| Originator: | Pope, Eric Status: Approved Department: WLD Welding |
| Date Created: | 02/25/2020 Submitted: 02/25/2020 Completed: 03/26/2020 |
| Effective Semester: | Fall |
| Catalog Year: | 2020-21 |
| Course Prefix: | WLD |
| Course Number: | 104 |
| Course Full Title: | Introduction to Thermal Cutting and Welding |
| Old course information: | |
| Reason for Evaluation: | CSLO, Competencies, and/or Outline Changes |
| Current Credit: | 5 |
| Lecture Hours: | |
| Lab Hours: | |
| Clinical Hours: | |
| New Credit Hours: | |
| New Lecture Hours: | |
| New Lab Hours: | |
| New Clinical Hours: | |
| New Internship Hours: | |
| New Externship Hours: | |
| SUN Course?: | No |
| AGEC Course?: | No |
| Articulated?: | No |
| Transfer: | Non Applicable |
| Prerequisite(s): | WLD 103 |
| Corequisite(s): | WLD 103 |
| Catalog Course Description: | This course introduces the materials in the industry, preparation of metal for welding, the characteristics and types of joints. Includes practice in oxygen-acetylene, plasma, and carbon-arc metal cutting. Introduces students to shielded metal arc welding, SMAW (stick). |
| Course Learning Outcomes: | 1. Prepare metals for welding properly (3)
2. Perform oxygen-acetylene, plasma, and carbon-arc metal cutting (6) 3. Perform basic shielded metal arc welding (SMAW or stick) (6) |
| Course Competencies: | 1. Relate an overview of welding, welding equipment, and equipment purposes.
2. Summarize the oxygen-acetylene fuel process. 3. Perform metal cutting using oxygen-acetylene technology and procedures. 4. Perform metal cutting with plasma arc technology. 5. Perform metal cutting and gouging with air carbon arc technology 6. Classify types of metal and chemical composition. 7. Summarize the preparation of base metals for welding. 8. Identify weld joint types and characteristics. 9. Summarize shielded metal arc welding (SMAW) equipment and setup. 10. Prepare metal for welding using the SMAW process. 11. Employ thermal cutting processes and the SMAW process to create a course project. |
| Course Outline: | 1. Overview of welding, welding equipment, and equipment purposes
a. Joining methods and processes i. Joining methods of different materials 1. Mechanical fastening 2. Joining 3. Adhesive bonding ii. Welding 1. Fusion welding and categories a. Fusion category by energy source (physical characteristics) i. Electrical fusion welding ii. Chemical fusion welding 2. Solid state welding 3. Welding process applications a. Adaptive control application b. Automatic control c. Manual control d. Mechanized control e. Robotic control f. Semiautomatic control iii. Brazing and soldering iv. Cutting processes 1. Chemical cutting process 2. Electrical cutting process 2. Oxy-fuel process a. Basic concepts of the oxygen-acetylene fuel (OFC) cutting process i. Materials on which OFC can be used ii. OFC related terms b. Safe work practices related to OFC c. Oxy-fuel cutting consumables. i. Oxygen ii. Acetylene d. Oxy-fuel cutting equipment identification i. Cylinders used during OFC cutting ii. Hoses by color iii. Oxygen and fuel gas regulators iv. Cutting torches v. Cutting tips vi. Oxy-fuel cutting accessories. vii. Specialized cutting equipment 3. Metal cutting using OFC technology and procedures a. OFC equipment procedures i. Properly preparing a torch set for operation ii. Leak test OFC equipment iii. Light and adjust the torch iv. Shut down OFC cutting equipment v. Disassemble OFC cutting equipment vi. Change empty gas cylinders b. Primary uses of oxy-fuel i. Cut both thick and thin steel 1. Appearance of both good and inferior cuts 2. Causes of good and inferior cuts ii. Bevel iii. Wash iv. Gouge v. Straight cuts with track burner vi. Bevel cuts with track burner vii. Circle cutter viii. Torch brazing 4. Metal cutting with plasma arc technology a. Plasma arc cutting processes b. Safety practices c. Cutting equipment identification i. Power units ii. Torches iii. Accessories iv. Gases v. Control devices d. Plasma arc cutting equipment i. Set up plasma arc cutting equipment and the adjacent work area ii. Care for plasma arc cutting equipment e. Plasma arc cutting equipment safety i. Setting the amperage and gas pressures or flow rates for the type and thickness of metal to be cut ii. Square-cut metal using plasma arc equipment iii. Bevel-cut metal using plasma arc equipment iv. Pierce and cut slots in metal using plasma arc equipment 5. Metal cutting and gouging with air carbon arc technology a. Air-carbon arc cutting process i. Air-carbon arc cutting equipment and consumables ii. Various types of electrodes iii. Safe practices related to air-carbon arc cutting b. Air-carbon arc cutting equipment. i. Prepare the equipment and work area for air-carbon arc cutting ii. Wash and gouge metals iii. Care for air-carbon arc cutting equipment c. Cutting with air-carbon arc equipment 6. Types of metals and chemical composition a. Define metal and the history of the development of metals b. Various types and properties of metals and alloys c. Properties of carbon steel d. Properties of stainless steel. e. Carbon steel classification system f. Stainless steel classification system 7. Preparing base metals for welding a. Basic metal cleaning procedures b. Basic metal cleaning concerns. c. Mechanical cleaning d. Chemical cleaning e. Edge preparation i. mechanical machines ii. Thermal cutting procedures 8. Weld joint types and characteristics a. Fundamental attributes of Welds i. Forces on welds ii. Most common types of surface welds iii. Fillet and groove welds iv. Joint details v. Common weld symbols vi. Purpose of welding sequences b. Joints by type i. Butt joint ii. Corner joint iii. T-joint iv. Lap joint v. Edge joint c. Groove type by shape of edge preparation i. Square edge shape ii. Single bevel edge shape iii. Double bevel edge shape iv. Single J edge shape v. Double J edge shape vi. Flanged edge shape vii. Round edge shape d. Fillet Weld profiles by shape of weld i. fillet weld reinforcement ii. fillet weld under fill iii. Fillet weld overlap iv. Fillet weld undercut v. Fillet weld reinforcement vi. Convex fillet weld vii. Concave fillet weld 9. SMAW a. SMAW safety practices i. Moving equipment ii. Electrical hazards iii. Lifting hazards iv. Working at heights b. SMAW equipment i. Types of SMAW power sources ii. Current characteristics 1. Open Current Voltage 2. Closed Circuit Voltage 3. Volt-Amp Output Curve iii. Polarity as related iv. Duty Cycle v. SMAW welding cable vi. SMAW welding connectors vii. SMAW welding quick connect lugs viii. SMAW welding ground clamps ix. SMAW electrode holders c. Procedures i. Set up ii. Start, stop, manual iii. Start, stop, engine driven iv. Amperage/Voltage adjustment v. Checking leads for serviceability vi. Preventative maintenance techniques vii. Assembly of SMAW welding cable and connector d. Electrodes i. Identification ii. Sizes iii. Selections 1. Filler metal specifications 2. Characteristics of groups 3. Base metal matching 4. Filler metal Position classifications 5. Filler metal code requirements iv. Filler metal storage 10. SMAW Preparation a. SMAW welding preparations i. PPE identification ii. Fire and explosion prevention iii. Work area ventilation iv. SMAW capabilities v. SMAW electrodes vi. SMAW technique flaws and dangers vii. Arc blow viii. Arc strikes ix. Porosity x. Overlap xi. Undercut b. SMAW techniques i. SMAW arc striking techniques ii. SMAW arc termination technique iii. SMAW weld restart iv. Travel angle v. Work angle vi. Arc gap / length vii. Stringer bead viii. Overlapping stringer bead / padding 11. SMAW technique application a. Welds i. Stringer Beads 1. E6010 rod 2. E7018 rod ii. Overlapping Stringer Beads (padding) 1. E6010 rod in 1F, 2F, 3F, and 4F positions 2. E7018 rod in 1F, 2F, 3F, and 4F positions iii. Multiple pass fillet welds 1. E6010 rod in 1F, 2F, 3F, and 4F positions 2. E7018 rod in 1F, 2F, 3F, and 4F positions b. AWS Qualification i. Fillet Weld Type ii. Material type and thickness iii. Positions 12. Course project: utilizing the thermal cutting processes and the SMAW process a. Course Project Fabrication i. Fabrication Quality 1. Welds 2. Dimensions 3. Craftsmanship |