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Course: |
WEL 140
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Title: | Welding Practices & Procedures |
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Long Title: | Welding Practices & Procedures |
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Course Description: | Teaches applied metallurgy, welding process applications, and related safety. This intensive course provides a one-of-a-kind opportunity for welding operators, technicians, and supervisors to learn more about the maintenance process and is ideal for improving the skills and on-the-job expertise of a wide range of personnel including: inexperienced welding operators, experienced welding operators in management positions, and anyone else working in a plant or equipment maintenance position where welding repairs are required. |
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Min Credit: | 1.5 |
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Max Credit: | |
REQUIRED COURSE LEARNING OUTCOMES:
1. Explain industry standards for safety.
2. Describe shielded metal arc welding.
3. Describe MIG.
4. Describe TIG.
5. Describe Oxy-acetylene methodology.
6. Recommend different methods of cutting and gouging.
7. Recognize how a knowledge of metallurgy will help in welding.
REQUIRED TOPICAL OUTLINE:
I. Safety
A. Eye and skin protection from arc radiation
B. Electric shock prevention
C. Fume and particulate concerns
D. Dangers of welding and cutting on containers
E. Dangers of arc welding near compressed gas cylinders
F. Specific safety concerns: SMAW, GMAW, FCAW, and GTAW equipment
G. Specific safety concerns: PAC and AAC equipment
II. Shielded Metal Arc Welding ("Stick")
A. Fundamentals of SMAW process
B. Applications of process in maintenance/repair welding
C. Limitations of process
D. Welding current types and application
E. Electrode numbering system
F. Electrode types, comparisons and selection
G. Welding variables
H. All position welding techniques
I. Troubleshooting weld defects: porosity, blowholes, undercut, coldlap, overlap, slag inclusions
III. Gas Metal Arc (MIG) and Flux Cored Arc Welding
A. Fundamentals of GMAW and FCAW processes
B. Applications of processes in maintenance/repair welding
C. Limitations of processes
D. Wire electrode numbering system
E. Wire electrode types, comparisons, and selection
F. Shielding gas blends, comparisons, and selection
G. Machine adjustment variables: amperage, voltage, and ipm feed rates
H. Preventive maintenance of equipment
I. All position welding techniques
J. Troubleshooting weld defects
IV. Gas Tungsten Arc Welding (TIG)
A. Fundamentals of GTAW process
B. Application of process in maintenance/repair welding
C. Limitations of process
D. Welding current types and applications
E. Tungsten electrode selection and preparation
F. Filler metal selection and applications
G. Equipment setup
H. Machine adjustment variables
I. All position welding techniques
J. Troubleshooting weld defects
V. Oxy-Acetylene
A. Oxygen-Acetylene Equipment
B. Properties of oxygen and acetylene
C. Dangers of oxygen-rich and oxygen-starved environments
D. Handling and storage of compressed gas cylinders
E. Setup, lightup, and shutdown procedures
F. Acetylene and oxygen line-pressure determination
G. Prevention of backfires and backflashes
H. Proper use of multi-orifice heating tips (¿rosebuds¿)
I. Safety considerations of oxy-fuel cutting
J. Flame Cutting/Gouging
1. Principles of flame cutting
2. Equipment setup, light-up, and shutdown procedures
3. Acetylene and oxygen line-pressure adjustment for cutting
4. Cutting tip types, sizes, and selection
5. Cutting techniques for plate and structural shapes, plus weld joint preparation
6. Flame gouging techniques for weld removal
7. Troubleshooting poor cuts
K. Braze Welding, Brazing, and Soldering
1. Principles of processes
2. Fluxes/function, selection, and application
3. Acetylene and oxygen line-pressure adjustment
4. Techniques for fusion welding, braze welding, brazing, and soldering
VI. Cutting and gouging
A. Air Carbon Arc Gouging
1. Principles of operation
2. Welding current selection
3. Carbon electrode selection
a. Equipment setup/amperages and air pressures
4. Arc gouging techniques for weld removal, and weld joint preparation
B. Plasma Arc Cutting & Gouging
1. Principles of operation
2. Equipment setup
3. Cutting techniques on carbon steel, stainless steel, and aluminum
4. Gouging techniques for weld removal on aluminum and stainless steel
C. Equipment preventive maintenance
VII. Metallurgy
A. Welding Certification Requirements
1. Why maintenance welders need certification
2. Structural certification under AWS code
3. Pressure vessel certification under ASME code
B. Controlling Weld Quality
1. Essentials for producing good welds
2. Weld profiles, plus weld size requirements and control
3. Starting and ending welds/cratering out, plus using run-off tabs
4. Radiography evaluation/examples of weld defects
C. Understanding Metals
1. Basic metallurgy/properties of metals
2. Metal identification
3. Effects of welding on various metals
4. Causes and prevention of weld failures
5. Causes and control of weldment distortion
D. Repair Welding Principles
1. Welding process selection/limitations
2. Filler metal/electrode selection
3. Weld joint preparation requirements
4. Weld size requirements
5. Weld joint reinforcement considerations
6. Sequence for tack welding and weld off
a. Determining preheat, inter-pass heat, and post heat
7. Considerations for wear surfacing/hard facing and buildup
8. Knowing when NOT to weld
9. Knowing where NOT to weld
E. Repair Welding Procedures
1. Metal identification methods
2. Repairing a failed weld
3. Repairing tubular frame members
4. Repairing pipe members
5. Repairing broken solid shafts
6. Repairing cracks and factures in high-carbon and alloy steels
7. Repairing steel forgings and steel castings
8. Repairing cracks and fractures in cast iron
9. Buildup and wear surfacing techniques
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Northeastern Junior College |
NJC |
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Pueblo Community College |
PCC |
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