WELDING SYLLABUS


WELDING 1 & 2  COURSE SYLLABUS
Welding Instructors:  Pedro S. Sanchez, Jr Certified Welding Educator International-IMWS
Course: SMAW,GTAW,GMAW, FCAW WELDING LEVEL 1 & 2

Course Description: This course will introduce students to welding and begin basic arc welding,
mig welding, tig welding, and oxyacetylene cutting.

Course Competencies:  “IMWS 4.0, NC- 11 STANDARD  AWS D1.1 ASME-1X API-11O4 approved committee"

Unit A: Introduction to Welding

1. Explain how each welding process works.
2. Define the terms weld, welding, forge welding, resistance welding, and fusion welding.
3. Describe the responsibilities and duties of a welder in various welding positions.
4. Describe the history of welding.

Unit B: Safety in Welding

1. Describe the types of protection that should be worn for welding.
2. Describe the proper method of handling, storing, and setting up cylinders.
3. Describe the proper way to ventilate a welding area.
4. Explain how to avoid electrical shock.
5. Describe fumes and gases associated with arc welding.

Unit C: Flame Cutting

1. Explain how flame cutting works.
2. Demonstrate how to properly set up and use an oxyfuel gas cutting torch.
3. Demonstrate a variety of cuts using the oxy fuel gas cutting torch.

Unit D: Plasma Arc Cutting

1. Define plasma and describe a plasma torch.
2. Describe how plasma cutting works.
3. Explain the advantages and disadvantages of using a plasma cutting torch.
4. Demonstrate the ability to set up and operate a plasma cutting torch.

Unit E: Shielded metal arc equipment, Setup, and Operation.
1. Explain the differences in welding with each of the three types of current.
2. Identify welding machines according to their type.
3. Demonstrate how to select and set the welding current.
4. Describe the proper maintenance of welding equipment.
5. Demonstrate how to safely set up an arc welding station.

Unit F: Shielded metal arc welding of plate.
1. Demonstrate the ability to set the welding amperage correctly.
2. Explain the effect of changing arc length on a weave pattern.
3. Control weld bead contour during welding by using proper weave pattern.
4. Demonstrate the ability to control undercut, overlap, porosity, and slag inclusions when welding.
5. Describe the effect of electrode angle on a weld.


Course Outline:

Unit A: Introduction to Welding

1. Welding defined.
2. Using of welding.
3. Welding processes.
4. Occupational opportunities in welding.
5. History of welding.

Unit B: Safety in Welding.

1. Introduction.
2. Burns.
3. Eye and Ear protection.
4. Respiratory protection.
5. Ventilation.
6. Electrical safety.
7. General work clothing.
8. Protective clothing.
9. Handling and storing cylinders.
10. Fire protection.
11. Equipment maintenance.
12. Work area.
13. Hand tools.
14. Power tools.
15. Material handling.

Unit C: Flame Cutting.

1. Introduction.
2. Cutting torches.
3. Cutting tips.
4. Hand cutting.
5. Layout.
6. Selecting correct tip and setting pressure.
7. Plate cutting.
8. Methods of improving cuts.
9. Distortion.

Unit D: Plasma Arc Cutting.

1. Introduction.
2. Plasma.
3. Arc plasma.
4. Plasma torch.
5. Power and gas cables.
6. Power requirements.
7. Heat input.
8. Distortion.
9. Applications.
10. Gases.
11. Machine cutting.
12. Manual cutting.
13. Safety.

Unit E: Shielded Metal Arc Equipment, Setup, and Operation.

1. Introduction.
2. Welding current.
3. Types of welding power.
4. Open circuit voltage.
5. Operating voltage.
6. Arc blow.
7. Types of power sources.
8. Generators and alternators.
9. Rectifiers.
10. Duty cycle.
11. Welding cables.
12. Electrode holders.
13. Work clamps.
14. Setup.

Unit F: Shielding metal arc welding of plate.
1. Introduction.
2. Effect of current settings.
3. Electrode size and heat.
4. Arc length.
5. Electrode angle.
6. Electrode manipulation.
7. Positioning of the welder and plate.
8. Practice welds.
9. Stringer beads.
10. Lap joint.
11. Tee joint.

Textbooks, References, and Resources:

Welding principles and applications, safety videos, welding lab.

Evaluation System

Completion of assigned competencies.
Unit tests and exams.
Daily grade average.


Pre- Final  Welding Syllabus

WELDING  level  2 & 3
Welding Instructor:   JONATHAN SANCHEZ
Course: International Certification ( IC - Level 2 & 3 Multiple Process)


Course Description: The Welding 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.

Objective:

Given the necessary equipment, material, and instruction, the student, on completion of the prescribed course of study, will be able to successfully accomplish the following core competencies and the standard application of welding law adoption of the United States of America.

Unit A: Performing Work Safety Practices.

1. Demonstrate the ability to work safely.
2. Demonstrate the ability to keep a clean, orderly, and safe work area.
3. Operate a fire extinguisher properly.
4. Demonstrate the safe use of hand and power tools.
5. Complete safety test.
6. Follow first aid procedures.
7. Follow welding law discussion procedures.
8. Practical welding  naval training discipline.
9. Field Training actual site situation Power plant,Oil Refinery, Shipyard.

Unit B: Reading Blueprints.

1. Read and interpret lines, views, dimensions, and notes on multi-view or pictorial drawings (or sketches).
2. Read and interpret the basic welding symbols and supplementary symbols on drawing or sketches.
3. Identify the basic types of weld joints.
4. Measure with a ruler within 1/16” accuracy when laying out a job from a drawing or sketch.

Unit C: Identifying Basic Metals

1. Identify selected metals by appearance, color, and weight.
2. Identify metal shapes used for welding.
3. Conduct the following test on selected metal:
a: Magnet test.
b: Spark test.
c: Chisel test.

Unit D: Demonstrate Oxyacetylene Metal Cutting Skills and Practices.

1. Set up and adjust oxyacetylene station.
2. Light and adjust flame.
3. Close down oxyacetylene station.
4. Lay out and cut straight lines (manual).
5. Lay out and cut angles.
6. Lay out and cut circles.
7. Lay out and cut patterns.
8. Lay out and cut beams, angle and channel iron.
9. Lay out and cut pipe.
10. Lay out and cut square and round solid stock.


Unit E: Demonstrating Shielded Metal Arc Welding  (SMAW)  Skills and Practices.

1. Set up and adjust shielded metal arc welder.
2. Strike and maintain an arc.
3. Weld straight bead patterns.
4. Weld weave bead patterns.
5. Construct a fillet weld, 3/16 equal legs, single pass, in the flat position.
6. Construct a fillet weld, ¼” equal legs, single pass, in the horizontal position.
7. Construct a fillet weld ½” equal legs, three passes, in the horizontal position.
8. Construct a fillet weld, single pass in the vertical up and down positions.
9. Construct a V-groove weld, multiple pass in the vertical position.
10. Construct a groove weld, multiple pass in the flat position.
11. Construct a groove weld, multiple pass in the horizontal position.
12. Construct a groove weld, multiple pass in the vertical position.
13. Construct a groove weld, multiple pass in the overhead position.
14. Construct a groove weld on pipe in the flat axis position.
15. Construct a groove weld on pipe in the vertical position.

Unit F: Demonstrating Tungsten Arc Welding (TIG) Skills and Practices.

1. Set up and adjust gas tungsten arc welder (AC/DC ferrous and nonferrous).
2. Construct a bead weld, flat position with filler material (AC/DC).
3. Construct a 1/8” fillet weld, lap or tee joint, horizontal position (mild steel, stainless steel, or aluminum.)
4. Construct an outside corner joint, flat position (AC/DC).
5. Construct an outside corner joint, horizontal position (AC/DC).
6. Construct an outside corner joint, single pass on mild steel overhead position (AC/DC).

Unit G: Demonstrate Gas Metal Arc Welding (MIG) skills and Practices.
1. Set up and shut down GMAW equipment.
2. Construct a multiple pass T-joint fillet weld in the horizontal position.
3. Construct lap-joint fillet weld in the vertical down position.
4. Construct a corner joint fillet weld in the vertical position for break test.
5. Construct a T-joint fillet weld in the overhead position with short arc for break test.
6. Construct a T-joint fillet weld in the horizontal position with short arc.
7. Construct a single V-groove butt joint in the flat position with short arc.
8. Construct a single V-groove butt joint in the vertical down position with short arc for test.
9. Construct a single V-groove butt joint in the in the overhead position with short arc for test.