of Vocational & Adult Education

U.S. Department of Education

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Machine Tool Advanced SkillsTechnology Program

rm.

VOLUME 6

-- WELDING --

Supported byThe Office of Vocational and Adult Education

U.S. Department of Education

September, 1996

3

Project Title:

Grant Number:

Act under whichFunds Administered:

Source of Grant:

Grantee:

Disclaimer:

Discrimination:

GRANT INFORMATION

Machine Tool Advanced Skills Technology Program

VI 99J40008

Carl D. Perkins Vocational Education ActCooperative Demo - Manufacturing Technology, CFDA84.199J

Office of Vocational and Adult EducationU.S. Department of EducationWashington, DC 20202

Texas State Technical CollegeWaco, Texas

This publication was prepared pursuant to a grant with the Office ofVocational and Adult Education, U.S. Department of Education.Grantees undertaking such projects under government sponsorshipare encouraged to express freely their judgement in professionaland technical matters. Points of view or opinions do not, therefore,necessarily represent official U.S. Department of Educationposition or policy.

Title VI of the Civil Rights Act of 1964 states: "No person in theUnited States shall, on the ground of race, color, or national origin,be excluded from participation in, be denied the benefits of, or besubjected to discrimination under any program or activity receivingfederal financial assistance." Title IX of the EducationAmendments of 1972 states: "No person in the United States shall,on the basis of sex, be excluded from participation in, be denied thebenefits of, or be subjected to discrimination under any educationprogram or activity receiving federal financial assistance."Therefore, the Machine Tool Advanced Skills Technology (MAST)project, like every program or activity receiving financial assistancefrom the U.S. Department of Education, operated in compliancewith these laws.

ii

4

ACKNOWLEDGMENTS

This project was made possible by the cooperation and direct support of the followingorganizations:

U.S. Department of Education, Office of Vocational & Adult EducationMAST Consortia of Employers and Educators

MAST DEVELOPMENT CENTERSAugusta Technical Institute - Itawamba Community College - Moraine Valley Community College - SanDiego City College (CACT) - Springfield Technical Community College - Texas State Technical College

INDUSTRIESAB Lasers - AIRCAP/MTD - ALCOA - American Saw - AMOCO Performance Products - AutomaticSwitch Company - Bell Helicopter - Bowen Tool - Brunner - Chrysler Corp. - Chrysler Technologies -Conveyor Plus - Darr Caterpillar - Davis Technologies - Delta International - Devon - D. J. Plastics - EatonLeonard - EBTEC - Electro-Motive - Emergency One - Eureka - Foster Mold - GeoDiamond/SmithInternational - Greenfield Industries - Hunter Douglas - Industrial Laser - ITT Engineered Valve - KaiserAluminum - Krueger International. - Laser Fare - Laser Services - Lockheed Martin - McDonnell Douglas -Mercury Tool - NASSCO - NutraSweet - Rapistan DEMAG - Reed Tool - ROHR, International - Searle -Solar Turbine - Southwest Fabricators - Smith & Wesson - Standard Refrigeration - Super Sagless - TaylorGuitars - Tecumseh - Teledyne Ryan - Thermal Ceramics - Thomas Lighting - FMC, United Defense - UnitedTechnologies Hamilton Standard

COLLEGE AFFILIATESAiken Technical College - Bevil Center for Advanced Manufacturing Technology - Central FloridaCommunity College - Chicago Manufacturing Technology Extension Center - Great Lakes ManufacturingTechnology Center.- Indiana Vocational Technical College - Milwaukee Area Technical College - Okaloosa-Walton Community College - Piedmont Technical College - Pueblo Community College - Salt LakeCommunity College - Spokane Community College - Texas State Technical Colleges at Harlington, Marshall,Sweetwater

FEDERAL LABSJet Propulsion Lab - Lawrence Livermore National Laboratory - L.B.J. Space Center (NASA) - Los AlamosLaboratory - Oak Ridge National Laboratory - Sandia National Laboratory - Several National Institute ofStandards and Technology Centers (NISI) - Tank Automotive Research and Development Center(TARDEC) - Wright Laboratories

SECONDARY SCHOOLSAiken Career Center - Chicopee Comprehensive High School - Community High School (Moraine, IL) -Connally ISD - Consolidated High School - Evans High - Greenwood Vocational School - Hoover Sr. High -Killeen ISD - LaVega ISD - Lincoln Sr. High - Marlin ISD - Midway ISD - Moraine Area Career Center -Morse Sr. High - Point Lamar Sr. High - Pontotoc Ridge Area Vocational Center - Putnam Vocational HighSchool - San Diego Sr. High - Tupelo-Lee Vocational Center - Waco ISD - Westfield Vocational High School

iii

ASSOCIATIONSAmerican Vocational Association (AVA) - Center for Occupational Research and Development (CORD) -CIM in Higher Education (CIMHE) - Heart of Texas Tech-Prep - Midwest (Michigan) ManufacturingTechnology Center (MMTC) - National Coalition For Advanced Manufacturing (NACFAM) - NationalCoalition of Advanced Technology Centers (NCATC) - National Skills Standards Pilot Programs - NationalTooling and Machining Association (NTMA) - New York Manufacturing Extension Partnership (NYMEP)- Precision Metalforming Association (PMA) - Society of Manufacturing Engineers (SME) - SoutheastManufacturing Technology Center (SMTC)

MAST PROJECT EVALUATORSDr. James Hales, East Tennessee State University and William Ruxton, National Tooling and MachineAssociation (NTMA)

SPECIAL RECOGNITIONDr. Hugh Rogers recognized the need for this project, developed the baseline concepts and methodology,and pulled together industrial and academic partners from across the nation into a solid consortium. Specialthanks and singular congratulations go to Dr. Rogers for his extraordinary efforts in this endeavor.

This report is primarily based upon information provided by the above companies, schools andlabs. We sincerely thank key personnel within these organizations for their commitment anddedication to this project. Including the national survey, more than 3,000 other companies andorganizations participated in this project. We commend their efforts in our combined attempt toreach some common ground in precision manufacturing skills standards and curriculumdevelopment.

This material may be found on the Internet at http://machinetool.tstc.edu

iv

VOLUME 1

VOLUME 2

CATALOG OF 15 VOLUMES

EXECUTIVE SUMMARYSTATEMENT OF THE PROBLEMMACHINE TOOL ADVANCED SKILLS TECHNOLOGY

PROJECTPROJECT GOALS AND DELIVERABLESPROJECT METHODOLOGYPROJECT CONCLUSIONS AND RECOMMENDATIONSAPPENDICES

CAREER DEVELOPMENTGENERAL EDUCATIONREMEDIATION

VOLUME 3 MACHINING - CORE COURSES (MAC)

VOLUME 4 MANUFACTURING ENGINEERING TECHNOLOGY (MET)

VOLUME 5 MOLD MAKING (MLD)

VOLUME 6 WELD/NO (WLD)....

VOLUME 7 INDUSTRIAL MAINTENANCE (1MM)

VOLUME 8 SHEET METAL (SML) AND COMPOSITES (COM)

VOLUME 9 TOOL AND DIE (TLD)

VOLUME 10 COMPUTER-AIDED DRAFTING AND DESIGN (CAD)

VOLUME 11 COMPUTER-AIDED MANUFACTURING ANDADVANCED CNC (CNC)

VOLUME 12 INSTRUMENTATION (INT)

VOLUME 13 LASER MACHINING (LSR)

VOLUME 14 AUTOMATED EQUIPMENT TECHNOLOGY (CIM)

VOLUME 15 ADMINISTRATIVE INFORMATION

7V

VOLUME 6

WELDING TECHNOLOGY

Table of Contents

TAB

Foreword 1

Development Center Profile 2

Welder Competency Profile 3

Welder Duty/Task/Sub-Task Outline

Course Listing/Course Descriptions 5

Technical Competency/Course Crosswalk 6

"SCANS"/Course Crosswalk 7

Individual Course Syllabi 8

Appendix A - Industry Competency Profiles 9

Appendix B - Pilot Program Narrative 10

FOREWORD

Under the pressure of changing consumer demands, global competition, and increasingly exactingproduct and inventory control requirements, United States manufacturing has entered an era ofautomation and technological sophistication with the inevitable impact of loss of blue collar andmid-level management jobs and assignment of more responsibility to technical employees. Theresult is a growing surplus of workers whose jobs are now obsolete, and a growing demand forworkers whose skills and knowledge straddle the once distinct areas of manufacturing,engineering, programming, and design. Workers who wish to remain employable in themanufacturing sector cannot rely on traditional skills for their economic survival. Upgrading ofskills or acquisition of a variety of skills is crucial.

The employment picture for the Welder exemplifies this trend. Welding is a traditionalmanufacturing skill which stills exists in its traditional forms - hand welding, stick welding,tungsten inert gas machine, metal inert gas machine, Bronco guns, and cutting by plasma cutters -in the contemporary manufacturing workplace. However, recent advances in technology havecaused the emergence of new manufacturing welding processes. The contemporary welder mustbe able to use automatic welding machines, precision hand-held measuring devices, andautomated cutting processes to produce finished products that meet the precision and exactnessdemands of the global marketplace. Existing welders who wish to remain employed or those whowish to enter the field must be willing and able to obtain training in all aspects of emergingwelding technology.

Recognizing the need to increase the supply of new skilled workers in this and otheroccupations for the metal and metals-related industries, the U.S. Department of Educationlaunched the Cooperative Demonstration Program (Manufacturing Technologies) as partof the National Skills Standards Act of 1994. The goal of the Department initiative was tofoster the development and implementation of national skill standards and a training modelfor certificate and Associate of Science degree programs. In July 1994, a multi-stateconsortium of community colleges led by Texas State Technical College received a grantawarded by the Department under the initiative. The Machine Tool Advanced SkillsTechnology (MAST) consortium, which includes six of the nation's leading AdvancedTechnology Centers (ATCs), was formed to develop, test, and disseminate industry-specificskill standards and model curricula for the U.S. machine tool industry over a two yearperiod. As part of the MAST consortium, Moraine Valley Community College in Illinoiswas tasked with developing and piloting skill standards and model curricula in thetechnical area of Welder.

After numerous interviews with practitioners from industry (see Appendix A) and discussionswith educators, managers, supervisors, and others involved with machine related occupations andspecifically welding technology, the MAST consortium partners have agreed to present ourdefinition of a Welder as follows:

9

WELDER: The Welder will be able to use arc/gas, shielded metal arc welding, gas metal arcwelding, gas tungsten arc welding, brazing, metallurgy, and print interpretation to performwelding operations necessary to produce a workpiece to required standards.

Moraine Valley Community College's curricula for welding technology is structured as a 26course, one year certificate course of study. Course options can be tailored to individual studentneeds.

This volume contains the justification, documentation, and course syllabi for the coursesrecommended as minimum training for individuals desiring to become welders.

10

PARTNER OCCUPATIONAL SPECIALITY ASSIGNMENTS

Although each of the six partner college development centers possessed detailed expertise in eachof the MAST 15 occupational specialities, a division of work was still very necessary to ensurecompletion of the project due to the enormity associated with industrial assessment and completecurriculum revision for each of the areas of investigation.

Each Collegiate Partner was responsible for development of a specialization component of theoverall model. Information for the future direction of this specialization area was obtained fromMST Manufacturing Centers and/or national consortia, professional societies, and industrialsupport groups addressing national manufacturing needs. Each Collegiate Partner tested itsspecialization model utilizing local campus resources and local industry. Information gained fromthe local experience was utilized to make model corrections. After testing and modification,components were consolidated into a national model. These events occurred during the first yearof the Program. During the second year of the Program, the national model was piloted at eachof the Collegiate Partner institutions. Experience gained from the individual pilot programs wasconsolidated into the final national model.

What follows is a profile of the MAST development center which had primary responsibility forthe compilation and preparation of the materials for this occupational specialty area. This collegealso had the responsibility for conducting the pilot program which was used as one of the meansof validation for this program.

1:1

MAST DEVELOPMENT CENTER, PALOS HILLS, ILMoraine Valley Community College

Center for Contemporary Technology

Dr. Vernon 0. Crawley, PresidentMoraine Valley Community CollegeDr. Richard HinckleyDean, Business and Industrial TechnologyDr. Richard KukacAssociate Dean, Business and Industrial Technology

10900 South 88th Ave.Palos Hills, II, 60465

College phone: 708/974-4300, fax:708/974-0078Center phone: 708/974-5410, fax:708/974-0078

e-mail:

Manufacturing in Moraine ValleyThe metropolitan Chicago area, including northwestern Indiana, is among the most heavily industrialized areas ofthe United States. The neighboring Moraine Valley area is home to hundreds of the small- to medium-sizedcompanies that supply the larger industrial concerns, including design, fabrication, metal-working and parts-assembly firms. The diversity of industry in the region and the continual need for qualified entry-level techniciansand retraining of current workers has created a great demand for the development of industrial training and theservices of Moraine Valley Community College and its Center for Contemporary Technology.

Moraine Valley Community College (MVCC) and the Center for Contemporary Technology (CTT)Moraine Valley Community College (MVCC) is a public, postsecondary institution serving all or part of 26communities in the southwest suburban area of Cook County, representing a population of more than 380,000.Located 25 miles southwest of downtown Chicago in Palos Hills, the college is the fourth largest communitycollege in Illinois and serves a diverse student body drawn from the surrounding communities. The focal point forbusiness and industry training in Moraine Valley is the 124,000 s.f. Center for Contemporary Technology (CTT).Opened in 1988, the Center is among the finest and most diverse advanced technology centers (ATC's) in thenation, with over $6 million of equipment and technology to provide training and education in AutomatedManufacturing; Automotive Technology; Computer-Aided Design; Corrosion Mitigation;Electronics/Telecommunications; Environmental Control Technology; Information Management; Machining;Mechanical & Fluid Power Maintenance; Non-Destructive Evaluation; and Welding.

Development TeamProject Director: Richard Hinckley, PhD., Dean of Instruction for Business and Industrial Technology andmanager of the Center for Contemporary Technology, served as director for the MAST project.SubjeCt Matter Expert: Charles H. Bales, Instructor of Mechanical Design/Drafting, had programresponsibility for developing skill standards and course/program materials for the mechanical design/draftingcomponent of the MAST project. Professor Bales also served as lead instructor for the MAST pilot programin Computer-Aided Drafting and Design (CADD) Technician.Subject Matter Expert: James E. Greer, MS Ed., Professor of Welding, was responsible for developing skillstandards and course/program materials for the welding component of the MAST project. ProfessorGreer also- served as lead instructor for the MAST pilot program in Welding.Skills Validation Coordinator: Richard Kukac, MPA, Associate Dean of Instruction of Business andIndustrial Technology, coordinated the industry skills verification process for MAST and facilitated theindustry validation sessions with teams of expert practitioners from each skill area.

12

THE MAST COMPETENCY PROFILE

Development of Competency Profiles at each of the MAST sites began with visits torepresentative companies for the purpose of surveying expert workers within the industry andoccupational areas under investigation. Each site began the survey process by asking a subjectmatter expert in the targeted technical area, generally a member of their faculty, to employ amodified version of the generally-accepted DACUM (Developing A Curriculum) method tocategorize the major skills needed to work in the selected occupation. As source materials, thecollege instructors drew on their professional knowledge and experience of current and futureindustry requirements. The initial skill standards developed by the subject matter expertsunderwent numerous internal reviews and revisions within each site, assuming final form as aseries of structured survey and interview statements designed to elicit a simple yes or no response.

To determine an appropriate survey sample, each site compiled a database of their region's smalland medium-sized manufacturers and searched for companies likely to employ workers in thetargeted occupational area. The resulting cross-industry samples were sorted further to achieve abalance of technological capability and workforce size; the sample companies within each regionwere then asked to participate in the project. Willing respondents were scheduled for interviews.

During the company interviews, MAST staff asked expert workers to identify the primary dutiesand tasks performed by a typical worker and to consider the special skills and knowledge, traitsand attitudes, and industry trends that will have an impact on worker training, employability, andperformance both now and in the future. The interview results were analyzed to create individualprofiles identifying the most common duties and skills required of workers at each company.Copies of individual company competency profiles are provided in Appendix A of this volume.These individual company Competency Profiles served two purposes. First, they showed, in aformat that could be easily understood by both industry and educators, a picture of theoccupational specialty at a given company at that particular time. Second, these individualcompany Competency Profiles furnished the company with a document for which they couldclaim ownership. This, in effect, made them "real" partners in the work of MAST.

Data for all companies were then aggregated to develop a composite Competency Profile ofindustry skill standards within the selected occupational specialty area of, as shown in thefollowing pages.

These same duties and tasks were then included in both the Texas and National Surveys forfurther validation (see Volume 1). As a result of the surveys, additional refinements were madeto the Competency Profiles. These changes were then incorporated into the individual coursesyllabi which were used for the pilot program.

The MAST Competency Profile for this occupational specialty area has been included on thefollowing pages.

13

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THE MAST TECHNICAL WORKPLACECOMPETENCY OUTLINE

The Competency Profiles derived from the industry survey process were returned to industry andfaculty members at each MAST partner college for review. Reviewers were asked to identifyspecific sub-tasks within each block of Duties and Tasks in the Profile; MAST staff at eachcollege broke the sub-tasks down further into the detailed steps required to actually perform theduties and tasks of the manufacturing process. It is these detailed skill standards that were thenincorporated into development of the curriculum and piloted as a training program by each of theMAST colleges. All results for the specific occupational specialty area have been organized as anoutline of the duties, tasks, and sub-tasks required to demonstrate technical competency in theworkplace, as shown in the following pages.

As a result of the Texas and the National Surveys, additional refinements were made to theCompetency Outlines. These changes were then incorporated into the individual course syllabi.

The MAST Technical Workplace Competency Outline for this occupational specialty area hasbeen included on the following pages.

20

WELDERTECHNICAL WORKPLACE COMPETENCIES

WELDER...and study arc/gas, SMAW, GMAW, GTAW, brazing, metallurgy, and printinterpretation to perform welding operations necessary to produce a workpiece to requiredstandards.

A. FOLLOW SAFE PRACTICES1. Wear Personal Protective Equipment

a. List personal protective equipment for shielded metal arc weldingb. List personal protective equipment for gas tungsten arc weldingc. List personal protective equipment for gas metal arc weldingd. List personal protective equipment for flux cored arc weldinge. List personal protective equipment for submerged arc weldingf. List personal protective equipment for oxy-fuel cuttingg. List personal protective equipment for plasma arc cuttingh. List personal protective equipment for air carbon arc gougingi. During shop work, wear applicable personal protective equipment at all

times2. Identify Safety Rules

a. List environmental safety precautions i.e. fume control, radiation reflection,electrical consideration, fire hazards and control, etc.

b. List equipment safety rules, i.e., ventilation, grounding, duty cyclec. Utilize safety when handling and storing compressed gas cylindersd. List general shop safety rulese. Maintain safe conditions in workstation. Student demonstrate by setting

up safe workstation.f. Comply with confined space entry safety proceduresg. Conduct a safety inspection of the student work areah. Conduct a safety inspection of the welding shopi. Conduct a safety inspection of the gas storage area

3. Familiarize Oneself With Safety at Facilitya. Attend safety tour of welding labb. Receive a safety orientation lecturec. Avoid fumes through proper ventilation and good practicesd. Operate exhaust systeme. Practice electric safety with respect to weldingf. Protection from radiation with an understanding of personal safety

equipment and conductg. Demonstrate a knowledge of fire prevention and protection for welding in

dress and conducth. List welding and cutting safety rulesi. Demonstrate oxy-fuel gas cutting safetyj. Demonstrate arc welding safety

B. DEMONSTRATE TECHNICAL COMMUNICATION1. Use Standard American Welding Standard Society Welding Terms and Definitions

a. Follow verbal instructions

21

Follow written detailsc. Prepare time and job cards (reports & records)

C. INTERPRET WELDING DRAWINGS1. Review Print Notes, Dimensions and Symbols

a. Interpret AWS standard welding symbolsb. List essential components found in general notes on drawingc. Determine acceptable tolerances for drawingd. Determine code requirements, process and procedure requirements

required by drawinge. Interpret 3 view drawingsf. Work from drawings, prints and sketches

2. Identify Basic Layouts of Drawings3. Interpret Drawing Lines and Views4. Interpret Welding Symbols5. Convert Metric to English6. Understand Print Specifications7. List Assembly Procedure Per Print8. Understand Various Types of Welding Prints9. Visualize Final Weldment From Print10. List Flaws and Errors on Drawings11. Interpret AWS Standard Welding Symbols

D. BASIC WELDING METALLURGY1. Become Conversant With Common Metallurgical Terms

a. Describe structure of metalsb. Describe critical temperaturec. Define allotropic transformationd. Describe eutectic pointe. Read phase diagramf. Define liquidus

g. Define solidush. Define annealingi. Define normalizej. Define heat treatmentk. Define stress relieveI. Define delta ferritem. Define ferriten. Define austeniteo. Define pearlitep. Define cementiteq. Define tempering

2. Describe the Properties of Various Types of Steela. Define low carbon steelb. Define medium carbon steelc. Define high carbon steeld. Define very high carbon steele. Define cast iron

22

f. Define low alloy high strengthg. Define alloy steelsh. Define stainless steelsi. Define non ferrous metals

3. List Various Alloys and Their Effect When Combined With Steela. Draw and describe substitutional alloysb. Draw and describe interstitial alloysc. Draw and describe multi phase alloysd. Define harden abilitye. Work carbon equivalent equations

4. Describe the Effect Welding Has on Properties of various Types of Carbon Steelsa. Sketch crystal structures of metalsb. Sketch face centered cubicc. Sketch body centered cubicd. Sketch hexagonal close packed

5. Identify Basic Concepts Relating to the Heat Affected Zonea. Define micro structureb. Define macro structurec. Define cold workingd. Define elongated grain structuree. Define grain boundaryf. Define grain growthg. Define fusion zoneh. Define fusion interface

E. BASIC SHIELDED METAL ARC WELDING (SMAW) AND OXY-FUEL GASCUTTING1. Define Selected Welding Terms Per AWS A3.0

a. Define arc welding process termsb. Define standard joint terminologyc. Define common weld discontinuitiesd. Name welding equipment, supply and consumablese. Define common shop terms including proper equipment namesf. Define material termsg. Define common metallurgy terms

2. Describe AWS Code for Mild Steel Electrodesa. List, describe and defineb. List low hydrogen electrodesc. List iron powder electrodesd. Describe electrode by welding positione. Describe electrode by current and polarityf. Describe electrode by penetration

3. Set Up Welding Machine to Required Polaritya. List polarities for commonly used electrodesb. Describe both polaritiesc. Describe advantages and disadvantages of alternating current

4. Use Correct Start and Stop Techniques for SMAW Electrodesa. Describe and demonstrate start for non-low hydrogen SMAW electrode

23.

b. Describe and demonstrate stop for non-low hydrogen SMAW electrodeswith filled craters

c. List reasons for the importance of low hydrogen in weld metald. Explain the reason for low hydrogen starts and stops and how they work

and why required specifically with E70185. Set Up Equipment for Shielded Metal Arc Welding

a. Inspect area for safetyb. Adjust current and polarity for specific job requirementsc. Choose type and size of electroded. Wear applicable personal safety equipment

6. Strike an Arc, Run Continuous Stringer Beada. Stand and position oneself correctlyb. Operate welding helmetc. Verbally warn others of intent to arc weldd. Strike an arce. Weld with stringer bead techniquef. Perform weld tie in's to make continuous bead

7. Weld Using Weave Techniquea. Maintain required weld qualityb. Maintain proper weld width uniformlyc. Maintain proper travel speedd. Match correct oscillation for various electrodese. Match- applications to weave techniques, as they applyf. List the advantages and disadvantages of weave techniquesg. List the advantages and disadvantages of stringer techniquesh. Perform weld using weave techniquei. Concentrate on dwell times at edges of weld pool

8. Weld Multi-Layer Buildupa. Weld a dam to outline area being welded for each layerb. Apply each layer neatly, straight and with good fusion throughoutc. Chip slag after each passd. Weld passes which over lap to crown of last weld beade. Demonstrate control of bead height

9. Set Up and Shut Down Oxy-Fuel Equipmenta. Follow manufacturer's recommended practiceb. Inspect equipment and work area for safetyc. Assemble oxy-fuel equipmentd. Open fuel gas cylinder 1/2 turne. Open oxygen as cylinder all the wayf. Adjust fuel gas and oxygen working pressure per manufacturer's

recommendationg. Purge lines one at a time. One second for each 10 feet of hose length

10. Cut Steel Plate Using Oxy-Fuel Equipmenta. Make manual free hand straight line cutsb. Cut manually straight lines using cutting jibc. Bevel plate with manual oxy-fuel equipmentd. Manually cut blind holes in thick materiale. Manually cut sheet metal with minimal distortion

24

11. Produce Welds with Properly Fused Starts and Filled Cratersa. Use non-low hydrogen electrodesb. Strike arc and hold long arc length 1" away from last weld craterc. Back-up to previous weld crater holding long arc lengthd. Pre-heat crater with long arce. Shorten arc length, fill crater and continue welding

12. Low Hydrogen Starts and Stopsa. Use low hydrogen electrodesb. Strike arc 1" from craterc. Immediately shorten arc length and back up quickly previous weld crater.

Holding short arc lengthd. Pause at the crater when it is filled. Continue welding

13. Design Welded Jointsa. List the names and draw side views of the five basic joint configurationsb. List the names and draw side views of the variations of groovesc. List the names and draw side views of the T-Joint variationsd. List the name of the type of weld made in each joint

14. Weld V Groove With Backing in Flat Positiona. Use oxy-fuel equipment to bevel 3/8" steel to 37 1/2°b. Clean bevel face with grinder as requiredc. Cut 1/4" material for backing strip

15. Set Up Air Carbon Arc Equipment for Gouginga. List the minimum rated amperage and duty cycle for a welding machine

used for air carbon arc gouging according to lectureb. List minimum flow rate and pressure for an air compressor used in air

carbon arc cutting and gougingc. List the polarity that air carbon arc is run ond. Describe approximate amperage settings for 1/8", 3/16", 1/4" and 3/8"

carbon electrodese. Connect air carbon torch arc and compressed air hose to welding

machinef. Inspect area for safety

16. Use Air Carbon Arc to Excavate a Partial Pen Groove Welda. Locate root of weldb. Demonstrate control of depth of cutc. Demonstrate control of width of cutd. Use air carbon arc cutting equipment to make shallow gouges (about 1/8"

deep max.) with stringer techniquee. Make gouges of uniform depthf. Observe discontinuities as gouging proceeds

g. Gouge until some weld metal is reached17. Gouge to Excavate Defect

a. Given the area of suspected discontinuity its size and depth; air carbon 1gouge using multi pass and stringer gouge to defect depth

b. Measure to make sure excavation is at proper location and depthc. Use air carbon arc equipment. Shape excavation to ensure proper fusiond. Clean area of all scale, carbon etc.

18. Make X-Ray Quality Weld Repair on a 2F Position T Joint 1/2" Plate

25

a. Check area for safetyb. Set SMAW equipment current and polarity for 1/8" E7018c. Attach work leadd. Preheat and maintain interpass temperature as requirede. Weld first pass paying special attention to low hydrogen techniquesf. Grind the weld start and stop to remove cold lap and lack of fusiong. Weld the second pass starting from opposite endh. Repeat starts and stops until weld is completedi. Inspect and submit for non-destructive testing RT or UT

19. Produce Fillet Weld on Sheet Steel T Jointsa. Check work area for safetyb. Position steel in a T joint and tack at endsc. Place T joint in the 2F position with a spacer on each end so the workpiece

is not touching the work bench. This stops any heat sink.d. Produce fillet welds equal in size to the thickness of the smallest joint

member. With SMAW E6011, E6013 and GMAW and GTAWe. Visually inspect to AWS D1.3

20. Produce Fillet Welds on T Joints Made Up of Both Thick and Thin Joint MembersUsing SMAWa. Inspect work area for safetyb. Set SMAW equipment for type and size of electrode and job requirementsc. Fit up and tack jointd. Weld joint keeping the major portion of heat on thicker sectione. Clean and visually inspect

21. Use Correct Starts for Low Hydrogen Electrodesa. List the AWS steel electrode code last digit designation for low hydrogen

electrodeb. Set up SMAW e.g. and check for safetyc. Using E7018 strike an arc 1" down the path of welding from where you

wish to startd. Shorten arc length immediately to low hydrogen arc lengthe. Quickly approximate 3 times as fast as welding travel speed back up the

one inch to the point at which the weld should startf. Stop movement at starting point and allow weld pool to formg. Begin normal travel speed once weld pool reaches required diameter

22. Use Correct Stops for Low Hydrogen Electrodesa. Use E7018 to begin weld correctlyb. Stop increase weld travel speedc. Observe weld pool when weld pool size decreases to smallest possible size,

break off arc by pulling away23. Weld Using Large Diameter SMA Electrodes

a. Set up SMAW equipment for use with 3/16" and E7018b. Tack up a T joint using 1/2" steelc. Set amperage from 180 to 200 DC ampsd. Begin the weld with a low hydrogen start by using a 75° lead angle (To

fight arc blow)e. Bring lead angle back to normal as the weld progresses 2" along joint

26

g.h.

Begin changing the lead angle to a push or forehand angle of 70° to 80° 3"from the end of jointMake multi-pass fillet welds with smooth contourVisually inspect to insure

F. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING1. Weld Single V Groove Welds With Open Roots From One Side

a. Bevel 3/8" steel plate to 37 1/2° using oxy-fuel gas cutting eg.b. Use grinder to remove oxide larger and smooth platec. Use grinder to create root face of 3/32" to 1/8"d. Tack single V groove joint with 3/32" root openinge. Place joint in the 1G positionf. Place joint in 2G position once task is masteredg. Place joint in 3G position once task is masteredh. Place joint in 4G position once task is masteredi. Weld the root with Direct Current Electrode Positive using 1/8" E6010.

Use tight arc length and keyhole technique to produce a well fused rootbead extending 1/16" above the plate.Weld chipped side slag and the root bead is wire brushedFill the balance of the groove with 3/32", 1/8" and/or 5/32" E7018 usingthe stringer bead technique

1. Visual test finished weld and root face bends evaluated to AWS D1.1criteria

2. Weld Various Diameters of Pipe to Platea. Inspect area for safetyb. Place plate flat on welding tablec. Place 3" pipe vertically on top of plate and tacked in placed. Leave weld coupon in the 2F fixed positione. Apply a 3/8" fillet weld using 1/8" E7018 and a stringer bead techniquef. Visually inspect weld to AWS D1.1

g. Fill pipe with water for 24 hoursh. Check for leak

3. Produce SMAW Pipe - 5G Positiona. Measure the pipeb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Tack the single V groove pipe joint with a 3/32" root openingg. Place the joint in the 5G fixed position, using an 1/8" E6010 and a keyhole

technique. Weld the root pass upward producing a root weld which iswell fused and has a 1/16" weld reinforcement above the plate

h. Chip slag and wire brush weldi. Grind any lack of fusion and/or high spotsj. Weld the balance of the groove upward with 3/32" or 1/8" E7018 using the

stringer bead techniquek. Visually inspect weld on the root and face sides to ASME Section 9

27

1. Remove four guided bend specimens from 2:00, 4:00, 8:00 and 10:00positions prepared and two & eight are root bend specimens. Four & tenare face bend specimens. Guided bend tests are evaluated to ASMESection 9 criteria

4. Produce SMAW - 2G Position Groove Weldsa. Measure the pipeb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Tack the single V groove pipe joint with a 3/32" root openingg. Weld pipe jointh. Place the joint in the 2G fixed position, using an 1/8" E6010 and a keyhole


i. Chip slag and wire brush. Grind any lack of fusion and/or high spotsj. Weld balance of the groove upward with 3/32" or 1/8" E7018 using the

stringer bead techniquek. Visually inspect weld on the root and face sides to ASME Section 91. Remove four guided bend specimens from 2:00, 4:00, 8:00 and 10:00

positions prepared and two & eight are root bend specimens. Four & tenare face bend specimens. Guided bend tests are evaluated to ASMESection 9 criteria

5. Roll Weld Pipe - SMAWa. Measure the pipeb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Tack the single V groove pipe joint with a 3/32" root openingg. Roll weld pipeh. Place pipe coupon on workbench in the 1G roll welding position.i. Weld the root bead using 1/8" E6010 and the keyhole technique. The weld

is performed in the 2:00 to 12:30 positionj. Chip slag and wire brush. Grind any lack of fusion and/or high spotsk. Weld balance of groove upward with 3/32" or 1/8" E7018 using the weave

technique1. Visually inspect weld on the root and face sides to ASME Section 9m. Remove four guided bend specimens from 2:00, 4:00, 8:00 and 10:00


6. Produce SMAW Pipe - 5G Positiona. Measure the pipe andb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"

28

f. Weld pipe

g. Tack the single V groove pipe joint with a 3/32" root openingh. Place the joint in the 5G fixed position, using an 1/8" E6010 and a keyhole

techniquei. Weld the root pass upward producing a root weld which is well fused and

has a 1/16" weld reinforcement above the platej. Chip slag and wire brush. Grind any lack of fusion and/or high spotsk. Weld balance of groove upward with 3/32" or 1/8" E7018 using the weave




techniqueh. Weld the root pass upward producing a root weld which is well fused and

has a 1/16" weld reinforcement above the platei. Chip slag and wire brush. Grind any lack of fusion and/or high spotsj. Weld balance of groove upward with 3/32" or 1/8" E7018 using the



8. Create SMAW Pipe to ASME Section 9a. Bevel two pieces of pipe to 30° bevel angle using oxy-fuel gas cutting

equipmentb. Clean bevel face and a 3/32" root face is applied using a hand held grinderc. Set welding condition to weld open rootsd. Tack pipe nipples together to form a V groove with a 1/8" root openinge. Place pipe in the 5G fixed position. The root pass is welded and cleaned by

wire brushingf. Weld balance of the V groove with this procedureg. Visual inspection is made and evaluated by ASME Section 9h. Make four bend samples and evaluate by ASME Section 9

9. Interpret Welding Proceduresa. Identify processb. Name joint designc. List base material

29

d. Give dimensions for root treatmente. Name electrode size and type being usedf. List filler material (if required), classification and specificationg. Identify shielding gas - type and mixtureh. List pre and post heat and interpass temperaturei. Describe initial and interpass cleaningj. Describe technique which is usedk. Produce single or multiple pass weld1. Choose current typem. Set current amperagen. Set current polarityo. Set voltage

G. PIPE WELDING - SMAW1. Produce End Preparations

a. Produce end preparations with oxy-fuel cuttingb. Produce end preparations with plasma cuttingc. Produce end preparations with mechanical cuttingd. Produce end preparations with grinding

2. Fit and Tack Weld Pipea. Cut and single bevel pipe to 37 1/2°b. Ground bevel face and touch up to within tolerancesc. Check that pipe ends are square within given tolerancesd. Prepare root face within given tolerancese. Align pipe to within given tolerancesf. Set root opening to within given tolerancesg. Tack pipe according to welding procedure specification - maintaining root

opening3. Roll Weld Open Root Pass on Pipe - 1G Position

a. Fit up and tack pipe joint using 1/8" E6010 electrode, weld the root passon pipe in the 1 o'clock to (2:00 o'clock position) according to procedureusing the roll welding technique

b. Weld remainder of pipe in the 1G roll welding position with E6010c. Weld the remaining portion of the groove using the weave technique using

5/32" E6010 electrode roll4. Weld Open Root Pipe Joint - 2G Position

a. Weld using 1/8" E6010b. Cut and grind pipe ends will be to single bevel edge preparations of 37 1/2°c. Fit together the two pipe ends to a single V edge preparation with given

tolerancesd. Weld root pass to ASME Section 9 requirementse. Fill balance of the groove with E6010 using .the stringer technique to

ASME Section 9 requirements5. Weld Open Root Pipe - 5G Position

a. Fit and tack weld pipe to within tolerancesb. Place pipe in the 5G positionc. Weld the rootpass using 1/8" E6010 to ASME Section 9 requirementsd. Grind the finished root pass to remove high spots and any slag at weld toes

30

e. Weld the remainder of the groove using 3/32" and/or 1/8" E7018 using thestringer bead technique to ASME Section 9 requirements

6. Pass Guided Bond Tests Per ASME Section 9a. Remove bend samples from pipe at the 10, 2, 8 & 4 o'clock positionsb. If the material is 3/8" or thinner 10 o'clock and 8 o'clock receive root bends

and 2 o'clock and 4 o'clock receive face bends. If the pipe wall thickness isover 3/8" side bends shall be performed on all samples.

c. Weld remainder of pipe in 1G position using E7018d. Perform low hydrogen starts and stopse. Weld using stringer bead techniquef. Weld using weave techniqueg Chip slag wire brush and grind as necessary to assure clean weld deposits

7. Weld Open Root Pipe - 2G Positiona. Use 1/8" E6010b. Cut and ground pipe ends to single bevel edge preparations of 37 1/2° c.Fit

together two pipe ends to a single V edge preparation within giventolerances

c. Weld root pass to ASME Section 9 requirementsd. Clean weld pass by chipping slag, wire brushing and grinding where

necessary to assure a clean, well fused weld deposite. Weld remainder of the groove using E7018 with the stringer bead

technique8. Weld Pipe Open Root Passes All Positions Using GMAW

a. Set up GMAW equipmentb. Adjust wire feeder drive systemc. Adjust shielding gas system and flow rated. Adjust GMAW gun to allow proper tip to work distance and gas coveragee. Set welding condition for short circuit transfer - Wire Feed Speedf. Set welding condition for short circuit transfer - Voltage

g. Set welding condition for short circuit transfer - Tip to work Distanceh. Weld root using a string bead technique

9. Weld Pipe With Backing Using FCAW-Ga. Bevel pipe endsb. Touch up bevel face with grinderc. Fit and tack backing ring to one pipe endd. Fit other pipe over backing ringe. Adjust gap and tack in placef. Adjust shielding gas flow

g. Adjust wire feed systemh. Adjust power source to procedure specificationi. Set wire feed speed to procedure specificationj. Adjust voltage to procedure specificationk. Adjust inductance to procedure specification1. Adjust GMAW gun for tip to work distance and shielding gasm. Weld according to procedure specification

H. GAS METAL ARC WELDING (GMAW)1. Assemble GMAW Gun and Name All Parts

31

a. Install adapter for particular brand of wire feederb. Insert liner of correct size until liner gasket meets adapter and tighten alien

screwc. Screw on gas defuser and tighten allen screwd. Install contact tipe. Install gas nozzlef. Adjust gun for tip to work distance

2. Understand Gas Metal Arc Power Sourcea. Compare and contrast constant current and constant voltage power sourcesb. List effects of inductance on circuitc. List effects of pinch effect

3. Shielding Gas Applicationa. List arc characteristics caused by welding with 100% carbon dioxideb. List arc characteristics caused by welding with 100% argonc. List arc characteristics caused by welding with 75% Argon and 25% CO2d. List arc characteristics caused by welding with 95% Argon and 5% CO2e. List arc characteristics caused by welding with 95% Argon and 5% oxygen

4. Weld With GMAW Using Spray Transfera. Choose the correct shielding gas and flow rate for the given application,

material and material thicknessb. Choose the correct electrode for given material and applications both type

and sizec. Set voltage and wire feed speed for a given application, material and

material thickness5. Weld With GMAW Using Short Circuit Transfer

a. Choose the correct shielding gas and flow rate for the given application,material and material thickness

b. Choose the correct electrode for given material and applications both typeand size

c. Set voltage and wire feed speed for a given application, material andmaterial thickness

6. Weld With GMAW Using Globular Transfera. Choose the correct shielding gas and flow rate for the given application,



material thickness7 Weld With GMAW Using Pulsed Spray Transfer




8. Weld T Joints on Carbon Steel Using GMAW Equipmenta. Inspect area for safety

32

b. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces ofcarbon steel

c. Adjust the welding parameters for this taskd. Tack a T joint using GMAWe. Weld 1/4" fillet welds in 2F position using string bead techniquef. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.1g. Change weld size once proficiency is reached on 6. to 3/16" go to step 1

then 5/16"9. Weld Multi-Pass Fillet Welds - All Positions

a. Inspect area for safetyb. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces of

carbon steelc. Adjust the welding parameters for this taskd. Tack a T joint using GMAWe. Weld the second pass with electrode centered at the bottom toe of the first

passf Weld the third pass with electrode centered at the top toe of the second

passg. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.1

10. Weld Multi-Pass Fillet Welds - 3F Vertical Positiona. Inspect area for safetyb. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces of

carbon steelc. Adjust the welding parameters for this taskd. Position the T joint in the 3F position for vertical welding. Weld a 1/4"

fillet in the vertical position, upward using a slight weave techniquee. Weld the second pass with electrode centered at the bottom toe of the first

passf. Weld the third pass with electrode centered at the top toe of the second

pass

g. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.111. Weld Multi-Pass Fillet Welds - 4F Overhead Position


carbon steelc. Adjust the welding parameters for this taskd. Place the T joint in the 4F overhead position approximately at eye levele. Weld a 1/4" fillet weld (wire brush weld after each pass)f. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.1

12. Weld Single V Groove With GMAWa. Inspect the work area and equipment for safetyb. Use oxy-fuel cutting equipment cut and bevel two pieces of 3/8" X 3"

X15" with 30° bevel anglec. Use grind to clean the bevel face and apply a 3/32" root faced. Adjust GMAW equipment to run .035" ER70S-3 with 75% Argon 25%

CO2 shielding gas at a flow rate of 30 cubic feet per hour at approximately16 arc volts and 100 amps

e. Using GMAW the two pieces are tacked together to produce a single Vgroove with a 1/8" root opening

f. Weld root upwardsg. Visual inspect finished root bead after wire brushing. Any high spots and

lack of fusion are removed by grinding.h. Using GMAW and upward Z weave technique the second weld pass is

applied. The electrode is moved from one root pass to the other with aslight upward motion

i. Complete the second pass using GMAW and upward Z weave techniquej. Using GMAW and on upward Z weave technique the third pass is welded.

The electrode is moved from the left toe of the second pass to the right toeon back. Each weave is accompanied by a slight upward motion. Becareful not to burn away the bevel edges

k. Make fourth and final pass with the same technique.1. The electrode is weaved from one bevel edge to anotherm. Visually inspect weld. The root reinforcement shall extend 1/16" above the

base metal, have good fusion etc. The weld face shall meet D1.1requirements and have parallel and straight edges

13. Weld Pipe - 1G Positiona. Fit up and tack pipe according to given tolerancesb. Adjust wire feeder drive systemc. Adjust shielding gas system and flow rated. Adjust GMAW gun to allow proper tip to work distance and gas coveragee. Set welding condition for spray transfer - Wire Feed Speedf. Set welding condition for short circuit transfer - Voltageg. Set welding condition for short circuit transfer - Tip to Work Distanceh. Weld using roll welding technique

I. GAS TUNGSTEN ARC WELDING (GTAW)1. Understand Technical Aspects of GTAW

a. List advantages and disadvantages of GTAWb. List five applications where GTAW or PAW are better suitedc. List give applications which are more suited to SMAW than GTAWd. Compare and contrast GTAW and plasma arc welding (PAC)e. List by name the parts of a GTAW torchf. Describe each control by name and function on the pulsed tig system such

as a Lincoln square wave 350 or Miller syncrowave 351 P.g. Assemble the GTAW torch, water cooler and GTAW machine

2. Weld Fillet - 2F Horizontal Positiona. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40

amps. Remote current control, assemble GTAW torch. With 1/16"pointed 2% thoriated tungsten

d. Cut stainless steel to .050" X 2" X 10"e. Fit up and tack a T joint and place in the 2F positionf. Weld a .050" fillet weld using .045" ER308-Lg. Visually inspect joint for burn through, weld size and workmanship

34

3. Weld Fillet - 3F Vertical Positiona. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40


d. Cut stainless steel to .050" X 2" X 10"e. Fit up and tack a T joint and place in the 3F vertical positionf. Weld a .050" fillet weld using .045" ER308-Lg. Visually inspect joint for burn through, weld size and workmanship

4. Weld Fillet - 4F Overhead Positiona. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40

amps. Remote current control, assemble GTAW torch. With 1/16"pointed 2% thoriated tungsten.

d. Cut stainless steel to .050" X 2" X 10"e. Fit up and tack a T joint and place in the 4F overhead positionf. Weld a .050" fillet weld using .045" ER308-Lg. Visually inspect joint for burn through, weld size and workmanship

5. Weld on 1/8" Material and 100% Penetrationa. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set up GTAW for high frequency start, direct current electrode negative,

40 amps. Remote current control, assemble GTAW torch. With 3/32"pointed 2% thoriated tungsten

d. Cut stainless steel and grind a .30" bevel on edgese. Place two pieces of stainless steel in the backing purge in the 1G position

fixture with a 0" gap. Using 100% Argon as the backing gas at a flow rateof 15 cubic feet per hour

f. Weld achieving full penetration while adding .062" ER308-L. Make a 2pass weld

g. Remove from backing purge and visually inspect for full penetration. Nocolor on welded surfaces except straw is permitted. The back or root ofthe weld shall be silver.

6. Weld 2G Position Using GTAWa. Set up GTAW for high frequency start, direct current electrode negative,


b. Cut stainless steel and grind a .30" bevel on edgesc. Place two pieces of stainless steel in the backing purge in the 2G position


d. Weld achieving full penetration while adding .062" ER308-L. Make a 2pass weld

e. Remove from backing purge and visually inspect for full penetration. Nocolor on welded surfaces except straw is permitted. The back or root ofthe weld shall be silver

355












e. Remove from backing purge and visually inspect for full penetration. Nocolor on welded surfaces except straw is permitted. The back or root ofthe weld shall be silver.

9. Weld Pipe Open Root Passes All Positions Using GTAWa. Fit up and tack weld pipe to within procedure tolerances. (Set up GTAW

equipment for welding carbon steel)b. Prepare tungsten for given procedurec. Set up GTAW torch for given procedured. Set current for proceduree. Adjust shielding gas flow ratef. Weld root using free hand technique and using the walking the cup methodg. Apply second pass using weave

J. MATHEMATICAL SKILLS1. Determine Measurements and Angles

a. Add fractionsb. Subtract fractionsc. Multiply fractionsd. Divide fractionse. Change fractions to decimalsf. Change decimals to fractionsg. Solve simple algebraic equationsh. Solve simple trigonometric equationsi. Convert English measurement to Metricj. Convert Metric measurement to English

36

K. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist

a. Sweep table top and floor in work areab. Clean equipment and toolsc. Return tools to proper storage aread. Dispose of waste materials and scrap in their proper receptacle containers

and storage arease. Store all unused materials to their respective storage areas

L. QUALITY INSPECTIONS1. Perform Visual Checks

a. Identify common welding defectsb. List terms for common welding defectsc. Rate common welding defects in order of severityd. Name size of limitations for defects given under various codes

37

THE MAST PILOT PROGRAM CURRICULUMAND COURSE DESCRIPTIONS

After completing the Competency Profile and Technical Workplace Competency Outline for eachoccupational specialty area, each MAST partner reviewed their existing curricula against theindustry-verified skill standards in order to identify a suitable foundation for new pilot trainingprograms. Because each college had to comply with the requirements of its respective collegesystem and appropriate state agency, the resulting pilot curricula for occupational specialty areastended to vary in format and academic requirements (e.g., some programs were based on thesemester system, others on the quarter system). Despite differences in the curricula developed atthe partner colleges, each of the pilot programs was designed to achieve the following two goalsmandated in the MAST grant proposal:

Pilot Program: "Conduct a one year pilot program with 25 or more selected applicants ateach college or advanced technology center to evaluate laboratory content andeffectiveness, as measured by demonstrated competencies and indicators of each programarea. ,,

Student Assessment: "Identify global skills competencies of program applicants both atpoint of entrance and point of exit for entry level and already-employed technicians."

(Note: All occupational specialty areas were not pilot tested at all Development Centers;however, all partner colleges conducted one or more pilot programs.)

Included on the following pages is the curriculum listing for the pilot program which was used tovalidate course syllabi for this occupational specialty area. This curriculum listing includedcourse names and numbers from the college which conducted the pilot program. The curriculumalso shows the number of hours assigned to each of the courses (lecture, lab and credit hours).Also included is a description of each of the courses.

3

First Semester

WELDING TECHNOLOGYONE YEAR CERTIFICATE

LEC LAB CRWLD 111 Basic Arc/Gas Welding I 1 4 3WLD 112 Basic Arc/Gas Welding II 1 4 3WLD 104 Electrical Welding Circuits 2 0 2WLD 105 Reading Welding Blueprints 3 0 3

7 8 11

Second SemesterWLD 121 Advanced SMAW and Cutting I 1 4 3WLD 122 Advanced SMAW and Cutting II 1 4 3WLD 123 MIG, TIG and Brazing I 1 4 3WLD 124 MIG, TIG and Brazing II 1 4 3WLD 113 Basic Welding Metallurgy 2 2 3

6 18 15

OptionsWLD 137 Individual Welding Problems I 0 5 3WLD 138 Individual Welding Problems II 0 5 3WLD 140 Basic Pipe Welding I 1 4 3WLD 141 Basic Pipe Welding II 1 4 3WLD 160 Visual Inspection of Welds 3 0 3

5 18 15

Option 1 = Program Totals 13 36 32WLD 137 Individual Welding Problems IWLD 138 Individual Welding Problems II

Option 2 = Program Totals 15 34 32WLD 140 Basic Pipe Welding IWLD 141 Basic Pipe Welding II

Option 3 = Program Totals 16 31 32WLD 137 Individual Welding Problems IWLD 160 Visual Inspection of Welds

33

WLD 111

WLD 112

WELDING TECHNOLOGYONE YEAR CERTIFICATECOURSE DESCRIPTIONS

Basic Arc/Gas Welding I (1-4-3) WLD 111 is the first half of the BasicArc/Oxy-fuel Welding and Cutting course. The student will learn introductoryskills in shielded metal, arc welding, oxy-acetylene welding and oxy-fuel cutting.The student will also learn safety procedures relating to these subjects and shopsafety in general. This course will be taught using industrial procedures and guidelines. It features hands on welding instruction. Your participation is your key tosuccess in this course.

Basic Arc/Bas Welding II (1-4-3) WLD 112 is the second half of the BasicArc/Gas Welding and Cutting course. This hands-on class expands the studentsknowledge and experience in using various types of shielded metal arc weldingelectrodes in the flat and horizontal positions. The student will advance to weldingsingle "V" groove welds in the 1G or flat position.

WLD 104 Electrical Welding Circuits (2-0-2) Theory and operation of the welding powersource, welding circuits and welding equipment.

WLD 105 Reading Welding Blueprints (3-0-3) Introduction to blueprint reading forwelding emphasizes basic interpretation of blueprints, welding symbols and basicsketching.

WLD 121

WLD 122

Advanced SMAW and Cutting I (1-4-3) In WLD 121 the student will practiceSMAW in various positions. The student will gain proficiency in oxy-fuel cuttingand air carbon arc cutting and gouging. The student will also study selectedtechnical areas related to welding. Special emphasis will be placed on weld sizeand AWS code welding.

Advanced SMAW and Cutting II (1-4-3) In this nine week course, the studentwill advance his technique in out of position shielded metal arc welding. Weldingof transitional joints and open groove welds will be stressed. Safety is our primaryconcern.

WLD 123 MIG, TIG and Brazing I (1-4-3) Welding, braze welding and brazing of variousjoints using GTAW, FMAW, FCAW, SAW and OFW.

WLD 124 . MIG, TIG and Brazing H (1-4-3) Position welding brazing various joints usingGTAW, GMAW, FCAW, SAW, and oxy/fuel.

WLD 113 Basic Welding Metallurgy (2-2-3) Students will earn about the physical andmetallurgical properties of carbon steels and how welding will effect theseproperties.

40

WLD 137

WLD 138

WLD 140

WLD 141

WLD 160

Individual Welding Problems I (0-5-3) In this course the student will prepare awritten proposal identifying specific problems to be addressed and submit it to theinstructor for approval. Upon approval, this contract will state class meeting timeand required written work. Students must make arrangements with instructorprior to signing up for class.

Individual Welding Problems II (0-5-3) In this course the student will preparea written proposal identifying specific problems to be addressed and submit it tothe instructor for approval. Upon approval, this contract will state class meetingtime and required written work. Students must make arrangements with instructorprior to signing up for class.

Basic Pipe Welding I (1-4-3) Shielded Metal Arc Welding (SMAW) of pipe inthe 2G & 5G positions. At the entry level of WLD 140, students are expected topass AWS D1.1 qualification tests on 1/2" carbon steel plate in the 3G and 4Gpositions using SMAW.

Basic Pipe Welding II (1-4-3) Shielded Metal Arc Welding (SMAW) of pipe inthe 6G positions. At the entry level of WLD 141, students are expected to passAWS D1.1 qualification test on 6" schedule 40 carbon steel pipe in the 2G and 5Gpositions using SMAW.

Visual Inspection of Welds (3-0-3) Utilizing a combination of lecture,discussion, demonstration, and practical application the student will becomefamiliar with the duties and responsibilities of the Welding Inspector and will beintroduced to the various concepts and the general body of knowledge required foreventual certification as a Welding Inspector, as defined by AWS D1.1 and asrealized by accomplishing the Specific Objectives of the course.

41

THE MAST TECHNICAL WORKPLACECOMPETENCY/COURSE CROSSWALK

Upon development of appropriate curricula for the pilot programs, each MAST college began todevelop individual course outlines for its assigned specialty area. The skill standards identified inthe Competency Profile were cross walked against the technical competencies of the courses inthe pilot curriculum. The resulting matrix provided a valuable tool for assessing whether currentcourse content was sufficient or needed to be modified to ensure mastery of entry level technicalcompetencies. Exit proficiency levels for each of the technical competencies were furthervalidated through industry wide surveys both in Texas and across the nation.

The Technical Workplace Competency/Course Crosswalk in the following pages presents thematch between industry-identified duties and tasks and the pilot curriculum for . Coursetitles are shown in columns, duties and tasks in rows. The Exit Level Proficiency Scale, anascending scale with 5 the highest level of proficiency, includes marked boxes indicating whetherthe task is covered by the instructor during the course; the numbers 1-5 indicate the degree ofattention given to the task and the corresponding proficiency expected on the part of the student.The crosswalk is intended to serve as an aide to other instructional designers and faculty incommunity college programs across the nation.

Included on the following pages is the Technical Workplace Competency/Course Crosswalk forthe pilot program curriculum. This crosswalk validates the fact that the duties and tasks whichwere identified by industry as being necessary for entry level employees have been incorporatedinto the development of the course syllabi.

42

Technical Workplace Competencies/Course

CROSSWALK

TECHNICAL COMPETENCYDING TECHNOLOGY.

of ' co ' 41 ' co Nc f e I -t-- -o / cZr .4 .4 .4 ,.4 ,-. ,.,..,-.1

A. FOLLOW SAFE PRACTICES

A-1. Wear Personal Protective Equipment X X X X X X X X X X X X 3

A-2. Identify Safety Rules X X X X X X X X X X X X 3

A-3. Familiarize Oneself With Safety at Facility XX_X X X X X X X X X X X X 2

B. DEMONSTRATE TECHNICAL COMMUNICATION

B-1. Use Standard American Welding Standard Society Welding Terms andDefinitions X X X XX.X X X X X X X X X 4

C. INTERPRET WELDING DRAWINGS

C-1. Review Print Notes, Dimensions and Symbols X 3

C-2. Identify Basic Layouts of Drawings X 3

C-3. Interpret Drawing Lines and Views X 3

C-4. Interpret Welding Symbols X 3

C-5. Convert Metric to English X 3

C-6. Understand Print Specifications X 3

C-7. List Assembly Procedure Per Print X 3

C-8. Understand Various Types of Welding Prints X 3

C-9. Visualize Final Weldment From Print X 3

C-10. List Flaws and Errors on Drawings X 3

C-11. Interpret AWS Standard Welding Symbols X 3

D. BASIC WELDING METALLURGY

D-1 Become Conversant With Common Metallurgical Terms X 4

D-2 Describe the Properties of Various Types of Steel X 3

D-3 List Various Alloys and Their Effect When Combined With Steel X 3

D-4 Describe the Effect Welding Has on Properties of Various Types of CarbonSteels X 4

D-5 Identify Basic Concepts Relating to the Heat Affected Zone X 3E. BASIC SHIELDED METAL ARC WELDING (SMAW) AND OXY-FUEL GAS

CUTTING

E-1. Define Selected Welding Terms Per AWS A3.0 X X X X X X X X X X X 3

E2. Describe AWS Code for Mild Steel Electrodes X X X X X X 4

E-3. Set Up Welding Machine to Required Polarity X X X X X X X X X X X 4

E-4. Use Correct Start and Stop Techniques for SMAW Electrodes X X X X X X 4

E-5. Set Up Equipment for Shielded Metal Arc Welding X X X X X_X 4

4 fl

7'echnical Workplace Competencies/Course ev,...

.0-..

.. .s e 4'... .' .... -0'Z. C.) 0 40 .4'CROSSWALK it,e4) 4' .6. 43. Q. 44 '-' k' %-.II 4° CQ : , e* 42 e.°

C? Ab 4 G g , e 1 4. A tTECHNICAL COMPETENCY # 4 If 60 cr ,?' i.? 4-.? 1

t.4 4 4I I 0- 0 ...9 i.* :b -4" . - .f- `1'WELDING TECHNOLOGY . re a -t. -e. ,-, -t, -t, .

E-6. Strike an Arc, Run Continuous Stringer Bead X X X X X X 4

E-7. Weld Using Weave Technique X X X X X X 3

E-8. Weld Multi-Layer Buildup X X 3

E-9. Set Up and Shut Down Oxy-Fuel Equipment X X X X X X X X X X 4

E-10. Cut Steel Plate Using Oxy-Fuel Equipment X X X X X X X X X X 4

E-11. Produce Welds with Properly.Fused Starts and Filled Craters X X X X X X X X X X 4

E-12. Low Hydrogen Starts and Stops X X X X X 4

E-13. Design Welded Joints X X X X X X X X X 4

E-14. Weld V Groove With Backing in Flat Position X X X X X 4

E-15. Set Up Air Carbon Arc Equipment for Gouging X X X X X X X X 3

E-16. Use Air Carbon Arc to Excavate a Partial Pen Groove Weld X X X X X 4

E-17. Gouge to Excavate Defect X X X X X X X 2

E-18. Make X-Ray Quality Weld Repair on a 2F Position T Joint 1f2 Plate X X X X 4

E-19. Produce Fillet Weld on Sheet Steel T Joints X X 4E-20. Produce Fillet Welds on T Joints Made Up of Both Thick and Thin Joint

Members Using SMAW X X 3

E-21. Use Correct Starts for Low Hydrogen Electrodes X X X X X 3

E-22. Use Correct Stops for Low Hydrogen Electrodes X X X X X 3

E-23. Weld Using Large Diameter SMA ElectrodesX 2

F. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING

F-1. Weld Single V Groove Welds With Open Roots From One Side X 3

F-2. Weld Various Diameters of Pipe to Plate X 4

F-3. Produce SMAW Pipe - 5G PositionX 3

F-4. Produce SMAW - 2G Position Groove WeldsX 3

F-5. Roll Weld Pipe - SMAWX 3



F-8. Create SMAW Pipe Weld to ASME Section 9 X 3

F-9. Interpret Welding Procedures X X X X 3

G. PIPE WELDING - SMAW

G-1. Produce End Preparations X X 3

Pige 3::Technical: Workplace Competencies/Course

CROSSWALK

TECHNICAL COMPETENCYWELDING TECHNOLOGY

G-2. Fit and Tack Weld Pipe

44 2 I 4,17 ' ,1 4 I 4:C' ,i'' 4' -e" I - I cp ....5, 1 ...,5, I ilj-

X

I co-

X

I ,.].-- I ki ..4-

3

G-3. Roll Weld Open Root Pass on Pipe - 1G Position X 3

G-4 Weld Open Root Pine Joint - 2G Position X 3

G-5. Weld Open Root Pipe - 5G Position X 3

G-6. Pass Guided Bond Tests Per ASME Section 9 X X 2

G-7. Weld Open Root Pipe - 2G Position X 3

G-8. Weld Pipe Open Root Passes All Positions Using GMAW X 3

G-9. Weld Pipe With Backing Using FCAW-G X 3

H. GAS METAL ARC WELDING (GMAW)

H-1. Assemble GMAW Gun and Name All Parts X X 3

H-2. Understand Gas Metal Arc Power Source X X 3

H-3. Shielding Gas Application X X 2

H-4. Weld With GMAW Using Spray Transfer X X 3

H-5. Weld With GMAW Using Short Circuit Transfer X X 3

H-6. Weld With GMAW Using Globular Transfer X X 3

H-7. Weld With GMAW Using Pulsed Spray Transfer X X 3

H-8. Weld T Joints on Carbon Steel Using GMAW Equipment X X 3

H-9. Weld Multi-Pass Fillet Welds - All Positions X X 3

H-10. Weld Multi-Pass Fillet Welds - 3F Vertical Position X X 3

H-11. Weld Multi-Pass Fillet Welds - 4F Overhead Position X X 3

H-12. Weld Single V Groove With GMAW X X 3

H-13. Weld Pipe - 1G Position X X 2

I. GAS TUNGSTEN ARC WELDING (GTAW)

1-1. Understand Technical Aspects of GTAW X X 3

1-2. Weld Fillet - 2F Horizontal Position X X 3

1-3. Weld Fillet - 3F Vertical Position X X 3

1-4. Weld Fillet - 4F Overhead Position X X 3

U-5. Weld on 1/8" Material and 100% Penetration X X 3

1-6. Weld 2G Position Using GTAW X X 3

1-7. Weld 3G Position Using GTAW X X 2

45

TeChnical WirkPlizee'Competencies/Coure.. ...6.: s s 47.. .

CROSSWALK' .., 4, a as c, d ' Zgq b C 4 'V le '0, i ., A.

-0 -c,

4 .. ct,4. .4. 64 4) A. A) QJ %

g64 "C37 c 1 gi" ? Eel2 g A 4' ,."TECHNICAL COMPETENCY -t,? ? 0 P. I- ' .... ..., 14..

n? P . 40 c. t... 3 ct, 4,S. -9WELDING TECHNOLOGY, :

. <, 4" g v t.,-. se . .. ':sr .., -t, b .... ... -?, t, 4 Z,

. . .

1-8. Weld 4G Position Using GTAW 1111, X X

1-9. Weld Pipe Open Root Passes All Positions Using GTAW 1111. X X

J. MATHEMATICAL SKILLS

J-1. Determine Measurements and Angles X

K. MAINTAIN HOUSEKEEPING

K-1. Clean Work Area and Insure That No Safety Hazards Exist X X X X X X X X X X X 3

L QUALITY INSPECTIONS

X X X X X X X X XL-1. Visual Checks

11111111

MI

WELDERTECHNICAL WORKPLACE COMPETENCIES

EXIT LEVEL PROFICIENCY MATRIX

Welder: and study arc/gas, SMAW, GMAW, GTAW, brazing, metallurgy, and printinterpretation to perform welding operations necessary to produce a workpiece torequired standards.

The following matrix identifies the five exit levels of technical workplace competencies for theWelding Certificate at Moraine Valley Community College Illinois.

EXIT LEVEL OF PROFICIENCY

TechnicalWorkplaceCompetency

1 2 3 4 5

rarely routinelywithsupervision

routinelywith limitedsupervision

routinelywithoutsupervision

initiates/improves/modifies andsupervisesothers

47

THE MAST SCANS/COURSE CROSSWALK

The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT' the following five competencies and athree-part foundation of skills and personal qualities that are needed for solid job performance:

COMPETENCIES:Resources:Interpersonal:Information:Systems:Technology:

FOUNDATION SKILLS:Basic Skills:

Thinking Skills:

Personal Qualities:

Identifies, organizes, plans, and allocates resourcesWorks with othersAcquires and uses informationUnderstands complex inter-relationshipsWorks with a variety of technologies

Reads, writes, performs arithmetic and mathematical operations,listens and speaksThinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasonsDisplays responsibility, self-esteem, sociability, self-management,and integrity and honesty

Recognizing the value of SCANS proficiencies to job performance, as well as the growingmandate in many states to include SCANS activities in course curricula, MAST asked surveyrespondents to review the SCANS skill sets in the context of the draft skill standards for eachoccupational specialty area. MAST also incorporated evaluation of SCANS competencies andfoundation skills into its assessment of the pilot training curricula. The results were summarizedin a crosswalk that allowed MAST staff to modify course content where needed to strengthenachievement of SCANS competencies.

The following pages present the SCANS/Course Crosswalk for the pilot curriculum inCourses are listed along the top and SCANS competencies and foundations are shown along theleft side of the matrix. An exit level proficiency matrix for SCANS competencies and foundationskills is provided as well.

As "soft" skills, the SCANS competencies are inherently difficult to quantify. MAST realizesthat some faculty will emphasize the SCANS more or less than others. The SCANS/CourseCrosswalk matrix has been included with this course documentation to show the importance ofthese "soft skills" and the importance of their being addressed in the classroom (particularly intechnical classes). In time, faculty will learn to make these types of SCANS activities an integraland important part of the teaching process.

Included on the following pages is the SCANS/Course Crosswalk for the pilot programcurriculum. This crosswalk validates the fact that the "soft skills" (SCANS) which wereidentified by industry as being necessary for entry level employees have been incorporated into thedevelopment of the course syllabi. Also included is a matrix which defines the exit level ofproficiency scale (1-5).

48

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1I

WELDING TECHNOLOGYSCANS

COMPETENCIES AND FOUNDATION SKILLSEXIT LEVEL PROFICIENCY MATRIX

The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" the following five competencies and athree-part foundation of skills and personal qualities that are needed for solid job performance:

COMPETENCIES:Resources: Identifies, organizes, plans, and allocates resourcesInterpersonal: Works with othersInformation: Acquires and uses informationSystems: Understands complex inter-relationshipsTechnology: Works with a variety of technologies

FOUNDATION SKILLS:Basic Skills: Reads, writes, performs arithmetic and mathematical operations, listens and

speaksThinking Skills: Thinks creatively, makes decisions, solves problems, visualizes, knows how

to learn and reasonsPersonal Qualities: Displays responsibility, self-esteem, sociability, self-management, and

integrity and honesty.

The following matrix identifies the five exit levels of proficiency that are needed for solid jobperformance.

EXIT LEVEL OF PROFICIENCY

SCANSCompetencies

and FoundationSkills

1 2 3 4 5

rarely routinelywithsupervision

routinelywith limitedsupervision

routinelywithoutsupervision

initiates/improves/modifies andsupervisesothers

MAST/00012296

51

THE MAST COURSE SYLLABI"PILOT PROGRAM"

MAST has produced a very unique set of course outlines, driven and validated by industry andencompassing the broad range of technologies covered by the MAST grant. The course outlinesalso include proposed SCANS activities that will be useful to an instructor in preparing studentsto enter the workforce of the future.

Included in the following pages are final course outlines developed and refined in the process ofpiloting the MAST training programs. The outlines include a brief course description; requiredcourse materials (e.g., textbook, lab manual, and tools, if available); proposed method ofinstruction; proposed lecture and lab outlines; and detailed course objectives for both TechnicalWorkplace Competencies and SCANS Competencies.

These outlines were completed and revised during the second year of MAST, followingcompletion of the pilot phase. The outlines are intended to serve as an aide to other instructionaldesigners and faculty in community college programs across the nation.

Included on the following pages are the Course Syllabi for each of the courses which were taughtduring the pilot program.

52


COURSE SYLLABUS

BASIC ARC/GAS WELDING I

53

MAST PROGRAMCOURSE SYLLABUS

BASIC ARC/GAS WELDING I

Lecture hours/week: 1

COURSE DESCRIPTION:

Lab hours/week: 4 Credit hours: 3

Basic Arc/Gas Welding I is the first half of the Basic Arc/Oxy-fuel Welding and Cutting course.The student will learn introductory skills in shielded metal, arc welding, oxy-acetylene weldingand oxy-fuel cutting. The student will also learn safety procedures relating to these subjects andshop safety in general. This course will be taught using industrial procedures and guidelines. Itfeatures hands on welding instruction. Your participation is your key to success in this course.

PREREQUISITES: NONE

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:A. Shielded Metal Arc Welding

1. Given a lecture and demonstration, the student will perform industrialhousecleaning duties to instructor satisfaction

2. Given a lecture/discussion on welding, shop and hand tool safety, the student willidentify safety rules and standards on written & oral tests to a Student TrainingStandard (B)

3. Given a lecture/discussion on welding terms the student will define selected termson written tests to a Student Training Standard (B)

4. Given lecture/discussion/demonstration, the student will strike an arc and runcontinuous stringer beads in the flat (1G) position using bare rods and givenelectrodes to a Student Training Standard (2b/B)

5. Given lecture/discussion/demonstration, the student will run selected electrodesusing the weave bead welding technique to a Student Training Standard (2b/B)

6. Given lecture/discussion on the A.W.S. mile steel shielded metal arc welding(SMAW) code the student will describe given electrodes on a written and/or oralexam to a Student Training Standard (B)

7. Given a lecture/discussion on direct current polarity for welding, the student willadjust the welding circuit to a given polarity to a Student Training Standard (2b/B)

8. - Given a lecture/discussion/demonstration on correctly starting and stoppingwelding with SMAW electrodes (including low hydrogen electrodes), the studentwill produce weld beads having hot starts and correctly ended with filled weldcraters to a Student Training Standard (2b/B)

9. Given a lecture/demonstration, the student will use 1/8" E6013 to weld a threelayer build up on a plate using the "damming" technique and leaving no craters to aStudent Training Standard (2b/B)

54

10. Given air carbon arc cutting equipment (ACA), the student will cut separate awelded butt joint to a Student Training Standard (2b/B)

11. The student will produce a college level five (5) page type written research paperon a welding topic. This topic must be approved by the instructor

B. Oxy-Fuel Cutting1. Given a lecture/discussion on oxy-fuel cutting equipment, the student will safely

setup and shut down oxy-fuel welding station according to manufacturers'recommended practice to a Student Training Standard (2b/A)

2. Given a discussion/demonstration on oxy-fuel cutting, the student will cut steelplate/sheet with oxy-fuel cutting equipment to a Student Training Standard (2b/A)

REQUIRED COURSE MATERIALS:

Textbook: Basic Arc Welding (SMAW), by Ivan H. Griffen, Edward M. Roden, Charles W.Briggs; Delmar

Supplies:1. Safety glasses (which will be worn at all times in the welding lab)2. Welder's helmet with Nos. 10-11 filter lenses3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Wire brush6. Large pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (shade 5-6)9. Flashlight10. Spark lighter

METHODS OF INSTRUCTION:

Lecture: Didactic presentations will include lecture, video and demonstrations.

Laboratory: Laboratory will be "hands-on" activities.

Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. perform the manipulative skills of the craft as required to satisfactorily complete

laboratory assignments2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual

55

LECTURE OUTLINE:Lecture Topics Text Reference Page Contact Hrs.

Welding & Shop Safety Unit #s 1, 2, 3, 4, 6 8Polarity, AC & DC currentHow to adjust welding machineSix variables of SMAW Unit # 7How to light & shut down

oxy-fuel termsMaking tie-ins SMAWCutting MovieHow to oxy-acetylene weld Unit # 8 1

How to run weave beadsA.W.S. electrode code 1

Build up and hard surface Unit # 9 1

TEST - Terms, Polarity, Safety, 26 variables of SMAW - oxy-fuel

cuttingReview 2Parts of a weld - fillet & grooveTie-ins, AWS electrode codePractical Test & Written Final 2

Total Lecture Hours 18

LAB OUTLINE:LabTopics Contact Hrs.

Shielded Metal Arc WeldingPerform Industrial Housecleaning DutiesStrike an Arc and Run Continuous Stringer Beadsin the Flat (1G) Position Using Bare Rods and GivenElectrodesRun Selected Electrodes Using the Weave BeadWelding TechniqueAdjust the Welding Circuit to a Given PolarityProduce Weld Beads Having Hot Starts and CorrectlyEnded With Filled Weld CratersUse 1/8" E6013 to Weld a Three Layer Build Up ona Plate Using the "Damming" Technique and LeavingNo CratersCut Separate a Welded Butt JointOxy-Fuel CuttingSafely Set Up and Shut Down Oxy-Fuel WeldingStation According to Manufacturers' RecommendedPracticeCut Steel Plate/Sheet With Oxy-Fuel CuttingEquipment

Total Lab Hours

58

COURSE OBJECTIVES: TECHNICAL COMPETENCIES

After the successful completion of this course the student will be able to:A. FOLLOW SAFE PRACTICES

1. Wear Personal Protective Equipmenta. List personal protective equipment for shielded metal arc weldingb. List personal protective equipment for gas tungsten arc weldingc. List personal protective equipment for gas metal arc weldingd. List personal protective equipment for flux cored arc weldinge. List personal protective equipment for submerged arc weldingf. List personal protective equipment for oxy-fuel cuttingg. List personal protective equipment for plasma arc cuttingh. List personal protective equipment for air carbon arc gougingi. During shop work, wear applicable personal protective equipment at all









a. Follow verbal instructionsb. Follow written detailsc. Prepare time and job cards (reports & records)

C. BASIC SHIELDED METAL ARC WELDING (SMAW) AND OXY-FUEL GASCUTTING1. Define Selected Welding Terms Per AWS A3.0

a. Define arc welding process termsb. Define standard joint terminologyc. Define common weld discontinuitiesd. Name welding equipment, supply and consumablese. Define common shop terms including proper equipment namesf. Define material termsg. Define common metallurgy terms

2. Describe AWS Code for Mild Steel Electrodesa. List, describe and defineb. List low hydrogen electrodesc. List iron powder electrodesd. Describe electrode by welding positione. Describe electrode by current and polarityf. Describe electrode by penetration


4. Use Correct Start and Stop Techniques for SMAW Electrodesa. Describe and demonstrate start for non-low hydrogen SMAW electrodeb. Describe and demonstrate stop for non-low hydrogen SMAW electrodes

with filled cratersc. List reasons for the importance of low hydrogen in weld metald. Explain the reason for low hydrogen starts and stops and how they work



6. Strike an Arc, Run Continuous Stringer Beada. Stand and position oneself correctlyb. Operate welding helmetc. Verbally warn others of intent to arc weldd. Strike an arce. Weld with stringer bead techniquef Perform weld tie in's to make continuous bead

7. Weld Using Weave Techniquea. Maintain required weld qualityb. Maintain proper weld width uniformlyc. Maintain proper travel speedd. Match correct oscillation for various electrodese. Match applications to weave techniques, as they applyf. List the advantages and disadvantages of weave techniquesg. List the advantages and disadvantages of stringer techniquesh. Perform weld using weave techniquei. Concentrate on dwell times at edges of weld pool

8. Weld Multi-Layer Buildup

58

a. Weld a dam to outline area being welded for each layerb. Apply each layer neatly, straight and with good fusion throughoutc. Chip slag after each passd. Weld passes which over lap to crown of last weld beade. Demonstrate control of bead height

9. Set Up and Shut Down Oxy-Fuel Equipmenta. Follow manufacturer's recommended practiceb. Inspect equipment and work area for safetyc. Assemble oxy-fuel equipmentd. Open fuel gas cylinder '/2 turne. Open oxygen as cylinder all the wayf. Adjust fuel gas and oxygen working pressure per manufacturer's

recommendation

g. Purge lines one at a time. One second for each 10 feet of hose length10. Cut Steel Plate Using Oxy-Fuel Equipment

a. Make manual free hand straight line cutsb. Cut manually straight lines using cutting jibc. Bevel plate with manual oxy-fuel equipmentd. Manually cut blind holes in thick materiale. Manually cut sheet metal with minimal distortion

11. Produce Welds with Properly Fused Starts and Filled Cratersa. Use non-low hydrogen electrodesb. Strike arc and hold long arc length 1" away from last weld craterc. Back-up to previous weld crater holding long arc lengthd. Pre-heat crater with long arce. Shorten arc length, fill crater and continue welding

D. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist



COURSE OBJECTIVES: SCANS COMPETENCIES

The Secretary's Commission on Achieving Necessary Skills (SCANS), U S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies and a three-part foundation of skills and personalqualities that are needed for solid job performance.

The following activities will be performed by each student for successful completion of thiscourse:

59

I. COMPETENCIESA. Resources: Identifies, organizes, plans, and allocates resources

1. self paced instruction with very little supervision requires time management2. projects require materials acquisition

B. Interpersonal: Works with others1. lab and class requires team work and cooperation to complete projects2. safety requires mutual cooperation, vigilance and communication

C Information: Acquires and uses information1. reading assignments contain material students are responsible for which are

to be obtained no where else2. lecture notes and research paper3. this is demonstrated by student's ability to complete projects

D. Systems: Understands complex inter-relationships1. program is geared toward training students to work and operate

technology and system2. as the students learn welding skills they learn to monitor and correct their

own performanceE. Technology: Works with a variety of technologies

1. projects require selection of various technologies2. all projects require applied technology3. constant trouble shooting is required

II. FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,

listens and speaks.1. Reading: Locates, understands, and interprets written information in

prose and in documents such as manuals, graphs, and schedulesa. reads and comprehends homework assignmentsb. reads complicated written instruction

2. Writing: Communicates thoughts, ideas, information, andmessages inwriting and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. completes written assignments and reportsb. completes written essay questions

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractionsd. computes angles

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. attends lecturesb. interprets complicated verbal instructions

5. Speaking: Organizes ideas and communicates orallya. responds to oral quiz questionsb. capsulizes lecture information

60

WLD I 1 I04/072496

B. Thinking Skills: Thinks creatively, makes decisions, solves problems, visualizes,knows how to learn and reasons.1. Decision Making: Specifies goals and constraints, generates alternatives,

considers risks, and evaluates and chooses best alternativea. identifies personal goalsb. identifies actions required to accomplish personal goals

2. Problem Solving: Recognizes problems and devises and implements planof actiona. answer assigned questionsb. makes daily accommodations to stay on schedule

3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. understands step by step procedure to produce given tasks

4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. tasks require individualized practice to develop learning skillsb. recognizes information to solve specific problems

5. Reasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. understands welding terminologyb. interprets different welding techniquesc. chooses processes to accomplish specific tasksd. chooses procedures to accomplish specific tasks

Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal

attainmenta. develops good work ethic

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in class objectivesb. ability to learn very challenging tasksc. successfully completes tasks with quality results

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. working together with other students in safetyb. working together with other students in learningc. assigned to group projects and assignments

4. Integrity/Honesty: Chooses ethical courses of actiona. accepts responsibility for own actionsb. exhibits personal honesty at all timesc. works with expensive tools and equipment - prompted to report all

problems

61


COURSE SYLLABUS

BASIC ARC/GAS WELDING II

62


BASIC ARC/GAS WELDING II


COURSE DESCRIPTION:


Basic Arc/Gas Welding II is the second half of the Basic Arc/Gas Welding I course. This hands-on class expands the student's knowledge and experience in using various types of shielded metalarc welding electrodes in the flat and horizontal positions. The student will advance to weldingsingle "V" groove welds in the 1G or flat position.

PREREQUISITES: Basic Arc/Gas Welding I

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:A. Shielded Metal Arc Welding

1. Given a welding and shop safety test, the student will pass with a minimum scoreof 100%

2. Given lab assignments, the student will conduct himself/herself in a safe manner atall times to a Student Training Standard (B)

3. Given a lecture/discussion on welding terms, the student will define selected termon written tests to a Student Training Standard (B)

4. Given lecture/discussion/demonstration, the student will run selected electrodesusing the weave bead welding technique to a Student Training Standard (3c/B)

5. Given lecture/discussion on the A.W.S. mild steel shielded metal arc welding(SMAW) code, the student will describe given electrodes on a written and/or oralexam to a Student Training Standard (B)

6. Given a lecture/discussion on direct current polarity for welding, the student willadjust the circuit to a given polarity to a Student Training Standard (2b/B)

7. Given a lecture/discussion/demonstration on correctly starting and stoppingwelding with SMAW electrodes (including low hydrogen electrodes), the studentwill produce weld beads having hot starts and correctly ended with filled weldcraters to a Student Training Standard (2b/13)

8. Given a lecture/discussion on the five basic joint configurations, the student, givena joint name, will draw the joint to a Student Training Standard (2b/B)

9. Given a lecture/discussion/demonstration, the student will weld using largediameter electrodes: 3/16", 1/4" and 5/16" in the flat and horizontal positions to aStudent Training Standard (2b/B)

10. Given a lecture/discussion/demonstration, the student will weld single "V" groovewelds in the 1G position using stringer bead and weave bead techniques to aStudent Training Standard (2b/B)

63

11. Given a lecture/discussion/demonstration, the student will use air carbon arccutting (ACA) equipment to gouge and repair single "V" groove welds

12. Given lecture/discussion/demonstration, the student will weld fillets on sheet steelin the .063" to .125" thickness range using S.M.A.W. to a Student TrainingStandard (2b/B)

13. Given lecture/discussion/demonstration, the student will weld various jointconfigurations of thick to thin material using given electrodes to a StudentTraining Standard (2b/B)

B. Oxy-Fuel Cutting1. All material used in class will be prepared using oxy-fuel cutting. Grinding will be

kept to an absolute minimum2. Oxy-fuel skill will be graded on improvement over class. Students are expected to

hold cutting to plus or minus 1/16"


Textbook: Basic Arc Welding (SMAW), by Ivan H. Griffen, Edward M. Roden, Charles W.Briggs; Delmar

Supplies:1. Safety glasses (which will be worn at all times in the welding lab)2. Welder's helmet with Nos. 10-11 filter lenses3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Wire brush6. Large pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (shade 5-6)9. Coarse half-round file






64

LECTURE OUTLINE:Lecture Topics

Review Arc Welding & Oxy-FuelSafety

Welding Techniques and Heat InputWeld DiscontinuitiesPrepare a Welding ProcedurePrepare a Welding ProcedureTurn in Welding ProcedureQualify ProcedureReview for Final

Text Reference Page Contact Hrs.

Unit 8, 14 and 15Unit 20Unit 23Unit 19Unit 18Unit 8Unit 24Unit 26

LAB OUTLINE:Lab Topics

Run Selected Electrodes Using the Weave BeadWelding TechniqueAdjust the Circuit to a Given PolarityProduce Weld Beads Having Hot Starts andCorrectly Ended With Filled Weld CratersWeld Using Large Diameter Electrodes:3/16", 1/4" and 5/16" in the Flat andHorizontal PositionsWeld Single "V" Groove Welds in the 1GPosition Using Stringer Bead and Weave BeadTechniquesUse Air Carbon Arc Cutting (ACA) Equipment toGouge and Repair Single "V" Groove WeldsWeld Fillets on Sheet Steel in the .063" to .125"Thickness Range Using SMAWWeld Various Joint Configurations of Thick to ThinMaterial Using Given Electrodes

Total Lecture Hours

1

242223

2

18

Contact Hrs.

Total Lab Hours



1. -Wear Personal Protective EquipmentList personal protective equipment forList personal protective equipment forList personal protective equipment forList personal protective equipment forList personal protective equipment forList personal protective equipment forList personal protective equipment for

a.b.c.d.e.f.

g.

shielded metal arc weldinggas tungsten arc weldinggas metal arc weldingflux cored arc weldingsubmerged arc weldingoxy-fuel cuttingplasma arc cutting

65

h. List personal protective equipment for air carbon arc gougingi. During shop work, wear applicable personal protective equipment at all










C. BASIC SHIELDED METAL ARC WELDING (SMAW) AND OXY-FUEL GASCUTTING1. Define Selected Welding Terms Per AWS A3.0

a. Define arc welding process termsb. Define standard joint terminologyc. Define common weld discontinuitiesd. Name welding equipment, supply and consumables.e. Define common shop terms including proper equipment namesf. Define material terms

g. Define common metallurgy terms2. Describe AWS Code for Mild Steel Electrodes

a. List, describe and defineb. List low hydrogen electrodesc. List iron powder electrodesd. Describe electrode by welding position

6$

e. Describe electrode by current and polarityf. Describe electrode by penetration


4. Use Correct Start and Stop Techniques for SMAW Electrodesa. Describe and demonstrate start for non-low hydrogen SMAW electrodeb. Describe and demonstrate stop for non-low hydrogen SMAW electrodes

with filled cratersc. List reasons for the importance of low hydrogen in weld metald. Explain the reason for low hydrogen starts and stops and how they work



6. Strike an Arc, Run Continuous Stringer Beada. Stand and position oneself correctlyb. Operate welding helmetc. Verbally warn others of intent to arc weldd. Strike an arce. Weld with stringer bead techniquef. Perform weld tie in's to make continuous bead

7. Weld Using Weave Techniquea. Maintain required weld qualityb. Maintain proper weld width uniformlyc. Maintain proper travel speedd. Match correct oscillation for various electrodese. Match applications to weave techniques, as they applyf. List the advantages and disadvantages of weave techniquesg. List the advantages and disadvantages of stringer techniquesh. Perform weld using weave techniquei. Concentrate on dwell times at edges of weld pool

8. Weld Multi-Layer Buildupa. Weld a dam to outline area being welded for each layerb. Apply each layer neatly, straight and with good fusion throughoutc. Chip slag after each passd. Weld passes which over lap to crown of last weld beade. Demonstrate control of bead height

9. Set Up and Shut Down Oxy-Fuel Equipmenta. Follow manufacturer's recommended practiceb. Inspect equipment and work area for safetyc. Assemble oxy-fuel equipmentd. Open fuel gas cylinder 1/2 turne. Open oxygen as cylinder all the way

6 7

f. Adjust fuel gas and oxygen working pressure per manufacturer'srecommendation

g. Purge lines one at a time. One second for each 10 feet of hose length10. Cut Steel Plate Using Oxy-Fuel Equipment

a. Make manual free hand straight line cutsb. Cut manually straight lines using cutting jibc. Bevel plate with manual oxy-fuel equipmentd. Manually cut blind holes in thick materiale. Manually cut sheet metal with minimal distortion

11. Low Hydrogen Starts and Stopsa. Use low hydrogen electrodesb. Strike arc 1" from craterc. Immediately shorten arc length and back up quickly previous weld crater.

Holding short arc lengthd. Pause at the crater when it is filled. Continue welding

12. Design Welded Jointsa. List the names and draw side views of the five basic joint configurationsb. List the names and draw side views of the variations of groovesc. List the names and draw side views of the T-Joint variationsd. List the name of the type of weld made in each joint

13. Weld V Groove With Backing in Flat Positiona. Use oxy-fuel equipment to bevel 3/8" steel to 37 1/2°b. Clean bevel face with grinder as requiredc. Cut 1/4" material for backing strip

14. Use Air Carbon Arc to Excavate a Partial Pen Groove Welda. Locate root of weldb. Demonstrate control of depth of cutc. Demonstrate control of width of cutd. Use air carbon arc cutting equipment to make shallow gouges (about 1/8"

deep max.) with stringer techniquee. Make gouges of uniform depthf. Observe discontinuities as gouging proceedsg. Gouge until some weld metal is reached

15. Gouge to Excavate Defecta. Given the area of suspected discontinuity its size and depth; air carbon 1

gouge using multi pass and stringer gouge to defect depthb. Measure to make sure excavation is at proper location and depthc. Use air carbon arc equipment. Shape excavation to ensure proper fusiond. Clean area of all scale, carbon etc.

16. Make X-Ray Quality Weld Repair on a 2F Position T Joint 1/2" Platea. Check area for safetyb. Set SMAW equipment current and polarity for 1/8" E7018c. Attach work leadd. Preheat and maintain interpass temperature as requirede. Weld first pass paying special attention to low hydrogen techniquesf. Grind the weld start and stop to remove cold lap and lack of fusiong. Weld the second pass starting from opposite endh. Repeat starts and stops until weld is completed

i. Inspect and submit for non-destructive testing RT or UT17. Produce Fillet Weld on Sheet Steel T Joints

a. Check work area for safetyb. Position steel in a T joint and tack at endsc. Place T joint in the 2F position with a spacer on each end so the workpiece

is not touching the work bench. This stops any heat sink.d. Produce fillet welds equal in size to the thickness of the smallest joint

member. With SMAW E6011, E6013 and GMAW and GTAWe. Visually inspect to AWS D1.3

18. Produce Fillet Welds on T Joints Made Up of Both Thick and Thin Joint MembersUsing SMAWa. Inspect work area for safetyb. Set SMAW equipment for type and size of electrode and job requirementsc. Fit up and tack jointd. Weld joint keeping the major portion of heat on thicker sectione. Clean and visually inspect

19. Use Correct Starts for Low Hydrogen Electrodesa. List the AWS steel electrode code last digit designation for low hydrogen

electrodeb. Set up SMAW e.g. and check for safetyc. Using E7018 strike an arc 1" down the path of welding from where you

wish to startd. Shorten arc length immediately to low hydrogen arc lengthe. Quickly approximate 3 times as fast as welding travel speed back up the

one inch to the point at which the weld should startf. Stop movement at starting point and allow weld pool to formg. Begin normal travel speed once weld pool reaches required diameter

20. Use Correct Stops for Low Hydrogen Electrodesa. Use E7018 to begin weld correctlyb. Stop increase weld travel speedc. Observe weld pool when weld pool size decreases to smallest possible size,

break off arc by pulling away21. Weld Using Large Diameter SMA Electrodes


fight arc blow)e. Bring lead angle back to normal as the weld progresses 2" along jointf. Begin changing the lead angle to a push or forehand angle of 70° to 80° 3"

from the end of jointg. Make multi-pass fillet welds with smooth contourh. Visually inspect to insure


a. Sweep table top and floor in work areab. Clean equipment and toolsc. Return tools to proper storage area

69

d. Dispose of waste materials and scrap in their proper receptacle containersand storage areas

e. Store all unused materials to their respective storage areas
















70

2. Writing: Communicates thoughts, ideas, information, and messages inwriting and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. completes written assignments and reportsb. completes written essay questions










Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility.- Exerts a high level of effort and perseveres towards goal


71

WLD 11204/072496

2. Self-Esteem: Believes in own self -worth and maintains a positive view ofselfa. achievement in class objectivesb. ability to learn very challenging tasksc. successfully completes tasks with quality results



problems

72


COURSE SYLLABUS

ELECTRICAL WELDING CIRCUITS

73


ELECTRICAL WELDING CIRCUITS

Lecture hours/week: 2 Lab hours/week: 0 Credit hours: 2

COURSE DESCRIPTION:

Theory and operation of the welding power source, welding circuits and welding equipment.

PREREQUISITES: NONE

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Give a lecture/discussion on welding shop safety and safety in using welding and cutting

equipment2. Given a lecture/discussion on welding processes used in industry, students will identify

tools and equipment used in various welding processes3. Given a lecture/discussion on oxy-acetylene cutting torch system, students will identify

various types of equipment and set up oxy-fuel cutting stations in shop4. Exam - on topics covered in first three weeks. Given lecture and discussions on single and

two stage regulators, students will be able to identify various types of regulators used inindustry

5. Given a lecture/discussion on various types of alternate fuel gasses, students will identifyand understand advantages and disadvantages in using propane, butane, MAPP andacetylene and natural gas

6. Given a lecture/discussion on Shield Metal Arc Welding process, students will identifyvarious parts and controls on Shield Metal Arc Welding power supplies and performvarious tasks in setting up welding system in weld shop

7. Given a lecture/discussion on stick electrodes, students will identify various electrodesused in industry today

8. Given a lecture/discussion on duty cycle of a welding power supply, students will be ableto understand and explain the various duty cycles used

9. (Mid-Term Examination) on topics discussed and explained on first half of course10. Given a lecture/discussion on Gas Metal Arc Welding power sources, students will

identify difference between GMAW & SMAW power supplies11. Given a lecture/discussion on wire feed systems & MIG welding guns, students will

perform various tasks in shop, set-up wire feed systems, change liners, tips, nozzles inMIG guns

12. Given a lecture/discussion on Argun based shielding gases, students will identifyadvantages and disadvantages of using Argun gas vs. CO2 gas

13. Given a lecture/discussion on various types of GMAW welding electrodes, student willidentify differences between flux cored electrode and solid GMA welding electrode

74

14. Given a lecture/discussion on stainless steel and aluminum welding, students will identifyvarious grades of stainless steel and aluminum used in industry, as well as identify variousprocesses used to weld them

15. Given a lecture/discussion on Gas Tungsten Arc Welding power sources, students willidentify theory and be able to perform various tasks in shop setting up TIG welding.system, as well as be able to change tungstens, collets, etc. and power cables on TIG torch

16. Given a lecture/discussion on plasma arc cutting systems, students will identify theory andbe able to assemble systems, change various parts on plasma cutting torch, includingchanging of tips, electrodes, gear shields and power cables

17. (Final Examination) on all topics discussed and explained throughout the course


Textbook: Welding Processes and Power Sources, by Edward R. Pierre

Supplies: None required






Safety Chapters 2, 4 4Identify tools Chapters 2, 4 2Set up and identify oxy-fuel Chapters 2, 4 3Regulators: identify and applications Chapters 5, 6, 7, 9, 10, 11, 12 3Fuel gas applications Chapters 5, 6, 8, 9, 10, 11, 12 3

SMAW equipment process and set up Chapters 15, 20 3

Electrode codes and specification 3Understand and explain duty cycle Chapters 7, 20 3Review 3 Chapters 17, 18, 19, 20 3

GMAW compared to SMAW; List GMAWequipment Chapters 13, 14, 15, 16, 18, 20 3

75

GTAW process and shielding gasapplications GTAW and GMAWPlasma arc applicationsPlasma arc applications and invertersReview

Chapter 20Chapter 22

Total Lecture Hours


23

36


1. Wear Personal Protective Equipmenta. List personal protective equipment for shielded metal arc weldingb. List personal protective equipment for gas tungsten arc welding

List personal protective equipment for gas metal arc weldingList personal protective equipment for flux cored arc weldingList personal protective equipment for submerged arc weldingList personal protective equipment for oxy-fuel cuttingList personal protective equipment for plasma arc cuttingList personal protective equipment for air carbon arc gougingDuring shop work, wear applicable personal protective equipment at alltimes

2. Identify Safety RulesList environmental safety precautions i.e. fume control, radiation reflection,electrical consideration, fire hazards and control, etc.List equipment safety rules, i.e., ventilation, grounding, duty cycleUtilize safety when handling and storing compressed gas cylindersList general shop safety rulesMaintain safe conditions in workstation. Student demonstrate by settingup safe workstation.

f. Comply with confined space entry safety proceduresg. Conduct a safety inspection of the student work areah. Conduct a safety inspection of the welding shopi. Conduct a safety inspection of the gas storage area

3. Familiarize Oneself With Safety at FacilityAttend safety tour of welding labReceive a safety orientation lectureAvoid fumes through proper ventilation and good practicesOperate exhaust systemPractice electric safety with respect to weldingProtection from radiation with an understanding of personal safetyequipment and conductDemonstrate a knowledge of fire prevention and protection for welding indress and conduct

c.

d.e.fg.h.i.

a.

b.c.

d.e.

a.

b.c.

d.

g.

h. List welding and cutting safety rulesi. Demonstrate oxy-fuel gas cutting safety

76

j. Demonstrate arc welding safetyB. DEMONSTRATE TECHNICAL COMMUNICATION

1. Use Standard American Welding Standard Society Welding Terms and Definitionsa. Follow verbal instructionsb. Follow written detailsc. Prepare time and job cards (reports & records)

C. GAS METAL ARC WELDING (GMAW)1. Assemble GMAW Gun and Name All Parts

a. Install adapter for particular brand of wire feederb. Insert liner of correct size until liner gasket meets adapter and tighten allen

screwc. Screw on gas defuser and tighten allen screwd. Install contact tipe. Install gas nozzlef. Adjust gun for tip to work distance



D. GAS TUNGSTEN ARC WELDING (GTAW)1. Understand Technical Aspects of GTAW

a. List advantages and disadvantages of GTAWb. List five applications where GTAW or PAW are better suitedc. List give applications which are more suited to SMAW than GTAWd. Compare and contrast GTAW and plasma arc welding (PAC)e. List by name the parts of a GTAW torchf. Describe each control by name and function on the pulsed TIG system such

as a Lincoln square wave 350 or Miller syncrowave 351 P.g. Assemble the GTAW torch, water cooler and GTAW machine

E. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist



77

















78

3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractionsd. computes angles .






3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb.. understands step by step procedure to produce given tasks



C Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal


2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in class objectivesb. ability to learn very challenging tasks

79

WLD 10404/072496

c. successfully completes tasks with quality results3. Sociability: Demonstrates understanding, friendliness, adaptability,

empathy, and politeness in group settingsa. working together with other students in safetyb. working together with other students in learningc. assigned to group projects and assignments


problems

So


COURSE SYLLABUS

READING WELDING BLUEPRINTS

81


READING WELDING BLUEPRINTS


COURSE DESCRIPTION:

Introduction to blueprint reading for welding emphasizes basic interpretation of blueprints,welding symbols and basic sketching.

PREREQUISITES: NONE

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to read blueprints, involvingweldments which includes:1. Interpretation of drawing lines, views & symbols2. Interpretation of welding symbols3. Understanding of converting metric dimensions & English dimensions and vice versa4. Understanding of specifications per print5. Understanding of assembly procedure per print6. Understanding variation in types of welding prints7. Visualization of final weldment8. Recognizing of flaws and mistakes on drawings


Textbook: Print Reading for Welders, 2nd EditionSymbols for Welding & Non-Destructive Testing, A.W.S., A2.4-84




Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:1. satisfactorily perform on written, oral, and practical examinations2. satisfactorily perform on outside assignments including writing assignments3. contribute to class discussions4. maintain attendance per current policy

8,?


Meaning of views and lines (includessymbols and nomenclature, visualizationof objects and drawings of views &sections) 6Size description (includes units ofmeasurement, dimensioning tolerances) 4Conversions (metric to English unitsand vice versa) 5

Basic elements of welding prints(includes drawing systems, types offabrication prints, title blocks, revisions,variations in different company standards,parts materials lists) 6Threaded fasteners and machine terminology 4Basic welding terms 4Welding symbols 6Pitfalls to avoid and errors to watch for onwelding 4Prints (why things work on paper but not inpractice) 4Working with codes on welding prints 4Review 7



After the successful completion of this course the student will be able to:A. DEMONSTRATE TECHNICAL COMMUNICATION

1. Use Standard American Welding Standard Society Welding Terms and Definitionsa. Follow verbal instructionsb. Follow written detailsc. Prepare time and job cards (reports & records)

B. INTERPRET WELDING DRAWINGS1. Review Print Notes, Dimensions and Symbols

a. Interpret AWS standard welding symbolsb. List essential components found in general notes on drawingc. Determine acceptable tolerances for drawingd. Determine code requirements, process and procedure requirements

required by drawinge. Interpret 3 view drawingsf. Work from drawings, prints and sketches

2. Identify Basic Layouts of Drawings3. Interpret Drawing Lines and Views4. Interpret Welding Symbols5. Convert Metric to English

83

6. Understand Print Specifications7. List Assembly Procedure Per Print8. Understand Various Types of Welding Prints9. Visualize Final Weldment From Print10. List Flaws and Errors on Drawings11. Interpret AWS Standard Welding Symbols

C. MATHEMATICAL SKILLS1. Determine Measurements and Angles

a. Add fractionsb. Subtract fractionsc. Multiply fractionsd. Divide fractionse. Change fractions to decimalsf. Change decimals to fractionsg. Solve simple algebraic equationsh. Solve simple trigonometric equationsi. Convert English measurement to Metricj. Convert Metric measurement to English


The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies and a three-part foundation of skills and personalqualities that are needed for solid job performance.




B. Interpersonal: Works with others1. works well with all members of classInformation: Acquires and uses information

=1. reading assignments contain material students are responsible for which areto be obtained no where else

2. lecture notes and research paper3. this is demonstrated by student's ability to complete projects


technology and system

84

2. as the students learn welding skills they learn to monitor and correct theirown performance

E. Technology: Works with a variety of technologies1. projects require selection of various technologies2. all projects require applied technology3. constant trouble shooting is required




2. Writing: Communicates thoughts, ideas, information, and messages inwriting and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. creates drawingsb. creates sketchesc. creates prints with symbols, headings, notes and technical

information3. Arithmetic/Mathematics: Perform basic computations and approaches

practical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractionsd. computes angles





2. Problem Solving: Recognizes problems and devises and implements planof actiona. recognizes finished print from isometric drawingsb. makes daily accommodations to stay on schedule

3. Seeing Things In the Mind's Eye: Organizes, and processes symbols,pictures, graphs, objects, and other informationa. visualizes final part, weldment, structure from drawings

85

WLD 10504/072496

b. interprets prints with symbols, headings, notes and technicalinformation

c. understands welding symbols4. Knowing How to Learn: Use efficient learning techniques to acquire and

apply new knowledge and skillsa. demonstrate mastery of basic skillsb. recognizes information to solve specific problems


C Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort and perseveres towards goal


2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in class objectivesb. attains quality resultsc. successfully completes tasks with quality results



problems

86


COURSE SYLLABUS

ADVANCED SMAW AND CUTTING I

87


ADVANCED SMAW AND CUTTING I


COURSE DESCRIPTION:


In Advanced SMAW and Cutting I the student will practice SMAW in various positions. Thestudent will gain proficiency in oxy-fuel cutting and air carbon arc cutting and gouging. Thestudent will also study selected technical areas related to welding. Special emphasis will be placedon weld size and AWS structural Welding Steel Code.

PREREQUISITES: Basic Arc/Gas Welding I and II

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. The student will demonstrate a thorough knowledge of safety at all times to the instructors

requirements2. Using SMA welding equipment and E6010 the student shall weld single and multi pass T

joints in 1F, 2F, 3F and 4F positions using the stringer bead technique to a StudentTraining Standard of 2b/B

3. Using SMA welding equipment and E6010 the student shall weld single and multi pass Tjoints in all positions using appropriate techniques and producing weld sizes directed bythe instructor to D1.1 code requirements

4. Using air carbon arc gouging equipment the student will excavate a portion of a multi passfillet weld as directed by the instructor and repair the excavated portion to a StudentTraining Standard of 2b/B

5. Using oxy-fuel cutting equipment the student shall cut straight lines, blind holes, bevelsand sheet metal to a Student Training Standard of 2b/B


Textbook: The Procedure Handbook of Arc Welding, by James F. Lincoln; Arc WeldingFdn.

Supplies:1. Safety glasses (which will be worn at all times in the welding lab)2. Welder's helmet with a No. 10, 11, and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes (no gym shoes)

88

8. Gas welding and cutting goggles (lens shade 5)

Special Equipment:1. Leather sleeves or jacket. Flame retardant clothing may be substituted at the

student's discretion.2. Bastard cut 'A round file3. Welding hat4. Safety glasses5. Text6. Flashlight







Safety Review Introduction 2Advanced Welding Techniques

Inspection 1

Low Hydrogen Starts and Stops 1

Effects of HydrogenLow Hydrogen TechniquesHorizontal WeldingAdvanced Cutting Techniques 1

Vertical Welding Techniques withE6010 1



Mid-Term Exam and PracticalEvaluation 89

Overhead Welding with E6010 2Visual Inspection of WeldingOverhead Welding Techniques with

E7018 2Weld DiscontinutiesVertical Welding Techniques with

E7018 1

Defect Removal with Air CarbonGouging


Defect Removal with Air CarbonGouging

Overhead Welding with E7018 1

Overhead Welding with E7018 1

Oxy-Fuel Gas Beveling 1

AWS D1.1 Single V Groove 3GQualification Practice Test

Oxy-Fuel Gas Beveling 1

AWS D1.1 Single V Groove 3GQualification Practice Test

Final ExamTotal Lecture Hours 18


Advanced Welding Techniques InspectionLow Hydrogen Starts and StopsEffects of HydrogenLow Hydrogen TechniquesHorizontal WeldingAdvanced Cutting TechniquesVertical Welding Techniques with E6010Vertical Welding Techniques with E6010Vertical Welding Techniques with E6010Overhead Welding with E6010Visual Inspection of WeldingOverhead Welding Techniques with E7018Weld DiscontinutiesVertical Welding Techniques with E7018Defect Removal with Air Carbon GougingVertical Welding Techniques with E7018Defect Removal with Air Carbon GougingOverhead Welding with E7018Overhead Welding with E7018Oxy-Fuel Gas BevelingAWS D1.1 Single V Groove 3G Qualification

Contact Hrs.

90

Oxy-Fuel Gas BevelingAWS D1.1 Single V Groove 3G Qualification

Total Lab Hours









equipment and conduct

g. Demonstrate a knowledge of fire prevention and protection for welding indress and conduct

h. List welding and cutting safety rulesi. Demonstrate oxy-fuel gas cutting safetyj. Demonstrate arc welding safety


a. Follow verbal instructions

b. Follow written detailsc. Prepare time and job cards (reports & records)

C. BASIC SHIELDED METAL ARC WELDING (SMAW) AND OXY-FUEL GASCUTTING1. Weld Using Large Diameter SMA Electrodes


fight arc blow)e. Bring lead angle back to normal as the weld progresses 2" along jointf. Begin changing the lead angle to a push or forehand angle of 70° to 80° 3"

from the end of jointg. Make multi-pass fillet welds with smooth contourh. Visually inspect to insure

D. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING1. Weld Single V Groove Welds With Open Roots From One Side


Use tight arc length and keyhole technique to produce a well fused rootbead extending 1/16" above the plate.

j. Weld chipped side slag and the root bead is wire brushedk. Fill the balance of the groove with 3/32", 1/8" and/or 5/32" E7018 using

the stringer bead technique1. Visual test finished weld and root face bends evaluated to AWS D1.1

criteria2. Weld Various Diameters of Pipe to Plate

a. Inspect area for safetyb. Place plate flat on welding tablec. Place 3" pipe vertically on top of plate and tacked in placed. Leave weld coupon in the 2F fixed positione. Apply a 3/8" fillet weld using 1/8" E7018 and a stringer bead techniquef. Visually inspect weld to AWS D1.1g. Fill pipe with water for 24 hoursh. Check for leak

3. Produce SMAW Pipe - 5G Positiona. Measure the pipeb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"

9.

f. Tack the single V groove pipe joint with a 3/32" root openingg. Place the joint in the 5G fixed position, using an 1/8" E6010 and a keyhole












technique1. Visually inspect weld on the root and face sides to ASME Section 9

93

m. Remove four guided bend specimens from 2:00, 4:00, 8:00 and 10:00positions prepared and two & eight are root bend specimens. Four & tenare face bend specimens. Guided bend tests are evaluated to ASMESection 9 criteria

6. Produce SMAW Pipe - 5G Positiona. Measure the pipe andb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Weld pipe

g. Tack the single V groove pipe joint with a 3/32" root openingh. Place the joint in the 5G fixed position, using an 1/8" E6010 and a keyhole






technique ,

h. Weld the root pass upward producing a root weld which is well fused andhas a 1/16" weld reinforcement above the plate

i. Chip slag and wire brush. Grind any lack of fusion and/or high spotsj. Weld balance of groove upward with 3/32" or 1/8" E7018 using the




equipmentb. Clean bevel face and a 3/32" root face is applied using a hand held grinderc. Set welding condition to weld open roots

94

d. Tack pipe nipples together to form a V groove with a 1/8" root openinge. Place pipe in the 5G fixed position. The root pass is welded and cleaned by


9. Interpret Welding Proceduresa. Identify processb. Name joint designc. List base materiald. Give dimensions for root treatmente. Name electrode size and type being used

List filler material (if required), classification and specificationg. Identify shielding gas - type and mixtureh. List pre and post heat and interpass temperaturei. Describe initial and interpass cleaningj. Describe technique which is usedk. Produce single or multiple pass weld1. Choose current typem. Set current amperagen. Set current polarityo. Set voltage

E. QUALITY INSPECTIONS1. Perform Visual Checks




The following.activities will be performed by each student for successful completion of thiscourse:



B. Interpersonal: Works with others

95

1. lab and class requires team work and cooperation to complete projects2. safety requires mutual cooperation, vigilance and communicationInformation: Acquires and uses information1. reading assignments contain material students are responsible for which are












5. Speaking: Organizes ideas and communicates orallya. responds to oral quiZ questionsb. capsulizes lecture information


considers risks, and evaluates and chooses best alternativea. identifies personal goals

96

WLD 12104/072496

b. identifies actions required to accomplish personal goals2. Problem Solving: Recognizes problems and devises and implements plan

of actiona. answer assigned questionsb. makes daily accommodations to stay on schedule









problems

g 7


a 1

3's3 Vt N ,-,

;,4

)..-,... '

COURSE SYLLABUS

ADVANCED SMAW AND CUTTING II

98


ADVANCED SMAW AND CUTTING II


COURSE DESCRIPTION:


In this nine week course, the student will advance his technique in out of position shielded metalarc welding. Welding of transitional joints and open groove welds will be stressed. Safety is ourprimary concern.


COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Weld Single V Groove welds with backing 1G, 2G, 3G and 4G positions to AWS D1.12. Weld Single V Groove welds with open roots in the 1G, 2G, 3G and 4G positions to

ASME IX3. Using Air Carbon Arc Gouging back gouge the above groove weld4. Extra credit welds as directed by the instructor

Oxy-Fuel Gas Cutting Manual1. Cut steel to given size + 1/16 - 02. Bevel steel to given angle


Textbook: Procedure Handbook of Arc Welding, by The Lincoln Electric Co.

Supplies:1. Safety glasses (which will be worn at all times in the welding lab)2. Welder's helmet with Nos. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (lens shade 5)


student's discretion

99

2. Bastard cut 1/2 round file3. Welding hat4. Safety glasses5. Text6. Flashlight







Safety ReviewSpecial Protective ClothingWelding ContainersAbrasionWeld QualityAppearance, WeldDistortion Cause and CureCause of CrackingCarbon EquivalentSMAW ProcessFast FreezeFill Freeze Fast FillLow HydrogenArc BlowPorosity, Weld Spatter, Undercut,

Joint RestraintReview for Final ExamFinal Exam

Text Reference Page Contact Hrs.Pages 13.3, 4; 13.5-4; 15.1-1---5 2Pages 15.1-2Pages 15.1-3 2Pages 13.7-19, 20Pages 11.1-3Pages 6.2-17, 18; 9.4-3, 8Pages 3.1-1---4Pages 2.5-5, 3.1-4---19

Pages 5.1-1---4Pages 5.5-2---4; 6.2-1; 6.2-7, 8Pages 5.5-2---4; 6.2-1Pages 6.2-10, 11; 12Pages 3.2-1---3

1

21

221

1

1

1

1

Pages 6.2-13, 18, 19 1


100


Weld single V groove welds with backing 1G,2G, 3G and 4G positionsWeld single V groove welds with open roots inthe 1G, 2G, 3G and 4G positionsUsing Air Carbon Arc Gouging, back gouge theabove groove weldsCut steel to given size + 1/16 - 0Bevel steel to given angle

Contact Hrs.

Total Lab Hours



1. Wear Personal Protective EquipmentList personal protective equipment for shielded metal arc weldingList personal protective equipment for gas tungsten arc weldingList personal protective equipment for gas metal arc weldingList personal protective equipment for flux cored arc weldingList personal protective equipment for submerged arc weldingList personal protective equipment for oxy-fuel cuttingList personal protective equipment for plasma arc cuttingList personal protective equipment for air carbon arc gougingDuring shop work, wear applicable personal protective equipment at alltimes

2. Identify Safety Rulesa. List environmental safety precautions i.e. fume control, radiation reflection,

electrical consideration, fire hazards and control, etc.List equipment safety rules, i.e., ventilation, grounding, duty cycleUtilize safety when handling and storing compressed gas cylindersList general shop safety rulesMaintain safe conditions in workstation. Student demonstrate by settingup safe workstation.

f. Comply with confined space entry safety proceduresg. Conduct a safety inspection of the student work areah. Conduct a safety inspection of the welding shopi. Conduct a safety inspection of the gas storage area

3. Familiarize Oneself With Safety at FacilityAttend safety tour of welding labReceive a safety orientation lectureAvoid fumes through proper ventilation and good practicesOperate exhaust systemPractice electric safety with respect to welding

a.b.c.

d.e.f.

g.h.i.

b.c.d.e.

a.

b.

c.d.e.

101

f. Protection from radiation with an understanding of personal safetyequipment and conduct

g. Demonstrate a knowledge of fire prevention and protection for welding indress and conduct

h. List welding and cutting safety rulesi. Demonstrate oxy-fuel gas cutting safetyj. Demonstrate arc welding safety



C. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING1. Weld Single V Groove Welds With Open Roots From One Side


Use tight arc length and keyhole technique to produce a well fused rootbead extending 1/16" above the plate.

j. Weld chipped side slag and the root bead is wire brushedk. Fill the balance of the groove with 3/32", 1/8" and/or 5/32" E7018 using

the stringer bead technique1. Visual test finished weld and root face bends evaluated to AWS D1.1

criteria2. Weld Various Diameters of Pipe to Plate

a. Inspect area for safetyb. Place plate flat on welding tablec. Place 3" pipe vertically on top of plate and tacked in placed. Leave weld coupon in the 2F fixed positione. Apply a 3/8" fillet weld using 1/8" E7018 and a stringer bead techniquef. Visually inspect weld to AWS D1.1

g. Fill pipe with water for 24 hoursh. Check for leak




102

E. QUALITY INSPECTIONS1. Perform Visual Checks



The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies and a three part foundation of skills and personalqualities that are needed for solid job performance.












listens and speaks.

103

1. Reading: Locates, understands, and interprets written information inprose and in documents such as manuals, graphs, and schedulesa. reads and comprehends homework assignmentsb. reads complicated written instruction











104

WLD 12204/072696

Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.1. Responsibility: Exerts a high level of effort andperseveres towards goal





problems

1 O 5


COURSE SYLLABUS

MIG, TIG AND BRAZING I

106


MIG, TIG AND BRAZING I


COURSE DESCRIPTION:


Welding, braze welding and brazing of various joints using GTAW, GMAW, FCAW, SAW andOFW.


COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Given lecture/discussion and demonstration of braze welding, the student will braze weld a

square groove joint in 1/8" steel to a 2b/A Training Standard2. Given lecture/discussion and demonstration, the student will braze weld a corn cob project

on 3" standard wall carbon steel pipe to a 2b/A Training Standard3. Given lecture/discussion and demonstration on brazing (hard solder) the student will braze

a lap joint in 1/8" steel to a la/A Training Standard4. Given lecture/discussion and demonstration on GTAW, the student will assemble a

GTAW torch to within given specs5. Given lecture/discussion and demonstration on GTAW, the student will weld a square

groove in 1/8" steel to a 2b/A Training Standard6. Given lecture/discussion and demonstration on GTAW, the student will weld a square

groove in aluminum to a 2b/A Training Standard7. Given lecture/discussion and demonstration on GTAW, the student will weld a square

groove in 1/8" stainless steel to a 2b/A Training Standard8. Given lecture/discussion and demonstration GTAW, the student will weld a T joint to a

2b/A Training Standard9. Given lecture/discussion and demonstration on GMAW, the student will assemble a

GMAW gun to within given specs10. Given lecture/discussion and demonstration on GMAW, the student will weld a square

groove of 1/8" carbon steel to a 2b/A Training Standard11. Given lecture/discussion and demonstration on GMAW, the student will weld a T joint

1/8" to a 3c/B Training Standard12. Given lecture/discussion and demonstration on GMAW, the student will weld a square

groove of 1/4" carbon steel to a 2b/A Training Standard13. Given lecture/discussion and demonstration on GMAW, the student will weld a T joint

1/4" carbon steel to a 2b/A Standard Training

107

14. Given lecture/discussion and demonstration on FCAW, the student will weld groove aweld of 1/4" carbon steel to a 2b/A Training Standard

15. Given lecture/discussion and demonstration on FCAW, the student will weld a 3/8 fillet on1/2" carbon steel to a 2b/A Training Standard

16. Given lecture/discussion and demonstration on SAW, the student will weld a T joint towithin given specs


Textbook: Welding Processes & Power Sources, by Ed Pierre

Supplies:1. Safety glasses - which will be worn at all times in the welding lab2. Welders hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes (no gym shoes)8. Gas welding and cutting goggles (lens shade 5)


student's discretion.2. Bastard cut 1/2 round file3. Welding hat4. Text5. Safety glasses6. Flashlight






108


Braze weld a square groove joint 1

Braze weld a corn cob project 1

Braze a lap joint in 1/8"1

Assemble a GTAW torch and nameparts 1

Weld a square groove with GTAW in1/8" steel 1

Weld a square groove in aluminumwith GTAW to a 2b/A 1

Weld a square groove in 1/8" stainlesssteel with GTAW 1

Weld a T joint to a 2b/A TrainingStandard stainless steel withGTAW 1

Weld a T joint to a 2b/A TrainingStandard carbon steel withGTAW 1

Weld a T joint to a 2b/A TrainingStandard Aluminum withGTAW 1

Assemble a GMAW gun 1

Weld a square groove of 1/8" carbonsteel with GMAW 1

Weld a T joint 1/8" with GTAW 1

Weld a square groove of 1/4" carbonsteel with GMAW 1

Weld a T joint 1/4" carbon steel withGMAW 1

Weld groove a weld of 1/4" carbonsteel with FACW

1

Weld a 3/8 fillet on 1/2" carbon steelwith FCAW 1

Weld a T joint on carbon steel with SAW 1



Braze weld a square groove joint in 1/8" steelBraze weld a corn cob project on 3" standard wall

carbon steel pipeBraze a lap joint in 1/8" steelAssemble a GTAW torch to within given specsWeld a square groove with GTAW in 1/8" steel

Contact Hrs.

109

Weld a square groove in aluminum with GTAWWeld a square groove in 1/8" stainless steel

with GTAWWeld a T joint with GTAW in stainless steelWeld a T joint with GTAW in carbon steelWeld a T joint with GTAW in aluminumAssemble a GMAW gun to within given specsWeld a square groove of 1/8" carbon steel

with GMAWWeld a T joint in 1/8" with GMAWWeld a square groove of 1/4" carbon steel

with GMAWWeld a T joint of 1/4" carbon steel with GMAWWeld groove a weld of 1/4" carbon steel with FACWWeld a 3/8 fillet on 'A" carbon steel with FCAWWeld a T joint on carbon steel with SAW

Total Lab Hours



1. Wear Personal Protective EquipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentList personal protective equipmentDuring shop work, wear applicabletimes

2. Identify Safety Rules

a.

b.c.d.e.

f.

g.h.i.

for shielded metal arc weldingfor gas tungsten arc weldingfor gas metal arc weldingfor flux cored arc weldingfor submerged arc weldingfor oxy-fuel cuttingfor plasma arc cuttingfor air carbon arc gougingpersonal protective equipment at all


b. List equipment safety rules, i.e., ventilation, grounding, duty cyclec. Utilize safety when handling and storing compressed gas cylindersd. List general shop safety rulese Maintain safe conditions in workstation. Student demonstrate by setting


3. Familiarize Oneself With Safety at Facility

110

a. Attend safety tour of welding labb. Receive a safety orientation lecturec. Avoid fumes through proper ventilation and good practicesd. Operate exhaust systeme. Practice electric safety with respect to weldingf. Protection from radiation with an understanding of personal safety





C. GAS METAL ARC WELDING (GMAW)1. Assemble GMAW Gun and Name All Parts

a. Install adapter for particular brand of wire feederb. Insert liner of correct size until liner gasket meets adapter and tighten alien

screwc. Screw on gas defuser and tighten alien screwd. Install contact tipe. Install gas nozzlef. Adjust gun for tip to work distance



4. Weld With GMAW Using Spray Transfera. Choose the correct shielding gas and flow rate for the given application,



material thickness5. Weld With GMAW Using Short Circuit Transfer


111



6. Weld With GMAW Using Globular Transfera. Choose the correct shielding gas and flow rate for the given application,



material thickness7 Weld T Joints on Carbon Steel Using GMAW Equipment


carbon steelc. Adjust the welding parameters for this taskd. Tack a T joint using GMAWe. Weld 1/4" fillet welds in 2F position using string bead techniquef. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.1g. Change weld size once proficiency is reached on 6. to 3/16" go to step 1

then 5/16"8. Weld Single V Groove With GMAW

a. Inspect the work area and equipment for safetyb. Use oxy-fuel cutting equipment cut and bevel two pieces of 3/8" X 3"

X15" with 30° bevel anglec. Use grind to clean the bevel face and apply a 3/32" root faced. Adjust GMAW equipment to run .035" ER70S-3 with 75% Argon 25%

CO2 shielding gas at a flow rate of 30 cubic feet per hour at approximately16 arc volts and 100 amps

e. Using GMAW the two pieces are tacked together to produce a single Vgroove with a 1/8" root opening

f. Weld root upwardsg. Visual inspect finished root bead after wire brushing. Any high spots and

lack of fusion are removed by grinding.h. Using GMAW and upward Z weave technique the second weld pass is

applied. The electrode is moved from one root pass to the other with aslight upward motion

i. Complete the second pass using GMAW and upward Z weave techniquej. Using GMAW and on upward Z weave technique the third pass is welded.

The electrode is moved from the left toe of the second pass to the right toeon back. Each weave is accompanied by a slight upward motion. Becareful not to burn away the bevel edges

k. Make fourth and final pass with the same technique.1. The electrode is weaved from one bevel edge to anotherm. Visually inspect weld. The root reinforcement shall extend 1/16" above the

base metal, have good fusion etc. The weld face shall meet D1.1requirements and have parallel and straight edges

112

D. GAS TUNGSTEN ARC WELDING (GTAW)1. Weld Fillet - 2F Horizontal Position

a. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40



2. Weld on 1/8" Material and 100% Penetrationa. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set up GTAW for high frequency start, direct current electrode negative,


d. Cut stainless steel and grind a .30" bevel on edgese. Place two pieces of stainless steel in the backing purge in the 1G position


f. Weld achieving full penetration while adding .062" ER308-L. Make a 2pass weld

g. Remove from backing purge and visually inspect for full penetration. Nocolor on welded surfaces except straw is permitted. The back or root ofthe weld shall be silver.










113


The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "Alt/ERICA 2000 REPORT" that all students should developa newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies and a three-part foundation of skills and personalqualities that are needed for solid job performance.












listens and speaks.I. Reading: Locates, understands, and interprets written information in


2. Writing: Communicates thoughts, ideas, information, and messages inwriting and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. completes written assignments and reports

b. completes written essay questions3. Arithmetic/Mathematics: Perform basic computations and approaches

practical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractionsd. computes angles


S. Speaking: Organizes ideas and communicates orallya. responds to oral quiz questionsb. capsulizes lecture information




3. Seeing Things In the Mind's Eye: Organizes, and processes .symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. understands step by step procedure to produce given tasks





2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in class objectives

115

WLD 12304/072696

b. ability to learn very challenging tasksc. successfully completes tasks with quality results



problems

ha


COURSE SYLLABUS

MIG, TIG AND BRAZING II

117


MIG, TIG AND BRAZING II


COURSE DESCRIPTION:

Position welding brazing various joints using GTAW, GMAW, FCAW, SAW, and oxy/fuel.

PREREQUISITES: Basic Arc/Gas Welding I and II; MIG, TIG and Brazing I

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Given lecture/discussion on braze welding butt joints, student will set up and braze weld a

lap joint to a 1G, 2G, 3G & 4G positions to a "2b/A" Training Standard2. Given lecture/discussion on braze welding T joints, student will set up and braze weld a T

joint in 1F, 2F, 3F & 4F positions to a "2b/A" Training Standard3. Given lecture/discussion on brazing T joint, student will set up and braze T joints to a

"2b/A" Training Standard4. Given lecture/discussion on soldering T joints, student will set up and soft solder tee joints

to a "2b/A" Training Standard5. Given lecture/discussion in GTAW T joint, student will set up and weld T joints in carbon

steel, stainless steel and aluminum in 2F, 3F & 4F positions to a "2b/A" Training Standard6. Given lecture/discussion in GTAW grooves, student will set up and weld grooves in

carbon steel, stainless steel and aluminum in 1G, 3G & 4G positions to a "2b/A" TrainingStandard

7. Given lecture/discussion in FCAW T joint, student will set up and weld edge joints incarbon steel in 2F, 3F & 4F positions to a "2b/A" Training Standard

8. Given lecture/discussion in GMAW fillet weld, student will set up and GMAW fillet weldsin mild steel to a "2 b/A" Training Standards

9. Given lecture/discussion in GMAW butt joint, student will set up and GMAW butt jointsin mile steel to a "2b/A" Training Standards


Textbook: Welding Processes and Power Sources, by Edward Pierre

Supplies:1. Safety glasses - which will be worn at all times in the welding lab2. Welders hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves

118

4. Chipping hammer5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes (no gym shoes)8. Gas welding and cutting goggles (lens shade 5)


student's discretion.2. Bastard cut 'A round file3. Welding hat4. Text5. Safety glasses6. Flashlight







Braze weld a lap joint in the 1G, 2G,3G and 4G Positions 2

Braze weld a T joint in 1F, 2F, 3F,and 4F Positions 2

Braze T joints 2Soft solder lab joints 2Weld T joints in carbon steel, stainless

steel and aluminum in 2F, 3Fand 4F Positions with GTAW 2

Weld grooves in carbon steel, stainlesssteel and aluminum in 1G, 3G 1 1 9

and 4F Positions with GTAWWeld T joints in carbon steel in 2F, 3F

and 4F Positions with FCAWWeld fillet welds in mild steel in 2F, 3F

and 4F Positions with GMAWWeld butt joints in mild steel in 2G, 3G

and 4G Positions with GMAW

Total Lecture Hours


Braze weld a lap joint in the 1G, 2G, 3G and4G Positions

Braze weld a T joint in 1F, 2F, 3F, and 4F PositionsBraze T jointsSoft solder lab jointsWeld T joints in carbon steel, stainless steel and

aluminum in 2F, 3F and 4F Positions with GTAWWeld grooves in carbon steel, stainless steel and

aluminum in 1G, 3G and 4F Positions with GTAWWeld T joints in carbon steel in 2F, 3F and 4F

Positions with FCAWWeld fillet welds in mild steel in 2F, 3F and 4F

Positions with GMAWWeld butt joints in mild steel in 2G, 3G and 4G

Positions with GMAW

2

2

2

2

18

Contact Hrs.

Total Lab Hours



1.

2.

Wear Personal Protective EquipmentList personal protective equipment for shielded metal arc weldingList personal protective equipment for gas tungsten arc weldingList personal protective equipment for gas metal arc weldingList personal protective equipment for flux cored arc weldingList personal protective equipment for submerged arc weldingList personal protective equipment for oxy-fuel cuttingList personal protective equipment for plasma arc cuttingList personal protective equipment for air carbon arc gougingDuring shop work; wear applicable personal protective equipment at alltimes

Identify Safety Rules

a.b.c.d.e.f.

g.h.i.









C. PIPE WELDING - SMAW1. Weld Open Root Pipe - 2G Position

a. Use 1/8" E6010b. Cut and ground pipe ends to single bevel edge preparations of 37 1/2° c.Fit


c. Weld root pass to ASME Section 9 requirementsd. Clean weld pass by chipping slag, wire brushing and grinding where

necessary to assure a clean, well fused weld deposite. Weld remainder of the groove using E7018 with the stringer bead

techniqueD. GAS METAL ARC WELDING (GMAW)

1. Assemble GMAW Gun and Name All Partsa. Install adapter for particular brand of wire feederb. Insert liner of correct size until liner gasket meets adapter and tighten allen

screwc. Screw on gas defuser and tighten allen screwd. Install contact tip

121

e. Install gas nozzlef. Adjust gun for tip to work distance

2. Weld With GMAW Using Short Circuit Transfera. Choose the correct shielding gas and flow rate for the given application,



material thickness3. Weld With GMAW Using Pulsed Spray Transfer




4. Weld Multi-Pass Fillet Welds - All Positionsa. Inspect area for safetyb. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces of

carbon steelc. Adjust the welding parameters for this taskd. Tack a T joint using GMAWe. Weld the second pass with electrode centered at the bottom toe of the first



5. Weld Multi-Pass Fillet Welds - 3F Vertical Positiona. Inspect area for safetyb. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces of

carbon steelc. Adjust the welding parameters for this taskd. Position the T joint in the 3F position for vertical welding. Weld a 1/4"

fillet in the vertical position, upward using a slight weave techniquee. Weld the second pass with electrode centered at the bottom toe of the first



6. Weld Multi-Pass Fillet Welds - 4F Overhead Positiona. Inspect area for safetyb. Use oxy-fuel gas cutting equipment cut two 1/4" X 3" X 10" pieces of

carbon steelc. Adjust the welding parameters for this taskd. Place the T joint in the 4F overhead position approximately at eye levele. Weld a 1/4" fillet weld (wire brush weld after each pass)f. Visual test welds for size, equal legs, acceptable weld profile to AWS D1.1

122

7. Weld Pipe - 1G Positiona. Fit up and tack pipe according to given tolerancesb. Adjust wire feeder drive systemc. Adjust shielding gas system and flow rated. Adjust GMAW gun to allow proper tip to work distance and gas coveragee. Set welding condition for spray transfer - Wire Feed Speedf. Set welding condition for short circuit transfer - Voltageg. Set welding condition for short circuit transfer - Tip to Work Distanceh. Weld using roll welding technique

E. GAS TUNGSTEN ARC WELDING (GTAW)1. Weld Fillet - 2F Horizontal Position

a. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40



2. Weld Fillet - 3F Vertical Positiona. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40


d. Cut stainless steel to .050" X 2" X 10"e. Fit up and tack a T joint and place in the 3F vertical positionf. Weld a .050" fillet weld using .045" ER308-Lg. Visually inspect joint for burn through, weld size and workmanship

3. Weld Fillet - 4F Overhead Positiona. Conduct safety inspection of the area and equipmentb. Weld on 304 stainless steelc. Set GTAW for high frequency start, direct current electrode negative, 40


d. Cut stainless steel to .050" X 2" X 10"e. Fit up and tack a T joint and place in the 4F overhead positionf. Weld a .050" fillet weld using .045" ER308-Lg. Visually inspect joint for burn through, weld size and workmanship



b. Cut stainless steel and grind a .30" bevel on edges

123

c. Place two pieces of stainless steel in the backing purge in the 3G positionfixture with a 0" gap. Using 100% Argon as the backing gas at a flow rateof 15 cubic feet per hour








e. Remove from backing purge and visually inspect for full penetration. Nocolor on welded surfaces except straw is permitted. The back or root ofthe weld shall be silver.

6. Weld Pipe Open Root Passes All Positions Using GTAWa. Fit up and tack weld pipe to within procedure tolerances. (Set up GTAW

equipment for welding carbon steel)b. Prepare tungsten for given procedurec. Set up GTAW torch for given procedured. Set current for proceduree. Adjust shielding gas flow ratef. Weld root using free hand technique and using the walking the cup methodg. Apply second pass using weave

F. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist




The Secretary's Commission on Achieving Necessary Skills (SCANS), U S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.

124

SCANS is made up of five competencies and a three-part foundation of skills andpersonalqualities that are needed for solid job performance.




B. Interpersonal: Works with others1. lab and class requires team work and cooperation to complete projects2. safety requires mutual cooperation, vigilance and communicationInformation: Acquires and uses information1. reading assignments contain material students are responsible for which are






IL FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,




3. Arithmetic/Mathematics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractions

125

d. computes angles4. Listening: Receives, attends to, interprets, and responds to verbal

messages and other cuesa. attends lecturesb. interprets complicated verbal instructions





3. Seeing Things In the Mind's Eye: Organizes, andprocesses symbols,pictures, graphs, objects, and other informationa. understands both written and verbal instructionsb. understands step by step procedure to produce given tasks







126

WLD 12404/072696


problems

127


COURSE SYLLABUS

BASIC WELDING METALLURGY

128


BASIC WELDING METALLURGY


COURSE DESCRIPTION:

Students will learn about the physical and metallurgical properties of carbon steels and howwelding will effect these properties.

PREREQUISITES: NONE

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. The student will learn the meaning of selected metallurgical terms2. The student will identify selected types of carbon steels and describe the process used in

their manufacture3. The student will demonstrate his knowledge of selected carbon steels by correctly

describing their properties and how these properties are changed by welding temperatures4. The student will describe the effect of selected alloying element on carbon steel5. The student will identify basic concepts relating to the heat effected zone (HAZ) caused

when welding different types of carbon steels6. The student will take Macro cross sections of selected welds, etch them and inspect the

weld interior and heat effected zone


Textbook: Welding Metallurgy, by Linnert

Supplies: None




Method of Evaluation: A student's grade will be based on multiple measures of performance.The assessment will measure development of independent critical thinking skills and will includeevaluation of the student's ability to:

129

1. perform the manipulative skills of the craft as required to satisfactorily completelaboratory assignments

2. apply theory to laboratory assignments3. satisfactorily perform on written, oral, and practical examinations4. satisfactorily perform on outside assignments including writing assignments5. contribute to class discussions6. maintain attendance per current policy7. follow all shop rules and safety regulations as stated in the laboratory manual


Define selected metallurgical terms 6Identify selected types of carbon steels

and describe process used intheir manufacture 6

Describe mechanical and physicalproperties of selected steelsand describe changes causedby welding 6

Describe the effect of selected alloyingelements on carbon steel 6

Identify basic concepts relating to theheat effected zone (HAZ) causedwhen welding different types ofcarbon steel 6

Make macro cross sections of selectedwelds, etch them and inspect theweld interior and heat effect zone 6



Make macro cross sections of selected welds, etch themand inspect the weld interior and heat effect zone

Total Lab Hours


Contact Hrs.


1. Wear Personal Protective Equipmenta. List personal protective equipment for shielded metal arc weldingb. List personal protective equipment for gas tungsten arc weldingc. List personal protective equipment for gas metal arc welding

130

d. List personal protective equipment for flux cored arc weldinge. List personal protective equipment for submerged arc weldingf. List personal protective equipment for oxy-fuel cuttingg. List personal protective equipment for plasma arc cuttingh. List personal protective equipment for air carbon arc gougingi. During shop work, wear applicable personal protective equipment at all










C. BASIC WELDING METALLURGY1. Become Conversant With Common Metallurgical Terms

a. Describe structure of metalsb. Describe critical temperaturec. Define allotropic transformationd. Describe eutectic pointe. Read phase diagramf. Define liquidusg. Define solidus

131

h. Define annealingi. Define normalizej. Define heat treatmentk. Define stress relieve1. Define delta ferritem. Define ferriten. Define austeniteo. Define pearliteP. Define cementiteq. Define tempering

2. Describe the Properties of Various Types of Steela. Define low carbon steelb. Define medium carbon steelc. Define high carbon steeld. Define very high carbon steele. Define cast ironf. 'Define low alloy high strengthg. Define alloy steelsh. Define stainless steelsi. Define non ferrous metals

3. List Various Alloys and Their Effect When Combined With Steela. Draw and describe substitutional alloys.b. Draw and describe interstitial alloysc. Draw and describe multi phase alloysd. Define harden abilitye. Work carbon equivalent equations

4. Describe the Effect Welding Has on Properties of various Types of Carbon Steelsa. Sketch crystal structures of metalsb. Sketch face centered cubicc. Sketch body centered cubicd. Sketch hexagonal close packed

5. Identify Basic Concepts Relating to the Heat Affected Zonea. Define micro structureb. Define macro structurec. Define cold workingd. Define elongated grain structuree. Define grain boundaryf. Define grain growthg. Define fusion zoneh. Define fusion interface


a. Sweep table top and floor in work areab. Clean equipment and toolsc. Return tools to proper storage area

4 n

Dispose of waste materials and scrap in their proper receptacle containersand storage areas

e. Store all unused materials to their respective storage areas


The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies anda three-part foundation of skills and personalqualities that are needed for solid job performance.












prose and in documents such as manuals, graphs, and schedulesa. reads and comprehends homework assignments

133

b. reads complicated written instruction2. Writing: Communicates thoughts, ideas, information, and messages in

writing and creates documents such as letters, directions, manuals,reports, graphs, and flow chartsa. completes written assignments and reportsb. completes written essay questions










Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.

134

WLD 11304/072496

I. Responsibility: Exerts a high level of effort andperseveres towards goalattainmenta. develops good work ethic




problems

135


COURSE SYLLABUS

INDIVIDUAL WELDING PROBLEMS I

136


INDIVIDUAL WELDING PROBLEMS 1


COURSE DESCRIPTION:


This is a self-directed study course. In other words the student is responsible for meeting allobjectives which the student will create. In this course the student will prepare a written proposalidentifying specific problems to be addressed and submit it to the instructor for approval by theend of the second week of the semester. This contract must be written. This contract will stateclass meeting time and required written work. Upon approval, the contract will be signed by thestudent and the instructor. The contract will then be attached to the syllabus. Students mustmake arrangements with instructor prior to signing up for class.


COURSE OBJECTIVES:

After the successful completion of this course the student will be able to state the objective of thecourse and show evidence of completion of stated objectives.1. Identify and define welding problems2. Organize tasks and develop procedures for accomplishment3. Develop independent work habits4. Variable technical skills depending on individual problems5. Acquire speed in work habits6. Use safe work procedures

Major Concepts:1. Self-direction2. Problem solving3. Variable technical content4. Develop speed5. Develop safety


Textbook: None. Library assignments are substituted for required text.

Supplies: Specific supplies are dictated by objective.1. Safety glasses - which will be worn at all times in the welding lab2. Welders hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer

13 7

5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (lens shade 5)






Self-Directed StudyContact Hrs.

Total Lab Hours


80


1.

2.

Wear Personal Protective EquipmentList personal protective equipment for shielded metal arc weldingList personal protective equipment for gas tungsten arc weldingList personal protective equipment for gas metal arc weldingList personal protective equipment for flux cored arc weldingList personal protective equipment for submerged arc weldingList personal protective equipment for oxy-fuel cuttingList personal protective equipment for plasma arc cuttingList personal protective equipment for air carbon arc gougingDuring shop work, wear applicable personal protective equipment at alltimes

Identify Safety Rulesa. List environmental safety precautions i.e. fume control, radiation reflection,

electrical consideration, fire hazards and control, etc.b. List equipment safety rules, i.e., ventilation, grounding, duty cyclec. Utilize safety when handling and storing compressed gas cylinders

a.

b.c.

d.e.f.

g.h.

i.

138

d. List general shop safety rulese. Maintain safe conditions in workstation. Student demonstrate by setting







C. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist




The Secretary's Commission on Achieving Necessary Skills (SCANS), U. S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students should develop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies and a three-part foundation of skills and personalqualities that are needed for solid job performance.


139













3. Arithmetic/Mathenzatics: Perform basic computations and approachespractical problems by choosing appropriately from a variety ofmathematical techniquesa. converts fractions to decimalsb. converts decimals to fractionsc. adds, subtracts, multiplies and divides fractionsd. computes angles

4. Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. interprets complicated verbal instructions


140

WLD 13704/072696



2. Problem Solving: Recognizes problems and devises and implements planof actiona. self-directed course requires problem solvingb. makes daily accommodations to stay on schedule



5. Reasoning:. Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. understands welding terminologyb. interprets different welding techniquesc. chooses processes to accomplish specific tasksd. chooses procedures to accomplish specific tasks


attainmenta. develops good work ethicb. self-directed study - student responsible for self-management

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in creating personal objectivesb. ability to learn very challenging tasks independentlyc. successfully completes tasks with quality results

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. self-directed study requires adaptability working independently


problemsd. self-direction requires integrity and honesty to keep working and

not misrepresent quality results

141


COURSE SYLLABUS

INDIVIDUAL WELDING PROBLEMS II

142


INDIVIDUAL WELDING PROBLEMS II


COURSE DESCRIPTION:


This is a self-directed study course. In other words the student is responsible for meeting allobjectives which the student will create. In this course the student will prepare a written proposalidentifying specific problems to be addressed and submit it to the instructor for approval by theend of the second week of the semester. This contract must be written. This contract will stateclass meeting time and required written work. Upon approval, the contract will be signed by thestudent and the instructor. The contract will then be attached to the syllabus. Students mustmake arrangements with instructor prior to signing up for class.


COURSE OBJECTIVES:

After the successful completion of this course the student will be able to the objective of thecourse and show evidence of completion of stated objectives.1. Identify and define welding problems2. Organize tasks and develop procedures for accomplishment3. Develop independent work habits4. Variable technical skills depending on individual problems5. Acquire speed in work habits6. Use safe work procedures

Major Concepts:1. Self direction2. Problem solving3. Variable technical content4. Develop speed5. Develop safety


Textbook: None. Library assignments are substituted for required text.

Supplies: Specific supplies are dictated by objective.1. Safety glasses - which will be worn at all times in the welding lab2. Welders hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer

143

5. Wire brush6. Pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (lens shade 5)





LAB OUTLINE:Lab Topic

Self-Directed StudyContact Hrs.

Total Lab Hours


80


1.

2.

Wear Personal Protective EquipmentList personal protective equipment for shielded metal arc weldingList personal protective equipment for gas tungsten arc weldingList personal protective equipment for gas metal arc weldingList personal protective equipment for flux cored arc weldingList personal protective equipment for submerged arc weldingList personal protective equipment for oxy-fuel cuttingList personal protective equipment for plasma arc cuttingList personal protective equipment for air carbon arc gougingDuring shop work, wear applicable personal protective equipment at alltimes

Identify Safety Rulesa. List environmental safety precautions i.e. fume control, radiation reflection,

electrical consideration, fire hazards and control, etc.b. List equipment safety rules, i.e., ventilation, grounding, duty cyclec. Utilize safety when handling and storing compressed gas cylinders

a.

b.c.d.e.

f.

g.h.i.

144

d. List general shop safety rulese. Maintain safe conditions in workstation. Student demonstrate by setting




dress and conducth. List welding and cutting safety rulesi. Demonstrate oxy-fuel gas cutting safetyj Demonstrate arc welding safety



C. MAINTAIN HOUSEKEEPING1. Clean Work Area and Insure That No Safety Hazards Exist






i4














4. 'Listening: Receives, attends to, interprets, and responds to verbalmessages and other cuesa. interprets complicated verbal instructions


WLD 13804/072696



2. Problem Solving: Recognizes problems and devises and implements planof actiona. self-directed course requires problem solvingb. makes daily accommodations to stay on schedule





attainmenta. develops good work ethicb. self-directed study - student responsible for self-management

2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in creating personal objectivesb. ability to learn very challenging tasks independentlyc. successfully completes tasks with quality results

3. Sociability: Demonstrates understanding, friendliness, adaptability,empathy, and politeness in group settingsa. self-directed study requires adaptability working independently


problemsd. self-direction requires integrity and honesty to keep working and

not misrepresent quality results

147


COURSE SYLLABUS

BASIC PIPE WELDING I

148


BASIC PIPE WELDING I


COURSE DESCRIPTION:


Shielded metal Arc Welding (SMAW) of pipe in the 2G and 5G positions. At the entry level ofBasic Pipe Welding I, students are expected to pass AWS D1.1 qualification tests on 1/2" carbonsteel plate in the 3G and 4G positions using SMAW.

PREREQUISITES: Basic Arc/Gas Welding I and II; Advanced SMAW andCutting I and II

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. The student using oxy-fuel gas cutting, will manually bevel pipe samples2. The student will fit up and tack weld single V groove open root pipe joints to within given

tolerances3. The student will weld the pipe joint in the 1G, 2G and 5G positions to ASME IX


Textbook: Pipe Welding Procedures, by Hoobasar Rampaul

Supplies:1. Safety Glasses - which will be worn at all times in the welding lab2. Welder's hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping Hammer5. Wire Brush6. Pliers or vice grips7. Appropriate clothing and shoes8. Gas welding and cutting goggles (lens shade 5)

Special Equipment:1. Leather sleeves or jacket. Flame retarding clothing may be substituted at the

student's discretion.2. Bastard cut 1/2 round file3. Welding hat4. Safety glasses

1 ,19

5. Text6. Flashlight







Safety review and special equipmentPreparation/tacking of pipe jointWelding root pass 1/8" E6010Welding hot pass and cover passTest, each student will bend test for

a gradeHorizontal position and stringer

beadsBegin final text, practicalPractical test and review and written

testFinal test, written

Text Reference Page

Section 1, 16 and 4Section 2, 5Section 7

Section 9


Preparation/tacking of pipe jointWelding root pass 1/8" E6010Welding hot pass and cover passHorizontal position and stringer beads

Total Lecture Hours

Contact Hrs.1

222

2

22

22

18

Contact Hrs.

Total Lecture Hours

150'













151

C. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING1. Weld Various Diameters of Pipe to Plate

a. Inspect area for safetyb. Place plate flat on welding tablec. Place 3" pipe vertically on top of plate and tacked in placed. Leave weld coupon in the 2F fixed positione. Apply a 3/8" fillet weld using 1/8" E7018 and a stringer bead techniquef. Visually inspect weld to AWS D1.1g. Fill pipe with water for 24 hoursh. Check for leak










positions prepared and two & eight are root bend specimens. Four & ten

are face bend specimens. Guided bend tests are evaluated to ASMESection 9 criteria





5. Produce SMAW Pipe - 5G Positiona. Measure the pipe andb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Weld pipeg. Tack the single V groove pipe joint with a 3/32" root openingh. Place the joint in the 5G fixed position, using an 1/8" E6010 and a keyhole





D. PIPE WELDING - SMAW1. Produce End Preparations


153

2. Fit and Tack Weld Pipea. Cut and single bevel pipe to 37 1/2°b. Ground bevel face and touch up to within tolerancesc. Check that pipe ends are square within given tolerancesd. Prepare root face within given tolerancese. Align pipe to within given tolerancesf. Set root opening to within given tolerancesg. Tack pipe according to welding procedure specification - maintaining root






tolerancesd. Weld root pass to ASME Section 9 requirementse. Fill balance of the groove with E6010 using the stringer technique to

ASME Section 9 requirements5. Weld Open Root Pipe - 5G Position

a. Fit and tack weld pipe to within tolerancesb. Place pipe in the 5G positionc. Weld the rootpass using 1/8" E6010 to ASME Section 9 requirementsd. Grind the finished root pass to remove high spots and any slag at weld toese. Weld the remainder of the groove using 3/32" and/or 1/8" E7018 using the

stringer bead technique to ASME Section 9 requirements6. Pass Guided Bond Tests Per ASME Section 9

a. Remove bend samples from pipe at the 10, 2, 8 & 4 o'clock positionsb. If the material is 3/8" or thinner 10 o'clock and 8 o'clock receive root bends

and 2 o'clock and 4 o'clock receive face bends. If the pipe wall thickness isover 3/8" side bends shall be performed on all samples.

c. Weld remainder of pipe in 1G position using E7018d. Perform low hydrogen starts and stopse. Weld using stringer bead techniquef. Weld using weave techniqueg Chip slag wire brush and grind as necessary to assure clean weld deposits

7 Weld Open Root Pipe - 2G Positiona. Use 1/8" E6010b. Cut and ground pipe ends to single bevel edge preparations of 37 1/2° c.Fit


c. Weld root pass to ASME Section 9 requirements

1

d. Clean weld pass by chipping slag, wire brushing and grinding wherenecessary to assure a clean, well fused weld deposit

e. Weld remainder of the groove using E7018 with the stringer beadtechnique





The Secretary's Commission on Achieving Necessary Skills (SCANS), U S. Department ofLabor, has identified in its "AMERICA 2000 REPORT" that all students shoulddevelop a newset of competencies and foundation skills if they are to enjoy a productive, full and satisfyinglife. These are in addition to the Technical Workplace Competencies required by industry.SCANS is made up of five competencies anda three-part foundation of skills and personalqualities that are needed for solid job performance.









1. projects require selection of various technologies2. all projects require applied technology

155

3. constant trouble shooting is required

IL FOUNDATION SKILLSA. Basic Skills: Reads, writes, performs arithmetic and mathematical operations,












156

WLD 14004/072696







problems

157


COURSE SYLLABUS

BASIC PIPE WELDING II

158


BASIC PIPE WELDING II


COURSE DESCRIPTION:


Shielded metal arc welding (SMAW) of pipe in the 6G positions. At the entry level of Basic PipeWelding II, students are expected to pass AWS D1.1 qualification tests on 6" schedule 40 carbonsteel pipe in the 2G and 5G positions using SMAW.

PREREQUISITES: Basic Arc/Gas Welding I and 111; Advanced SMAW andCutting I and II; Basic Pipe Welding I

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Advanced welding skills2. Pass ASME guided bend tests:

a. root bendsb. face bendsc. side bends

Major Concepts:1. Pipe welding2. Pipe cutting and weld joint preparation3. Safety4. Understand the ASME pipe test5. Attendance6. Punctuality


Textbook: Pipe Welding Procedures, by Hoobasar Rampaul

Supplies:1. Safety glasses - which will be worn at all times in the welding lab2. Welder's hood with a No. 10, 11 and 12 filter lens3. Heavy gauntlet style welder's gloves4. Chipping hammer5. Pliers or vice grips6. Appropriate clothing and shoes7. Gas welding and cutting goggles (lens shade 5)

159


student's discretion.2. Bastard cut 1/2 round file3. Welding hat4. Safety glasses5. Text6. Flashlight







Preparation/tacking of pipe joint6G position

Welding root pass 1/8" E60106G position

Welding intermediate and coverpass with low hydrogenprocedures. Write aprocedure.

Test, each student will bend testfor a grade

Begin reviewBegin final test, practicalPractical test and review for

written testFinal test, written

Text Reference Page Contact Hrs.Sections Review 16 and 4

Section 15 Review 5

Section 13 Review 6

Section 11Section 12Section 14

Total Lecture Hours

160

2

3

3

222

22

18


Preparation/tacking of pipe joint in 6G positionWelding root pass 1/8" E6010 in 6G positionWelding intermediate and cover pass with low

low hydrogen procedures

Contact Hrs.

Total Lab Hours










dress and conducth. List welding and cutting safety rules;

6

i. Demonstrate oxy-fuel gas cutting safetyJ. Demonstrate arc welding safety



C. ADVANCED SHIELDED METAL ARC WELDING (SMAW) AND CUTTING1. Produce SMAW Pipe - 6G Position

a. Measure the pipeb. Mark the cut line with a wrap around and soapstonec. Cut the bevel using oxy-fuel gas equipmentd. Clean the bevel face with a grinder, remove all oxide and smooth bevel facee. Use the grinder to add a root face of from 3/32" to 1/8"f. Tack the single V groove pipe joint with a 3/32" root openingg. Place the joint in the 6G fixed position, using an 1/8" E6010 and a keyhole

techniqueh. Weld the root pass upward producing a root weld which is well fused and

has a 1/16" weld reinforcement above the platei. Chip slag and wire brush. Grind any lack of fusion and/or high spotsj. Weld balance of groove upward with 3/32" or 1/8" E7018 using the




equipmentb. Clean bevel face and a 3/32" root face is applied using a hand held grinderc. Set welding condition to weld open rootsd. Tack pipe nipples together to form a V groove with a 1/8" root openinge. Place pipe in the 5G fixed position. The root pass is welded and cleaned by


D. PIPE WELDING - SMAW1. Produce End Preparations


2. Fit and Tack Weld Pipea. Cut and single bevel pipe to 37 1/2°b. Ground bevel face and touch up to within tolerances

i62

c. Check that pipe ends are square within given tolerancesd. Prepare root face within given tolerancese. Align pipe to within given tolerancesf. Set root opening to within given tolerancesg. Tack pipe according to welding procedure specification - maintaining root






tolerancesd. Weld root pass to ASME Section 9 requirementse. Fill balance of the groove with E6010 using the stringer technique to

ASME Section 9 requirements5. Weld Pipe Open Root Passes All Positions Using GMAW

a. Set up GMAW equipmentb. Adjust wire feeder drive systemc. Adjust shielding gas system and flow rated. Adjust GMAW gun to allow proper tip to work distance and gas coveragee. Set welding condition for short circuit transfer - Wire Feed Speedf. Set welding condition for short circuit transfer - Voltageg. Set welding condition for short circuit transfer - Tip to work Distanceh. Weld root using a string bead technique

6. Weld Pipe With Backing Using FCAW-Ga. Bevel pipe endsb. Touch up bevel face with grinderc. Fit and tack backing ring to one pipe endd. Fit other pipe over backing ringe. Adjust gap and tack in placef. Adjust shielding gas flowg. Adjust wire feed systemh. Adjust power source to procedure specificationi. Set wire feed speed to procedure specificationj. Adjust voltage to procedure specificationk. Adjust inductance to procedure specification1. Adjust GMAW gun for tip to work distance and shielding gasm. Weld according to procedure specification


a. Sweep table top and floor in work area

1 6 3

b. Clean equipment and toolsc. Return tools to proper storage aread. Dispose of waste materials and scrap in their proper receptacle containers















prose and in documents such as manuals, graphs, and schedules

164

a. reads and comprehends homework assignmentsb. reads complicated written instruction









4. Knowing How to Learn: Use efficient learning techniques to acquire andapply new knowledge and skillsa. tasks require individualized practice to develop learning skillsb. recognizes information to solve specific problemsReasoning: Discovers a rule or principle underlying the relationshipbetween two or more objects and applies it when solving a problema. understands welding terminologyb. interprets different welding techniquesc. chooses processes to accomplish specific tasksd. chooses procedures to accomplish specific tasks

Personal Qualities: Displays responsibility, self-esteem, sociability, self-management, and integrity and honesty.

165

WLD 14104/072696

1. Responsibility: Exerts a high level of effort and perseveres towards goalattainmenta. develops good work ethic




problems

166


COURSE SYLLABUS

VISUAL INSPECTION OF WELDS

167


VISUAL INSPECTION OF WELDS


COURSE DESCRIPTION:


Using visual inspection, the student will determine ifa weld meets given code requirements insize, configuration, profile, process, acceptable discontinuities, print requirements, procedurerequirements, qualification requirements, etc.

PREREQUISITES: NONE

COURSE OBJECTIVES:

After the successful completion of this course the student will be able to:1. Given a lecture/discussion on the Metric measuring system as it pertains to welded

structures, the student will be able to convert standard measurements to metricmeasurements as they pertain to welding of the various joints to a 3BM training standard

2. Given a lecture/discussion on joint design, the student will identify the parts to a weldedjoint to a "C" Training Standard

3. Given a lecture/discussion on joint design, the student will use various tools to give adescription of the joint and detail to a "C" Training Standard of 3

4. Given a lecture/discussion on weld bead types, the student will identify selected weldsamples to a "C" Training Standard

5. Given a lecture/discussion and demonstration on welding processes, the student willidentify welding processes to a Student Training Standard (3BM)

6. Given a lecture/discussion on visual weld defects, the student will identify welddiscontinuities to a 3B/B Training Standard

7. Given a lecture/discussion on selected codes, the student will classify asacceptable/unacceptable selected weld samples to a 3B/C Training Standard

8. Given a lecture/discussion on the procedure for weld inspection the student will explainand document a weld inspection to a 3B/B Training Standard

9. Given a lecture/discussion on weld size and weld gauges the student will gage variouswelds to a Student Training Standard (3BM)

10. The student will produce a 10 page written report on visual welding inspection as it relatesto a gien welding process


Textbook: American Welding Society. Welding Inspection, 2nd Edition, Miami, FL, 1980

168







Convert standard measurements tometric measurements 4

Identify parts to a welded joint 4Use various tools to give a description

of the joint 4Identify selected weld samples 4Identify welding processes 12Identify weld discontinuities 8Classify as acceptable/unacceptable

selected weld samples 6Explain and document a weld inspection 4Gage various welds 2Produce a ten page written report



After the successful completion of this course the student will be able to:A. QUALITY INSPECTIONS

1. Perform Visual Checksa. Identify common welding defectsb. List terms for common welding defectsc. Rate common welding defects in order of severityd. Name size of limitations for defects given under various codes

169
















170












2. Self-Esteem: Believes in own self-worth and maintains a positive view ofselfa. achievement in class objectivesb. ability to learn very challenging tasks

171

WLD 16004/072696

c. successfully completes tasks with quality results3. Sociability: Demonstrates understanding, friendliness, adaptability,

empathy, and politeness in group settingsa. working together with other students in safetyb. working together with other students in learningc. assigned to group projects and assignments


problems

1 72

APPENDIX A - INDUSTRY COMPETENCY PROFILES

The following pages contain the individual Competency Profiles for each of the companiessurveyed by the MAST development center for the occupational specialty area of . TheseCompetency Profiles/skill standards were used to develop the curriculum for the pilot program.

The participation of the companies as partners in the MAST effort is greatly appreciated. Eachcompany has approved the use of its logo in MAST materials. None of the participatingcompanies shall be held responsible or liable for any of the findings of the project.

173

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OD

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BE

ST C

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AV

AIL

AB

LE

197

-1'

4, ;

WE

LD

ER

....

inte

rpre

t dra

win

gs; c

ut a

nd p

repa

re m

ater

ials

; lay

out a

nd f

itup

wor

k; s

elec

t and

set

up w

eldi

ng d

evic

es; a

nd p

erfo

rm w

eldi

ngop

erat

ions

nec

essa

ry to

pro

duce

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requ

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Set

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men

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B-3

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Bill

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proc

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ntif

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StandardREFRIGERATION COMPANY

2050 North Ruby StreetMelrose Park, Illinois 60160-1133

708 345 5400 fax 345 3513

January 8, 1996

Richard A. KukacAssociate DeanBusiness and Industrial TechnologyMoraine Valley Community College10900 S. 88th AvenuePalos Hills, Illinois 60465-0937

Dear Dean Kukac,

Standard Refrigeration is pleased to be included in yourcurriculum documentation.

We would be happy to assist you in your efforts to developa standards program nationally.

Please do not hesitate to contact us for any consideration.

cc: Jeff LevinDavid Goldberg

Regards,

h llip LucasOperations Manager

APPENDIX B - PILOT PROGRAM NARRATIVE

What follows is a narrative of the pilot program which was conducted for this particularoccupational specialty.

207

August 7, 1996

Mr. Wallace Pe ltonSite CoordinatorTexas State Technical College3801 Campus DriveWaco, TX 76705

Re: Testing of Welding Students in the Pilot Program

Dear Mr. Pelton:

Every effort was made to fulfill the expectations of the MAST Pilot Project with respect to thepre- and post-testing process of Moraine Valley Community College's Welding students.However, in order to fully appreciate the test outcomes, one must be familiar with MoraineValley's program.

The Welding program, at Moraine Valley, is an open enrollment program and generally followsthe course material of the MAST Pilot program. As a result of the open enrollment policy, thereis not an identifiable cohort of students who enter the program each year and matriculate throughthe program. In fact, many students enroll in only one course each semester and take severalyears to achieve their degree. As a result, only 19 new students were available to be administeredthe pre-test in the Fall of 1995. As a group, the test scores ranged from 13% to 45% with anaverage score of 26%.

Sixteen (16) students completed the course of study and achieved a 70% or better on their exitexam. The scores ranged from 70% to 97% with an average of 86.43% and all sixteen (16)students proceeded to the next level of welding courses in the 1996 Spring semester.

Please feel free to call me if you require further clarification on the testing process.

Sincerely,

Richard A. KukacAssociate DeanBusiness and Industrial Technology

208

209

For more information:

MAST Program DirectorTexas State Technical College3801 Campus DriveWaco, TX 76705

(817) 867-4849FAX (817) 867-33801-800-792-8784http://machinetool.tstc.edu

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