Welding 20

Module 1: General Shop Safety ( 2-3 hours)

1. Identify the purpose and demonstrate the proper use and fit of personal protective equipment (PPE) while identifying the hazards from which they protect individuals.

   1. eye protection (lens shades)

   2. Clothing

   3. hearing protection

   4. footwear

2. Recognize hazards (flashback & backfire) associated with oxy-acetylene welding equipment:

   1. Tanks

   2. Hoses

   3. gauges

3. Recognize hazards associated with electric welding processes

4. Demonstrate the proper procedures to follow when reporting an unintentional injury

Module 2: Intermediate Safety (1-2 hours)

Prerequisite: Module 1 Welding 10

1. Express knowledge of safe handling of materials according to WHMIS, using materials safety data sheets (MSDS).

2. Research and discuss Occupational Health and Safety regulations which apply to the welding industry.

3. Recognize and apply safe and fair work practices including freedom from violence and harassment.

4. Complete an assessment of all safety and welding equipment and, in consultation with the instructor, perform maintenance to repair or replace defective or worn parts.

Tasks for Completion

1. Safety Presentation & Worksheet

2. Hand-write a Copy of “Welding Shop Rules”

3. MW01 Safety In The Welding Shop

4. Worksheet

5. MW01 Safety Quiz (Must Score 100%)

6. WHMIS and MSDS Presentation & Worksheet

7. WHMIS and MSDS Presentation & Quiz

Module 3: Hand and Power Tools ( 3-15 hours)

1. Identify and define the safe use of hand tools:

   1. Hammers

   2. Pliers

   3. Wire brushes

   4. Strikers

   5. Anvils

   6. Files

   7. Tip cleaners

   8. Hand shears

   9. Hacksaws

   10. Clamps

   11. Vices

   12. Marking tools

2. Demonstrate and articulate the correct procedures for operating power tools:

   1. grinders (stationary and portable)

   2. buffers (stationary and portable)

   3. power shear

   4. power hacksaw

   5. band saw

   6. drill press.

Module 4: Intermediate Hand and Power Tools (1-2 hours)

Prerequisite : Module 3 Welding 10

1. Demonstrate the proper method for cleaning weld-spattered tools.

2. Assess and report any potential faults with electrical cords and receptacles.

3. Repair or replace welding-distorted surfaces on benches or table tops in consultation with the instructor.

4. Demonstrate the proper techniques to remove and replace saw blades.

5. Identify potential maintenance issues with hand and power tools and consult with the instructor to determine a solution.

Tasks for Completion

1. Hand & Power Tools Presentation & Worksheet

2. Mastercraft Tools Project

3. Hand and Power Tools Quiz (Must Score 100%)

4. MW 02 - Print Reading & Worksheet

5. MW 02 - Print Reading Quiz (Must Score 100%)

6. MW 03 - Reading Welding Symbols & Worksheet

7. MW 03 - Reading Welding Symbols Quiz (Must Score 100%)

Module 7A: Oxy-acetylene Cutting Skills (5-7 hours)

Prerequisite : Module 6 Welding 10

1. Cut straight lines on 3⁄8” mild steel.

2. Complete bevel cuts on 3⁄8” mild steel.

3. Cut holes and circles on 3⁄8” mild steel.

Module 10: Intermediate Oxy-acetylene Welding (1-2 hours)

Prerequisite : Module 9 Welding 10

1. Effectively use oxy-acetylene equipment to increase the quality of the specified welds.

2. Perform and analyze a variety of specified welds, including butt weld, edge weld, and lines of fusion.

Module 11A: Oxy-acetylene Welding Practice ( 10-12 hours)

1. Create examples of basic oxy-acetylene welding practices:

   1. beads with no filler

   2. edge weld

   3. corner weld

   4. beads with filler

   5. butt weld

   6. lap weld

   7. Perform an outside corner weld, no filler rod, in the flat position, on gauge mild steel.

   8. Run lines of fusion using filler rod, in the flat position, on gauge mild steel.

   9. Perform a butt weld using filler rod, in the flat position, on gauge mild steel.

   10. Assess personal technique and results in consultation with the instructor.

Module 11B: Oxy-acetylene Welding Practice (20-25 hours)

Prerequisite : Module 10

1. Perform a butt weld using filler rod, flat position, gauge mild steel ensuring 100% penetration.

2. Perform a butt weld using filler rod, in the vertical position, on gauge mild steel.

3. Perform a lap weld using filler rod, in the flat position, on gauge mild steel; overlap by half.

4. Assess personal technique and document results in consultation with the instructor.

Tasks For Completion

Welding 10 Review:

1. Watch Video “Oxyacetylene Welding” 1:50 - 20:15 & Worksheet

2. MW 14 Oxyfuel Gas Cutting Equipment and Supplies & Worksheet

3. MW 15 Oxyfuel Gas Cutting & Worksheet

4. MW 15 Oxyfuel Gas Cutting Quiz

5. Oxy-Acetylene Rebuild and Leak Test Demonstration

6. Oxy-Acetylene Cutting Task 1

7. Watch Video "Oxyacetylene Welding" 20:15 - 42:15 & Worksheet

8. Oxy-Acetylene Welding Task - Bead (No Filler Rod)

9. Oxy-Acetylene Welding Task - Bead (With Filler Rod)

Welding 20:

1. MW 12 Oxyfuel Gas Welding Equipment and Supplies & Worksheet

2. Oxy-Acetylene Cutting Task 2

3. Oxy-Acetylene Welding Task - Outside Corner Flat

4. Oxy-Acetylene Welding Task - Lap Joint Flat

5. Oxy-Acetylene Welding Task - Butt Joint Flat

6. Acetylene Metal Dice Project

Module 20A: Electric Arc Welding Skills (25-30 hours)

Prerequisite : Module 19 Welding 10

1. Perform a lap weld on ¼” mild steel using 7014, 7018, and 6010 electrodes.

2. Perform an outside corner weld (horizontal and vertical fillet on ¼” mild steel) using 7018 electrode.

3. Perform horizontal fillets (¼” and 3⁄8” multi-pass on ¼” mild steel) using 7014, 7018, and 7024 electrodes.

4. Perform a butt weld flat (single pass; 6010 electrode; 75% penetration on ¼” mild steel).

5. Perform a 3⁄8” vee butt flat (introductory only; 6010 root, 7018 fill and cap).

Tasks for Completion

Welding 10 Review:

1. SMAW Terms

2. Watch Video "SMAW 1" 0:35 - 23:45 & Worksheet

3. MW 05 SMAW Equipment and Supplies & Worksheet

4. Watch Video "SMAW 1" 23:45-42:40 & Worksheet

5. MW 06 SMAW & Worksheet

6. SMAW Task - 7018 Pad

7. Watch Video "SMAW 2" 1:15 - 44:10 & Worksheet

8. SMAW Similarities and Differences Worksheet

9. SMAW Quiz (Must Score 100%)

10. SMAW Task - 6010/6011 Pad

11. SMAW Task - 6010 Butt & 7018 Cap

Welding 20:

1. SMAW - Arc Welding Safety Worksheet

2. SMAW - Inspecting and Setting up the Arc Welding Station

3. SMAW Task - 3 Electrode Pad (6010, 7018, & 7024)

4. SMAW Task - 6010 Butt & 7018 Cap

5. SMAW Task - 7024 Horizontal V

6. SMAW Task - 7018 Flat Corner

7. SMAW Task - 7018 Vertical Lap

8. SMAW Task - 6010/6011 Horizontal Lap

9. SMAW Task - 6010/6011 Vertical Corner

10. SMAW Metal Dice Project

GMAW Skills

Module 25B: GMAW Safety and Equipment (1-2 hours)

Prerequisite : Module 25A Welding 10

1. Review personal protective equipment (PPE) standards for usage.

2. Adjust the machine for appropriate wire speed, voltage, and amperage.

3. Turn on shielding gas and describe the reading on the flow meter.

4. Demonstrate the correct start-up and shut-down procedures, including checking and cleaning up the work station.

Module 26: GMAW Care and Maintenance Requirements (1-2 hours)

1. Demonstrate proper use of GMAW equipment assembly including disassembly of welding gun, adjustment of flow meter, and wire selection and installation.

2. Safely operate hand tools, power hand tools, and power equipment.

Module 27B: GMAW Procedures and Practice (7-10 hours)

Prerequisite : Module 25B, 27A Welding 10

1. Perform a horizontal fillet on 14 gauge steel.

2. Perform a horizontal lap on 14 gauge steel.

3. Perform a lap weld on ¼” mild steel.

4. Perform horizontal fillets (¼” and 3⁄8” multi-pass on ¼” mild steel; short circuit transfer).

5. Perform horizontal fillets (¼” and 3⁄8” multi-pass on ¼” mild steel; spray transfer).

6. Compare and chart personal progress to identify increasing skill.

7. Assess personal technique and results in consultation with the instructor.

Tasks for Completion

Welding 10 Review:

1. Watch Video "GMAW" 0:45 - 19:00 & Worksheet

2. MW 07 GMAW Equipment and Supplies & Worksheet

3. GMAW Task - Backhand-Forehand Half Pad

4. Watch Video "GMAW" 19:00 - 43:25 & Worksheet

5. GMAW Quiz (Must Score 100%)

6. GMAW Task - Lap Flat Position

7. GMAW Task - Butt Flat Position

8. GMAW Task - Corner Flat Position

Welding 20:

1. GMAW - Equipment and Supplies Worksheet

2. GMAW - Inspecting and Setting up the Welding Station

3. GMAW Task - Sculpture

4. GMAW Task - Lap Horizontal Position

5. GMAW Task - Butt Horizontal Position

6. GMAW Task - Corner Horizontal Position

7. GMAW Task - Butt Vertical Position

8. GMAW Metal Dice Project