Industrial Welder Level 1

Transcription

1 Industrial Welder Level 1 Rev. September 2008

2 Industrial Welder Unit: A1.a Trade Safety Awareness (ATQ Board Standard) Level: Duration: One 7 hours Theory: Practical: 7 hours 0 hours Overview: Safe working procedures and conditions, injury prevention, and the preservation of health are of primary importance to industry in Canada. These responsibilities are shared and require the joint efforts of government, employers, and employees. It is imperative that all parties become aware of circumstances that may lead to injury or harm. Safe learning experiences and environments can be created by controlling the variables and behaviours that may contribute to incidents or injury. It is generally recognized that safety-conscious attitudes and work practices contribute to a healthy, safe, and incident-free working environment. It is imperative to apply and be familiar with the Workplace Safety and Health Act and Regulations. As well, it s essential to determine workplace hazards and take measures to protect oneself, co-workers, the public, and the environment. Safety education is an integral part of Welder apprenticeship training program both in school and on-thejob. Unit content is supplemented throughout Technical Training by trade-specific information about Welder safety hazards and precautions presented in the appropriate contexts of discussion and study. Percentage of unit mark for each section is at the discretion of the instructor. Percent of Objectives and Content: Unit Mark (%) 1. Identify safety and health requirements a. Overview of Workplace Health and Safety Act Rights and responsibilities of employees under the Act Rights and responsibilities of employers Rights and responsibilities of supervisors under the Act b. Fourteen (14) Regulations c. Codes of Practice d. Guidelines e. Right to refuse f. Explanation of right-to-refuse process Rights and responsibilities of employees under the Act Rights and responsibilities of employers Rights and responsibilities of supervisors under the Act 2. Identify personal protective equipment (PPE) and PPE procedures. a. Employer and employee responsibilities as related to PPE b. Standards: CSA; ANSI, and Guidelines. c. Work protective clothing and danger if it fits poorly d. Gloves importance of proper selection for handling chemicals, cold items, etc.) e. Headwear Appropriate headwear when required and the approved type of head wear 1 Rev. September 2008

3 f. Eye protection Comparison/contrast between eyeglasses, industrial safety glasses, and safety goggles g. Foot protection standards/requirements for selection and use h. Hearing protection Noise hazards and noise-hazard rating standards (re: when protection is required) Regulations Types of hearing protection i. Respiratory protection Variety; standards for use and selection j. Fall-protection equipment standards Manitoba standards and guidelines; ANSI (U.S. standards); etc. k. Ladders and scaffolding l. Safety principles for working around hoisting, transport, and materials-handling equipment (e.g. boom trucks, forklifts, pallet trucks, semis, etc.) 3. Identify electrical safety. a. Effects of electric current on the human body b. Three factors that affect the severity of an electric shock c. The effects of electrical arc and blast of the human body and on equipment d. Hazards/precautions re: working with and/or around energized equipment 4. Identify fire safety. a. Types of fires b. Types of fire-fighting equipment c. Classification of fire extinguishers (A, B, and C) d. Location of fire extinguishers and fore exits e. Fire alarms and drills 5. Identify ergonomics. a. Definition/scope of ergonomics as a field of knowledge b. Ergonomically hazardous conditions and precautions regarding: Postures during work Repetitive activity/impacts Force Lifting Tool use Safety equipment Hand-tool accidents Equipment Materials handling (including lifting, carrying, and putting down a load) 6. Identify hazard recognition and control. a. Safe work practices b. Basic risk assessment c. Injury prevention and control measures d. Hazards/precautions re: use of pneumatic tools 7. Describe the hazards of confined-space entry. a. Definition and identification of confined space(s) b. Confined space hazards Physical Biological c. Precautions when working in confined space d. Emergency Response Plan e. Self-Contained Breathing Apparatus (SCBA) 8. Identify First Aid/Cardiopulmonary Resuscitation (CPR). a. Overview of First Aid Regulation b. Employer obligations re: First Aid Who is certified to provide First Aid? What is to be done while awaiting First Aid? Where is First Aid Kit? 2 Rev. September 2008

4 c. Describe basic First Aid requirements and techniques Definition, and scope/limits of First Aid interventions Procedure for specific intervention re: cuts; burns; abrasions; sprains, fractures; suffocation; shock; electrical shock Interface with other services and agencies (e.g. Workers Compensation claims) d. Describe basic CPR requirements and techniques Definition, and scope/limits of CPR interventions Varieties of CPR training and certification Obtaining certification 9. Identify safety requirements as they apply to the WHMIS. a. WHMIS as a system b. Manitoba provincial regulation under the Safety and Health Act; WHMIS in other provinces c. Federal Hazardous Product s Act d. WHMIS generic training, including: Identification, use, and format of WHMIS information tools WHMIS and labeling by manufacturers, suppliers, and workplace sources Definition and hazards/precautions re hazardous materials Compliance with government safety standards and regulations e. WHMIS special-purpose certifications and associated rationale f. Typology of WHMIS labels, symbols, and classifications g. Scope and use of Materials Safety Data Sheets (MSDS) 10. Describe the identification and control of specified hazards. a. Basic control measures (injury-prevention) b. Safe work procedures c. Importance and scope of industrial housekeeping requirements d. Employer responsibilities e. How/where to store materials f. Safety hazards/precautions re walkways, stairs, floor/wall/roof openings, etc. *** 3 Rev. September 2008

5 Industrial Welder Unit: A1.b Orientation and Safety Level: Duration: One 7 hours Theory: Practical: 7 hours 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of the Manitoba Apprenticeship training program for the Welder trade. Certain safety precautions must be followed depending on each specific situation. The selection and use of proper hand tools and power tools is required in order to do the job quickly, accurately and safely. Material covered includes: Welding apprenticeship training orientation Safe work practices Safety guidelines Hand tools Power tools Materials handling Percent of Objectives and Content: Unit Mark (%) 1. Describe welding apprenticeship training program orientation. 0% a. The apprenticeship training system in Manitoba History Designated trades and occupations in Manitoba Apprenticeship trades Pattern of apprenticeship training Provincial Trade Advisory Committees, functions of the Provincial Trade Advisory Committees The Red Seal Program Technical training registration procedures Safety education Employer s responsibilities Employees responsibilities b. The training program of the welding apprenticeship in Manitoba Development of a welder technical training profile chart c. The welder program outline learning outcomes and objectives Development of learning outcomes and objectives Apprenticeship exam questions d. The responsibilities for the Contract of Apprenticeship by the apprentice, employer and Manitoba Apprenticeship Contract of Apprenticeship Responsibilities of the employer Responsibilities of the apprentice Responsibilities of Manitoba Apprenticeship e. Industrial, commercial and construction field that provide employment opportunities for welders Employment opportunities for welders 4 Rev. September 2008

6 Dual trade and multi-trade qualifications Related fields f. Contents of the apprenticeship practical training record book Record of work experience Changing employers g. The ability to complete an acceptable résumé The résumé Chronological Functional Combination Cover Letter 2. Identify welding safe work practices. 20% a. Physical hazards that are common to welding and cutting operations Radiant energy hazards Visible light rays Ultraviolet rays Infrared rays X-rays and gamma rays Hazards associated with temperature extremes Burns Frostbite and hypothermia Noise hazards Noise intensity and exposure limits b. The use of personal protective equipment (PPE) for welding and cutting operations Head protection Eye protection Safety glasses Full face visor Clear goggles Welding goggles Welding helmets and filter plates Photoelectric welding helmets Protective clothing Welding gloves Footwear c. Fire hazards and methods of fire prevention Fire triangle Fuel, heat, oxygen Classes of fires Check surroundings d. Hazards involved with welding fumes and gases Metals that produce fumes Metal, source, results of metal fume inhalation Metal fume fever Fumes from base metal coatings and welding fluxes Welding gases and gases produced by welding Occupational exposure limits Hydrogen sulphide gas and sulphur dioxide gas e. Welding fume ventilation methods Keep your head out of the plume Natural general ventilation Mechanical general ventilation Local ventilation Portable smoke extractor Isolation chambers Fume extracting welding gun f. Personal protective equipment for hazardous and toxic materials Protecting from fumes Face Piece 5 Rev. September 2008

7 Types of Respirators Air-purifying respirators Airline respirators Self-contained breathing apparatus Emergency escape breathing apparatus Emergency rescue procedures g. Effects of electricity and precautions used to prevent injury Electric shock hazard Avoiding electric shock Rescue procedures for electric shock victims 3. Identify safety guidelines. 20% a. Applications of the Workers Compensation Act in the workplace Workers Compensation Act - Persons deemed workers - Eligibility for compensation - Payment of compensation - Out-of-province accidents - Notice by worker - Inspection of records - Compensation to learner and apprentice - Clothing allowance b. The Workplace Safety and Health Act General Safety Regulation as they apply to welding Workplace Safety and Health Act - Housekeeping - Falling hazards - Grinding - Guardrails - Ladders Generally - Portable ladders - Eye protection - Foot protection - Limb and body protection - Refueling of vehicles - Vehicle hoists - A-frames and gin poles - Scaffolds generally - Free standing or rolling scaffolds - Hot work - Compressed and liquefied gas systems - Isolation of pipes and pipelines - Confined Spaces c. The Workplace Hazardous Materials Information System (WHMIS) program WHMIS system Worker education Labels - Supplier labels - Workplace labels Other means of identification Material Safety Data Sheets d. The procedure for welding or cutting in confined spaces or on potentially dangerous enclosures Welding or cutting in the presence of flammables - Preventing fires or explosions Working in a confined space - Safety procedures for working in a confined space - Working in or on containers - Heat stress from working in a confined space e. Rendering containers safe for welding and cutting Boil the container in a caustic solution Inert gas purging 6 Rev. September 2008

8 Steaming 4. Identify hand tools. 20% a. Safety precautions for hand tools b. General safety procedures when using hand tools Hammers Screwdrivers Chisels Punches Files Hacksaws Wrenches Metal cutting snips and shears c. Measuring and layout tools and their uses Three general categories for measuring and layout tools - Measuring tools o Rules o Measuring procedures o o Straightedges Measuring tapes Short line tapes Long line tapes - Layout tools o o o o o Squares Carpenter s square Try square (also known as solid square, block square, set square or machinist s square) Combination square Steel ruler Square head Bevel protractor Centre head Levels Wrap-arounds Contour markers - Marking tools o Soapstone o Chalk lines o Scribers o Dividers o Trammel points o Centre punches and prick punches d. Clamping tools e. Pliers Tongue and groove pliers Slip joint pliers Interlocking joint pliers Side-cutting pliers Needlenose pliers Locking pliers Welding pliers f. Clamps C-clamps Bar clamps Spring clamps Parallel clamps Pipe clamps Vises g. Cutting tools and their uses Hacksaws Hacksaw blades 7 Rev. September 2008

9 - Selecting hacksaw blades - Selecting a suitable pitch - Set - Using a hacksaw - Safety precautions h. Files Size and cut of a file Shapes of files Care, handling and storage of files i. Chisels Flat chisel Cape chisel Diamond point chisel Round nose chisel Chisel maintenance and safety j. Metal snips k. Diagonal pliers and bolt cutters l. Hand shears m. Other hand tools Hammers - Peening hammers - Sledge hammers - Safe use of hammers - Chipping hammers Screwdrivers Punches - Pin punches - Drift punches Pinch bars and pry bars Wrenches - Hand wrenches o Box end wrenches o Open end wrenches o Combination wrenches o Socket wrenches o Adjustable wrenches o Allen wrenches o Pipe wrenches o Chain pipe wrenches o Strap wrench Wire brushes 5. Identify power tools. 20% a. The safe operation of bench and pedestal grinders and angle and straight grinders General grinding safety Pedestal and bench grinders - Pedestal grinders - Bench grinders o Eye shields and wheel guards o Tool rest Grinding wheels - Blotters - Dressing and truing grinding wheels - Replacing a grinding wheel Portable grinders - Angle grinder - Straight grinders - Portable grinder use b. The use and safe operation of portable power drills, drill presses and twist drills Drilling machines and twist drills 8 Rev. September 2008

10 - Portable hand drills - Sensitive drill presses - Upright drilling machines - Magnetic base drills - Radial drilling machines Drill chucks - Three common types o Key-type drill chuck o Keyless chuck o Drill socket and sleeve - Drill sleeves and sockets Twist drills - The shank o Straight shank o Taper shank - Body - Point - Sizing of twist drills o Methods used to designate twist drill sizes: Number Letter Fractional and Metric - Sharpening a twist drill - Sharpening procedure - Modifying the drill point o Thinning the chisel edge - Special application twist drills Lubricants, coolants and cutting fluids c. Metal forming and shaping tools Metal forming and shaping machines Plate rolls Power brakes Power benders Presses - Hydraulic presses - Pneumatic presses - Electric presses Trip hammers d. Procedures for cutting metals using shearing machines, cut-off saws and metal cutting band saws Cutting machines Plate shears - Mechanical shears - Hydraulic shears Ironworker machine Machine operation - General safety precautions - Punch operation - Shearing operations - Rod shear - Angle and channel (C Shape) shear - Notcher (nibbler) Cut-off saws - General safety precautions Metal cutting band saws - Vertical band saws - Horizontal band saws o Horizontal band saw adjustments and use 9 Rev. September 2008

11 6. Identify safe materials handling procedures. 20% a. Safe procedures for handling and storing materials Personal protection Housekeeping Safe lifting and carrying Safe handling of loads supported by cranes Correct storage practices b. Weight and centre of gravity of loads Calculating the weight of structural steel shapes Centre of gravity - Unstable loads c. The effect that sling angles have on safe lifting Sling angle Sling stress formula d. Identification of load limits of commonly used wire rope and synthetic slings Wire rope slings Working load limit Synthetic slings e. Causes and effects of shock loading on rigging Actual working load Shock loading How to avoid shock loads f. Occupational Health and Safety Regulations regarding safety factors Provincial Occupational health and safety regulations g. Identification and use of hand signals for crane operations Hand signal procedures for crane and hoist operations Instructions to signalmen Hand signals h. Safe procedures for lifting, hoisting or moving loads Softeners Slings - Wire and synthetic rope and sling inspection and maintenance Sling attachment arrangements - Single vertical hitch - Bridle hitch - Single basket hitch - Double basket hitch - Double wrap basket hitch - Single choker hitch - Double choker hitch - Double wrap choker hitch - Spreader beams Crane leveling Planning a lift - Load radius deflection Pick and carry operations i. Care and use of wire rope, synthetic rope and chains Wire Rope - Wire rope construction - Wire rope lay - Strand classification - Wire rope seizing - Replacing wire rope - Rule of thumb for working load limit - Unreeling wire rope Synthetic rope - Breaking strength reductions o Safety factors Chains - Chain grade identification 10 Rev. September 2008

12 - Chain inspection j. Correct use of plate clamps k. Correct procedure for applying cable clips Wire rope clips Double saddle and bolt type rope clip U-bolt and saddle type rope clip *** 11 Rev. September 2008

13 Industrial Welder Unit: A2 Oxy-fuel Welding, Brazing and Cutting Level: Duration: One 41 hours Theory: Practical: 8 hours 33 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of oxy-fuel welding, brazing and cutting. The Industrial Welder Apprentice must be able to identify weld faults, know their causes, and decide how they may be avoided or corrected. Material covered includes: Weld faults Oxy-fuel equipment Oxy-fuel welding Brazing Oxy-fuel cutting Carbon arc Cutting air Plasma arc cutting Percent of Objectives and Content: Unit Mark (%) 1. Describe the causes of weld faults in welds and methods for their prevention. 10% a. Major classification of weld faults Weld faults classification Definition of weld faults Three general classes of weld faults: - Dimensional defects - Structural discontinuities in the weld zone - Defective properties (weld metal and base metal) b. Notching effect Notch effect and nick break test Stress flow lines and notch effect Failure to taper out rapid changes in cross-section Tapered transition Stress flow on lap joints Failure to taper out rapid changes in contour Failure to fill craters or to fill and float over weld ends c. Basic weld faults, their causes and ways to avoid them Dimensional defects Dimensional faults prior to welding - Causes - Effects - Remedies for incorrect joint fit-up - Remedies for discontinuities on the surfaces to be welded - Sheared surfaces - Flame-cut surfaces - Gouged surfaces 12 Rev. September 2008

14 Dimensional faults after welding - Distortion or warpage o Causes o Effects o Remedies - Incorrect weld profiles o Convexity and excessive reinforcement o Concavity, insufficient throat and insufficient leg o Overlap o Undercut Structural discontinuities - Surface defects - Internal defects (Spherical faults and laminar faults) o Porosity o Slag inclusions o Other inclusions o Oxidation o Lack of fusion o Incomplete penetration - Cracking 2. Identify oxyfuel equipment. 10% a. Characteristics and handling procedures for oxygen and fuel gases Oxygen - Air liquefaction process - Hazards associated with pure oxygen - Oxygen and oxidation of steel Acetylene - Acetylene generators - Acetylene is flammable and highly explosive - Leak detection fluids - Acetylene is an unstable compound Alternative fuel gases - Methylacetylene-propadiene stabilized (MPS) - Propane gas - Propylene - Natural gas b. Functions of oxyfuel equipment components: Oxygen storage and use - Liquid oxygen tanks - Oxygen cylinders o Information specific to oxygen cylinders o Oxygen cylinder valve safety device Acetylene cylinders - Safely storing acetylene gas - Acetylene cylinder valves - Acetylene sold by the cubic metre - Fusible metal plugs - Draw limit of acetylene cylinders - Manifold systems o Rules for acetylene gas manifold systems Rules for handling compressed gas cylinders Identification of gases in cylinders - Identification of cylinders o Workplace Hazardous Materials Information System (WHMIS) The oxyacetylene outfit - Regulators - Principles of operation - Main working arts and classification of regulators - Single stage regulator 13 Rev. September 2008

15 o Outlet pressure setting and gas flow o Application of single stage regulators - Two stage regulators o Settings and applications for two-stage regulators - Gauges o Regulator gauge faces - Storing out-of service regulators - Oxyfuel hoses o Hoses for fuel gases o Hoses for oxygen - Welding torches - Cutting torches o Combination torch o Standard or heavy duty hand torch o Machine cutting - Mixers o Positive pressure o Injector - Welding tips - Cutting tips - Reverse flow check valves - Flashback arrestors c. The use, care and maintenance of oxyfuel equipment components Regulator malfunctions - Creep - Creep remedies Hose maintenance Torch and torch mixer maintenance Care and maintenance for tips d. Recommended procedures for placement, set-up and shutdown of oxyfuel equipment Setting up the oxyacetylene outfit - Shutting down equipment e. Causes and preventive measures for backfires, flashbacks and burnbacks Backfires, burnbacks and flashbacks Backfires - Causes of backfires Burnback - Causes of burnback Flashbacks - Emergency shutdown procedure in case of flashback o Causes of flashbacks f. Pressure and flame adjustments Lighting the torch Gas speed and the speed of flame propagation - Gas speed - Speed of flame propagation - Checking and balancing of pressure for welding tips - Procedure for balancing pressure - Flame types and their effects on welding o Carbonizing flame Reactions of carbonizing flame on mild steel Reactions visible in the puddle Uses of carbonizing flame o Neutral flame Reactions of neutral flame on mild steel Reactions visible in the puddle Uses of neutral flame o Oxidizing flame Reactions of oxidizing flame on mild steel Reactions visible in the puddle 14 Rev. September 2008

16 o Uses of oxidizing flame Stages of combustion 3. Identify Oxyfuel cutting and welding. 10% a. The ability to safely operate a hand-held oxyfuel cutting torch on mild steel plate and structural shapes Principles of rapid oxidation Terms associated with cutting Travel speed and drag Gases used for oxyfuel cutting - Oxygen (chemical symbol O2) o Effect of oxygen purity Fuel gases - Acetylene (chemical symbol C2H2) - Methylacetylene-propadiene Stabilized (MPS) (chemical symbol C3H4) - Propylene - Propane gas (chemical symbol C3H8) - Natural gas (chemical symbol CH4) Torch and tip designs - Combination welding and cutting torches - Standard or heavy duty cutting torches Categorizing hand torches by mixing systems - Machine cutting equipment Control systems for machine cutting torches Manual and machine tracers Magnetic tracer-guided cutting machines Electronic tracer-guided cutting machines Types of cutting tips - Cutting tips for different fuel gases and different torch types o Cutting tips for MPS gas o Accessories for hand cutting Points to consider for good cutting: o Factors controlling tip selection o Setting gas pressures o Cleaning the tip o Lighting the torch o Checking preheat flames and cutting jet stream Starting the cut o Travel speed o Torch inclination o Cut slag to scrap or waste and save cleaning time Piercing of holes o The still torch method o Travelling torch method Stack cutting Metals that present problems to flame cutting o Cast iron Carbonizing flame and mild steel rod The oxygen lance o Stainless steel o Non-ferrous metals Common cutting faults b. Identify straight line, bevel and shape cutting on mild steel. Cutting methods - Across cut - Push or pull methods 4. Identify oxyfuel welding, brazing and braze welding. a. Filler rods and fluxes Definition of terms related to filler rods and fluxes Selecting an oxyfuel filler rod to suit the job 15 Rev. September 2008

17 Filler metal types and specifications AWS A specifications for carbon and low alloy steel rods for oxy-fuel gas welding A specifications for filler metals for brazing and braze welding - Methods of classification - Brazing filler metals o Six basic steps for a properly brazed joint: Good fit-up and proper clearances Clean metal Proper fluxing Assembly and support Heating and flowing the brazing alloy Final cleaning - Selecting a brazing filler metal - Brazing alloy types o Silver filler metals (BAg) o Aluminum-silicon filler metals (BAISi) o Aluminum brazing rod (BAISi-4) (AA 4047) o Nickel filler metals (BNi) o Copper-phosphorous filler metals (BCuP) o Gold filler metals (BAu) o Cobalt filler metals (BCo) o Magnesium filler metals (BMg) - Braze welding filler metals o Advantages of braze welding o Disadvantages of braze welding o Classification details o Welding considerations - Fluxes o Functions of fluxes b. The ability to run lines of fusion with and without filler rods in the flat and vertical positions Preparation of materials for welding - Fitting of material - Welding variables o Tip size and torch settings o Angle o Inclination o Torch to work distance o Travel speed o Torch manipulation c. The ability to weld lap joints on 10 or 11 Ga. ( mm) mild steel in the horizontal (2F) and vertical (3F) positions using a comparable filler material Fusion welding on lap joints d. The ability to weld butt joints on 10 or 11 Ga. mild steel in the flat (1G) and vertical (3G) positions using a comparable filler material Fusion welding on butt joints e. The ability to weld lap joints on 10 or 11 Ga. mild steel in the vertical position using a braze welding filler material Braze welding 5. Perform Oxyfuel cutting and welding 80% a. Identify the ability to safely operate a hand-held oxyfuel cutting torch on mild steel plate b. and structural shapes c. Identify the ability to perform straight line, bevel and shape cutting on mild steel d. Identify the ability to pierce and cut holes in mild steel plate e. Identify the ability to cope 3/8 mild steel to fit a 4 channel member f. Identify the ability to safely operate a machine oxyfuel cutting torch on mild steel plate *** 16 Rev. September 2008

18 Industrial Welder Unit: A3 Introduction to GMAW, FCAW, SAW and MCAW Processes Level: Duration: Overview: One 24 hours Theory: Practical: 20 hours 4 hours This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of GMAW, FCAW and SAW processes. Material covered includes: Introduction to GMAW, FCAW, SAW and MCAW processes GMAW, FCAW,SAW and MCAW power sources Filler metals for GMAW, FCAW, SAW and MCAW Shielding Gases for GMAW and FCAW GMAW, FCAW, SAW and MCAW equipment maintenance and troubleshooting Percent of Objectives and Content: Unit Mark (%) 1. Describe the principles of operation of GMAW: 15% a. History of GMAW b. GMAW principles of operation c. Components of basic GMAW set-up Equipment for GMAW Power sources Wire feeder Electrode holders and cable assembly Spooled filler wire Shielding gas Regulator/Flow meters Cooling system d. Modes of metal transfers obtained with GMAW Short-circuiting transfer Globular transfer Spray transfer e. Pinch effect f. Short-circuiting metal transfer g. Global transfer h. Spray transfer Variations of spray arc - Pulsed Arc Transfer (GMAW-P) i. Power sources and wire feeders Power sources for GMAW - Selection guidelines - Rating welding power sources - Constant current versus constant voltage o Characteristics of CV power source Wire feed control and drive units 17 Rev. September 2008

19 - Wire feed systems - Constant speed wire feeders - Voltage-sensing wire feed controls - Microprocessor-controlled wire feeders - Drive roll assemblies o Dual roll design o Wire feeder panel controls Power source and wire feeder operating variables - Voltage - Amperage - Effects of polarity o Polarity and heat distribution in the Arc Electrode extension (stickout) Slope - Slope control systems - Open circuit voltage as it relates to slope Inductance Power sources for pulsed spray arc transfer mode j. GMAW wire drive systems and gun and cable assemblies Wire drive systems: - Push system - Pull system - Push-pull system - Choosing a wire feed system - Maintenance Welding gun and cable assemblies - Welding guns - Contact tube - Nozzle - Cable assemblies o Shielding gas supply systems for GMAW Shielding gas supply systems: - Compressed gas cylinders - Carbon dioxide liquid-filled cylinder o CO2 Gas dew point o CO2 Gas flow rates o Line heaters Cylinder valves Liquid bulk systems k. Cylinder Identification, storage and handling l. Regulators m. Flowmeters n. Regulator/flowmeters o. Equipment selection guidelines p. Hoses q. Solenoid valves 2. Identify GMAW filler metals, shielding gases and safety: 15% a. GMAW filler metals Terms associated with GMAW filler metals Manufacture of filler wires Chemistry and wire sizing Testing requirements Identification and packaging Cast and helix - Cast - Helix Wire finish Selection of filler wire Choosing the correct wire size 18 Rev. September 2008

20 Filler wire classifications AWS specifications CSA standards Classification of low-carbon steel filler metals for GMAW Electrode wire applications GMAW electrode wire characteristics and applications GMAW filler metals packaging Consumables storage and handling Storing GMAW consumables b. Shielding gases for GMAW Definition of terms Shielding gas selection guidelines c. Basic properties of shielding gases Specific gravity Ionization potential Thermal conductivity Dissociation and recombination characteristics Reactivity/oxidation potential - Reactive - Inert d. Shielding gases used for GMAW Inert gases - Argon (Ar) - Helium (He) Reactive Gases - Carbon Dioxide (CO2) - Oxygen (O2) - Hydrogen (H2) - Nitrogen (N2) Shielding Gas Mixes - Argon-oxygen mixes - Argon-CO2 - Argon-helium- CO2 - Argon-CO2-Hydrogen Multiple Gas Mixtures Gas flow rates e. Applications of shielding gases used with GMAW f. Advantages and disadvantages of various shielding gases GMAW using short circuit metal transfer GMAW using spray metal transfer g. Gas metal arc welding h. Precautions that are taken against electrical shock, toxic fumes and radiant energy associated with GMAW Safety Electrical hazards Toxic fumes - Ventilation Personal protection - Protective clothing and footwear - Eye and face protection - Hearing protection 3. Identify GMAW equipment maintenance and troubleshooting. 15% a. Set-up and maintenance required for wire drive systems and gun assembles Equipment set-up for GMAW Select and feed the electrode wire - Feeding wire Attaching a wire cleaner Adjusting the brake Daily shutdown procedure 19 Rev. September 2008

21 Ongoing maintenance of equipment - Periodic inspection of power cables - Cable liner maintenance - Hoses - Contact tubes - Gas nozzles b. Corrective measures for malfunctioning GMAW equipment. Corrective measures with welding techniques - Electrode angle - Electrode inclination o Forehand inclination o Backhand inclination - Electrode extension - Travel speed Corrective measures with wire feed equipment - Nozzles and contact tips - Work lead connection - Stubbing - Wire pileups - Arc hunting Troubleshooting wire feed equipment - Process - Electrical - Mechanical Weld defects - Porosity - Undercut - Lack of fusion - Burn-through - Lack of Penetration - Whiskers - Inclusions - Cracking 4. Identify FCAW. 10% a. The principles of operation of FCAW. History of FCAW Applications - Principles of operation - Gas-shielded FCAW - Self-shielded FCAW b. Components of basic FCAW set-up. Equipment set-up for FCAW Power sources Wire feeder Electrode holders and cable assembly Spooled filler wire Shielding gas Regulator/flowmeters Cooling system c. FCAW power sources, wire feeders and gun and cable assemblies FCAW power sources - Selection guidelines - Rating welding power sources - Constant current versus constant voltage o Power sources for self-shielded FCAW Wire feed control and drive units - Constant speed wire feeders - Voltage-sensing wire feed controls - Micro-processor-controlled wire feeders 20 Rev. September 2008

22 Wire feeder drive roll assemblies Welding gun and cable assemblies - Welding guns - Contact tube and gas diffuser - Nozzle - Cable assemblies d. FCAW operating variables Operating variables - Voltage - Amperage - Effects of polarity o Polarity and heat distribution in the arc Electrode extension (stickout) e. Shielding gases for FCAW Applications of shielding gases used with FCAW - Gas-shielded FCAW on various metals FCAW shielding gas flow rates f. FCAW filler metals Terms associated with FCAW filler metals - AWS - Cast - CSA - Consumable electrode - Composite electrode - Filler metal - Flux - Helix - Mechanical Property - Specification - Standard - Welding wire Manufacture of flux-cored wires Operating characteristics of FCAW wires Functions of the flux of FCAW wires Selection of filler wires Choosing the correct wire size FCAW filler metals packaging Filler wire classifications AWS specifications CSA standards Filler wire classifications for FCAW Consumables storage and handling Electrode wire applications FCAW electrode wire characteristics and applications Metal-cored electrode wire characteristics and applications g. FCAW equipment maintenance and troubleshooting Ongoing maintenance of FCAW equipment Troubleshooting FCAW equipment - Process - Electrical - Mechanical h. Advantages and disadvantages of FCAW 5. Identify submerged arc welding (SAW). 10% a. Principles of operation of SAW History of submerged arc welding SAW principles of operation Applications b. Components of a basic SAW set-up Equipment for SAW 21 Rev. September 2008

23 SAW power sources Welding head assembly Travel carriage Fixtures and positioners Spooled filler wire Flux Flux feed and recovery equipment Work lead connection c. SAW power sources, welding head assemblies, control systems and flux feed systems SAW power sources - Power source selection guidelines Welding head assembly - Control unit - Wire straightener, variable speed electric motor and gearbox and drive roll assembly - Wire feed set-ups for SAW - Torch assembly - Flux feed and recovery d. SAW operating variables Main operating variables of a SAW system and how they can influence the quality of welding: - Amperage - Voltage - Travel speed - Electrode diameter - Electrode extension - Width and depth of flux layer Effects of polarity e. SAW filler metals and fluxes Terms associated with SAW filler metals and fluxes Manufacture of filler wires Chemistry and wire sizing Testing requirements Identification and packaging Cast and Helix Wire finish Choosing the correct wire size Electrode and flux designations for SAW - CSA standards CSA classification system of carbon steel SAW flux-electrode combinations (CSA Standard) AWS classification system of carbon steel flux-electrode combinations (AWS Specifications) Points to consider in choosing SAW consumables CSA mechanical properties requirements for SAW flux/electrode combinations SAW fluxes SAW fluxes classified according to method of manufacture - Fused fluxes - Bonded fluxes SAW fluxes classified according to effect on alloy content of the weld deposit - Neutral fluxes - Active fluxes - Alloy fluxes Typical SAW flux/electrode combination characteristics and applications Storing SAW consumables f. SAW maintenance of equipment g. Corrective measures SAW equipment h. Troubleshooting SAW equipment Process Electrical Mechanical i. Advantages and disadvantages of SAW 22 Rev. September 2008

24 6. Identify Metal Core Arc Welding (MCAW). 10% a. MCAW operating variables. b. MCAW weld defects. c. MCAW safe operation. d. Proper care, use and troubleshooting of equipment. 7. Perform GMAW, FCAW, SAW or MCAW process. 25% *** 23 Rev. September 2008

25 Industrial Welder Unit: A4 Shop/Lab Practices Level: Duration: One 45 hours Theory: Practical: 0 hours 45 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of GMAW, FCAW, SAW and MCAW processes. Material covered includes: GMAW welds on mild steel FCAW welds on mild steel Combined GMAW welds on mild steel MCAW welds on mild steel Percent of Objectives and Content: Unit Mark (%) 1. GMAW welds on mild steel: 25% a. Demonstrate the ability to weld stringer/weave beads in the flat and horizontal positions Practical welding applications Definitions of terms Setting GMAW welding parameters b. Demonstrate the ability to weld 1F welds on mild steel plate. Exercise: fillet welds in the 1F (Flat) position c. Fillet welds in the 2F position Exercise: fillet welds in the 2F (Horizontal) position d. Demonstrate the ability to weld fillet welds in the vertical (3F) position (downhill root and uphill fill and cover pass) on mild steel plate Exercise: fillet welds in the 3F (Vertical) position e. Prepare and fit up butt joints without backing Preparation and fit up of butt joints - Fit up f. Demonstrate the ability to weld butt joints in the 1G (Flat) Position g. Demonstrate the ability to weld butt joints in the 2G position Exercise: Butt joints in the 2G (Horizontal) position h. Demonstrate the ability to weld butt joints in the 3G position Exercise: butt joints in the 3G (vertical) position 2. FCAW welds on mild steel: 25% a. Demonstrate the knowledge to weld stringer/weave beads in the flat and horizontal positions on mild steel plate Getting started with FCAW Setting FCAW welding parameters - Exercise: surface welding b. Demonstrate the knowledge to weld 1F welds on mild steel plate Exercise: fillet welds in the 1F (Flat) position c. Demonstrate the knowledge to weld fillet welds in the horizontal (2F) position on mild steel 24 Rev. September 2008

26 Exercise: fillet welds in the 2F (Horizontal) position d. Demonstrate the knowledge to weld fillet welds in the vertical (3F) position on mild steel Exercise: Fillet welds in the 3F (Vertical) position e. Preparation of joints with backing material f. Demonstrate the knowledge to weld butt joints in the 1GF position with backing on mild steel plate. Exercise: butt joints in the 1GF (Flat) position g. Demonstrate the knowledge to weld butt joints in the 2G position with backing on mild steel plate Exercise: butt joints in the 2G (Horizontal) position h. Demonstrate the knowledge to weld butt joints in the 3GF position with backing on mild steel plate Exercise: butt joints in the 3GF (Vertical) position 3. Combined GMAW and FCAW welds on mild steel 25% a. Demonstrate the knowledge to weld butt joints in the 1G position on mild steel using GMAW for the root bead and FCAW fill and cap Using two processes for one weld - GMAW root beads and FCAW fill and cap passes Setting GMAW and FCAW welding parameters - Setting GMAW welding parameters - Setting FCAW welding parameters Exercise: 1G (Flat position) welds on mild steel using GMAW and FCAW b. Demonstrate the knowledge to weld butt joints in the 2G position on mild steel using GMAW for the root bead and FCAW fill and cap Exercise: butt joints in the 2G (Horizontal) position c. Demonstrate the knowledge to weld butt joints in the 3G position on mild steel using GMAW for the root bead and FCAW fill and cap using. Butt joints in the 3G (Vertical) position Exercise: butt joints in the 3G (vertical) position 4. MCAW weld on mild steel 25% *** 25 Rev. September 2008

27 Industrial Welder Unit: A5 Trade Problems Level: Duration: One 29 hours Theory: Practical: 29 hours 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of trade problems. Material covered includes: Fractions Decimals Percentages and ratios Metric and imperial measurement Geometric formulas Percent of Objectives and Content: Unit Mark (%) 1. Solve problems involving fractions: 20% a. Key terms and concepts used in working with fractions terminology b. Fractions to a common denominator. Finding the common denominator c. Problems using whole numbers and fractions Change fractions to higher terms Change fractions to lowest terms Changing mixed numbers to improper fractions Changing improper fractions to mixed numbers Multiply fractions Divide fractions Add fractions Subtract fractions - Subtraction of fractions with common denominators - Subtraction of fractions without common denominators - Subtraction of mixed numbers without common denominators d. Problems using whole numbers and fractions in practical applications Practical applications using whole numbers and fractions - Holes and spaces Scientific calculators 2. Solve problems involving decimals. 20% a. Decimal fractions Knowledge of reading and writing decimals - Expression of decimals in words - Conversion of decimals in word format to a written decimal b. Rounding decimal fractions to specified place values Rounding decimal fractions 26 Rev. September 2008

28 c. Converting decimals to fractions d. Converting fractions to decimals Converting mixed numbers to equivalent decimal fractions e. Adding and subtracting decimals f. Multiplying and dividing decimal fractions g. Converting decimal inches to fractions with a practical denominator h. Converging decimal feet to feet and inches with a practical denominator 3. Solve problems involving percentage and ratios. 20% a. Ratio problems Express two quantities in the form of a ratio b. Express two ratios in the form of a proportion c. Converting between fractions and percents Converting a fraction to a percent Converting a percent to a fraction d. Converting decimals and percents Converting decimals to percents Converting a percent to a decimal e. Percent problems Solving percent problems 4. Solve problems involving metric and imperial measure. 20% a. Commonly used metric units of measurement Length Area Volume and capacity Mass and weight b. Converting between units of measurement: Converting metric and imperial measurements of length Converting between metric measurements of area Converting between metric measurements of volume Converting metric and imperial measurements of weight Converting other welding-related measurements - Temperatures - Tensile strength - Notch toughness c. Converting imperial: feet to inches, square inches to square feet and cubic measures to gallons Converting feet and inches Converting square inches and square feet Converting cubic inches and cubic feet Converting cubic measures to gallons 5. Solving problems involving geometric formulas. 20% a. Problems involving geometric formulas Key terminology - Equation - Formula - Constant - Variable - Term - Solution Order of operations in solving equations Solving equations b. Common formulas and solve problems for perimeter. Perimeter - Perimeter of a rectangle - Perimeter of a square - Perimeter of a triangle - Circumference of a circle - Perimeter of a combined geometric figure 27 Rev. September 2008

29 c. Common formulas and solve problems for area Area of a rectangle Area of a square Area of a triangle Area of a circle Area of a trapezoid Area of a parallelogram Lateral surface area of a cylinder Total surface area of a closed cylinder Lateral surface area of a right rectangular solid Total surface area of a right rectangular solid d. Common formulas and solve problems for volume Volume of a right rectangular solid Volume of a cylinder Volume of any regular shaped object Calculating the capacity of a container in gallons e. Calculate the weight of a solid f. Calculate the capacity of a container in gallons *** 28 Rev. September 2008

30 Industrial Welder Unit: B1 Introduction to SMAW Level: Duration: One 24 hours Theory: Practical: 24 hours 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of SMAW equipment and safety, mild steel electrodes, basic joints and weld types and mild steel electrodes. Material covered includes: Introduction to SMAW safety SMAW equipment Mild steel electrodes Basic types and weld faults Percent of Objectives and Content: Unit Mark (%) 1. Identify SMAW safety procedures. 10% a. Physical hazards and personal protective equipment that are common to the SMAW process b. The effects of electricity and precautions used to prevent injury 2. Identify SMAW equipment. 30% a. SMAW related terms b. AC and AC-DC rectified welding power sources AC transformers AD-DC rectifier power sources c. AC-DC generator welding power sources AC and DC Generators and alternators DC Generators and alternators d. Multi-process inverter welding power sources Inverter welding power sources e. Welding cables and accessories for welding power sources Machine installation and maintenance Welding cables Cable connectors and cable lugs Electrode holders Work lead clamps f. Effect of arc length on amperage and voltage How amperage and voltage are affected by arc length 3. Identify mild steel electrodes. 30% a. Terms associated with SMAW electrodes Types of welding electrodes - Non-consumable electrodes - Consumable electrodes The coated electrode 29 Rev. September 2008

31 The SMAW process Mechanical properties of metal: - Ductility - Tensile strength - Brittleness - Hardness - Toughness - Elasticity - Malleability - Yield strength - Impact strength Dynamic and Static loading considerations - Dynamic loading - Static loading b. CSA and AWS classification and specifications for SMAW electrodes AWS classification system - Last digit interpretation - AWS optional supplementary designators CSA classification system - CSA optional supplementary designator Comparing the AWS and CSA classification systems c. Types and functions of SMAW electrode coatings Core wire Electrode coating - Materials used in electrode coatings Grouping electrodes according to operating characteristics - Fast freeze electrodes - Fast fill electrodes - Fill freeze electrodes Grouping electrodes according to usability characteristics Iron powder electrodes d. Functions of the slag e. Basic care, handling and storage procedures for these electrodes Electrode packaging, storage and handling Low hydrogen electrodes packaging and storage Consequences of using low hydrogen electrodes with too much moisture - Cracking - Porosity f. Commonly used mild steel SMAW electrodes and their applications 4. Identify basic types and weld types. 30% a. Five basic joints b. Types of welds and their acceptable dimensions Four weld types - Surfacing welds - Plug or slot welds - Fillet welds - Groove welds c. Joint and weld type variations Corner joint Edge joint Tee joint Lap joint Butt joint Position designations for groove and fillet welds d. Major considerations to accounted for in the design of a joint for welding *** 30 Rev. September 2008

32 Industrial Welder Unit: B2 SMAW Welds on 3/8 Mild Steel Plate Level: Duration: One 67 hours Theory: Practical: 0 hours 67 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of shop/lab practices with SMAW equipment. Material covered includes: SMAW welds on mild steel plate Arc cutting and gouging Percent of Objectives and Content: Unit Mark (%) 1. Perform arc cutting and gouging. 20% 2. Perform SMAW safety procedures with shop/lab practices and SMAW welds. 20% 3. Perform surface welds in the flat position. 10% 4. Perform 1F welds using SMAW. 10% 5. Perform 2F welds using SMAW. 10% 6. Perform 3F welds using SMAW. 10% 7. Perform 1G welds using SMAW. 10% 8. Perform 1GF welds using SMAW. 10% *** 31 Rev. September 2008

33 Industrial Welder Unit: E1 Introduction to Pattern Development and Geometric Construction & Isometric and Oblique Drawings Level: Duration: Overview: One 26 hours Theory: Practical: 26 hours 0 hours This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of Pattern Development and Geometric Construction and Isometric and Oblique Drawings. Material covered includes: Pattern development Geometric construction Isometric drawings Oblique drawings Percent of Objectives and Content: Unit Mark (%) 1. Identify pattern development 30% a. Alphabet of lines b. Principles of scale drawings Scales - Reduced scales o Metric reduced scales o Imperial reduced scales Enlarged scales c. Perspective, oblique and isometric drawings Pictorial drawings Perspective drawings Oblique drawings Isometric drawings d. Principals of oblique and isometric drawings Making oblique drawings Making isometric drawings e. Principles of orthographic projection Orthographic views - Orthographic view positioning f. Simple objects in orthographic projection g. SI metric and imperial dimensioning h. Size, location and notation of dimensions Dimensioning drawings Lines used for dimensioning - Arrowheads o Extension lines and dimensioning lines o Leader lines 32 Rev. September 2008

34 Dimensioning methods - Conventional dimensioning - Baseline dimensioning - Running dimensions - Number placement Dimensioning in confined spaces Dimensioning of angles Arc dimensions Circle dimensions Tolerance dimensions Preferred practice for locating dimensions on a drawing - Dimension outside objects - Dimensioning of hidden lines - Dimension placement - Locating hole centres 2. Identify geometric construction 30% a. Drawing equipment: T-squares, set squares, compass, rulers(rules) and pencils b. Circle and its components Circular shapes c. Compass and straightedge to bisect lines, angles and arcs Definition of terms - Lines - Angles - Vertex - Triangle - Other geometric shapes - Other geometric terms 3. Identify basic isometric and oblique drawings 40% a. Make isometric drawings General guidelines Procedure b. Make oblique drawings General guidelines Procedure *** 33 Rev. September 2008