CED Welding CTE Summer School - Boulder Valley School...

High School CTE Summer School

Welding Program Curriculum Essentials

Document

Boulder Valley School District Department of CTEC

June 2014

6/12/2014 BVSD Curriculum Essentials 2

INTRODUCTION

Beginning Welding offers a curriculum leading to careers in the welding industry. Students will explore three different welding methods and teach welding and general metal shop safety. The first area covered will be Oxy-Acetylene welding. The second method will be Flux-core wire feed welding and the final area will be traditional Arc or (Stick) welding. Students will gain a basic understanding and proficiency level in each of these areas. Small fabrication or repair projects will be allowed as time permits. All safety equipment and supplies are included.


Welding Overview

Course Description

Introduction to the field of welding. Explore careers in welding and metal work. Learn how to weld using three different welding methods. Make or repair things made out of steel. This is a very interesting hands-on class that allows you to earn High School credit while learning a skill!

Topics at a Glance

Basic Metallurgy General Shop Safety Metal tool and Machine Safety Welding Safety Machine set up Oxy-Acetylene Welding Flux core wire feed welding Arc (Stick) welding Basic fabrication skills

Assessments

Reading packets and questions Welding exercises Welding projects-new or repair

Beginning welding is a hands on class. Students will be practicing and producing welds for self and teacher evaluation. Students are encouraged to give each other feedback as well as helping each other when needed. A shop atmosphere promoting teamwork is one of the goals of this class.


Prepared Graduates

The preschool through twelfth-grade concepts and skills that all students who complete the Colorado education system must master to ensure their success in a postsecondary and workforce setting.

1. CTE Essential Skills: Academic Foundations ESSK.01: Achieve additional academic knowledge and skills required to pursue the full range of career and postsecondary education opportunities within a career cluster.

Prepared Graduate Competencies in the CTE Essential Skills standard:

Complete required training, education, and certification to prepare for employment in a particular career field

Demonstrate language arts, mathematics, and scientific knowledge and skills required to pursue the full range of post-secondary and career opportunities

2. CTE Essential Skills: Communications Standards ESSK.02: Use oral and written communication skills in creating, expressing, and interrupting information and ideas, including technical terminology and information


Select and employ appropriate reading and communication strategies to learn and use technical concepts and vocabulary in practice

Demonstrate use of concepts, strategies, and systems for obtaining and conveying ideas and information to enhance communication in the workplace

3. CTE Essential Skills: Problem Solving and Critical Thinking ESSK.03: Solve problems using critical thinking skills (analyze, synthesize, and evaluate) independently and in teams using creativity and innovation.



Employ critical thinking skills independently and in teams to solve problems and make decisions

Employ critical thinking and interpersonal skills to resolve conflicts with staff and/or customers

Conduct technical research to gather information necessary for decision-making

4. CTE Essential Skills: Safety, Health, and Environmental

ESSK.06: Understand the importance of health, safety, and environmental management systems in organizations and their importance to organizational performance and regulatory compliance


Implement personal and jobsite safety rules and regulations to maintain safe and helpful working conditions and environment

Complete work tasks in accordance with employee rights and responsibilities and employers obligations to maintain workplace safety and health

5. CTE Essential Skills: Leadership and Teamwork ESSK.07: Use leadership and teamwork skills in collaborating with others to accomplish organizational goals and objectives


Employ leadership skills to accomplish organizational skills and objectives


6. CTE Essential Skills: Employability and Career Development ESSK.09: Know and understand the importance of employability skills; explore, plan, and effectively manage careers; know and understand the importance of entrepreneurship skills


Indentify and demonstrate positive work behaviors and personal qualities needed to be employable

Develop skills related to seeking and applying for employment to find and obtain a desired job


COLORADO COMMUNITY COLLEGE SYSTEM CAREER & TECHNICAL EDUCATION TECHNICAL STANDARDS REVISION & ACADEMIC ALIGNMENT PROCESS

Colorado’s 21st Century Career & Technical Education Programs have evolved beyond the historic perception of vocational education. They are Colorado’s best kept secret for:

• Relevant & rigorous learning

• Raising achievement among all students

• Strengthening Colorado’s workforce & economy

Colorado Career & Technical Education serves more than 116,000 Colorado secondary students annually through 1,200 programs in 160 school districts, 270 High Schools, 8 Technical Centers, 16 Community Colleges & 3 Technical Colleges. One of every three Colorado high school students gains valuable experiences by their enrollment in these programs.

ALIGNMENT REQUIRED BY SB 08-212

22-7-1005. Preschool through elementary and secondary education - aligned standards - adoption - revisions.

2(b): In developing the preschool through elementary and secondary education standards, the State Board shall also take into account any Career & Technical Education standards adopted by the State Board for Community Colleges and Occupational Education, created in Section 23-60-104, C.R.S., and, to the extent practicable, shall align the appropriate portions of the preschool through elementary and secondary education standards with the Career and Technical standards.

STANDARDS REVIEW AND ALIGNMENT PROCESS

Beginning in the fall of 2008, the Colorado Community College System conducted an intensive standards review and alignment process that involved:

NATIONAL BENCHMARK REVIEW

Colorado Career & Technical Education recently adopted the Career Cluster and Pathway Model endorsed by the United State Department of Education, Division of Adult and Technical Education. This model provided access to a national set of business and industry validated knowledge and skill statements for 16 of the 17 cluster areas. California and Ohio provided the comparative standards for the Energy cluster

• Based on this review Colorado CTE has moved from program-specific to Cluster & Pathway based standards and outcomes

• In addition, we arrived at fewer, higher, clearer and more transferrable standards, expectations and outcomes.


COLORADO CONTENT TEAMS REVIEW

The review, benchmarking and adjusting of the Colorado Cluster and Pathway standards, expectations and outcomes was through the dedicated work of Content Teams comprised of secondary and postsecondary faculty from across the state. Participation by instructors from each level ensured competency alignment between secondary and postsecondary programs. These individuals also proposed the draft academic alignments for math, science reading, writing and communication, social studies (including Personal Financial Literacy) and post secondary and workforce readiness (PWR.)


ACADEMIC ALIGNMENT REVIEW

In order to validate the alignment of the academic standards to the Career & Technical Education standards, subject matter experts in math, science, reading, writing and communication, and social studies were partnered with career & technical educators to determine if and when a true alignment existed.

CURRENT STATUS

• One set of aligned Essential skills to drive Postsecondary and Workforce Readiness inclusion in all Career & Technical Education programs.

• 52 pathways with validated academic alignments

• 12 pathways with revised standards ready for alignment (currently there are no approved programs in these pathways)

• 21 pathways where no secondary programming currently exists. Standards and alignments will be developed as programs emerge.

• Available for review at: www.coloradostateplan.com/content_standards.htm


Colorado Career & Technical Education Standards Academic Alignment Reference System

The Career & Technical Education standards have been organized by Career Cluster (17) and Pathway (81). In addition, a set of “Essential Skills” was developed to ensure the Postsecondary and Workforce Readiness within any cluster or pathway. These workforce readiness skills are applicable to all career clusters and should form the basis of each CTE program.

Organization

Essential Skills

There exists a common set of knowledge and skills that are applicable to all students regardless of which cluster or pathway they choose. This set of standards, is meant for inclusion in each program to enhance the development of postsecondary and workforce readiness skills.

Career Cluster

A Career Cluster is a grouping of occupations and broad industries based on commonalities. The 17 Career Clusters organize academic and occupational knowledge and skills into a coherent course sequence and identify pathways from secondary schools to two- and four-year colleges, graduate schools, and the workplace. Students learn in school about what they can do in the future. This connection to future goals motivates students to work harder and enroll in more rigorous courses.

Career Pathway

Pathways are sub-groupings of occupations/career specialties used as an organizing tool for curriculum design and instruction. Occupations/career specialties are grouped into Pathways based on the fact that they require a set of common knowledge and skills for career success.

Prepared Completer Competency

This level targets the “big ideas” in each pathway. These are the competencies that all students who complete a CTE pathway must master to ensure their success in a postsecondary and workforce setting. Prepared Completer Competencies will not usually be “course” specific but grow with the student’s progression through the sequence of courses.

Concept/Skill

The articulation of the concepts and skills that indicates a student is making progress toward being a prepared completer. They answer the question: What do students need to know and be able to do?

Evidence Outcome

The indication that a student is meeting an expectation at the mastery level. How do we know that a student can do it? Pathway Abbreviation (4 Letter)


Academic Alignments

Academic alignments, where appropriate in Math, Reading, Writing and Communication, Science and Social Studies (including Personal Financial Literacy) were defined by CTE and academic subject matter experts using the following criteria:

• It was a point where technical and academic content naturally collided;

• The student must demonstrate adequate proficiency with the academic standard to perform the technical skill; and

• It could be assessed for both academic and technical understanding.

Colorado’s CTE programs have had academic alignments dating back to the early 1990’s. While these alignments resulted in an increase in academic focus in CTE programs, the reality is that a true transformation in intentional teaching toward the academic standard was limited.

With these alignments comes a new expectation: If a CTE instructor is teaching a CTE concept that has an identified alignment, they must also be intentional about their instruction of the academic standard. CCCS will be providing professional development and instructional resources to assist with the successful implementation of this new expectation. In addition, this expanded expectation will require increased collaboration between CTE and academic instructors to transform teaching and learning throughout each school.

For each set of Cluster and Pathway standards, the academic alignments have been included and are separated by academic area. CCCS chose to align at the “Evidence Outcome” level. The aligned academic evidence outcome follows the CTE evidence outcome to which it has been aligned. For a sample, see Illustration A.


The academic standard number used in the alignments matches the Colorado Department of Education standards numbering convention.

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Demonstrate finishing processes and identify the difference between various types of finishing materials used in the manufacture of welded parts and products.

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Understand the purposes and processes of inspection and quality control in welding manufacturing process.

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Demonstrate various welding systems that require standard hand and machine tools.

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Demonstrate various automated welding systems, welding design for manufacturing, flexible manufacturing systems and material resource planning.

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Demonstrate various joining or combining processes, including welding processes used in manufacturing, maintenance and repair.

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Understand how a manufacturing company is organized and the elements of welding production management.

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Identify skills to pursue careers as interpretation and layout of machined and formed-part prints; the cutting, shaping, fastening and finishing of machine tools; and casting, forging, molding, cold forming and shearing processes.

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Demonstrate the planning and layout operations used in machine tooled and materials forming process.

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Understand and demonstrate how materials can be processed through the use of machine tools, such as milling, drilling, turning and shaping machines and forming equipment such as dies, presses and rolls.

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Demonstrate the use of various types of machine and forming assembly processes, such as flow, pressure, cold and adhesive bonding and mechanical fasteners.

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Demonstrate finishing processes and the differences between various types of finishing materials used in the manufacturing and machined and formed parts and products.

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Interpret the purposes and processes of inspection and quality control in machining and forming manufacturing processes.

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Demonstrate the use of various machining and forming manufacturing systems that require standard hand and machine tools.

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Demonstrate the use of various machining and forming automated manufacturing systems, tool design, design for manufacturing, flexible manufacturing systems and materials resource planning.

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Interpret the development of emerging machining and forming technology systems.

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Demonstrate the use of industrial forming processes and their application to specific types of materials.

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Understand how a manufacturing company is organized and the elements of a machining and forming production management system.


Vocabulary

Abrasive - A material, such as sand, silicon or crushed stone, used for surface cleaning.

Acetylene Gas - A chemical combination of two elements: carbon and hydrogen.

Alloy - A metal that is made by mixing two or more metals, or a metal and another substance.

Alternating Current (AC) - Is an electrical current in which magnitude and direction change in

cycles, as opposed to direct current, in which direction is constant.

Arc Welding (Shielded Metal Arc Welding) - A welding process where similar materials are joined

with a heating process caused by an electric arc. In the most common use, this process includes the

use of a filler metal.

Argon - Is a chemical element designated by the symbol Ar. Argon has atomic number 18 and is the

third element in group 18 of the periodic table (noble gases). Argon is present in the Earth's

atmosphere at slightly less than 1%, making it the most common noble gas on Earth.

Brazing - are joined by using a filler metal that melts at a temperature above 450ºC.

Butt Joint (Butt Weld) - A joint (or weld) where A process where metals the two pieces being

connected come directly together in the same plane.

Buzz Box - Another term for a general-purpose arc welder. The name is derived from the sound made when the welder is running. Consumable & non-consumable electrodes - Consumable electrodes provide a path for the current. They also supply fuller metal to the joint. Nonconsumable electrodes are only used as a conductor for the electrical current, such as in gas tungsten arc welding. Cutting Tip - The part of an oxygen torch that directs the flow of the gas. Cutting Torch - The device used in oxygen cutting to control and direct the flow of the gasses used for cutting and heating metal. Cylinder - A container to store and transport compressed gas. Defective Weld - A weld with one or more of the following defects: Porosity, undercut, slag inclusion and improper weld size. Direct Current (DC) - Or "continuous current," is considered as the constant flow of electrons in the


single direction from low to high potential. Down Hand Weld - A vertical weld where the welder starts at the top and works downward. Edge Weld - A weld where the edges of two pieces come together. *Electrode (Arc Welding) - A rod made up of filler metal with a coating on it designed to aid and protect the bead during the welding process. Electrode Holder - The "handle" portion of the arc welder that holds the electrode in place. Face Shield (Helmet) - A safety device worn over the face to protect the eyes and face from the arc, sparks and molten metal. Arc welding without proper eye protection can lead (quickly) to permanent damage to the eyes. Ferrous - Containing or relating to iron. Fillet Weld - A weld joining two pieces of metal that are more or lessperpendicular to each other. Filler metal - Is a metal added in the making of a joint through welding, brazing or soldering. Various types of filler metals exist. Fixture - A tool or device used to hold pieces in place for welding. Flat Weld - A weld where the pieces being joined come together horizontally in front of and below the welder. Flux - A substance that facilitates soldering, brazing and welding by chemically cleaning the metals to be joined. Forge - A device used to heat metal for forming and bending. (Blacksmithing) Fuel Gases - Gases mixed with oxygen in heating and cutting operations. Gas Tungsten Arc Welding (GTAW) or (TIG) - Commonly known as tungsten inert gas (TIG) welding; an arc welding process that uses a non-consumable tungsten electrode to produce the weld. Hand Shield - Similar to a Face Shield or Helmet, but held in front of the face rather than worn. Iron - A base element that is the primary substance in the makeup of steel, cast iron and wrought Iron. . Inert gas/Shielding gas - A gas that does not normally combine chemically with materials. Their


purpose is to protect the weld area from atmospheric gases, such as oxygen, nitrogen, carbon dioxide and water vapor. Lap Joint - A joint where two pieces of metal lap over each other, allowing a bead to be placed between the edge of one piece and the face of the other. *MIG Welding (Metal Inert Gas) - Also known as wire-feed welding, although it is possible to do wire-feed welding without the inert gas. Metals that are difficult to arc weld may be MIG welded. Mild Steel - Steel with less than 0.15% carbon. (Also called low carbon steel). Most steel in common use is mild steel. Out-Of-Position Weld - Any weld where the work is not flat in front of the welder. Overhead Weld - An inverted weld where the pieces being joined are above the welder. Oxyfuel - Pure oxygen combined with gas. Plasma - A gas that has been heated to the point where it will conduct electricity. Plasma Cutting - A cutting process where the metal is heated to the melting point by an arc through the plasma and then removed by the pressure of the gas as directed by the nozzle. CNC (computer numeric control) plasma cutters are used for precise cutting of complex patterns in metal. Polarity - The polarity of a machine refers to direction of current flow. Polarity can only be obtained on a DC machine. Radiation - Energy from heat or light that you cannot see. Shielding Gas - See Inert gas. Slag Inclusion - Non-metallic material trapped in a weld. Soldering - A method of joining metal parts using a filler material (solder) that has a melting temperature below 450°C (842°F). Spot Weld - A weld between two overlapping pieces of material; normally used for sheet metal.


Tack Weld - A small weld used to hold pieces of an assembly in place prior to the final (continuous) welding. TIG Welding (Tungsten Inert Gas) - A welding process where an inert gas protects the molten metal from the atmosphere to produce a high quality weld. Tungsten - A non-consumable material used in TIG welding to carry current to the weld puddle. (very hard, heavy, steel-grey-to-white transition metal; W in the periodic table.) Up Hand Weld - A vertical weld where the welder starts at the bottom and works upward. Ventilate - To cause fresh air to enter and move around an enclosed space. Weave Bead - A welding pattern often used in butt welds where the welder moves the arc back and forth across the joint while also moving along it. Weld - To join two pieces of metal together permanently by melting the parts that touch. Welder (noun) - A person whose job is welding. Welding Power Supply - A device that provides an electrical current to perform welding. Welding Rod - A means of delivering filler metal to the weld. In arc welding, the rod is called an electrode. Voltage (V) - Is the pressure required to move the electric current.

http://www.jcfswinnipeg.org/documents/Welders-Terminology.pdf

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