J Harley Bonds CAREER CENTER
COURSE SYLLABUS
Charles Squires, Instructor
Todd Varholy, Instructor
COURSE: Welding I
COURSE CODE: 634010CT
COURSE DESCRIPTION: The Welding Technology program is designed to prepare students to perform entry-level welding tasks under the supervision of an experienced certified welder. Welding students receive training in gas and electric welding. Included in the course of study is instruction related to blueprint reading, properties of metal, and safety.
CREDITS: 4 units per school year
PREREQUISITES: Algebra 1 or Algebra 1 CP Part B
TEXT BOOKS: Welding Principles and Applications, NCCER Welding Level 1, NCCER Welding Level 2.
COURSE COMPETENCIES:
MODULE A: BASIC SAFETY
1. Identify the responsibilities and personal characteristics of a professional craftsperson.
2. Explain the role that safety plays in the construction crafts.
3. Describe what job-site safety means.
4. Explain the appropriate safety precautions around common job-site hazards.
5. Demonstrate the use and care of appropriate personal protective equipment.
6. Follow safe procedures for lifting heavy objects.
7. Describe safe behavior on and around ladders and scaffolds.
8. Explain the importance of the HazCom (Hazard Communication Standard) requirement and MSDs (Material Safety Data Sheets).
9. Describe fire prevention and fire fighting techniques.
10. Define safe work procedures around electrical hazards.
11. Complete 10-hour OSHA course/assessment and receive card. (SDE Requirement)
MODULE B: BASIC MATH
1. Add, subtract, multiply, and divide whole numbers, with and without a calculator.
2. Use a standard ruler and a metric ruler to measure.
3. Add, subtract, multiply, and divide fractions.
4. Add, subtract, multiply, and divide decimals, with and without a calculator.
5. Convert decimals to percents and percents to decimals.
6. Convert fractions to decimals and decimals to fractions.
7. Explain what the metric system is and how it is important in the construction trade.
8. Recognize and use metric units of length, weight, volume, and temperature.
9. Recognize some of the basic shapes used in the construction industry and apply basic geometry to measure them.
MODULE C: INTRODUCTION TO HAND TOOLS
1. Recognize and identify some of the basic hand tools used in the construction trade.
2. Use these tools safely.
3. Describe the basic procedures for taking care of these tools.
MODULE D: INTRODUCTION TO POWER TOOLS
1. Identify commonly used power tools of the construction trade.
2. Use power tools safely.
3. Explain how to maintain power tools properly.
MODULE E: INTRODUCTION TO BLUEPRINTS
1. Recognize and identify basic blueprint terms, components, and symbols.
2. Relate information on blueprints to actual locations on the print.
3. Recognize different classifications of drawings.
4. Interpret and use drawing dimensions.
MODULE F: BASIC RIGGING (Optional)
1. Explain how ropes, chains, hoists, loaders, and cranes are used to move material and equipment from one location to another on a job site.
2. Describe inspection techniques and load-handling safety practices.
3. Explain the American National Standards Institute (ANSI) hand signals.
MODULE G: BASIC COMMUNICATION SKILLS (SDE Requirement)
1. Explain techniques for communicating effectively with coworkers and supervisors.
2. Demonstrate verbal and written communication skills necessary in the workplace.
3. Demonstrate telephone and e-communication skills necessary in the workplace.
MODULE H: BASIC EMPLOYABILITY SKILLS (SDE Requirement)
1. Identify the roles of individuals and companies in the construction industry.
2. Explain the importance critical thinking and problem solving skills in the workplace.
3. Describe computer systems and their industry applications.
4. Explain interpersonal relationship skills, self-presentation, and key workplace issues such as sexual harassment, stress, and substance abuse.
WELDING COMPETENCIES
UNIT A: WELDING SAFETY
1. Identify some common hazards in welding.
2. Explain and identify proper personal protection used in welding.
3. Demonstrate how to avoid welding fumes.
4. Explain some of the causes of accidents.
5. Identify and explain uses for material safety data sheets.
6. Demonstrate safety techniques for storing and handling cylinders.
7. Explain how to avoid electric shock when welding.
8. Demonstrate proper material handling methods.
UNIT B: OXYFUEL CUTTING
1. Identify and explain the use of oxyfuel cutting equipment.
2. Set up oxyfuel equipment.
3. Light and adjust an oxyfuel torch.
4. Shut down oxyfuel cutting equipment.
5. Disassemble oxyfuel equipment.
6. Change empty cylinders.
7. Perform oxyfuel cutting:
· Straight line and square shapes
· Piercing and slot cutting
· Bevels
· Washing
· Gouging
8. Operate a motorized, portable oxyfuel gas cutting machine.
UNIT C: BASE METAL PREPARATION
1. Clean base metal for welding or cutting.
2. Identify and explain joint design.
3. Explain joint design considerations.
4. Using a nibbler, cutter, or grinder, mechanically prepare the edge of a mild steel plate ¼” to ¾” thick at 22½° (or 30° depending on equipment available).
5. Using a nibbler, cutter, or grinder, mechanically prepare the end of a pipe with a 30° or 37½° bevel (depending on equipment available) and a 3/32” land. Use 6", 8", or 10" Schedule 40 or Schedule 80 mild steel pipe.
6. Select the proper joint design based on a welding procedure specification (WPS) or instructor direction.
UNIT D: SMAW – EQUIPMENT AND SETUP
1. Identify and explain shielded metal arc welding (SMAW) safety.
2. Identify and explain welding electrical current.
3. Identify and explain arc welding machines.
4. Explain setting up arc welding equipment.
5. Set up a machine for welding.
6. Identify and explain tools for weld cleaning.
UNIT E: SMAW – ELECTRODES AND SELECTION
1. Identify factors that affect electrode selection.
2. Explain the American Welding Society (AWS) and the American Society of Mechanical Engineers (ASME) filler metal classification system.
3. Identify different types of filler metals.
4. Explain the storage and control of filler metals.
5. Explain filler metal traceability requirements and how to use applicable code requirements.
6. Identify and select the proper electrode for an identified welding task.
UNIT F: SMAW – BEADS AND FILLET WELDS
1. Set up shielded metal arc welding (SMAW) equipment.
2. Describe methods of striking an arc.
3. Properly strike and extinguish an arc.
4. Describe causes of arc blow and wander.
5. Make stringer, weave, and overlapping beads.
6. Make fillet welds in the:
· Horizontal (2F) position
· Vertical (3F) position
· Overhead (4F) position
UNIT G: SMAW – GROOVE WELDS WITH BACKING
1. Identify and explain groove welds.
2. Identify and explain groove welds with backing.
3. Set up shielded metal arc welding (SMAW) equipment for making V-groove welds.
4. Perform SMAW for V-groove welds with backing in the:
· Flat (1G) position
· Horizontal (2G) position
· Vertical (3G) position
· Overhead (4G) position
UNIT H: JOINT FIT-UP AND ALIGNMENT
1. Identify and explain job code specifications.
2. Use fit-up gauges and measuring devices to check joint fit-up.
3. Identify and explain distortion and how it is controlled.
4. Fit up joint using plate and pipe fit-up tools.
5. Check for joint misalignment and poor fit-up before and after welding.
UNIT I: WELDING SYMBOLS
1. Identify and explain the various parts of a welding symbol.
2. Identify and explain fillet and groove weld symbols.
3. Read welding symbols on drawings, specifications, and welding procedure specifications.
4. Interpret welding symbols from a print.
5. Draw welding symbols based on the observation of actual welds.
UNIT J: READING WELDING DETAIL DRAWINGS
1. Identify and explain a welding detail drawing.
2. Identify and explain lines, material fills, and sections.
3. Identify and explain object views.
4. Identify and explain dimensioning.
5. Identify and explain notes and bill of materials.
6. Interpret basic elements of a welding detail drawing.
7. Develop basic welding drawings.
UNIT K: PLASMA ARC CUTTING (PAC)
1. Identify and understand plasma arc cutting processes.
2. Identify plasma arc cutting equipment.
3. Prepare and set up plasma arc cutting equipment.
4. Use plasma arc cutting equipment to make various types of cuts.
5. Properly store equipment and clean the work area after use.
UNIT L: GMAW AND FCAW – EQUIPMENT AND FILLER METALS
1. Explain gas metal arc welding (GMAW) and flux cored arc welding (FCAW) safety.
2. Explain the characteristics of welding current and power sources.
3. Identify and explain the use of GMAW and FCAW equipment:
· Spray transfer
· Globular
· Short circuiting
· Pulse
4. Identify and explain the use of GMAW and FCAW shielding gases and filler metals.
5. Set up GMAW and FCAW equipment and identify tools for weld cleaning.
UNIT M: GMAW AND FCAW – PLATE
1. Perform GMAW multiple-pass fillet welds on plate, using solid or composite wire and shielding gas in multiple positions.
2. Perform GMAW multiple-pass open-root V-groove welds on plate, using solid or composite wire and shielding gas, in multiple positions.
3. Perform GMAW spray fillet and open-root V-groove welds on plate, using solid or composite wire and shielding gas, in flat and horizontal positions.
4. Perform FCAW multiple-pass fillet welds on plate in multiple positions using flux cored wire and, if required, shielding gas.
5. Perform FCAW multiple-pass open-root V-groove welds on plate in multiple positions using flux cored wire and, if required, shielding gas.
COURSE EVALUATION:
Nine Weeks Grade:
60% Major
20% Minor
20% Employability Grade
Grading Scale:
A = 90 – 100
B = 80 – 90
C = 70 – 80
D = 60 – 70
F = 59 - Below
Associated Cost: $ 180.00
The Advisory Committee is made up of a panel of industry experts that meets with our program twice a year. They review our training procedures to make sure they are in line with their employment needs. They will make suggestions to improve our program. If you are interested in becoming a member of our advisory committee please contact us at csquires@greenville.k12.sc.us
For student expectation please go to the J Harley Bonds website and visit the welding page.
https://www.greenville.k12.sc.us/bonds/_staff/
· Welding students will need to purchase a pair of leather work boots and have work clothes that are made of natural fibers such as cotton, wool, etc.
CLASS RULES:
1. Be on time.
2. Come prepared for class.
3. Be patient and courteous at all times.
4. Respect yourself and other classmates.
5. Respect school property and equipment.
6. Complete all assignments given on a daily basis.
7. Follow the instructors guidelines for safety at all times.
8. strive to do your best.
SHOP RULES:
1. Be alert at all times.
2. Always wear safety glasses, boots, welding jackets, and gloves.
3. Use equipment as it is intended.
4. Never use equipment without instructors permission.
5. Absolutey NO horseplay in the shop.
6. Always wear a welding helmet when welding.
7. Cell phones are not allow to be out during class per industry standards.
COURSE: Welding II
COURSE CODE: 634111CT
COURSE DESCRIPTION: The Welding Technology program is designed to prepare students to perform entry-level welding tasks under the supervision of an experienced certified welder. Welding students receive training in gas and electric welding. Included in the course of study is instruction related to blueprint reading, properties of metal, and safety.
CREDITS: 4 units per school year
TEXT BOOKS: Welding Principles and Applications, NCCER Welding Level 1, NCCER Welding Level 2.
WELDING – ADVANCED
UNIT A: WELD QUALITY
1. Identify and explain codes governing welding.
2. Identify and explain weld imperfections and their causes.
3. Identify and explain nondestructive examination practices.
4. Identify and explain welder qualification tests.
5. Explain the importance of quality workmanship.
6. Identify common destructive testing methods.
UNIT B: SMAW – OPEN V-GROOVE WELDS
1. Prepare shielded metal arc welding (SMAW) equipment for open-root V-groove welds.
2. Perform open-root V-groove welds in the:
· Flat (1G) position
· Horizontal (2G) position
· Vertical (3G) position
· Overhead (4G) position
UNIT C: SMAW – OPEN-ROOT PIPE WELDS
1. Prepare shielded metal arc welding (SMAW) equipment for open-root V-groove pipe welds.
2. Identify and explain open-root V-groove pipe welds.
3. Perform SMAW for open-root welds in the:
1. Flat (1G-ROTATED) position
2. Horizontal (2G) position
3. Multiple (5G) position
4. Multiple inclined (6G) position
UNIT D: AIR CARBON ARC CUTTING AND GOUGING
1. Identify and explain the air carbon arc cutting (CAC-A) process and equipment.
2. Select and install CAC-A electrodes.
3. Prepare the work area and CAC-A equipment for safe operation.
4. Use CAC-A equipment for washing and gouging activities.
5. Perform storage and housekeeping activities for CAC-A equipment.
6. Make minor repairs to CAC-A equipment.
UNIT E: GTAW – EQUIPMENT AND FILLER METALS
1. Explain gas tungsten arc welding (GTAW) safety.
2. Identify and explain the use of GTAW equipment.
3. Identify and explain the use of GTAW filler metals.
4. Identify and explain the use of GTAW shielding gases.
5. Set up GTAW equipment.
UNIT F: GTAW – PLATE
1. Build a pad in the flat position with stringer beads using GTAW and carbon steel filler metal.
2. Make multiple-pass open-root V-groove welds on carbon steel plate in the 1G (flat) position using GTAW and carbon steel filler metal.
3. Make multiple-pass open-root V-groove welds on carbon steel plate in the 2G (horizontal) position using GTAW and carbon steel filler metal.
4. Make multiple-pass open-root V-groove welds on carbon steel plate in the 3G (vertical) position using GTAW and carbon steel filler metal.
5. Make multiple-pass open-root V-groove welds on carbon steel plate in the 4G (overhead) position using GTAW and carbon steel filler metal.
UNIT G: GTAW – ALUMINUM PLATE
1. Identify and explain aluminum metallurgy.
2. Explain and identify characteristics of aluminum.
3. Explain GTAW and set up equipment to weld aluminum plate.
4. Explain and practice GTAW techniques for plate, including padding in the flat position with stringer beads, using aluminum filler metal.
5. Make fillet welds on aluminum plate in the following positions:
· 1F (flat)
· 2F (horizontal)
· 3F (vertical)
· 4F (overhead)
6. Make multiple-pass V-groove welds with backing on aluminum plate in the following positions:
· 1G (flat)
· 2G (horizontal)
· 3G (vertical)
· 4G (overhead)
UNIT H: GAS TUNGSTEN ARC WELDING (GTAW) – CARBON STEEL PIPE
1. Set up GTAW equipment.
2. Identify and explain open-root V-groove pipe weld techniques.
3. Perform open-root V-groove pipe welds using GTAW in the following positions:
· 1G-ROTATED
· 2G
· 5G
· 6G
UNIT I: GAS TUNGSTEN ARC WELDING (GTAW) – LOW-ALLOY AND STAINLESS STEEL PIPE
1. Set up GTAW equipment to perform stainless and/or low-alloy steel pipe welding.
2. Identify and explain open-root V-groove pipe weld techniques.
3. Perform open-root V-groove pipe welds using GTAW in the following positions:
· 1G-ROTATED
· 2G
· 5G
· 6G
COURSE EVALUATION:
Nine Weeks Grade:
60% Major
20% Minor
20% Employability Grade
Grading Scale:
A = 90 – 100
B = 80 – 90
C = 70 – 80
D = 60 – 70
F = 59 - Below
Associated Cost: $ 90.00
The Advisory Committee is made up of a panel of industry experts that meets with our program twice a year. They review our training procedures to make sure they are in line with their employment needs. They will make suggestions to improve our program. If you are interested in becoming a member of our advisory committee please contact us at csquires@greenville.k12.sc.us
For student expectation please go to the J Harley Bonds website and visit the welding page.
https://www.greenville.k12.sc.us/bonds/_staff/
· Welding students will need to purchase a pair of leather work boots and have work clothes that are made of natural fibers such as cotton, wool, etc.
CLASS RULES:
1. Be on time.
2. Come prepared for class.
3. Be patient and courteous at all times.
4. Respect yourself and other classmates.
5. Respect school property and equipment.
6. Complete all assignments given on a daily basis.
7. Follow the instructors guidelines for safety at all times.
8. strive to do your best.
SHOP RULES:
1. Be alert at all times.
2. Always wear safety glasses, boots, welding jackets, and gloves.
3. Use equipment as it is intended.
4. Never use equipment without instructors permission.
5. Absolutey NO horseplay in the shop.
6. Always wear a welding helmet when welding.
7. Cell phones are not allow to be out during class per industry standards.
Monday - Friday 11:45 -12:30
Office number : 864-355-8276 email : csquires@greenville.k12.sc.us
Procedures for Makeup Work
Examples of make-up work may include: (1) after-school and/or weekend make-up programs that address both time and academic requirements of the course(s), or (2) extended-year programs that address both time and academic requirements of the course(s). All make-up time and work must be completed within thirty (30) days from the last day of the course(s) unless approved by the principal as a result of extenuating circumstances. Make-up requirements that extend beyond thirty days due to extenuating circumstances must be completed prior to the beginning of the subsequent new year.
A. Provision for makeup of school work missed due to absences shall be worked out with the teacher(s) concerned at the earliest time possible, but should not exceed five (5) school days after the student returns to school.
B. In addition to the above, each school will develop procedures to handle absences consistent with the following:
1. The status of all student absences shall be communicated by the Attendance Clerk. Students must see the Attendance Clerk to pick up an admission slip once returning to school. The Attendance Clerk notifies the student and teacher of the number of excused/unexcused days.
2. Students have (5) school days after returning to school to make-up missing assignments. Any assignments not made up within the (5) will be calculated as a zero in the gradebook.
3. Student absences for school activities, WBL events, college visitation may be excused by the principal.