WDF-0105 Hand, Measuring and Layout Tools

Transcription

1 WDF-0105 Hand, Measuring and Layout Tools NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 24 - Metal Fabricator (Fitter) task 5 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - select, use and maintain hand tools. - select, use and maintain measuring instruments. - select and use layout tools. - identify the various steel structural shapes. Theory: 1. Identify the types of hand tools and describe their applications, use, care and storage. - pliers - chisels and punches - wrenches - offset - sockets - adjustable - open end - combination - box end - allen - pipe - speed - vices - pipe - soft jaw - swivel - straight edges - screwdrivers - files - bolt cutters

2 - hammers and mallets - ball peen - cross peen - engineers - sledge - torque wrenches - sequence - torque multipliers - reamers - chain hoists - jacks - tubing tools - flaring - bending - cutting - annealing - electrode bag - punches - center - prick - pin - line up bars (draft pins) - connecting bar 2. Describe the imperial and metric measuring systems and their use in the trade. 3. Identify measuring tools and instruments and describe their parts, applications and procedures for use. - square - bevel - measuring tape - t-square - compass - protractor - builders level - depth gauge - feeler gauge - laser level - fillet gauge - magnetic level - micrometer - plumb bob - scribers - spirit level - stop watch

3 - straight edge - try square - vernier caliper - welding gauge - water level - chalk line - trammel points - dividers - combination square 4. Identify and describe the various steel structural shapes. - beams - H - WF - WWF - S - channels - standard - miscellaneous - types of bars - types of plate - angles - pipe - tubing - terminology - leg - web - flange, etc - determination of sizes - fractional - decimal - weight per linear ft. - method of stipulating dimensions

4 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Identify and select various hand tools. 2. Check a framing square for accuracy. 3. Divide a circle. 4. Lay out a weld gauge. 5. Lay out a drill gauge. 6. Lay out a parallel clamp. 7. Lay out a coupon grinding clamp. 8. Identify structural shapes. 9. Estimate weight of common structural shapes.

5 WDF-1110 Hand and Power Cutting Tools NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis:: - Welder tasks 29, 31 and 32 - Metal Fabricator (Fitter) task 6 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - demonstrate knowledge of cutting tools, their applications, care and use. Theory: 1. Describe hand shears, their applications and procedures for correct use. - cutting techniques - sheet metal in a straight line - circles - angular shapes 2. Describe power shears and nibblers, their applications and procedures for correct use. - cutting techniques - sheet metal in a straight line - circles - angular shapes 3. Describe squaring shears, their applications and procedures for correct use. - parts of the shear - type of blade 4. Describe hand hacksaws, their applications and procedures for correct use. - parts of the saw - type of blade 5. Describe electrical metal-cutting band saws, their applications and procedures for correct use. - parts of the saw - type of blade 6. Describe abrasive saws, their applications and procedures for correct use. - type of disc - maintenance

6 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Use cutting tools. - hand hacksaw - cold chisel - hand shears - band saw - abrasive saw - power shears - squaring shears

7 WDF-1115 Drilling, Threading and Fastening NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 26 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - select and sharpen drills. - make threads using taps and dies. - use clamps - use power drills, drill presses, and magnetic-base drills Theory: 1. Identify the types of drills, and describe their applications, use and care. - parts - sharpening 2. Describe the use and care of hand power drills, drill presses, and magnetic-based drills. 3. Describe taps and dies, their applications, use and care. - external - internal 4. Identify the types of clamps, and describe their applications, use and care. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Sharpen a drill. 2. Use C-clamps and adjustable clamps. 3. Use hand power drills, drill presses, and magnetic-base drills.

8 4. Make external threads with a die. 5. Make internal threads with a tap.

9 WDF-1120 Grinding and Finishing NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 28 - Metal Fabricator (Fitter) task 8 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - dress a grinding wheel. - select and use portable grinders. - select and use portable sanders. - use stationary grinders Theory: 1. Describe grinding wheels, their applications and use. - types of dressers - procedures used to dress 2. Describe the use of portable grinders. - type of abrasive - grit - speed - attachments - accessories 3. Describe the use of portable sanders. - type of abrasive - grit - speed - attachments - accessories 4. Describe the use of stationary grinders. - speed - bond - grit - attachments - accessories - tool rest adjustment

10 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Use a wheel dresser. 2. Grind metal parts with a portable grinder. 3. Grind metal parts with a stationary grinder. 4. Sand metal with a sander. 5. Install grinding wheels.

11 WDF-1125 Bending and Rolling NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 25 - Metal Fabricator (Fitter) task 6 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - use electric and mechanical equipment to bend and roll metal. - use manual equipment to bend and roll metal. Theory: 1. Identify the types of electric, mechanical and manual equipment used to bend and roll metal, and describe their applications, care and use. - tonnage - spacing - clearance - calculations - bending procedures - rolling procedures Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Roll sheet metal to specified dimensions using manual equipment. 2. Use manual equipment to roll a cone. 3. Use a pan brake to make a pan. 4. Make a 90 bend in a 1¼" pipe using OAW equipment. 5. Twist a 3/8" square bar stock a predetermined number of turns.

12 6. Make a frame with an angle measuring 1" x 1" x 1/8".

13 WDF-1130 Oxy-Fuel Welding and Cutting NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 44, 45 & 46 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - set up and use oxy-fuel equipment. Theory: 1. Describe the procedures used to set-up oxy-fuel equipment. - cleaning - threads - pressure - fuel gas - oxygen 2. Describe the procedures for use of oxy-fuel equipment to cut: - sheet metal - plate - structural shapes - pipe 3. Describe the procedures for use of automatic flame-cutting equipment to cut plate.

14 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. List the safety rules for using oxy-fuel equipment. 2. Set-up oxy-fuel equipment. - propane - acetylene 3. Cut various steel structural shapes using manual flame-cutting equipment. 4. Cut steel plate and pipe using automatic flame-cutting equipment. 5. Cut a square hole in 3/8" plate. 6. Cut a 30 bevel on 3/8" plate. 7. Pierce a 2 1/2" diameter hole in 3/8" plate.

15 WDF-1135 SMAW 1 - Set-up NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 49 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - set up and maintain an arc. - establish an electric arc. - deposit a weld bead. - cut metal. Theory: 1. Describe the terminology associated with arc welding. - mild steel and low alloy steel electrodes - AC & DC - Arc Blow - duty cycle - rated amperage - thawing pipes - striking and maintain an arc - stringer and weave beads 2. Describe the SMAW process. - general precautions - equipment and accessories - electrodes - codes and standards 3. Describe the set up and maintenance of welding equipment used in the SMAW process. - welder s helmet - electrode holder - ground clamp - type of machine and components - brush - chipping hammer - polarity 4. Describe characteristics and applications of different power sources.

16 - AC transformers - AC/DC rectifiers - DC generators - engine drive (gasoline, diesel) - inverters 5. Describe the procedures and equipment used for set up - ground clamp and/or terminal lug - electrode holder - electrode selection - current - polarity settings - arc length - travel speed - electrode angles - work and travel angles 6. Describe the procedures used to establish and maintain an electric arc. - sequence (steps in the arc welding process) - control - maintenance - stopping and restarting - length 7. Describe the procedures used to deposit a weld bead. - selection of electrode - stringer - weave - speed - spatter loss and electrode stub - angle - handling - inspection - appearance - lack of fusion 8. Describe the procedures used to cut metals using the SMAW process. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Set up welding equipment and check the various external components.

17 2. Tack weld with E41011 (E6011) and E48018 (E7018) electrodes. 3. Deposit stringer beads and welds with E41010 (E6010) or E41011 (E6011) and E48018 (E7018) electrodes. 4. Deposit weave beads with E41010 (E6010), E41011 (E6011) and E48018 (E7018) electrodes. 5. Perform buildup with E41010 (E6010) or E41011 (E6011) and E48018 (E7018) electrodes.

18 WDF-1140 SMAW 2 - Fillet Weld All Positions F-3 NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 49 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - fillet weld mild steel in all positions using the SMAW process with F-3 class electrodes. - perform weld tests. Theory: 1. Define terminology associated with the SMAW process. 2. Describe the procedures used to perform fillet welds on mild steel in the flat position. - tee - lap - corner joints - size - destructive testing 3. Describe the procedures used to perform fillet welds on mild steel in the horizontal position. - tee (multi pass) - lap (single pass) - plug - corner joints - strength - tack - composite 4. Describe the procedures used to perform fillet welds on mild steel in the upward vertical position. - tee - lap - corner joints - electrode - angle

19 5. Describe the procedures used to perform fillet welds on mild steel in the overhead position. - tee - lap - corner joints - force of gravity - limitations - adjustment - body stance 6. Describe the procedures used to test welds. 7. Describe weld faults - slag inclusions - lack of penetration - porosity Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Run stringer beads in all positions. 2. Perform fillet welds on T-joint and lap joint using F-3 electrodes.

20 WDF-1145 SMAW 3 - Fillet Weld All Positions F-4 Mild Steel NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 49 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - fillet weld mild steel in all positions using the SMAW process with F-4 class electrodes - perform weld tests Theory: 1. Define terminology associated with the SMAW process. 2. Describe the procedures used to perform fillet welds on mild steel in the flat position. - tee - lap - corner joints - size - destructive testing 3. Describe the procedures used to perform fillet welds on mild steel in the horizontal position. - tee (multi pass) - lap (single pass) - corner joints - strength - tack - plug - composite 4. Describe the procedures used to perform fillet welds on mild steel in the upward vertical position. - tee - lap - corner joints - electrode - angle

21 - slag inclusions - lack of penetration - porosity 5. Describe the procedures used to perform fillet welds on mild steel in the overhead position. - tee - lap - corner joints - force of gravity - limitations - adjustment - body stance 6. Describe the procedures used to test welds. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Run stringer beads in all positions. 2. Perform fillet welds on T-joint and lap joint using F-4 electrodes.

22 WDF-1150 GMAW 1 - Set-up NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 50 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - set up GMAW equipment, strike and maintain an arc. - disassembly and reassembly GMAW welding systems - perform weld tests Theory: 1. Define terminology associated with the GMAW process. 2. Describe the GMAW process. - general precautions - equipment and accessories - shielding gas and regulators - electrode wire - gun - feeder - electrode extension - power source - nozzle - cable - pulsed arc machines - assembly of equipment - metal transfer - polarity - arc voltage - slope and adjustment - inductance - welding variables and effects - welding voltage and current - travel speed - penetration - travel and work angles - manipulation - maintenance of tube

23 - codes and standards 3. Describe the procedures used for disassembly and reassembly and care of GMAW welding equipment. - troubleshooting 4. Describe the procedures used to establish and maintain an arc. - starting and stopping the weld - finishing end of the joint - power source - filler metal - adjustment - shielded gases (pre and post weld) - feed rolls - gun - variables - stick-out - speed - maintenance - common faults 5. List the various gases and gas mixtures and describe their applications. - conventional and pulse transfer - starting and stopping - travel angles - end of weld 6. Describe the procedures used to test welds. 7. Describe weld faults. - slag inclusions - lack of penetration - porosity Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Set up GMAW equipment. 2. Change the electrode wire guide. 3. Adjust and check the flow meter.

24 4. Deposit fillet welds on mild steel of various thicknesses using the GMAW processes.

25 WDF-1155 GTAW 1 - Set-up NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 52 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - set up equipment, strike and maintain an arc. - perform weld tests. Theory: 1. Define terminology associated with the GTAW process. 2. Describe the GTAW process. - general precautions - equipment and accessories - pulsed arc machines - sycrowave machines - the GTAW torch - flowmeter - electrodes - gas cups - conditioning of the thoriated electrode - current requirement - shielding gases - travel and work angles - filler rods - joint types and their preparation - edge preparations - weld types - methods of transfer - codes and standards 2. List various types of gas mixtures and describe their applications. - purging gases - shielding gases 3. Describe the procedures used for disassembly and reassembly and care of GTAW welding equipment.

26 4. Describe the procedures used to establish and maintain an arc. - conventional and pulse transfer welding 5. Describe the procedures used to test welds. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Set up GTAW equipment, strike and maintain an arc 2. Change the electrode collet and collet body. 3. Adjust and check the flowmeter.

27 WDF-1160 Plasma Arc Cutting & Gouging NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 54 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - set up and operate plasma arc equipment. - cut stainless steel. - cut aluminum. Theory: 1. Define terminology associated with the plasma arc process. 2. Describe the plasma arc process. - general precautions - types of torches - types of arcs - shielding gases - electrodes - power source - codes and standards - procedures to set up equipment and check its operation 3. Describe the procedures used to cut various thicknesses of steel. - structural shapes - plate - pipe 4. Describe the procedures used to cut stainless steel. - sheet - plate - pipe 5. Describe the procedures used to cut aluminum. - sheet - plate - structural shapes

28 6. Describe the process used to set up and operate equipment for gouging. - carbon steel - stainless steel - aluminum - copper Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Set up equipment, check its operation, and check the torch. 2. Cut steel of various thicknesses. 3. Cut stainless steel of various thicknesses. 4. Cut aluminum of various thicknesses. 5. Gouge mild steel.

29 WDF-1165 Stud Welding and Spot Welding NOA Reference: This material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 60 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - stud weld. - spot weld on sheet metal. Theory: 1. Define terminology associated with the stud weld and spot weld process. 2. Describe the stud weld process. - general precautions - principles of operation - equipment - weld quality - variables 3. Describe the procedures used to stud weld. 4. Describe the spot weld process. - general precautions - principles of operation - equipment - weld quality - types of joints 5. Describe the procedures used to spot weld on sheet metal. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include:

30 1. Set up and check stud weld equipment. 2. Weld studs of various diameters. 3. Set up and check spot weld equipment. 4. Spot weld sheet metal.

31 WDF-0170 Blueprint Reading 1 (Basic) NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 19 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - demonstrate a basic knowledge of blueprints, shop drawings and sketches and their use in the trade. Theory: 1. Identify the various types of lines used on blueprints and describe their applications. - centre - hidden - dimension - extension - object - break - long - short 2. Identify the various views and describe their purpose. - front - right side - left side - top - bottom - back - section - detailed 3. Identify notes and specifications and describe their purpose. - parts of objects - drawing titles - revisions - drawing numbers 4. Identify sectioning practices and describe their purpose. - enlarged

32 - isometric - auxiliary - rotation - developed - detail 5. Identify and interpret common abbreviations and symbols. - supplementary symbols - outdated and preferred symbols - references - location of symbols on drawings Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Identify the basic lines used in drafting. 2. Identify the various elements in blueprints. - views - notes and spectifications - sections - common symbols and abbreviations.

33 WDF-1175 Blueprint Reading 2 (Welding Symbols) NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 19 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - Interpret welding abbreviations and symbols. Theory: 1. Identify common welding abbreviations and describe their applications. - back gouging - melt through - finishing - processes 2. Identify and interpret the symbols for fillet welds. - pitch - dimension - shape - finishing 3. Identify and interpret the symbols for groove welds. - preparation - preparation depth - root spacing - preparation angle 4. Identify and interpret the symbols for melt-through welds. - root spacing - preparation angle - backing - fusible inserts 5. Identify and Interpret the symbols for plug welds. - dimensions - bevel angle - filler thickness - number

34 - pitch - shape 6. Identify and interpret weld finishing symbols. - grinding - machining - chipping - laminating - hammering - rolling - unspecified 7. Identify and interpret pipe welding symbols. - dimensions - pipe layout - determine methods of representing layout - symbols Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Locate and interpret abbreviations and symbols relevant to the trade. - fillet welds - groove welds - melt through - weld finishing

35 WDF-1180 Blueprint Reading 3 (Advanced/CAD) NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 19 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - interpret dual dimensions. - interpret international symbols. - interpret test and inspection symbols - demonstrate knowledge of the basics of computer-aided drafting Theory: 1. Describe dual dimensions and their use in the trade. - variation - flexibility - accuracy - disadvantages. 2. Identify and interpret international symbols. 3. Identify and interpret test and inspection symbols. - visual inspection - ultrasound - X-rays - dye penetrates - OSD symbols - dimensioning - eddy current - magnetic particle - acoustic emissions - leak test 4. Describe computer-aided drafting and its use in the trade. - components - software

36 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Interpret dual dimensions. 2. Locate and interpret test and inspection symbols. 3. Locate and interpret international symbols. 4. Use computer-aided drafting software.

37 WDF-1185 Blueprint Reading 4 (Shop Drawings) NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 19 - Metal Fabricator (Fitter) task 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - identify structural components from shop drawings - draw templates for structural parts Theory: 1. Identify and interpret abbreviations used on shop drawings. - centre to centre (C/C) - not to scale (N/S) - F/S - B/S - B/B - gauge (GA) - cast iron (CL) - FLG - standard (STD) 2. Identify and interpret various structural components found on shop drawings. - column - beam - truss - purlin - joists 3. Identify and interpret instructions contained in working drawings. - beams - columns - stairs - brace 4. Describe the procedures used to cut beams to desired dimensions. - notch - cut

38 - cope 5. Describe the procedures used to draw templates for structural parts. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Interpret instructions and symbols found on working drawings. 2. Draw templates for structural parts.

39 WDF-0190 Metallurgy, Expansion & Contraction Control NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder tasks 18, 19, and 54 - Metal Fabricator (Fitter) tasks 6 and 7 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - select appropriate fabrication practices and principles to control expansion, contraction and distortion. - use forces resulting from expansion and contraction for the straightening or bending of structural members. Theory: 1. Define terminology associated with metallury. 2. Describe the types and characteristics of ferrous and non ferrous metals. - ferrous - low carbon - medium carbon - high carbon - alloy steel - non-ferrous 3. Describe mechanical and physical properties of metals. - tensile strength - yield strength - elasticity - ductility - hardness - compressive strength - fatigue strength - impact strength - toughness - density - melting point - thermal conductivity - thermal expansion - electrical conductivity and resistance

40 - corrosion resistance - brittleness - malleability - plasticity - reaction to heat - specific heat - heat of fusion 4. Describe the effects on properties when: - forming - shearing - punching - drilling - cutting - welding 5. Describe the effects of stresses and shrinkage on materials. - hard - brittle - tough - ductile 6. Describe common tests to determine the type of material and/or weldability. - spark - clip - chip 7. Describe pre-heat and post-heat processes. - purpose - applications - temperature 8. Describe various classification systems used for ferrous metals. - numbering systems - SAE - AISI - ASTM - colour coding of materials 9. Describe common problems in welding high carbon steel. 10. Describe expansion and contraction of metals. - heating compared with cooling 11. Describe stresses resulting from: - welding - flame cutting

41 - shearing - unsatisfactory preparation for welding - forming - rivetting 12. Describe control of shrinkage in weldments. - WDFup - welding sequence - back step and skid back step - staggered - intermittent - weld size and number of passes - balancing of shrinkage and other forces - pre-heat requirements 13. Describe stress relief. - purpose - methods - heating - peening - aging - requirements 14. Describe controlled shrinkage for: - straightening of bent or distorted members - alignment of sub-assemblies - pre-bending - removal of corroded or seized parts Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Visually identify types of metal. 2. Identify metals using spark test. 3. Shape, grind and heat treat chisels. 4. Attend lab sessions to witness tensile test, ductility, harness, etc. 5. View film or demonstration on expansion and contraction.

42 6. Upset heated metal. 7. Use upsetting to straighten bent members. 8. Perform prebending. 9. Use setting of vertical members to allow for contraction.

43 WDF-1195 Quality Control NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 6 and 17 - Metal Fabricator (Fitter) tasks throughout the document Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - demonstrate knowledge of quality control operations. - perform visual inspection Theory: 1. Describe the identification and selection of steel. - scope of quality control - standards and specifications - inspection methods - templates and/or gauges - drawing (compliance with) - visual inspection practices - electronic inspection - radiography - magna flux - ultrasonic 2. Describe standards and specifications applicable in the trade. 3. Describe the procedures used to ascertain compliance with design and code specifications. 4. Describe the methods of inspection and testing of structural materials and welds and their associated procedures. - visual inspection - bend test - etch test - magnetic particle test - die penetrant test - leak test - air and soap (pneumatic test) - water pressure (hydrostatic test)

44 - paint thickness Practical: The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Perform visual inspection of welds. 2. Inspect & test structural materials & welds. - inspect items and note irregularities (visual inspection) - bend specimen and determine ductility and soundness (destruction) - perform etch test on item (destruction) - visual inspect radiographic film for irregularities and note - use magnetic particle test - perform die penetrant test - perform leak test on small vessel as outlined by instructor - air and soap (pneumatic test) - water pressure (hydrostatic test) 3. Perform inspection and test for paint thickness on item.

45 WDF-1200 Material Handling and Rigging NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 4 and 9 - Metal Fabricator (Fitter) task 4 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - use efficient material handling practices using both manual and mechanical means - identify the limitations of equipment used for rigging - operate slings, cables and cranes - select appropriate equipment for the job, using rigging charts and manuals as well as rule of thumb methods Theory: 1. Describe Workers Compensation Board regulations applicable to material handling and rigging. 2. List the Occupational Health and Safety Regulations applicable to material handling and rigging. 3. Describe responsibilities and liabilities in the use of rigging, lifting and hoisting equipment. 4. Describe the various methods of hoisting, their applications and procedures for use. - weight of objects - object configuration - materials - materials for blocking 5. Describe the various types of wire ropes, chains, cables and cable clamps and their accessories. - characteristics - applications - precautions - procedures for use - inspection

46 6. Identify and describe the various types of lifting clamps. - characteristics - applications - precautions - inspection - procedures for use 7. Identify types of come alongs, rope and chain falls, and describe their applications and procedures for use. 8. Identify types of jacks and describe their applications and procedures for use. - hydraulic - screw - ratchet 9. Describe stacking and blocking. - structural shapes - plate and sheet - weldments and components 10. Describe the methods of securing chains to provide for manipulation of structural shapes. 11. Identify types of slings and describe their applications and procedures for use. - rope slings - wire rope slings - nylon slings 12. Describe use of hooks and shackles. 13. Describe lines or rope and their use. - sizes - care and inspection - knots - bowline and a bight - square or reef - round turn and two half hitches - scaffold hitch - whipping ends and eyes 14. Describe use of chokers, slings and tag lines. 15. Describe spooling of line on drums. - over wind - under wind - left and right hand lay lines

47 16. Describe practices for use of tackle. - safety factors of line - reeving practices 17. Identify other types of hoisting methods and describe their procedures for use. - overhead crane - jib crane - boom crane - mobile crane - manual lifting 18. Describe standard hand signals. 19. Identify the different types of scaffolds, and describe their applications and procedures for use. - tube and clamp - manufactured platforms and scaffolding - rolling scaffolding - suspended scaffolding 20. Describe safety requirements for erecting and working on scaffolding. - kick plates - braces - ties - planking - permits - tagging - fall arrest 21. Describe special problems of rolling and suspended scaffolding and guidelines for their use. 22. Identify types of ladders and describe their applications and use.

48 Practical: The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Make up spreader bar (single). 2. Whip or seize one end of fibre rope. 3. Tie knots using fibre rope. - reef knot - bowline - round turn & hitch - scaffold hitch 4. Demonstrate hand signals. 5. Select appropriate scaffold for various job situations. 6. Prepare safety harness/fall arrest with tie off points.

49 WDF-1205 Stationary Powered Shearing NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 33 - Metal Fabricator (Fitter) task 6 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - use powered shearing equipment. - perform adjustment and basic maintenance operations. Theory: 1. Identify types of powered shearing equipment and describe their characteristics and applications. 2. Describe the operation of shearing equipment. - capacity - rake angle - blade clearance - back edge calibration - lateral guide squaring - operating procedures - maintenance 49

50 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Determine the capacity of the shear. 2. Set up and operate guillotine plate shears. 50

51 WDF-1210 Iron Worker Operation NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 33 - Metal Fabricator (Fitter) task 6 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - operate iron worker equipment for the punching and shearing of structural shapes, plate and sheet sections. - perform necessary operational maintenance and adjustments. Theory: 1. Describe the procedures used to set up the iron worker. - capacity - clearances 2. Describe coping and notching operations. - blade clearance 3. Describe shearing operations. - dies - capacity 4. Describe angular and square cuts of angle stock. - capacity - back gauge clearance 5. Describe punching operations. - configuration - round - oblong 6. Describe operator level maintenance procedures. 7. Identify ironworker accessories and attachments and describe their applications. - flanging on flatbar 51

52 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Notching. 2. Punching. 3. Shearing. 4. Make a frame from 2" x 2" x 1/4" angle. 52

53 WDF-1215 Jigs and Fixture Fabrication NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis: - Welder task 26 - Metal Fabricator (Fitter) task 5 Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - demonstrate knowledge of the elements and processes of jig and fixture design. - select and use jigs and fixtures Theory: 1. Identify common types of jigs and fixtures and describe their applications. - purpose - method of construction - operating practices 2. Describe the procedures used to fabricate jigs and fixtures. 3. Identify special purpose types of jigs and fixtures and describe their applications. - purpose - one of a kind assembly - unusual assembly operation - design considerations - fabrication practices - operating principles 53

54 Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Fabricate jigs and fixtures. - set up multi-punch operation - fabricate jig to allow multi drilling - set up jig to allow for shearing - fabricate jig to accommodate truss assembly and welding - fabricate jig to accommodate ladder assembly 54

55 WLD-1305 SMAW 4 - Groove Weld All Positions F-3 Mild Steel NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - groove weld on mild steel in all positions using the SMAW process with F-3 class electrodes. - perform weld tests. Theory: 1. Describe the procedures used to perform butt joints on mild steel in the flat position. - joint design and terminology - inspection and testing - electrode angle 2. Describe the procedures used to perform butt joints on mild steel in the horizontal position. - electrode manipulation - adjustment 3. Describe the procedures used to perform butt joints on mild steel in the upward vertical position. - direction of travel - electrode angle - speed 4. Describe the procedures used to perform butt joints on mild steel in the overhead position. - general precautions - force of gravity - limitations - adjustment - penetration - codes and standards 5. Describe the procedures used to test welds. 55

56 6. Describe weld faults. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Weld a square edge butt joint on mild steel in all positions. 2. Weld a single-vee groove butt joint on mild steel in all positions. 56

57 WLD-1310 SMAW 5 - Groove weld All Positions F-4 Mild Steel NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - groove weld on mild steel in all positions using the SMAW process with F-4 class electrodes. - perform weld tests. Theory: 1. Describe the procedures used to perform butt joints on mild steel in the flat position. - joint design and terminology - inspection and testing - electrode angle 2. Describe the procedures used to perform butt joints on mild steel in the horizontal position. - electrode manipulation - adjustment 3. Describe the procedures used to perform butt joints on mild steel in the upward vertical position. - direction of travel - electrode angle - speed 4. Describe the procedures used to perform butt joints on mild steel in the overhead position. - general precautions - force of gravity - limitations - adjustment - penetration - code and standards 5. Describe the procedures used to test welds. 57

58 6. Describe weld faults. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Weld a square edge butt joint on mild steel in all positions. 2. Weld a single-vee groove butt joint on mild steel in all positions. 58

59 WLD-1315 SMAW 6 - Fillet and Butt Weld High & Medium Carbon Steel NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - weld on medium and high-carbon steel in all positions using the SMAW process. Theory: 1. Describe the SMAW process as it applies to welding medium and high-carbon steel. - general precautions - characteristics of materials - weldability of materials - procedures 2. Describe the procedures used to test welds. 3. Describe weld faults. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Weld a tee joint on medium and high-carbon steel in all positions. 2. Weld a lap joint on medium and high-carbon steel in all positions. 3. Weld pieces of medium high-carbon steel in all positions. 59

60 WLD-1320 SMAW 7 - Pipe F-3 All Positions NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - weld pipe in all positions using the SMAW process with F-3 class electrodes. Theory: 1. Describe the procedures used to weld pipe and tubing in the flat (rolled) position. - types of pipe and tubing - root gap - root face - angle of cut. - operation of contour marker - wall thickness 2. Describe tack welding of pipe sections. - cutting and grinding - preparation of test specimens 3. Describe the procedures used to weld pipe in the horizontal fixed position. - joint position - tacking - thickness - standard operations 4. Describe the procedures used to weld pipe in the vertical fixed position. - technique - electrode angle 5. Describe the procedures used to test welds. 6. Describe weld faults. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet 60

61 the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Weld pieces of mild steel pipe in all positions using stringer and weave beads. 61

62 WLD-1325 SMAW 8 - Pipe F-4 All Positions NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - weld pipe in all positions using the SMAW process with F-4 class electrodes. Theory: 1. Describe the procedures used to weld pipe and tubing in the flat (rolled) position. - types of pipe and tubing - root gap - root face thickness - angle of cut - operation of contour marker - wall thickness 2. Describe tack welding of pipe sections. - cutting and grinding - preparation of test specimens 3. Describe the procedures used to weld pipe in the horizontal fixed position. - joint position - tacking - thickness - standard operations 4. Describe the procedures used to weld pipe in the vertical fixed position. - technique - electrode angle - length of pieces 5. Describe the procedures used to test welds. 6. Describe weld faults. Practical: 62

63 Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Weld pieces of mild steel pipe in all positions using stringer and weave beads. 63

64 WLD-1330 SMAW 9 - Exotic Metals NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 49. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - weld alloy steels using the SMAW process. - weld stainless steels using the SMAW process. - weld nickel alloy using the SMAW process. Theory: 1. Describe the procedures used to weld alloy steels for production and maintenance purposes using the SMAW process. - identification of materials - alloying elements - weldability - techniques - problems - probable causes 2. Describe the procedures used to weld stainless steels using the SMAW process. - identification of materials - thermal conductivity - expansion - weldability - techniques - problems - probable causes 3. Describe the procedures used to weld with nickel alloy using the SMAW process. - identification of materials - types of nickel - alloys - weldability - types of joints - techniques - filler metals - distortion 64

65 4. Describe the procedures used to test welds. 5. Describe weld faults. Practical: Suggested learning activities are assigned to enhance the apprentices ability to meet the objectives of the course. The learning activities outlined in this course are provided as suggestions only and may be substituted by the instructor for other relevant activities. Suggested learning activities include: 1. Deposit groove welds on stainless and alloy steel plates of various thicknesses using the SMAW process. 2. Weld fillet and square edge butt joints in the flat position using the SMAW process. 65

66 WLD-1335 GMAW 2 - Fillet Weld All Positions, Mild Steel NOA Reference: The material covered satisfies in whole or in part, the requirements of National Occupational Analysis Welder task 50. Course Outcomes: Upon successful completion of this course, the apprentice will be able to: - fillet weld on mild steel in all positions using the GMAW process. Theory: 1. Describe the procedures used to fillet weld in the flat position. - conventional and pulse - shielding gas selection - addition of carbon dioxide - electrode wires - wires for carbon steel - operating problems - work and travel angles - gun manipulation 2. Describe the procedures used to fillet weld in the vertical position. - conventional and pulse - tee joint - lap joint - running stringer beads in vertical position on mild steel 3. Describe the procedures used to fillet weld in the horizontal position. - conventional and pulse - running stringer beads in horizontal position m.s. - tee joint - lap joint 4. Describe the procedures used to fillet weld in the overhead position. - conventional and pulse - running stringer beads in overhead position - joints positions - faults - travel angles - gas mixtures 66