WLDG 1337 Introduction to Welding Metallurgy CIP

Transcription

1 WLDG 1337 Introduction to Welding Metallurgy CIP Course Description A study of ferrous and nonferrous metals from the ore to the finished product. Emphasis on metal alloys, heat treating, hard surfacing, welding techniques, forging, foundry processes, and mechanical properties of metal including hardness, machinability, and ductility. (3 SCH, 2 lecture, 2 lab) 2. Prerequisites None 3. Course Goals Each student will be able to correctly answer a minimum of 60% of the questions regarding the aspects of welding metallurgy on minor and major quizzes. Each student will be able to prepare samples for metallurgical examination and various structures present. Class material will be administered in the form of the instructor s lecture and demonstration along with the aid of the textbook. Each student will have a basic understanding of fundamentals and practical experiences in as many welding processes as possible. 4. Instructor Information SYLLABUS PREPARED BY: James R. Bailey DATE: August 2011 INSTRUCTOR RECOMMENDED BY: DATE: DIVISION CHAIRMAN APPROVED BY: DATE: DEAN. For Distance Education: provide contact for technical help such as the IT Helpdesk, or helpdesk@brazosport.edu, for students who have difficulty logging in the first time or have other technical issues such as browser problems. Consider Virtual Office Hours so your students know when you will be online and be able to reach you, either through or chat. 5. Textbook or Course Material Information A. Metallurgy Welding a. Definition 1. Process metallurgy b. Equipment B. Types of Steel and Their Manufacture

2 a. Steel making process 1. Reduction to iron ore 2. Acid and basic steelmaking 3. Furnaces and converters 4. Charging and melting 5. Refining 6. Finishing and deoxidation a. Rimmed steel b. Capped steel c. Killed steel d. Semikilled steel e. Vacuum deoxidized steel 7. Electric furnace 8. Vacuum furnace 9. Mill processing a. Hot working b. Cold finishing b. Types of steel 1. Carbon steel a. Low carbon b. Mild steel c. Medium steel d. High steel 2. Allow steel a. Definition 1. Construction steels 2. Auto, aircraft and machinery steels 3. Low-temperature service steels 4. High-temperature steels 3. High alloy steels a. Austenitic manganese steels b. Stainless steel c. Heat-resisting steels 4. Tool steels 5. Classifications 6. Specifications a. ASISI-SAE b. ASTM c. Consideration 1. Qualities important to welding a. Chemical composition b. Mechanical properties d. Minor quiz over A & B C. Temperature Changes in Welding a. Heat and time in welding 1. Rate of heating 2. Generation of heat a. Heat input formula

3 3. Maximum temperature 4. Temperature distribution 5. Time at temperature a. Temp colors 6. Cooling rates in welding a. Heat source or nugget b. Effect of base metal mass 7. Temperature gradient a. Preheating b. Postheating 2. Minor quiz over C D. The structure of metals a. Atoms 1. Elementary particles 2. The elements 3. Metallic state b. Crystalline structure 1. BCC 2. FCC 3. HCP c. Crystal growth d. Dendrite formation e. Grain formation 1. Size 2. Shape 3. Growth 4. Orientation 5. Refinement f. Crystal imperfections 1. Dislocations a. Edge b. Screw g. Solid state solubility h. Allotropy 2. Laboratory exercises a. Use of equipment 1. Mounting 2. Grinding 3. Polishing 4. Metallorgraphic examination E. The Properties of Metals a. Structural sensitivity b. Mechanical properties 1. Tensile strength 2. Modulus of elasticity 3. Yield strength

4 4. Strain hardening a. Twinning 5. Fatigue strength 6. Hardness 7. Ductility 8. Toughness 9. Fracture c. Physical properties 1. Density 2. Thermal properties a. Specific heat b. Conductivity c. Melting point or range d. Heat of fusion e. Boiling point f. Coefficient of expansion 3. Electrical conductivity a. Magnetic properties 4. Corrosion properties a. Uniform attack b. Pitting c. Intergranular attack d. Stress-corrosion cracking 2. Laboratory exercise a. Microhardness b. Macrohardness 3. Major quiz over A through E F. Effects of Alloying Elements a. Alloying 1. Liquid state 2. Solid state b. Equilibrum diagrams c. Influence 1. During freezing 2. Crystalline structure 3. Mechanical properties d. Elements effect 1. Carbon 2. Manganese 3. Phosphorus 4. Sulfur and selenium 5. Silicon 6. Copper 7. Chromium 8. Nickel 9. Molybdenum 10. Columbium 11. Titanium

5 12. Tungsten 13. Vanadium 14. Cobalt 15. Aluminum 16. Boron 17. Nitrogen 18. Lead G. Fumes, Slags and Gases for Shielding a. Atmosphere effects 1. Oxidation a. Prevention 2. Scaling b. Shielding slags 1. Properties c. Fumes d. Controlled atmospheres e. Vacuum f. Welding techniques g. Welding processes shielding 1. SMAW 2. GMAW 3. FCAW 4. SAW 5. EBW h. Gases 1. Carbon dioxide 2. Propane 3. Hydrogen 4. Argon 5. Helium 6. Mixed gases 2. Minor quiz over G & H H. Simple Welds in Iron and Steel a. Weld melt in iron 1. Transformations 2. Solidifications 3. Single pass 4. Multipass b. Weld melt in steel 1. Microstructure changes a. Heat affected zone 2. Effect of cooling rate a. Transformations 1. Transformation of martensite b. Critical cooling rates

6 2. Major quiz over F through H For Distance Education: Contact the Brazosport College Bookstore, 500 College Drive, Lake Jackson, TX, 77566, Phone: , Fax: with a credit card for these materials. 6. Lab Requirements (if any) (This item may be omitted if no lab is required) The student must demonstrate proper manner in classroom participation by having appropriate materials, keeping work area clean and organized, observing all safety rules pertaining to laboratory work, being present for all test or quizzes, being punctual, and turning in all assignments when due. Each student will spend at least 7 hours per week preparing for class. Each student will be asked to complete an Instructor/Course Evaluation at the end of the course. Attendance is critical in the class. 7. Students with Disabilities BC is committed to providing equal education opportunities to every student. BC offers services for individuals with special needs and capabilities including counseling, tutoring, equipment, and software to assist students with special needs. Please contact Phil Robertson, Special Populations Counselor, for further information. 8. Academic Honesty BC assumes that students eligible to perform on the college level are familiar with the ordinary rules governing proper conduct including academic honesty. The principle of academic honesty is that all work presented by you is yours alone. Academic dishonesty including, but not limited to, cheating, plagiarism, and collusion shall be treated appropriately. Please refer to the BC Student Guide for more information, this is available online at click on the link found on the left side of the homepage. 9. Attendance and Withdrawal Policies The class meets for 1 lecture hour and 5 lab hours per week. Students are responsible for all class work assigned during any absence. The instructor will accept work without penalty, when, in his judgment an absence could not be avoided. Absences: Students not attending class regularly will be administratively withdrawn from class by the instructor. Students will be considered absent if not in class within the first hour of a five hour class time. Students in this class are subject to withdrawal for accumulating 3 consecutive or 4 total semester absences. The instructor may reinstate the student after withdrawal if, in the judgment of the instructor, the absences do not jeopardize satisfactory course completion or may not reinstate the student. Student will be dropped: Cell phones in the class room or in welding lab will no longer be allowed. If the student is caught using a cell phone 3 times, it will be an automatic drop from the class. Butane Lighters are not allowed with no further warning the student will be dropped from class. For Distance Education: Online students should be informed of course login policies, attendance requirements, submission of work as evidence of attendance, and how to withdraw from the course. 10. Course Requirements and Grading Policy = A = B = C = D Below 60 F

7 11. Testing Three major exams at 10% each 30% Attendance 20% Laboratory projects 7 minor 25% 1 major bend test 25% 100% For Distance Education: Be sure to state if testing is required to be proctored and explain the procedures clearly, including logging in to a test site. 12. Make-up policy If you allow students to makeup assignments or assessments include that information here, if no makeup is allowed state it clearly. 13. Student Responsibilities The student must demonstrate proper manner in classroom participation by having appropriate materials, keeping work area clean and organized, observing all safety rules pertaining to laboratory work, being present for all test or quizzes, being punctual, and turning in all assignments when due. Each student will spend at least 7 hours per week preparing for class. Each student will be asked to complete an Instructor/Course Evaluation at the end of the course. Attendance is critical in the class. Students are expected to fully participate in the course. The following criteria are intended to assist you in being successful in this course. a. Time Management b. Understanding the Syllabus Requirements c. Utilizing Online Components (such as WebCT) d. Communicating with the Instructor e. Completing Course Work 14. Projects, Assignments, Portfolios, Service Learning, Internships, etc. This should be a brief list, an overview, not the actual details for each activity or assignment a basic road map through the semester without specific dates or timeframes. This will enable you to carry the syllabus forward each semester so long as you will take care of any major changes in the learning objectives or the way you plan to conduct the course. For Distance Education: The earlier we can post the course with its syllabus, the more likely that we will be able to attract students from other colleges. (See separate section details of course content and calendar.) 15. Other Student Services Information This list is provided to assist students locate available services. Information about the BC Library is available at or by calling Tutoring for Math, Reading, Writing, Biology, Chemistry, and other subjects is available in the LAC, To contact the (name of dept.) Department call (add phone # here). The Student Services area provides the following services Counseling and Advising, ; Financial Aid,3294; and Student Activities,3355. For Distance Education: Distance Learning Support Information, To reach the Information Technology dept. for technical assistance call the Helpdesk ,.

8 (See the next page for information regarding course schedule and calendar; do not include this statement on your syllabus)

9 On a Separate Page to be updated every semester. ****Additional Information not part of the syllabus File. ****Within WebCT as a separate HTML page add the following information to be linked. 1. Course Content Describe the course content here in detail. 2. Course Calendar with Assignments Enter your calendar here with specific dates; this should include any reading, homework, posting, and lab assignments.