I.

Course Description

A.

This course will cover the processes and procedures used in welding; also, repairing broken, damaged and worn equipment.  The principles of welding, nomenclature of equipment and cutting of ferrous metals will be followed.  Lab time will give the students "hands on" experience in cutting, welding, and brazing.

Safety is a must at all times.

B.

The purpose of this course is to provide the student with the knowledge and the manipulative skills to assure sound judgments and proper procedures involved in basic welding.

C.

This course will also provide the student knowledge on metals, how to identify metals and the selection of welding procedures.

II.

Objectives

A.

Students will be given training in the following topics.

1.

Safe operation of Oxy-fuel equipment

2.

Identify and set up Oxy-fuel equipment

3.

Identify and set up Shielded Metal Arc equipment

4.

Burn and weld ferrous plates

5.

Burn and weld ferrous pipe

6.

Understand and perform proper procedures in brazing and soldering

7.

Know the difference between good and bad welds and how they are inspected.

III.

Topics to be Covered

A.

Safety in welding

1.

Regulations for storing cylinders

2.

Know and understand the possible welding mishaps

3.

Know and understand Oxy-fuel equipment

4.

Know and understand arc welding equipment

5.

Know the hazards of the welding fumes

6.

Demonstrate personal protection

B.

Students will identify the following equipment

1.

Cylinders

2.

Regulators

3.

Hoses

4.

Torch Body

5.

Flashback Arrester

6.

Safety Valves

7.

Right Hand Fittings

8.

Left Hand Fittings

9.

Blowpipe

10.

Air Arc Equipment

11.

Arc Welding Equipment

C.

The student will assemble, inspect, light, adjust, extinguish, shut down, and disassemble the Oxy-fuel equipment according to the manufacturers specifications.

D.

Ferrous Metal Cutting Plate.

To complete the competencies required, the student will use the available Oxy-fuel equipment and accessories needed for cutting mile steel plate.

1.

Make Freehand Cuts

2.

List Reasons for Poor Cuts

E.

Safe Operation of Welding Machines

1.

Input Power

2.

Output Power

3.

Electric Shock

F.

Identify and Set Up Arc Welding Equipment

1.

Transformer

2.

Generator

3.

Duty Cycle

4.

Alternating Current

5.

Direct Current

6.

Polarity

G.

Study the Shielded Metal Arc Process

1.

What Arc Welding Is

2.

What Happens in the Arc

3.

The Arc Circuit

4.

Possibilities of Welding

H.

Safe Work Habits in the Welding Shop

1.

Operation of the Equipment

2.

Arc Welding Precautions

3.

Installation of Welding Equipment

4.

Maintenance of Equipment

I.

Arc Welding Theory and Techniques

1.

Striking the Arc

2.

Running a Bead

3.

Setting the Current

4.

Restarting the Bead

5.

Filling a Crater

6.

Whipping a Bead

7.

Weaving a Bead

J.

Ferrous Metal Welding, Structural Steel and Pipe

To complete the competencies required, the student will use the available equipment and accessories needed for welding metal plate and pipe.

*

1.

Weld Beads

a.

Flat

b.

Vertical

c.

Horizontal

d.

Overhead

*

2.

Weld a Pad

a.

Flat

b.

Vertical

c.

Horizontal

d.

Overhead

*

3.

Weld Butt Joint

a.

Flat

b.

Vertical

c.

Horizontal

d.

Overhead

*

4.

Weld Fillet Type Joint

a.

Flat

b.

Vertical

c.

Horizontal

d.

Overhead

K.

Brazing

To complete the competencies required in brazing, the student will use the available Oxy-fuel equipment and accessories needed to braze mild steel or cast iron plate.

*

1.

Braze on Mild Steel

*

2.

Braze on Cast Iron

L.

Know the difference between good and bad welds and how they are inspected

1.

Optimum Conditions and Welding Adjustments

2.

The Weld is Free From the Following:

a.

Excessive Distortion

b.

Excessive Penetration

c.

Excessive Reinforcement

d.

Inadequate Reinforcement

e.

Overlap

f.

Oxides

g.

Porosity

h.

Slag Inclusion

i.

Undercut

j

Visual Defects

k.

NDT

IV.

Laboratories

*

Topics that have Laboratories

V.

Materials and Equipment

A.

School Owned:

1.

Oxyacetylene cutting stations

2.

Oxyacetylene welding stations

3.

Hand Grinders

4.

Hack Saw

5.

Bench Grinder

6.

Welding Consumables

7.

Air Arc Equipment

8.

Arc Welding Equipment

B.

Student Owned (Personal Equipment)

1.

Safety Glasses

2.

Wire Brush

3.

Chipping Hammer

4.

Long Sleeves

5.

Safety Shoes

6.

Measuring Tape

7.

Leather Gloves

8.

Burning Goggles

VI.

Bibliography

Welding Handbook, Seventh Edition, Volume 1-5, American Welding Society

New Lessons In Arc Welding, Lincoln Welding Foundation, Cleveland , Ohio

VII.

Evaluation

A.

Manipulative

1.

Job Evaluations

2.

Laboratory Observations

3.

Shop Projects

4.

Misc-specific Objectives Evaluations