GTAW (TIG Welding) II

Transcription

1 SOUTHWESTERN MICHIGAN COLLEGE DIVISION OF ADVANCED TECHNOLOGIES Dowagiac, Michigan COURSE SYLLABUS Fall Semester/Session 2012 COURSE TITLE: GTAW (TIG Welding) II COURSE NO.: WELD166 SECTION NO.: 2538 DAYS AND TIMES: Lecture: MW 6:30 7:29pm Lab: 5:30 6:29pm, 7:40 9:25pm CREDITS/CONTACTS: Credit Hours: 2 Lecture hours/weekly: 1 (Room 122, NAC) Laboratory hours/weekly: 3 (Room 227, M-TEC) Weekly Contact Hours: 4 FINAL EXAM INFORMATION: INSTRUCTOR: Refer to the Final Exam Schedule posted on SMC Wired for time and location of final exam. Name Mr. Nathan Kramb Office: NAC Room 120A Phone Number: nkramb01@swmich.edu OFFICE HOURS: As posted PREREQUISITE: COURSE DESCRIPTION: COURSE OUTCOMES: Minimum grade of C in WELD 162, concurrent enrollment allowed; and READ 100 or satisfactory test score, concurrent enrollment allowed. This course covers the application of the gas tungsten arc welding process for different joints in all positions. Includes welding of non-ferrous metals. Students successfully completing WELD 166 will be able to: 1. Safely set-up, adjust, operate, and properly shutdown an electric arc welding machine for the Gas Tungsten Arc Welding (GTAW) process. 2. Demonstrate the ability to interpret drawings, sketches or Weld Procedure Specifications (WPS) into the proper completed weldments. 3. Demonstrate a basic knowledge of GTAW process theory, shielding gases, filler metals, base metal identification, and weld metallurgy. 4. Demonstrate welding, cutting, and welding laboratory safety skills; perform safety inspections of equipment and accessories. 5. Successfully complete a groove weld in the vertical up (3G) position. (Carbon) 6. Successfully complete a groove weld in the overhead (4G) position. (Carbon) 7. Successfully complete a fillet weld in the vertical up (3F) position (Carbon, Stainless and Aluminum) 8. Successfully complete a fillet weld in the overhead (4F) position. (Carbon) 9. Successfully complete a groove weld in the flat (1G) position, using pulsed current. (Stainless) 10. Successfully demonstrate how to inspect a completed weld or cut, identify

2 the causes of discontinuities or defects, and make the necessary corrections or repairs TEXTBOOK: REQUIRED: Hobart, EW369 GTAW Gas Tungsten Arc Welding Hobart, Welding Procedures and Qualifications Hobart, Welding Discontinuities & Defects OPTIONAL: ADDITIONAL REQUIRED RESOURCES: Lincoln: The Procedure Handbook of Arc Welding Hobart, Gas Tungsten Arc Welding Pipe & Tube WELD Voucher, Slip-joint pliers METHOD OF INSTRUCTION: will use classroom lecture/discussion, audio-visual materials, written assignments, and welding projects. Welding Procedure Specifications (WPS), Visual Inspection Criteria and Weld Test Records will be used. EVALUATION METHOD: Upon completion of this course, the student will demonstrate achievement of the course objectives by obtaining a final minimum grade of 73%, as measured by quizzes, laboratory projects, the final examination and attendance. The final grade for this course will be made up of the following percentages: Written Quizzes 25 % Written Final Exam 25 % Weld Projects 50 % 100% Students who participate in unsafe activities, exhibit unacceptable behaviors or misuse tools/equipment, could lose up to 20% of their final grade, will be asked to leave the classroom, and must meet with the Dean of Advanced Technologies before being allowed to return. Written quizzes and projects must be completed the semester they are assigned. GRADING SCALE: The following grading scale will be in effect for this course: % = A 73 76% = C 90 92% = A % = C % = B % = D % = B 63 66% = D 80 82% = B % = D % = C+ Below 60% = F ATTENDANCE POLICY: TESTING POLICY: ATTENDANCE IS REQUIRED FOR CLASSROOM AND LAB. It is the responsibility of each student to complete the time required for the course in which they are enrolled. When a student completes the total hours of lecture/lab, lab projects and quizzes/tests required for the specific course, they have completed the course. Students are expected to take all examinations as scheduled. Students who

3 are ill must contact the instructor within the following week and make up the examination within two weeks of the original testing date. The instructor reserves the right to determine whether a make-up test will be given and the format of the testing method. NOTICE: OTHER COURSE EXPECTATIONS: Representative student work will be used as a part of SMC s on-going curriculum assessment program. SAFETY AND EQUIPMENT REQUIREMENTS FOR CLASS: 1. Approved safety glasses. 2. Approved ear protection. 3. Leather apron and sleeves or approved welding jacket. 4. Approved welding gloves. 5. Approved welding hat or skullcap. 6. Clothing should made of non-flammable material and be free of oil and grease. Pants must be full length, without cuffs. 7. Leather shoes or work boots. 8. Pliers (either slip joint or vise grip). 9. Wire cutting pliers (for wire welding). 10. Scribe and/or soapstone. Upon entry to the weld laboratory, all students should note the location of safety items such as extinguishers; fire blankets, and is aware of the location of the nearest exits. No welding should be performed unless ventilation hood systems in the welding booths are functioning properly. All students will be required to sit through a safety orientation before being allowed to participate in welding activities. Upon completion of the orientation, students will sign a checklist signifying that they have received and understand the safety requirements for the class. A $40 Welding Voucher Fee is required for each student upon entry to the weld lab. This voucher is used for welding supplies and consumables such as welding rod and wire, contact tips, tungsten, welding gases, and weld material to be used in the laboratory. The voucher is purchased at the bookstore and is given to your instructor before you will be allowed to participate in the welding class. PROJECT EVALUATION: ACCEPTABLE USE OF PERSONAL COMMUNICATION TECHNOLOGY: All projects will be inspected by the instructor to determine if the weld is full size, full length and free of defects that would render the weld unsound. To ensure that students attain expected welding skills, assigned projects will be redone until they are acceptable. All phones, ipods, Black Berries, palm pilots, pagers, laptops and other technological devices including devices capable of taking photographs must be turned off or placed on vibrate mode and may not be brought our during class.. If you are expecting or receiving an urgent call, you are required to leave the classroom before answering. Violation of this policy will result in your removal from the classroom for the class period. Multiple violations of this policy will be referred to the appropriate dean for disciplinary action. Further details or ramifications of violations maybe found elsewhere in this syllabus. The instructor has the right to modify this policy to meet the needs of your course. HONESTY POLICY: Cheating or plagiarizing will absolutely not be tolerated at Southwestern Michigan College. Any student found cheating or plagiarizing material in any

4 manner may be assigned a failing semester/session grade in this course. A second such incident while at SMC could result in suspension or expulsion from the institution. A student found in violation of this section of the syllabus will not be allowed to drop this course. Additional detail regarding cheating and/or plagiarism may be found elsewhere in this syllabus. For more detailed information consult the SMC Student Code of Conduct. NOTICE: Information in this syllabus was, to the best knowledge of the instructor, considered correct and complete when distributed for use at the beginning of the semester. The instructor, however, reserves the right, acting within the policies and procedures of, to make changes in course content or instructional techniques. All submitted course assignments will be returned to the student within 2 class sessions of submission. COURSE OUTLINE WEEK 1 WEEK 2 WEEK 3 WEEK 4 WEEK 5 WEEK 6 WEEK 7 WEEK 8 Discussion of Sketching, Blueprint Reading, Welding Codes, and WPS Discussion of Welding Dissimilar Metals Discussion of Pre and Post Weld Heating Discussion of Welding Dissimilar Thickness Materials Discussion of Non-Ferrous Metals Identification and Non-Ferrous Metallurgy Weld Projects Due Pre Exam Review WRITTEN FINAL EXAM COMPREHESIVE COURSE ASSIGNMENTS BIBLIOGRAPHY CLASSROOM BEHAVIOR: Students are expected to assist in maintaining a classroom environment that is conducive to learning. In order to assure that all students have the opportunity to gain from time spent in class; students are prohibited from engaging in any form of distraction. Inappropriate behavior in the classroom shall result, minimally, in a request to leave class.

5 VISUAL INSPECTION and WELD TEST RESULTS Welder Name WPS Number PRE-WELD INSPECTION 1.) Use of Proper Welding Procedure 2.) Base Metal Cleanliness 3.) Edge Preparation 4.) Joint Fit-up 5.) Proper Electrode / Filler Metal Selection 6.) Power Source (Proper Grounds, Condition of Equipment) 7.) Proper Safety Equipment IN-PROCESS INSPECTION 8.) Proper Welding Materials and Equipment 9.) Proper Welding Parameters 10.) Correct Electrode Travel Angle, Work Angle, and Direction 11.) Full Penetration 12.) Weld Size 13.) Pre-Heat Temperatures, if applicable 14.) Cleaning Of All Passes 15.) Ventilation and Safety Equipment 16.) Tack Weld Condition 17.) Stop / Start Appearance FINAL VISUAL INSPECTION 18.) Excessive Spatter 19.) Weld Profile (Size, Reinforcement, Contour) 20.) Cracks 21.) Crater Condition 22.) Undercut 23.) Distortion 24.) Final Appearance of Weld 25.) Incomplete Fusion / Overlap 26.) Porosity (Diameter of Largest ) 27.) Arc Strikes 28.) Penetration 29.) Correct Length Weld

6 WELD TEST RESULTS FACE AND ROOT BEND TEST RESULTS 30.) FACE-BEND - LENGTH OF EACH DISCONTINUITY SUM 31.) ROOT-BEND - LENGTH OF EACH DISCONTINUITY SUM 32.) FACE-BEND - LENGTH OF EACH DISCONTINUITY SUM 33.) ROOT-BEND - LENGTH OF EACH DISCONTINUITY SUM NICK BREAK TEST RESULTS 34.) SPECIMEN # 35.) SPECIMEN # FILLET WELD BREAK TEST RESULTS 36.) SPECIMEN # 37.) SPECIMEN # DYE PENETRANT TEST RESULTS 38.) SPECIMEN # 39.) SPECIMEN # Welder Name (Signature) Date Instructor Name (Signature)

7 WELDING LABORATORY / CLASS TIME LOG NAME CLASS Date Time In Time Out Total Hrs. Description of Time Use

8 SAFETY RULES 1. Know where safety equipment is located. 2. Notify instructor of any injuries - immediately. 3. Notify instructor of any equipment damage immediately. 4. Never use a new piece of equipment without instruction. 5. Never repair a piece of equipment without instruction. 6. If you are unsure about an assigned project or use of equipment ask instructor. 7. Check equipment condition before use, and make sure welding environment is safe. 8. Keep combustibles out of the welding areas. 9. Always wear non-flammable, protective clothing and shoes suitable for the welding to be done. 10. Safety glasses must be worn under your welding helmet, and whenever you are in welding laboratory. 11. Make sure helmet has correct lens shade for the process being used. 12. Always handle welding material with proper gloves and pliers. 13. Always wear hearing protection and a face shield when grinding. 14. Always turn equipment off when leaving booth, and hang electrode holder in the brackets provided. 15. Never use electrode holders as chipping hammer, or tighten with pliers. (Use proper equipment.) 16. Never change polarity, amperage or voltage settings while equipment is in use. 17. Never open a welding machine cabinet when the machine is operating. 18. Make sure ground clamp is secure and tight on worktable. 19. Make sure fume exhaust is working properly before welding. 20. Never stand in front of the gauges when opening a cylinder. Stand aside and slowly open cylinder valves. 21. When cylinders are not in use, the cylinder valve should be closed and the diaphragm screw should be released. 22. Always clean up your work area when you are done.

9 SAFETY ORIENTATION AND CLASS ATTENDANCE REQUIREMENTS WELD 166 I HAVE RECEIVED THE SAFETY ORIENTATION AND THE CLASS ATTENDANCE REQUIREMENTS. I UNDERSTAND AND AGREE TO FOLLOW THESE REQUIREMENTS. PRINTED NAME: SIGNATURE: DATE:

10 HONESTY POLICY REQUIREMENTS WELD 166 I understand that all welding and fabrication projects, for any and all WELD courses, at must be completed, in their entirety, on the premises of the Welding Lab. All materials used for these projects must also be supplied by the Welding program. Any student who is found to have violated these terms, without the express written permission of their Instructor(s), will be considered as having cheated and will be subject to the consequences as described within the Honesty Policy*. *Available in all class syllabi and the online student handbook. PRINTED NAME SIGNATURE DATE