Course #: IT73 Grade Level: 9-12 Course Name: Welding and Materials Processes Level of Difficulty: Average Prerequisites: IT72 # 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: 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. Unit 2: Measurement and Layout Students will understand and apply advanced measurement skills including area and volume calculations, incorporating them into projects chosen with the guidance of the instructor. Unit 3: Oxy-fuel Cutting (OFC) Students will understand the use of appropriate cutting equipment and techniques for all types of metals. Unit 4: Equipment and Tools Students will understand the proper use of hand and power tools, and the welding equipment used for the processes taught in the scope of this class. Unit 5: Weldment Testing Students will make weldments in each process suitable for physical testing purposes. Unit 6: Shielded Metal Arc Welding (SMAW) Students will make SMAW weldments with mild steel and construct projects using SMAW. Unit 7: Gas Metal Arc Welding (GMAW) Students will make GMAW weldments with mild steel and construct projects using GMAW. Unit 8: Gas Tungsten Arc Welding (GTAW) Students will make GTAW weldments with mild steel and construct projects using GTAW. 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
IT73 Welding and Materials 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 1.2 weeks Unit 3: Oxy-fuel Cutting (OFC) 1 week Unit 4: Equipment and Tools Unit 5: Weldment Testing Unit 6: Shielded Metal Arc Welding (SMAW) 1.2 weeks 1 week 2 weeks 3.2 weeks 3.8 weeks Unit 7: Gas Metal Arc Welding (GMAW) 2.8 weeks 4 weeks 4 weeks Unit 8: Gas Tungsten Arc Welding (GTAW) 3.4 weeks 4 weeks 3.4 weeks 3
Unit 1: Safety Students will understand the importance of a safe and secure work environment in a welding shop. Proper procedures for equipment operations Job site hazards in welding Personal protective equipment 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 Explain safety rules 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 equipment 4
Unit 2: Measurement and Layout Students will understand and apply advanced measurement skills including area and volume calculations, incorporating them into projects chosen with the guidance of the instructor. How to read a ruler and understand fractions How to add, subtract, multiply and divide fractions and whole numbers Use of fit up tools (triangle, square, tape measure, protractor, compass) How to interpret welding symbols on drawings 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 symbols on drawings Produce a simple drawing incorporating welding print symbols Working from a drawing, lay out, cut the parts, fit up, and perform the welds called for to build a simple project 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 and aluminum 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 Drawings, materials, and equipment for simple projects 5
Unit 3: Oxy-Fuel Cutting (OFC) Students will understand the use of appropriate cutting equipment and techniques for all types of metals. The components of the following cutting equipment: o Oxy-fuel o Plasma arc o Semi-automatic Safe and proper set-up and use of the following cutting equipment: o Oxy-fuel o Plasma arc o Semi-auotmatic 2.0 Set up and use cutting equipment 2.1 Set up and use oxy-fuel equipment 2.2 Set and use plasma arc cutting equipment 2.4 Set up and use semi-automatic cutting equipment Measurement and layout tools The following cutting equipment: o Oxy-fuel o Plasma arc o Semi-automatic Steel and aluminum Safety Study guides and assessments Steel Demonstrate safe and proper setup, use and shut down of the following cutting equipment: o Oxy-fuel o Plasma arc o Semi-automatic Analyze and choose which cutting method to use in a given situation 6
Unit 4: Equipment and Tools Students will understand the proper use of hand and power tools, and the welding equipment used for the processes taught in the scope of this class. The safe and proper use of hand and power tools used in this course Safely utilize hand and power tools Analyze and choose which tools are best for a given task 8.0 Use auxiliary equipment and tools 8.1 Use power saw/abrasive wheel to cut material 8.2 Use power equipment to wire brush metal 8.3 Use multi-purpose shear and punch 8.4 Use metal brake 8.5 Use metal roller (slip roll) 8.6 Use drilling equipment Study guides and assessments Teacher assessments Abrasive cut-off saw Angle grinder Wire wheel Multi-purpose shear and punch Drill press and power drills Band saws Metal brake Metal roller (slip roll) 7
Unit 5: Welding Testing Students will make weldments in each process suitable for physical testing purposes. The process of destructive and nondestructive testing of weldments Identify the use of nondestructive weldment testing tools and equipment Demonstrate and evaluate the results of a destructive test on a completed weld sample 9.0 Perform welding testing 9.1 Describe nondestructive test 9.2 Perform destructive test Safety study guides and assessments Welding cutting and polishing equipment Hydraulic press and bend testing fixtures Nondestructive testing teaching aids 8
Unit 6: Shielded Metal Arc Welding (SMAW) Students will make SMAW weldments with mild steel and construct projects using SMAW. Components of SMAW equipment Safe, proper set up and use of Shielded Metal Arc Welding (SMAW) equipment Proper amperage for different size and types of electrodes, materials and positions Identify components of SMAW equipment Safely complete the following acceptable welds: o 2F (flat fillet), 3F(vertical up fillet) and 4F (overhead fillet) with 6010 and 7018 o 3G(vertical up groove) 4G (overhead groove) with 1/8 7018 on 3/8 w/ consumable backing plate (D1.1 structural certification)* o 1G pipe weld (flat, pipe rotated +/- 15 degrees) using 1/8 7018 with 2 pipe Safely complete a surface build up on a 2 x 6 weld plate Explain the AWS numbering system for SMAW welding electrodes 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) equipment 3.1 Set up SMAW equipment 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 Hard face and build up steel surface with SMAW equipment Teacher assessments SMAW equipment Steel and welding rod *D1.1 is the AWS structural welding code manual for steel. 9
Unit 7: Gas Metal Arc Welding (GMAW) Students will make GMAW weldments with mild steel and construct projects using GMAW. Components of GMAW equipment Safe, proper set up and use of Gas Metal Arc Welding (GMAW) equipment Proper voltage for different types, size of electrode wire and positions Proper application of different wire types and sizes Identify components of GMAW equipment Safely complete an acceptable weld bead on the following: 2F (flat fillet), 3F (vertical up fillet) and 4F (overhead fillet) with 6010 and 7018 3G (vertical up groove) with 1/8 7018 on 3/8 w/consumable backing plate (D1.1 structural certification) 2G pipe weld (flat, pipe rotated +/- 15 degrees) using 1/8 7018 with 2 pipe Prep and weld T-joint on square tubing and saddle joint on round tubing Prep and weld a 45 degree joint on square tube and saddle joint on round tubing 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) equipment (MIG)* 4.1 Set up GMAW equipment 4.4 Make flat and horizontal fillet welds on carbon steel 4.5 Perform routine maintenance on GMAW wire feed assembly *MIG Metal Inert Gas Teacher assessments GMAW equipment Steel and welding rod 10
Unit 8: Gas Tungsten Arc Welding (GTAW) Students will make GTAW weldments with mild steel and construct projects using GTAW. Components of GTAW equipment The safe, proper set up and use of Gas Tungsten Arc Welding equipment Proper amperage for different size of tungsten, filler wire and positions Identify components of GTAW equipment Safely complete an acceptable weld bead open butt joint, 2F (flat fillet), 3F (vertical up), joint in aluminum and carbon steel Safely point tungsten for different weld processes 6.0 Set up and use gas tungsten arc welding (GTAW) equipment (TIG)* 6.1 Set up GTAW equipment 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 equipment Steel, aluminum and appropriate filler rod *TIG Tungsten Inert Gas 11