Course #: IT72 Grade Level: 9-12 Course Name: Welding II Level of Difficulty: Average Prerequisites: None # of Credits: 2 semesters 1 credit The following is a Career and Technical Education (CTE) class under the Welding Program. Welding Units and Understanding Statements Unit 1: Unit 2: Unit 3: Unit 4: Unit 5: Unit 6: Unit 7: Unit 8: Unit 9: Safety No State Standards are available; district materials will be utilized. There will be one week of general safety education, plus additional safety education for specific processes as they are covered during this course. Students will understand the importance of a safe and secure work environment in a welding shop. Measurement and Layout Students will understand and apply advanced measurement skills including area and volume calculations. Oxy-Fuel Cutting (OFC) Students will understand appropriate cutting and techniques for all types of metals. Equipment and Tools Students will understand the proper use of hand and power tools, and the welding used for the processes taught in the scope of this class. Shielded Metal Arc Welding (SMAW) Students will make SMAW weldments with mild steel. Oxy-fuel Welding (OFW) Students will make OFW weldments with mild steel. Gas Metal Arc Welding (GMAW) Students will make GMAW weldments with mild steel. Gas Tungsten Arc Welding (GTAW) Students will make GTAW weldments with mild steel and aluminum. Flux Cored Arc Welding (FCAW) Students will make FCAW weldments with mild steel and aluminum. Unit 10: Weldment Testing Students will make weldments in each process suitable for physical testing purposes. 1
AZ COLLEGE AND CAREER READY ENGLISH LANGUAGE ARTS CONNECTIONS The following Reading and Speaking and Listening AZ College and Career Ready Standards are integrated as applicable in this course: Reading: Key Ideas and Details Standard 1: Cite specific textual* evidence to support analysis of science and technical texts, attending to the precise details of explanations or descriptions. Standard 3: Follow precisely a complex multistep procedure when carrying out experiments, taking measurements, or performing technical tasks attending to special cases or exceptions defined in the text. Craft and Structure Standard 4: Determine the meaning of symbols, key terms, and other domain-specific words and phrases as they are used in specific scientific or technical context relevant to grade specific text and topics. Standard 5: Analyze the structure of the relationships among concepts in a text, including relationships among key terms. Integration of Knowledge and Ideas Standard 9: Compare and contrast findings presented in a text to those from other sources (including their own experiments), noting when the findings support or contradict previous explanations or accounts. Speaking and Listening: Comprehension and Collaboration Standard 1: Initiate and participate effectively in a range of collaborative discussions (one-on-one, in groups, and teacher-led) with diverse partners on gradelevel topics, texts, and issues, building on others ideas and expressing their own clearly and persuasively. 2
IT72 Welding II Processes - Suggested Teaching Timeline First Semester Second Semester August Sept. Oct. Nov. Dec. Jan. Feb. March April May Unit 1: Safety Unit 2: Measurement and Layout 1 week 2.2 weeks Unit 3: Oxy-fuel Cutting (OFC) Unit 4: Equipment and Tools Unit 5: Shielded Metal Arc Welding (SMAW) 2.2 weeks 1.2 weeks 8 weeks 3.2 weeks 3.8 weeks Unit 6: Oxy-fuel Welding (OFW) 2.8 weeks Unit 7: Gas Metal Arc Welding (GMAW) 4 weeks Unit 8: Gas Tungsten Arc Welding (GTAW) 4 weeks 3.4 weeks Unit 9: Flux Cored Arc Welding (FCAW) Unit 10:Weldment Testing 4 weeks 2. 4 weeks 1 week 3
Unit 1: Safety Students will understand the importance of a safe and secure work environment in a welding shop. Proper procedures of operations Job site hazards in welding PPE (Personal Protective Equipment) Develop personal daily safety habits Select and wear appropriate PPE (Personal Protective Equipment) for different welding processes and tasks Analyze and choose appropriate safety procedures with all tools and Differentiate between which safety procedures are applicable at all times and which are used only for specific processes and tasks There are no CTE Arizona State Standards available related to welding safety, so MPS district guidelines will be utilized. District safety study guides and assessments Computer lab and software Safety demos in lab as appropriate 4
Unit 2: Measurement and Layout Students will understand and apply advanced measurement skills including area and volume calculations. How to read a ruler and understand fractions How to add, subtract, multiply and divide fractions and whole numbers Uses for fit up tools (triangle, square, tape measure, protractor, compass) Calculation of area for different shapes and solids How to interpret welding print symbols Demonstrate how to measure within 16 th of an inch Add and subtract mixed numbers including fractions Safely utilize fit up tools (triangle, square, tape measure, protractor, compass) Calculate area and volume for various shapes and solids Calculate best possible efficiency for materials layout Interpret welding print symbols on drawings Produce a simple drawing incorporating welding print symbols 1.0 Layout and fit up project from blueprints 1.1 Interpret drawings, symbols and procedures 1.2 Use measuring devices 1.3 Lay out projects from blueprints 1.4 Measure and cut materials Teacher generated assessments Computer lab and software Triangle, square, tape measure, protractor, compass soapstone Steel Sample welding prints Print symbols study materials, i.e. Symbols for Welding from the Hobart Institute of Welding Technology or Welding Print Reading from Goodheart- Willcox 5
Unit 3: Oxy-fuel Cutting (OFC) Students will understand appropriate cutting and techniques for all types of metals. The components of the following cutting o Oxy-fuel o Plasma arc o Semi-automatic Demonstrate safe and proper setup, use and shut down of the following cutting o Oxy-fuel o Plasma arc o Semi-automatic 2.0 Set up and use cutting 2.1 Set up and use oxy-fuel 2.2 Set and use plasma arc cutting 2.4 Set up and use semi-automatic cutting Measurement and layout tools Identify the following cutting o Oxy-fuel o Plasma arc o Semi-Automatic Safety study guides and assessments Steel 6
Unit 4: Equipment and Tools Students will understand the proper use of hand and power tools, and the welding used for the processes taught in the scope of this class. The safe and proper use of all hand and power tools used in this course Demonstrate safe and proper use of hand and power tools as noted in the Arizona CTE Standards column for this unit 8.0 Use auxiliary and tools 8.1 Use power saw/abrasive wheel to cut material 8.2 Use power to wire brush metal 8.3 Use multi-purpose shear and punch 8.4 Use metal brake 8.5 Use metal roller 8.6 Use drilling Teacher assessments Abrasive cut-off saw Angle Grinder Wire wheel Multi-purpose shear and punch Drill press and power drills Band saws 7
Unit 5: Shielded Metal Arc Welding (SMAW) Students will make SMAW weldments with mild steel. Components of SMAW The safe, proper set up and use of Shielded Metal Arc Welding Proper amperage for different size and types of electrodes, materials and positions Select proper amperage for different size and types of electrodes, materials and positions Safely produce the following acceptable welds: 2F (flat fillet), 3F (vertical up fillet) and 4F (overhead fillet) with 6010 and 7018 electrodes 3G (vertical up groove) with 1/8 7018 on 3/8 w/consumable backing plate (D1.1 structural certification)* Safely produce a surface build up on 2 x 6 weld plate Explain the American Welding Society (AWS) numbering system for SMAW welding electrodes *D1.1 is the AWS structural welding code manual for steel. 1.0 Layout and fit up project from blueprints 1.5 Tack materials into position for welding 3.0 Set up and use shielded metal arc welding (SMAW) 3.1 Set up SMAW 3.2 Identify and use types, storage, and handling of electrodes 3.3 Make fillet weld (all positions) on carbon steel in flat position (all positions not required for S.E.N.S.E.)* 3.4 Make fillet weld (all positions) on carbon steel in flat position 3.5 Hard face and build up steel surface with SMAW *Schools Excelling through National Skills Standards Education Teacher made common assessments SMAW Steel and welding rod 8
Unit 6: Oxy-fuel Welding (OFW) Students will make OFW weldments with mild steel. The components of oxy-fuel welding How to set up oxy-fuel welding Demonstrate safe and proper setup, use and shut down of oxy-fuel welding Safely complete an acceptable weld bead, open butt joint, corner joint and 2F (horizontal fillet) 1.0 Layout and fit up project from blueprints 1.5 Tack materials into position for welding 5.0 Set up and use oxy-fuel 5.1 Set up oxy-fuel to industry standards 5.2 Weld carbon steels flat position Teacher assessments Measurement tools and layout tools Oxy-fuel welding Steel Safety assessment 9
Unit 7: Gas Metal Arc Welding (GMAW) Students will make GMAW weldments with mild steel. Components of GMAW The safe, proper set up and use of Gas Metal Arc Welding Proper voltage for different types, size of electrode wire and positions Proper application of different wire types and sizes Set up GMAW Safely produce an acceptable weld bead in the 2F (horizontal fillet), 3F (vertical up fillet) and 4F (overhead fillet weld) positions Safely produce a 3G (vertical up groove) position with.035 ER70S wire on 3/8 w/consumable backing plate (D1.1 structural certification) Prep and produce a T-joint weld on square tubing and saddle joint weld on round tubing Explain maintenance procedures for GMAW 1.0 Layout and fit up project from blueprints 1.5 Tack materials into position for welding 4.0 Set up and use Gas Metal Arc Welding (GMAW) (MIG) 4.1 Set up GMAW 4.4 Make flat and horizontal fillet welds on carbon steel 4.5 Perform routine maintenance on GMAW wire feed assembly Teacher made common assessments GMAW Steel and welding wire 10
Unit 8: Gas Tungsten Arc Welding (GTAW) Students will make GTAW weldments with mild steel and aluminum. Components of GTAW The safe, proper set up and use of Gas Tungsten Arc Welding Proper amperage for different size of tungsten, filler wire and positions Technique for pointing tungsten Safely produce an acceptable weld bead open butt joint and 2F (horizontal fillet) joint in aluminum, and carbon steel Safely grind on tungsten electrodes, resulting in the proper point for each GTAW process 6.0 Set up and use gas tungsten arc welding (GTAW) (TIG) 6.1 Set up GTAW 6.2 Identify and use types and handling of filler material 6.3 Select and use gases appropriately 6.4 Weld aluminum 6.6 Weld carbon steels Note: Measurement criterion 6.5 is omitted because it requires the welding of stainless steel. This process is not permitted at the high school level due to the production of hexavalent chromium fumes which are extremely hazardous and must not be ingested. Teacher assessments GTAW Steel, aluminum and appropriate filler rod 11
Unit 9: Flux Cored Arc Welding (FCAW) Students will make FCAW weldments with mild steel and aluminum. Components of FCAW The safe, proper set up and use of Flux Core Arc Welding Proper voltage for different type and size of electrode wire and positions Select proper voltage for different type and size of electrode wire and positions Safely produce an acceptable weld bead, 2F (horizontal fillet), 3F (vertical up fillet) and 4F (overhead fillet) welds Explain maintenance procedures for GTAW 7.0 Set up and use flux cored arc welding (FCAW) 7.1 Set up FCAW 7.2 Identify and use types, storage, and handling of filler material 7.3 Make fillet welds (all positions) on carbon steel 7.4 Perform maintenance on FCAW wire feed assembly Teacher made common assessments FCAW Steel and welding wire 12
Unit 10: Weldment Testing Students will make weldments in each process suitable for physical testing purposes. The processes of destructive and nondestructive testing of weldments Identify the use of nondestructive weldment testing tools and Demonstrate and evaluate the results of a destructive test on a completed weld sample 9.0 Perform weldment testing 9.1 Describe nondestructive test 9.2 Perform destructive test Welding, cutting and polishing Hydraulic press and bend testing fixtures Nondestructive testing teaching aids 13