Description:

Upon successful completion of this course, the student should be able to perform oxy-fuel cutting (OFC), oxy-fuel welding (OFW) and brazing, shielded metal arc welding (SMAW). The SMAW portion of the course will cover positions but will be limited to AWS U-bend tests with backing and fillet welds. All welds will be tested according to industry standards. The student will be required to provide ANSI Z87 safety glasses and may be expected to provide other basic hand tools and/or equipment. 1 hr. lecture, 6 hrs. lab/wk.

Associated Costs: These are additional (out-of-pocket) expense considerations that students should expect in addition to the course tuition, fees, and textbooks. $30 to $150.

Supplies: Refer to the instructor's course syllabus for details about any supplies that may be required.

Textbook(s): For information see - http://bookstore.jccc.net

Course Fees: NONE

Course Objectives:

Upon successful completion of this course the student should be able to:

1. Identify and practice appropriate shop safety rules.
2. Identify the basic welding joints and welding positions.
3. Demonstrate awareness of oxyacetylene safety and setup procedures.
4. Successfully produce fillet and groove welds in the flat position using the OAW process.
5. Explain the basic theory of how the SMAW/GMAW process works.
6. Demonstrate an understanding of SMAW electrodes and the AWS identification system.
7. Successfully produce a variety of welds using the SMAW/GMAW process with a variety of electrodes.
8. Define and recognize basic metallurgy terminology as it pertains to ferrous metals.
9. Demonstrate a basic knowledge of blueprints as they relate to welding.

Content Outline & Competencies:

I. Shop Safety Rules
   A. Identify JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective clothing and
equipment for OAW, OFC, SMAW and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning basic safety rules for oxy-acetylene
cylinders and gasses.
   F. Complete statements concerning eye protection.
   G. Complete a list of safety rules for the oxyacetylene work area.
   H. List hazards concerning electrical safety for arc welding.
   I. Select true statements concerning hazards associated with arc rays.
   J. Determine steps in selecting a safe lens shade.
   K. Select true statements concerning environmental safety
requirements.

II. Welding Joints and Positions
   A. List the five basic welding joints.
   B. Compare and contrast the 1G, 2G, 3G, 4G, 5G and 6G welding positions
with the 1F, 2F, 3F and 4F welding positions.

III. Oxyacetylene Welding
   A. List equipment required for oxyacetylene welding.
   B. Complete statements concerning pressure regulating valves.
   C. Identify welding torch functions and mixer types.
   D. Complete statements concerning setup of cylinders and regulators.
   E. Complete statements concerning pressure-regulating valves.
   F. Identify characteristics of various welding hoses.
   G. Complete statements concerning setup of cylinders and regulators.

   H. Complete statements in the final steps of setting up oxy-fuel
equipment.
   I. Demonstrate the ability to light, adjust and shut off an
oxyacetylene welding torch.
   J. Identify the step of purging oxygen and fuel gas regulators.
   K. Identify correct guidelines for flame adjustment.
   L. Demonstrate how to adjust the torch for flame types.
   M. Determine causes for various torch operation problems.
   N. Select true statements concerning welding tip selection and its
relation to other welding elements.
   O. Identify true statements concerning filler rod selection, handling
and safety.
   P. Complete statements concerning what beginners gain from learning
oxyacetylene welding and cutting.
   Q. Identify welding positions.
   R. Demonstrate elements of good fusion welding.
   S. Select true statements concerning rod and torch angle rules of
thumb.
   T. Complete statements concerning characteristics of forehand and
backhand techniques in fusion welding.
   U. Complete statements concerning control of flame and rod motions.
   V. Select true statements concerning joint preparation and heating.
   W. Complete statements concerning clean-up, inspection and testing.
   X. Demonstrate proper start up and shut down procedures.
   Y. Successfully produce the following oxygen-acetylene welds and cuts
as shown in Hobarts oxyacetylene workbook:
      1. Stringer beads w & w/o filler
      2. Lap joint, horizontal position
      3. Inside corner joint, horizontal position
      4. Inside corner joint, vertical position up
      5. Butt joint flat position
      6. Braze weld butt joint flat position
      7. Brazing, lap joint, horizontal position

IV. Oxyacetylene Cutting
   A. Match terms with definitions.
   B. Select true statements concerning oxyacetylene cutting
characteristics.
   C. Identify parts of an oxyacetylene cutting torch.
   D. Complete statements about cutting-tip design, cleaning, selection
and uses.
   E. Complete statements concerning control of kerf and drag.
   F. List reasons for poor cuts and elements of a good cut.
   G. Identify proper working surfaces for oxyacetylene cutting.
   H. Identify special safety requirements for oxyacetylene cutting.
   I. Complete statements concerning technique for cutting straight
lines.
   J. Demonstrate proper start up and shut down procedures.
   K. Demonstrate the ability to make the following cuts as shown in
Hobart oxyacetylene workbook:
      1. Flame cutting

V. SMAW and GMAW Welding Theory and Setup
   A. Match terms and definitions related to SMAW/GMAW equipment,
applications and techniques.
   B. Define volts, amps and watts, and explain how each is controlled in
the  SMAW/GMAW process.
   C. Describe three types of polarity, and common names for each.
   D. Compare and contrast constant current (C.C.) and constant voltage
(C.V.) power sources and know other common names for each.
   E. Explain when C.C. and C.V. should be used.
   F. Complete statements concerning basic SMAW/GMAW accessories and
purposes.
   G. Identify parts of an arc welder.
   H. Demonstrate the proper setup of a SMAW/GMAW power source.
   I. Explain basic SMAW/GMAW techniques.
   J. Match characteristics of good and bad welds with causes.
   K. List the five essentials of proper arc welding.
   L. Describe various bead running techniques.
   M. Explain two methods of initiating your arc in SMAW.
   N. Describe the proper techniques for filling the crater at the
conclusion of your weld.
   O. Demonstrate basic skill using the OFC and PAC processes.

VI. Electrode Use and Identification
   A. List the two main functions of the core wire.
   B. Describe at least five functions of the flux coating on a SMAW
electrode.
   C. Identify at least three organizations that have electrode
identification methods.
   D. Demonstrate the ability to use the AWS numbering system to identify
SMAW electrode characteristics.

VII. Shielded Metal Arc Welding and Gas Metal Arc Welding Demonstration
   A. Demonstrate the correct setup of a SMAW/GMAW welding station.
   B. Show the use of proper safety techniques while performing
SMAW/GMAW.
   C. Successfully produce the following SMAW welds as shown in the Hobart
basic shielded metal arc welding workbook:
      1. Striking and controlling arc
      2. Pad of beads flat position with E-6012
      3. Lap joint, horizontal position with E-6012
      4. Pad of beads flat position with E-6010
      5. Tee joint horizontal position with E-6010
      6. Tee joint vertical up position with E-6010 
      7. Tee joint weave vertical up position with E-6010 
      8. Tee joint overhead position with E-6010 
      9. Lap joint horizontal position with E-7024 
     10. Tee joint vertical up position with E-7018 
     11. Tee joint overhead position with E-7018 
   D. Successfully produce the following GMAW welds:
      1. Pad of beads
      2. Butt weld flat position
      3. Tee weld horizontal position

VIII. Metallurgy
   A. Match terms related to basic metals and metallurgy with
definitions.
   B. Identify reasons for proper metal identification.
   C. Identify alloy characteristics.
   D. Demonstrate the ability to conduct magnet tests and conduct chisel
tests.
   E. Match mechanical properties of metals with characteristics.
   F. Distinguish between types of mechanical strengths in metals.
   G. Match physical properties with characteristics of metals.
   H. Describe aspects of annealing, hardening and tempering processes.
   I. Select appropriate ways of testing metal properties.
   J. Match principal alloying agents of steel with characteristics.
   K. Match metals with ways to identify them by appearance.
   L. Solve problems concerning systems for identifying steel.
   M. Complete charts of carbon steel classifications, characteristics
and
uses.
   N. Identify alloy steels by classification, characteristics and uses.
   O. Identify irons by classification, characteristics and uses.
   P. Identify equipment requirements for spark testing.
   Q. Conduct spark tests to identify common welding metals.

IX. Welding Blueprints
   A. List the five basic views used in blueprints.
   B. Identify the symbol for a fillet weld.
   C. Demonstrate an understanding of how to determine arrow side and
other side in reference to welding symbols.

Methods of Evaluation of Competencies:

Evaluation of student mastery of course competencies will be accomplished using the following methods:

Class work and lab competencies will include some subjective
evaluation on the part of the instructor and such items as attendance and
class participation.

Lab competencies will be assigned a level of competency on a scale of
0-10. 10 being high.

The semester grade will be determined as follows:

Participation                10%
Lab Competencies             40%
Class and Homework         10%
Test and Quizzes           10%
Midterm Exam               10%
Final Exam                 20%
TOTAL                     100%

Testing:  Tests must be made up immediately upon return from an excused
absence.

Caveats:

1. AWS Entry Level Welder Certification. Johnson County Community College has agreed to act as an American Welding Society Participating Organization in the Training and Testing of Entry Level Welders and abides by the requirements of AWS QC10, Specification for Qualification and Certification of Entry Level Welders and AWS EG2.0, Guide for the Training and Qualification of Welding Personnel - Entry Level Welder. Students successfully completing all of the courses in the JCCC Metal Fabrication Vocational Certificate (including the required AWS workmanship tests) are eligible to apply for certification which requires a practical knowledge written test and limited thickness SMAW performance tests. Students meeting these requirements will be listed on the AWS National Registry of Entry Level Welders. To apply, simply contact your instructor or the JCCC Assistant Dean of Industrial Technology Programs (ATB 123).
2. Projects: All lab competencies must be met with a rating of 80% before any project work will be considered. Before any projects are started you must have permission from your instructor. Exceptions to this rule will only be granted after an evaluation of the student’s progress is made by the instructor. Part of the final exam will include T-fillet 3G up position SMAW. This weld is detailed in the AWS D1.1 code book and represents a standard weld test given for certification purposes made by many companies.
3. Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
4. Face Shield: When grinding is being performed, full face safety shields must be worn in addition to approved safety glasses or goggles.
5. Boots: Approved leather footware is required when working in all metal fabrication/welding labs.

Disabilities:

If you are a student with a disability, and if you will be requesting accommodations, it is your responsibility to contact Access Services. Access Services will recommend any appropriate accommodations to your professor and his/her director. The professor and director will identify for you which accommodations will be arranged.

JCCC provides a range of services to allow persons with disabilities to participate in educational programs and activities. If you desire support services, contact the office of Access Services for Students With Disabilities (913) 469-8500, ext. 3521 or TDD (913) 469-3885. The Access Services office is located in the Success Center on the second floor of the Student Center.