Grade 11 Term 1. Welding Simulation Project

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Sara Rogers
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Performance Criteria: 1.1,1.4-1.6, 2.1-2.

1 Grade 11 Term 1 Welding Simulation Project Unit/Topic: STSENGS873 Welding Simulation STS Performance Criteria: 1.1, , AQF Unit & PC: N/A to selected TAFE units (AWS positions,1g,2g,2f) Name: : Class: Assessment Event: Term 1 Project : Oct 2013 Mark: /30 Time: 180mins

2 Task 1 Process A Process B Process C STS G11 Term 1 Welding SimulationProject Version

3 Read the statements below and choose which of the welding processes shown on the previous page is being described. Statement MMA Manual Metal Arc (also called Stick welding or Shielded Metal Arc Welding SMAW) MIG - Metal Inert Gas welding (also called Gas Metal Arc Welding GMAW) TIG Tungsten Inert Gas welding (also called Gas tungsten Arc Welding - GTAW) In this welding process the electrode is a thin metal wire that feeds through the welding gun and melts onto the base metal due to the electric arc between the wire and the base metal. In this welding process the electrode made of Tungsten. It makes an arc with the base metal and produces a molten pool of metal. Additional metal (filler rod) is usually added into the molten metal pool. In this welding process the electrode is metal rod coated in flux that is held in an electrode holder. The welding rod melts on to the base metal due to an electric arc between the rod a and the base metal. A flow of gas passes out of the welding torch during welding. This inert gas (usually ARGON) acts as a shield to protect the weld process The flux coating on the electrode melts over the weld pool and acts as a shield to protect the weld process. This forms a hard coating on the weld called slag that must be chipped off after each weld. A flow gas passes through the welding gun at the same time as the wire electrode. This inert gas (ARGON, CO 2 or a mixture of these) acts as a shield to protect the weld process. This process is most commonly used to weld thin sections of stainless steel and aluminium. Process Mark ( /10) STS G11 Term 1 Welding SimulationProject Version

4 Practical Exercises For industry standards we need to be able to produce good clean welds in different positions. The American Welding Society provide internationally recognised welding competency positions or codes. In this project you should demonstrate arc welding in positions 1G, 2F and 2G using the welding simulator for MMA (SMAW) equipment and MIG (GMAW) equipment. We will simulate these welds to take place in a WELDING BOOTH. STS G11 Term 1 Welding SimulationProject Version

Task 2 SMAW Groove weld in position 1G Select the Groove Plate coupon and set it on the welding stand in a suitable position for you to do flat plate welding.

5 Task 2 SMAW Groove weld in position 1G Select the Groove Plate coupon and set it on the welding stand in a suitable position for you to do flat plate welding. Use the stick welding process SMAW (MMA) and set up the simulator for use in a welding booth. Record your settings in the table below : Plate thickness Electrode type Current Task Complete 3 GMAW one Groove weld run weld and record in position your score. 1G Save your weld result onto a USB pen Repeat and print the this above out welding for your simulation portfolio. exercise but this time simulate the GMAW Short Arc (MIG) welding process. Record Welding the Score settings % you use for this weld. Plate thickness Wire speed GAS type and flowrate. Voltage STS G11 Term 1 Welding SimulationProject Version

Task 4 SMAW Fillet weld position 2F Select the TEE JOINT coupon and set it in the welding stand in a suitable position for you to demonstrate fillet welding in position 2F.

6 Task 4 SMAW Fillet weld position 2F Select the TEE JOINT coupon and set it in the welding stand in a suitable position for you to demonstrate fillet welding in position 2F. Use the stick welding process SMAW (MMA) and set up the simulator for use in a welding booth. Record your settings in the table below : Plate thickness Electrode type Current STS G11 Term 1 Welding SimulationProject Version

7 Task 5 GMAW PIPE Groove weld position 2G Select the 2 PIPE coupon and set it in the welding stand in a suitable position for you to demonstrate groove welding in position 2G. Set up the equipment to simulate GMAW Short Arc (MIG) welding process in. a welding booth Record the settings you use for this weld. Pipe thickness Wire speed GAS type and flowrate. Voltage STS G11 Term 1 Welding SimulationProject Version

EML 2322L -- MAE Design and Manufacturing Laboratory. Welding

EML 2322L -- MAE Design and Manufacturing Laboratory Welding Intro to Welding A weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough