Edu Wel801B

2010

Prince Edward Island Department of Education

and Early Childhood Development

P.O. Box 2000, Charlottetown

Prince Edward Island

Canada, C1A 7N8

Tel. (902) 368-4600

Fax. (902) 368-4622

http://www.gov.pe.ca/eecd/

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Welding TechnologyGas Metal Arc Welding (GMAW) (WEL801B)Course Description Gas metal arc welding is extensively used in industry and is a process that a welder is most likely to use throughout his/her career. During this course, students will learn to identify, describe, and safely use the equipment and tools required to perform GMAW welds; select the proper GMAW fi ller metals and shielding gases; and correctly identify and select proper weld joints. Industry demands and sets a high standard for welders. Students are expected to develop the physical hand skills in GMAW required by industry, and to perform GMAW welds in all relative positions.

SCO - Identifi es the Specifi c Curriculum Outcome (SCO)

Column 1SCO - DelineationsDescribes what the students are expected to know, be able to do, and value in order to achieve the SCO.The teacher is responsible for the planning and facilitation of learning as well as the assessment of each SCO - Delineation.

Column 2Student Knowledge, Abilities and Competencies Provides clarity to the SCO by describing the knowledge, abilities, and competencies that the students develop. This column is designed to indicate the depth and breadth of the SCO. It is not necessary to use all of these suggestions or that all of the students be engaged in the same learning activity.

Column 3Teacher Lessons / DemonstrationsProvides suggestions for developing and delivering the content for student learning.

Student Activities / AssessmentsProvides suggestions for creating meaningful activities to allow the student to achieve the SCO.

Column 4ResourcesLists a variety of resources that support the teaching and learning related to the SCO. These resources are suggested to support the teacher in developing an effective instructional package for delivery to the students.

Classroom Component–Suggested time: 24 hours This component of the curriculum is required to teach the knowledge and skills associated with the learning outcomes of the curriculum.

Skill Development Component–Suggested time: 86 hours This component of the curriculum is required by the student to apply the knowledge and develop the skills related to the learning outcomes of the curriculum.

CAREER AND TECHNICAL EDUCATION CURRICULUM2

CURRICULUM OUTCOMES

Module 1: Basic Joint and Weld Types (~4 hours Classroom Component)

12. Students will be able to identify basic joints and weld types.

Students will be expected to12.1 identify the fi ve basic joints12.2 describe the types of welds and their acceptable dimensions12.3 identify joint and weld type variations12.4 outline the major considerations to be accounted for in the design of a joint for welding

Module 2: Gas Metal Arc Welding (GMAW) Equipment (~4 hours Classroom Component)

13. Students will be able to select GMAW equipment.

Students will be expected to13.1 describe the principles of operation of GMAW13.2 identify the components of a basic GMAW set-up13.3 describe the modes of metal transfer obtained with GMAW13.4 describe GMAW power sources and wire feeders13.5 describe GMAW wire drive systems and gun and cable systems assemblies13.6 identify shielding gas supply systems of GMAW

Module 3: GMAW Filler Metals, Shielding Gases, and Safety (~4 hours Classroom Component)

14. Students will be able to select GMAW consumables and apply safe work practices.

Students will be expected to14.1 identify GMAW fi ller metals14.2 identify shielding gases for GMAW14.3 identify advantages and disadvantages of GMAW14.4 identify the precautions you must take against electrical shock, toxic fumes, and radiant energy associated with GMAW

Module 4: GMAW Equipment Maintenance and Troubleshooting (~7 hours Classroom Component)

15. Students will be able to set up, maintain, and troubleshoot GMAW equipment.

Students will be expected to15.1 describe and demonstrate the set-up and maintenance required for wire drive systems and gun assemblies15.2 diagnose and demonstrate corrective measures for malfunctioning GMAW equipment

CURRICULUM OUTCOMES

CAREER AND TECHNICAL EDUCATION CURRICULUM 3

Module 5 : Shop/Lab Practices: GMAW Welds on Mild Steel (~30 of 86 hours Skill Development Component)

16. Students will be able to perform surface welds in the fl at and horizontal positions and perform 1F, 2F, 3F, 1G, 2G, and 3G positions on mild steel. Students will be expected to16.1 demonstrate the ability to weld stringer/weave beads in the fl at and horizonatal positions16.2 demonstrate the ability to weld 1F welds on mild steel plate16.3 demonstrate the ability to weld fi llet welds in the horizontal (2F) position on mild steel plate16.4 demonstrate the ability to weld fi llet welds in the vertical (3F) position (downhill root and uphill fi ll and cover pass) on mild steel plate16.5 prepare and fi t up butt joints without backing16.6 demonstrate the ability to weld butt joints in the 1G position16.7 demonstrate the ability to weld butt joints in the 2G position16.8 demonstrate the ability to weld butt joints in the 3G position

Module 6 : Percentage and Ratio (~5 hours Classroom Component)

17. Students will be able to solve problems involving percentage and ratios.

Students will be expected to17.1 calculate ratios (express two quantities in the form of a ratio)17.2 calculate proportions (express two ratios in the form of a proportion)17.3 convert between fractions and percent17.4 convert between decimals and percent17.5 solve percent problems

5CAREER AND TECHNICAL EDUCATION CURRICULUM

WEL801B - GAS METAL ARC WELDING (GMAW)

Basic Joint and Weld Types (~4 hours Classroom Component)

Introduction The ability to select and prepare proper weld joints is an essential skill for any welder. Joints must be carefully prepared and designed for the intended function of the product. Apprentices must be able to prepare joints and select the proper weld for any given job.

12. Students will be able to identify basic joints and weld types.

Assessment

Strategies

Resources Alberta Module 120101c, Basic Joint and Weld TypeNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to12.1 identify the fi ve basic joints12.2 describe the types of welds and their acceptable dimensions12.3 identify joint and weld type variations12.4 outline the major considerations to be accounted for in the design of a joint for welding

Specifi c

Curriculum

Outcome

SCO - Delineations

Paper/PencilSelf/Peer-AssessmentsSkills PerformanceTeacher ObservationCareer Portfolio

SCO - Delineations Student Knowledge, Abilities, and Competencies

Students will be expected to

Basic Joint and Weld Type (~4 hours Classroom Component) SCO 12. Students will be able to identify basic joints and weld types.

WEL801B - GAS METAL ARC WELDING (GMAW) - MODULE 1


12.1 identify the fi ve basic joints

Topic: Basic Joints• Identify the fi ve basic types of joints: - butt joint - lap joint - corner joint - tee joint - edge joint

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Teacher Lessons / Demonstrations Resources

CAREER AND TECHNICAL EDUCATION CURRICULUM



Topic: Basic Joints• Create an overhead transparency or slideshow of fi gure 1 (p. 2) of the ILM.• Discuss the construction, advantages, disadvantages, and application of each of the fi ve basic joints.

Student Activities / Assessments

• Draw each of the basic weld joints.• Complete a matching diagram.• Correctly identify the type of joint used on various items/shop projects.

Texts / Teacher ResourcesAlberta Module 120102cBasic Joint and Weld Typep. 2

Software / DatabasesNOA, HRSDC: Occupational Analyses Series - Welder

StudentsAchieve (SAS)

Visuals / Handouts / TestsWall Moutain Company Video Series:GMAW (MIG) Wire Feed






12.2 describe the types of welds and their acceptable dimension

Topic: Weld Types• List the four basic types of welds: surfacing, plug or slot, fi llet, and groove.• Describe the characteristics of each of the four basic welds.• Explain the typical application for each of the four basic welds.• Describe the key terminology associated with fi llet welds. - theoretical throat - toe - face - depth of fusion - leg• Identify acceptable and unacceptable fi llet weld profi les.• List and describe the functions of the four variations of fi llet welds. - continuous - intermittent - chain intermittent - staggered intermittent• Explain the key terminology associated with groove welds. - groove angle - bevel angle - “t” plate thickness - root gap - root face - depth of fusion - face - toe - throat - beads/passes - root bead - weld reinforcement• Describe characteristics and the maximum material thicknesses for the following types of groove welds: - square groove - bevel groove - vee groove - u-groove - j-groove

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Topic: Weld Types• Create visuals or a slideshow from the graphics CD to explain various weld type characteristics.• Discuss the characteristics and application of the various types of welds.

Literacy• Anticipation Guide: Use as pre-reading strategy. Focus questions on weld types.• Create a vocabulary list of the terminology the students will be expected to use when discussing basic joint and weld types, both in writing and verbally.


• Discuss common problems with various weld types.• Complete a matching diagram of weld types.• Correctly identify the type of weld used on various shop projects.• Label diagrams of fi llet and groove welds. Literacy• Vocabulary Development: Use as a during-reading strategy while reading about various weld types.

Texts / Teacher ResourcesAlberta Module 120102cBasic Joint and Weld Typepp. 3-12




Alberta ILM Graphics CDWelding Period 1






12.3 identify joint and weld type variations

Topic: Variations• Describe the characteristics and functions of each of the following joint and weld variations: - corner joint > single bevel > single vee > double bevel > single j > single u > double j - edge joint > single bevel > single vee > single j > single u - tee joint > square tee > single bevel > double bevel > single j > double j - lap joint > single lap > double lap - butt joint > with backing strip• Correctly identify and describe the standard two-digit code that is used to specify the joint and weld type required on a weldment: - fl at position (1G , 1F) - horizontal position (2G, 2F) - vertical position (3G, 3F) - overhead position (4G, 4F) - pipe fi xed in horizontal plane (5G) - pipe fi xed in 45˚ plane (6G)

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Topic: Variations• Prepare a slideshow describing variations of joint and weld types and provide real applications for these variations.• Display mock-ups of prepared joint variations.


• Label diagrams related to variations and positions of groove and fi llet welds. • Prepare coupons for the following weld joints, using 3/16" - 2" mild steel plate: - square groove butt joint - single bevel butt joint - single vee groove joint

Texts / Teacher ResourcesAlberta Module 120102cBasic Joint and Weld Typepp. 13-18









12.4 outline the major considerations to be accounted for in the design of a joint for welding

Topic: Joint Design• Describe the responsibility of the design engineering personnel and the welder for proper joint and weld selection.• State considerations used to determine and test the effectiveness and appropriateness of a joint design.

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Topic: Joint Design• Develop a welding problem that will require the students to apply their knowledge of joint construction.• In groups of two or three have students design welds to solve the problem and present their solution to the class.

Literacy• Anticipation Guide: Use as a pre-reading strategy. Focus questions on joint design.


• Design appropriate weld joints and techniques for shop projects.

Literacy• Free Writing: Use as a pre-reading strategy to activate students prior knowledge of joint design.

Texts / Teacher ResourcesAlberta Module 120102cBasic Joint and Weld Typep. 19




14 CAREER AND TECHNICAL EDUCATION CURRICULUM




Gas Metal Arc Welding (GMAW) - Equipment (~4 hours Classroom Component)

Introduction Gas metal arc welding (GMAW) is a wire feed process. GMAW was developed for increased production and effi ciency in a variety of welding fabrication processes. It was originally developed to eliminate the need for fl uxes used when welding aluminum and magnesium alloys.

13. Students will be able to select GMAW equipment.

Assessment

Strategies

Resources Alberta Module 120103a, Gas Metal Arc Welding (GMAW) - EquipmentNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to13.1 describe the principles of operation of GMAW13.2 identify the components of a basic GMAW set-up13.3 describe the modes of metal transfer obtained with GMAW13.4 describe GMAW power sources and wire feeders13.5 describe GMAW wire drive systems and gun and cable systems assemblies13.6 identify shielding gas supply systems of GMAW

Specifi c

Curriculum

Outcome

SCO - Delineations




Gas Metal Arc Welding (GMAW) - Equipment (~4 hours Classroom Component)GCO 13. Students will be able to select GMAW equipment.



13.1 describe the principles of operation of GMAW

13.2 identify the components of a basic GMAW set-up

Topic: Principles• Defi ne the following terms: - MIG - MAG - GMAW• State why GMAW was originally developed.• Describe the GMAW welding process.• Label a GMAW welding process diagram.• Describe applications of GMAW (the process).

Topic: Set-up• List the basic equipment required for a GMAW set-up: - welding power source - wire feeder - welding gun and cable assembly - spooled fi ller wir e - shielding gas and gas control equipment• Label the components of a GMAW equipment set-up.• Describe the function of the welding power source.• State the three main type of power sources. - motor-driven generators - transformer-rectifi ers - inverter designs• Describe the function of each of the following pieces of equipment: - wire feeder - welding gun and cable assembly - spooled fi ller wire - shielding gas - regulators and fl owmeters - cooling system

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Topic: Principles• Review the history and principles of operation of GMAW.• Make an overhead transparency or use and LCD projector and the graphics CD Period 1 to display fi gure 2 from p. 3 of the ILM to help wiith the explanation of the principles of GMAW.

Topic: Set-up• Show chapters 1-7 of the GMAW Wire Feed Video.• Lead students through a tour of the shop to identify the components and equipment used for the GMAW process.• Discuss the proper safe handling procedures and storage procedures related to the GMAW equipment.• Demonstrate the proper setup of the GMAW welding equipment.

• Correctly label a diagram of the GMAW process.• Correctly label a diagram of a GMAW equipment set-up.• Properly set up a GMAW welding outfi t.• Complete a question sheet related to chapters 1-7 of the GMAW video.

Literacy• Free Writiing: Use as a pre-reading strategy to activate prior knowledge related to wire feed welding and welding equipment.• Vocabulary Development: Use as a post-reading strategy. Complete a series of tables (similar to the example below) for each component of a GMAW set-up.

Term / Component

Wire Feeder

Visual Representation

draw image here(could be multiple examples)

Defi nition / FunctionHouses a control system, drive roll, and variable speed feed motor.Responsible for regulating the speed of the feed motor and starting and stopping the electrode feed.

Texts / Teacher ResourcesAlberta Module 120103aGas Metal Arc Welding (GMAC) - Equipmentpp. 3-12










13.3 describe the modes of metal transfer obtained with GMAW

Topic: Metal Transfer• Defi ne “metal transfer”.• List the three basic modes of metal transfer. - short-circuiting transfer - globular transfer - spray transfer• List the factors that determine the mode of metal transfer used. - welding current - fi ller wire diameter - arc length - type of shielding - welding position• Defi ne “pinch effect” and explain its function related to GMAW welding.• Describe the features of short-circuiting metal transfer related to - wire size - current settings - voltage settings.• Explain the characteristics of and the operation of a short- circuit metal transfer.• Describe the features of globular metal transfer related to - wire size - current settings - voltage settings.• Explain the characteristics of and the operation of a globular metal transfer.• Describe the features of spray metal transfer related to - wire size - current settings - voltage settings.• Explain the characteristics of and the operation of a spray metal transfer.• Compare and contrast the three main modes of metal transfer.

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Topic: Metal Transfer• Create visuals (overheads or slideshow) from the graphics CD Period 1 to support and guide the lesson.• Describe the various modes of metal transfer available on selected welding machines.

Literacy• Anticipation Guide: Use as a pre-reading strategy for pp. 7 - 9.


• Label diagrams related to metal transfer.











13.4 describe GMAW power sources and wire feeders

Topic: Power Sources• List guidelines to consider when selecting a welding power source.• Describe how the National Electrical Manufacturing Association (NEMA) rates welding power sources as regards duty cycle, current, and voltage.• Defi ne “duty cycle”.• Compare constant current (CC) and constant voltage (CV) power sources.• Explain why CV power sources are recommended for GMAW welding.• Describe the characteristics of a CV power source.• Identify and describe the two main controls found on CV power sources.

Topic: Wire Feeders• List the components of a wire feed system.• List and describe the common controls found on wire feed systems: - wire speed control - remote voltage control - drive roll system - voltage sensing control - micro-processing control pre-settings (optional) - shielding gas control• Defi ne the two main types of wire feed systems. - constant-speed wire feeder - voltage sensing wire feeder• Explain the operation of each type of wire feeder.• Compare and contrast each type of wire feeder.• Describe the function of the drive roll assembly.• Demonstrate the ability to properly set the drive roll pressure.• Troubleshoot problems related to the drive roll assembly.• Describe the design features and recommended application of each of the four types of drive rolls.• Describe the features and function of wire feed panel controls.• Identify the main operating variables in a GMAW system and explain how they can infl uence the weld quality.

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Topic: Power Sources• Explain electricity with reference to CC and CV.• Compare and contrast both processes.

Topic: Wire Feeders• Demonstrate the proper set-up and operation of a GMAW outlet.• Demonstrate GMAW, using equipment to reinforce the variables.

Numeracy• Develop worksheets on duty cycle. - E.g., What is the duty cycle of a power source which may be operated 6 minutes out of a 10-min. time period? (6/10 x 100% = 60% duty cycle)

Literacy• Read the section “Wire Feed Control and Drive Units” (p. 13) aloud to the class using the Think Aloud Reading Strategy. Pay particular attention to how you dissect the information as you read so that the students will see how you make sense out of what you are reading.• Introduce the Say Something reading strategy to the students. Select one of the students in the class to model the Say Something with you as you read through one of the sections.• Break the class up into pairs and assign a section of the text for the pairs to read as a Say Something activity.

***The more you model and guide your students through this type of reading strategy, the more the students get from the activity. This is an excellent method for helping students identify what is important in a piece of text***


• Complete worksheets on duty cycle.• Set up a drive roll assembly.• Label diagrams that relate to power sources and wire feeders.










13.5 describe GMAW wire drive systems and gun and cable systems assemblies

Topic: Drive Systems• List the three types of wire drive systems: - push type - pull type - push-pull type• Describe the operation and characteristics of each wire drive system.• Describe factors to consider when choosing a wire drive system.• Demonstrate the ability to maintain a wire drive system.• State the rating and characteristics of each type of welding gun: - air-cooled - water-cooled• List the components of an air-cooled welding gun and explain the function of each: - gun body (angle) - gas diffuser - contact tube - nozzle - cable assembly - conduit and liner

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Topic: Drive Systems• Create visuals (overheads or slideshow) of each type of wire drive system.• Have examples of the system that will be used in your welding facility.• Discuss the advantages and disadvantages of the three types of wire drive systems.• Discuss the advantages and disadvantages of water-cooled and air- cooled drive systems.• Demonstrate how to break down a welding gun assembly.• Demonstrate proper care, handling, and storage of welding drive systems and accessories.


• Identify the components of a welding gun and wire drive system.• Break down a welding gun into its components, explain the function of each, and reassemble the gun correctly.

Literacy• Vocabulary Development: Use as a post-reading strategy. Complete a series of tables (similar to the example below) for each component of a wire drive system.

Term / Component

Contact Tube

Visual Representation

Draw image here.(could be multiple examples)

Defi nition / Function










13.6 identify shielding gas supply systems of GMAW

Topic: Shielding Gas Systems• List the three types of shielding gas storage cylinders: - compressed gas cylinder - liquid-fi lled cylinder - liquid bulk cylinder• Describe the physical characteristics of each type of storage cylinder.• Explain why CO

2 cylinders must always be used in the vertical

position.• State how each of the following shielding gases are sold: - carbon dioxide - argon - helium - hydrogen - nitrogen• Defi ne “CO

2 gas dew point”.

• Defi ne “CO2 gas fl ow rates”.

• Describe the effect a low fl ow rate may have on the quality of a weld.• Explain the function and operation of the following components: - line heater - cylinder valves - metal rupture disc• Identify the different types of connections used to attach the regulators to cylinders.• Identify the type of thread used on shielding gas cylinder valve connections (right hand thread).• Describe the dangers and safety features of liquid bulk systems (dewars).• State the temperatures of the following cryogenic liquids: - argon - nitrogen - hydrogen - oxygen• Properly identify cylinders.• Demonstrate an ability to properly store and handle shielding gas cylinders.• Explain the function and operation of the regulator.• Explain the function and operation of fl owmeters.• Describe factors to consider when selecting regulators and fl owmeters.• Explain the function and operation of hoses.• Explain the function and operation of solenoid valves.

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Topic: Shielding Gas Systems• Create visuals (overheads or slideshow) from the ILM to support the lesson.• Demonstrate how to properly connect a regulator to a cylinder.• Review WHMIS information related to shielding gases, and have MSDS on hand for demonstration and study. • Demonstrate how to use and maintain regulators, fl owmeters, hoses, and solenoid valves.

CBL• Guest Speaker: Invite a sales rep from a local gas retailer to present to students.


• Properly set up the GMAW welding outfi t and correctly identify all of the components.

Literacy• Free Writing: Use as a pre-reading strategy to activate prior knowledge of welding fuel gases, regulators, and fl owmeters.







GMAW Filler Metals, Shielding Gases, and Safety (5 hours Classroom Component)

Introduction With the wide range of applications of GMAW, it is important that the welding apprentice develop a solid working knowledge of the fi ller metals and shielding gases that are commonly used to achieve the goals of the fi nished product or job.

14. Students will be able to select GMAW consumables and apply safe work practices.

Assessment

Strategies

Resources Alberta Module 120103b, GMAW Filler Metals, Shielding Gases and SafetyNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to14.1 identify GMAW fi ller materials14.2 identify shielding gases for GMAW14.3 identify advantages and disadvantages of GMAW14.4 identify the precautions you must take against electrical shock, toxic fumes, and radiant energy accociated with GMAW

Specifi c

Curriculum

Outcome

SCO - Delineations


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GMAW Filler Metals, Shielding Gases, and Safety (~4 hours Classroom Component)SCO 14. Students will be able to select GMAW consumables and apply safe work practices.



14.1 identify GMAW fi ller metals

Topic: Filler Metals• Defi ne the following terms associated with GMAW fi ller metals: - AWS - cast - CSA - consumable electrode - composite electrode - fi ller metal - helix - mechanical property - specifi cation - standard - welding wire• List the characteristics referenced for specifi cations of welding wires.• Describe the process of drawing a wire to size.• Interpret the information found on the packaging and identifi cation labels of wires.• Describe the function and measurement of the following as they relate to fi ller wires: - cast - helix• Describe the fi nish on the fi ller wire.• List factors that infl uence the selection of fi ller wire.• List factors to consider when choosing the correct wire size.• Interpret CSA and AWS specifi cations relevant to fi ller metals and shielding gases used in GMAW.• Interpret the CSA and AWS classifi cation systems.• Identify the applications common to various GMAW wire electrodes.• Describe the various methods of packaging GMAW fi ller metals.• Describe proper methods of storing and handling GMAW consumables.

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Topic: Filler Metals• Show chapters 8-10 of GMAW (MIG) Wire Feed (video).• Show shop examples of worn tips, liners, and cleaners.• Discuss the importance of the CSA and AWS specifi cations required for fi ller metal classifi cation.

Literacy• Anticipation Guide - Use as a pre-reading strategy for pp. 2-13.

• Complete a worksheet on wire sizes and characteristics: - List six points related to correct wire size. - Label the diagram of drawing dies from p. 3 of ILM. - Measure the helix and cast of various rolls of wire. - Explain CSA and AWS classifi cations of wire. - Describe benefi ts of wire fi nish, storage, lubricants, and clean wire.• Complete a scenario worksheet on contextual examples of types of wire. Which wire would you use for - hard facing a bucket on a loader - farm equipment - stainless application?• Create an instruction sheet on how to properly store wire.

Literacy• Free Writing: Use as a pre-reading strategy to activate prior knowledge of AWS and CSA classifi cation systems.• Vocabulary Development: Complete a matching activity with terms and defi nitions.

CBL• Call manufacturers for proper information and applications of various wire types.

Texts / Teacher ResourcesAlberta Module 120103aGMAW Filler Metals, Shielding Gases, and Safetypp. 2-13




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14.2 identify shielding gases for GMAW

Topic: Shielding Gases• Defi ne the following terms used in describing GMAW shielding gases: - arc plasma - compressed gas - cryogenic liquid - dewar - liquifi ed compressed gas• State the purpose of the shielding gas.• List factors to consider when selecting a shielding gas.• Discuss the function and characteristics of each of the basic properties of shielding gases: - specifi c gravity - ionization potential - thermal conductivity - dissociation and recombination characteristics - reactivity/oxidation potential• Describe the characteristics and basic function of each of the following types of shielding gases used for GMAW: - inert gases > argon (Ar) > helium (He) - reactive gases > carbon dioxide (CO

2)

> oxygen (O2)

> hydrogen (H2)

> nitrogen (N2)

- gas mixes > argon-oxygen mixes > argon-carbon dioxide mixes > argon-helium mixes > argon-helium-carbon dioxide mixes > argon-carbon dioxide-hydrogen mixes• List factors that infl uence the effectiveness of shielding gases.• Describe the basic applications of shielding gases used with GMAW.• Discuss the advantages and disadvantages of various shielding gases when using - short circuit metal transfer - spray metal transfer - globular transfer.

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• Show chapters 8-10 of GMAW (MIG) Wire Feed (video).• Develop slides to identify improper shielding gases.

Literacy• Think Aloud: Use as a during-reading strategy. Pay particular attention to how you dissect the information as you read so that the students will see how you make sense out of what you are reading.• Say Something: Use as a during-reading strategy. Select one of the students in the class to model the Say Something with you as you read through one of the sections.• Break the class up into pairs and assign a section of the text for each pair to read as a Say Something activity.

***The more you model and guide your students through this type of read-ing strategy, the more the students get from the activity. This is an excellent method for helping students identify what is important in a piece of text***


• Complete a worksheet in which you correctly identify the shielding gas to use when performing particular welding projects. For example, which type of shielding gas is appropriate for use on - copper pipe - stainless steel - excavator boom - aluminum?• List 12 factors that affect gas fl ow rates (p. 24 of ILM).• List 5 properties of shielding gases.• Identify shielding gas problems from sample welds.• Copy and complete a table for shielding gases.

Gas Splatter Penetration /Bead Characteristics Cost Metals


Cross-Curricular Reading Tools Think Aloud Say Something




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14.3 identify advantages and disadvantages of GMAW

14.4 identify the precautions you must take against electrical shock, toxic fumes, and radiant energy associated with GMAW

Topic: Advantages and Disadvantages• Demonstrate an understanding of the advantages and disadvantages of gas metal arc welding (GMAW).

Topic: Safety• Discuss PPE and demonstrate an understanding of the precautions one must take to protect oneself from - electrical shock - toxic fumes - radiant energy.

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Topic: Advantages and Disadvantages• Review information covered in table 7 of the ILM (p. 28).• Make an overhead of table 7, or use an LCD projector to help focus the discussion.

Topic: Safety• Have all the personal protective equipement (PPE) on display.• Demonstrate the proper way to wear the PPE.• Observe students’ attention to PPE while welding.• Develop fi re watch procedures for situations that may arise.

Literacy• Anticipation Guide: Use as a pre-reading strategy for pp. 2-13 of the ILM.


• Answer questions related to the advantages and disadvantages of GMAW.• Identify and describe the function of PPE and tools from a component ID table.• Complete a worksheet on proper dress and safety equipment (do’s and don’t list). (The students’ ability to work safely will be assessed while they are completing their practical assignments.)

Literacy• Free Write: Use as a pre-reading strategy to activate prior knowledge of welding safety.


Cross-Curricular Reading Tools Think Aloud Say Something






GMAW Equipment Maintenance and

Troubleshooting (~7 hours Classroom Component)

Introduction Keeping welding equipment running smoothly not only results in better quality welds but also improves effi ciency, which reduces the high cost of equipment downtime. The more apprentices know about the function, operation, and maintenance of GMAW equipment, the better prepared they are to set welding parameters, diagnose problems, and take preventative steps to avoid problems.

15. Students will be able to set up, maintain, and troubleshoot GMAW equipment.

Assessment

Strategies

Resources Alberta Module 120103c, GMAW Equipment Maintenance and TroubleshootingNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to15.1 describe and demonstrate the set-up and maintenance required for wire drive systems and gun assemblies15.2 diagnose and demonstrate corrective measures for malfunctioning GMAW equipment

Specifi c

Curriculum

Outcome

SCO - Delineations


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GMAW Equipment Maintenance and Troubleshooting (~7 hours Classroom Component)GCO 15. Students will be able to set up, maintain, and troubleshoot GMAW equipment.



15.1 describe and demonstrate the set-up and maintenance required for wire drive systems and gun assemblies

Topic: Set-up and Maintenance• Describe basic safety procedures to follow when setting up GMAW welding equipment.• Describe typical procedures used to set up the wire feed equipment used for GMAW.• State the proper position for regulator/fl owmeter on the cylinder.• Describe the importance of matching the drive rolls with the electrode wire size and type.• Demonstrate the ability to set up the wire gun assembly and attach it to the wire feed assembly.• Describe the procedure for feeding the wire into the assembly.• State the function and need for a wire cleaner.• Describe the importance of properly adjusting the brake on the spool support hub.• Describe the proper shut-down procedure.• List factors to consider when setting up an ongoing maintenance schedule.• Demonstrate an understanding of the proper maintenance and handling procedures for each of the following: - power cables - cable liners - hoses - contact tubes - gas nozzles

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Topic: Set-up and Maintenance• Demonstrate the proper assembly and adjustment of a GMAW set-up.

CBL• Guest Speaker: Invite a service person and salesperson from a local machine supplier to speak to the class about equipment maintenance.

Literacy• Anticipation Guide: Use as a pre-reading strategy. Relate questions to pp. 2 -13 of ILM.

• Identify the components of the GMAW set-up.• Correctly set up and adjust a GMAW set-up.• Develop a routine maintenance schedule.

Literacy• Free Writing: Use as a pre-reading strategy to activate prior knowledge of welding equipment maintenance.

Texts / Teacher ResourcesAlberta Module 120103cEquipment Maintenance and Troubleshootingpp. 2-13




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15.2 diagnose and demonstrate corrective measures for malfunctioning GMAW equipment

Topic: Corrective Measures• Discuss techniques used to control the placement of the fi ller metal. - Electrode Angle > Describe the proper electrode angle for fi llet welds. > Describe the proper electrode angle for butt joints.

- Electrode Inclination > Defi ne “electrode inclination”. > Describe forehand (push angle) inclination and backhand (pull/drag angle) inclination. > Compare and contrast forehand and backhand inclination.

- Electrode Extension (stick out or wire extension) > Defi ne “electrode extension”.

- Travel Speeds > Defi ne “travel speed”. > Identify various weld faults that occur as result of variations in travel speed.

(continued on p. 40...)

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Topic: Corrective Measures• Develop a slideshow from the graphics CD to help explain corrective measures with welding techniques.• Discuss the application of both methods of inclination.• Discuss the applications and benefi ts of short and long electrode extensions.• Review tables on pp. 21-22: - process related problems - electrical related problems - mechanical related problems


• Diagnose welds and welding equipment and take action to correct the problems.• Work through solutions to sample problems discussed in class. • Diagnose problems/defects in welds from shop examples and explain how to correct the problem.• Diagnose and explain solutions to problems as they arise while working on shop projects.

Literacy• Free Writing: Use as a pre-reading strategy to activate prior knowledge related to troubleshooting welding equipment and techniques.

• Jigsaw: Break into groups. With each group assigned one section from pp. 14-30 of the ILM. Each group must study, summarize, and report on that particular section. The summary must include a written overview as well as any relevant drawings or illustrations. Share this information with the other groups to create a study guide for this section of the ILM (pp. 14-30). (Students must be reminded that even though they are reporting on only one section, they are responsible for all of the information covered.)

Texts / Teacher ResourcesAlberta Module 120103cEquipment Maintenance and Troubleshootingpp. 2-13





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(...continued from p. 38)

Topic: Corrective Measures• Identify and correct typical problems experienced with wire feeders: - Gas Nozzle/Contact Tip Arrangement > Demonstrate proper nozzle and contact tip alignment. > Demonstrate the ability to identify and clean spatter build-up on nozzles and contact tips. > Describe problems resulting from misalignment and spatter build-up. - Work Lead Connections > Identify commonly used work lead connections. > Describe the proper method for connecting the work lead. > Describe problems resulting from poor work lead connections. - Stubbing > Defi ne “stubbing”. > Identify malfunctions or set-up problems that may lead to stubbing. - Wire Pileups > Defi ne “wire pile-ups”. > Describe conditions that may cause wire pile-ups to occur. > Demonstrate how to correct a wire pile-up. - Arc Hunting > Defi ne “arc hunting”. > Describe conditions and causes of arc hunting. > Describe actions that can help prevent arc hunting.

• Categorize (three categories) problems related to wire feed equipment: - process - electrical - mechanical• Identify probable causes of and corrective measures for various problems related GMAW equipment.

(continued on next p. 42...)

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See p. 39.Texts / Teacher ResourcesAlberta Module 120103cEquipment Maintenance and Troubleshootingpp. 2-13





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(...continued from previous pages)

Topic: Corrective Measures• Describe common weld defects encountered when using GMAW: - Porosity > lack of gas coverage > wet shielding gas > excessive tip-to-work distance > excessive gas fl ow > excessive travel speed > foreign material on base metal > excessive current or voltage > incorrect weld metal analysis > impurities in the base metal - Undercut > incorrect electrode angle > excessive current > excessive travel speed > insuffi cient pause time on the edges of weave beads - Lack of Fusion > improper manipulation of electrode holder > excessive puddle > insuffi cient welding current > poor joint preparation - Burn Through > excessive current > excessive root opening or inadequate root face > inadequate travel speed - Lack of Penetration > root opening too narrow or root face too large > electrode angle incorrect for fi llet welds > arc voltage too high > heat input inadequate > stickout too long > puddle too large

(continued on next p. 44...)

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(...continued from previous pages)

Topic: Corrective Measures• Describe common weld defects encountered when using GMAW: - Whiskers > root opening is too wide > root face is too thin > starting position is incorrect > travel speed is too fast > wire feed speed is excessive > electrode inclination is incorrect > wire extension is short

- Inclusions > preceding pass too convex > too much voltage on succeeding passes > improper electrode manipulation > inadequate preweld cleaning > inadequate interpass cleaning > current setting too low

- Cracking > faulty design > rigidity of joint > improper technique > weld bead too small > weld depth-to-width ratio too hight > rapid cooling of the crater > residual stresses too high > hydrogen embrittlement of carbon steels > hardening of carbon steels in heat-affected zones

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Shop/Lab Practices: GMAW Welds on Mild

Steel (30 hours Classroom Component)

Introduction A welder apprentice must be able to perform GMAW welds to an acceptable standard. This module is a hands-on, practical module that will develop the students’ ability to perform GMAW welds on mild steel plate.

16. Students will be able to perform surface welds in the fl at and horizontal postitions and perform 1F, 2F, 3F, 1G, 2G, and 3G position welds on mild steel.

Assessment

Strategies

Resources Alberta Module 120103f, Shop/Lab Practices: GMAW Welds on Mild SteelNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to16.1 demonstrate the ability to weld stringer/weave beads in the fl at and horizontal positions16.2 demonstrate the ability to weld 1F welds on mild steel plate16.3 demonstrate the ability to weld fi llet welds in the horizontal (2F) position on mild steel plate16.4 demonstrate the ability to weld fi llet welds in the vertical (3F) position (downhill root and uphill fi ll and cover pass) on mild steel plate16.5 prepare and fi t up butt joints without backing16.6 demonstrate the ability to weld butt joints in the 1G position16.7 demonstrate the ability to weld butt joints in the 2G position16.8 demonstrate the ability to weld butt joints in the 3G position

Specifi c

Curriculum

Outcome

SCO - Delineations


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Shop/Lab Practices: GMAW Welds on Mild Steel (~30 of 86 hours Skill Development Component) GCO 16. Students will be able to perform surface welds in the fl at and horizontal positions and perform 1F, 2F, 3F, 1G, 2G, and 3G position welds on mild steel.

WEL 801B - GAS METAL ARC WELDING (GMAW) - MODULE 5


16.1 demonstrate the ability to weld stringer/weave beads in the fl at and horizontal positions

Topic: Stringer/Weave Beads• Describe a welding technique in reference to the following variables: - current setting - electrode inclination - electrode angle - arc length - stringer bead or weave bead - single or multipass welding• Assess the value of a welding technique with reference to the following factors: - weld quality required - speed and cost of application - residual stress or distortion - the positions in which the technique gives satisfactory results - the time it takes to master the technique• Defi ne terms associated with the welding process.• Demonstrate an understanding of a welding procedure specifi cation (WPS) document to support a welding application.• Demonstrate the ability to set up GMAW welding parameters specifi c to the welding application: - shielding gas type - mode of transfer - current type - polarity - amperage/wire speed - voltage

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Topic: Stringer/Weave Beads• Review and demonstrate proper safety procedures.• Demonstrate the set-up of GMAW welding parameters.• Review weld procedure specifi cation (WPS), and make a visual of the review for students to have (p. 4).• Perform a class demonstration for each of the exercises.• Create a quiz on key terms.• Show the video GMAW (MIG) Wire Feed.


• Complete exercise 1 pp 6 -9 in ILM 120103f. ** Instead of 1 1/2" steel, 1" steel could be used for some welding projects. **

Literacy• Summarizing: Use as a post-reading strategy after you have read the exercises.

Enrichment / Research Activities

• Participate in Skills Canada competitions.

Texts / Teacher ResourcesAlberta Module 120103fEquipment Maintenance and Troubleshootingpp.




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16.2 demonstrate the ability to weld 1F welds on mild steel plate

16.3 demonstrate the ability to weld fi llet welds in the horizontal (2F) position on mild steel plate

16.4 demonstrate the ability to weld fi llet welds in the vertical (3F) position (downhill root and uphill fi ll and cover pass) on mild steel plate

Topic: GMAW Welds• Complete exercises on pp. 9-20 of ILM 120103f. For each, demonstrate the ability to - select/prepare and identify correct materials - prepare work area - interpret welding parameters - evaluate the quality of the fi nal weld.

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Topic: GMAW Welds• Demonstrate each of the exercises in the ILM.• Review visual inspection parameters. - weld size - weld uniformity - weld contour - weld defects - penetration, fusion and tie-ins around corners


• Complete exercises on pp. 9-20 of ILM 120103f.

Literacy• Summarizing: Use a post-reading strategy once you have read the exercises.





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16.5 prepare and fi t up butt joint without backing

16.6 demonstrate the ability to weld butt joints in the 1G position



Topic: GMAW Welds• Complete exercises on pp. 21-30 of ILM 120103f. For each, demonstrate the ability to - select/prepare and identify correct materials - prepare work area - interpret welding parameters - evaluate the quality of the fi nal weld.

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Topic: GMAW Welds• Demonstrate each of the exercises in the ILM.• Review visual inspection parameters: - joint alignment - weld size - weld uniformity - weld contour - weld defects - penetration, fusion, and tie-ins around corners


• Complete exercises on pp. 21-30 of ILM 120103f.• Upon completion of the module, complete a lab test covering - single beads - single fi llets - multipass fi llets and groove welds in fl at, horizontal and vertical positions.

Literacy• Summarizing: Use as a post-reading strategy once you have read the exercises.







Percentage and Ratio (5 hours Classroom Component)

Introduction Solving problems involving ratio and percentage is a necessary skill when working inthe skilled trades. For interpreting the duty cycle of a welder calculating percentage increases/decreases in costs, reading blueprints, etc., understanding percentage and ratio are two math skills that an apprentice will frequently use.

17. Students will be able to solve problems involving percentages and ratios.

Assessment

Strategies

Resources Alberta Module 120103c, Shop/Lab Practices: GMAW Welds on Mild SteelNational Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - WelderWall Mountain Company Video Series: GMAW (MIG) Wire FeedStudentsAchieve (http://sas.edu.pe.ca)

Students will be expected to17.1 solve ratio problems: express two quantities in the form of a ratio17.2 solve ratio problems: express two ratios in the form of a proportion17.3 convert between fractions and percent17.4 convert between decimals and percent17.5 solve percent problems

Specifi c

Curriculum

Outcome

SCO - Delineations


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Percentage and Ratio (~5 hours Classroom Component) SCO 17. Students will be able to solve problems involving percentage and ratios.



17.1 solve ratio problems: express two quantities in the form of a ratio

Topic: Ratio• Defi ne “ratio”.• Identify ratios in various forms.• Simplify ratios to unit ratios.

Topic: Proportion• Defi ne “proportion”.• Explain direct proportions.• Explain indirect proportions.• Identify proportions in various forms.• Explain “proportional form”.• Explain “fractional form”.

Topic: Conversion• Defi ne “percent”.• Convert a fraction to a percent.• Convert a percent to a fraction.• Convert a decimal to a percent.• Convert a percent to a decimal.

Topic: Problem Solving• Identify various type of percent-related problems.• Explain how to solve problems involving percent.

17.2 solve ratio problems: express two ratios in the form of a proportion

17.3 convert between fractions and percent

17.4 convert between decimals and percent

17.5 solve percent problems

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Percentage and Ratio (~5 hours Classroom Component) SCO 17. Students will be able to solve problems involving percentage and ratios.

• Work through examples with students.• Describe where this skill is used in industry.• Provide additional contextual examples.• Demonstrate practical examples on the shop fl oor, using examples from outcomes 17.1–17.5.

Numeracy• Using the 7-step model, create a series of math-enhanced lessons on ratio and percent that can be covered while solving relevant welding problems.

Literacy• Anticipation Guide: Use as a pre-reading strategy to help determine what the students already know about ratio and percent.


• Complete the exercises in the ILM.

Literacy• Free Writing: - Use as a pre-reading strategy to help activate students prior knowledge of ratio and percent.

Texts / Teacher ResourcesAlberta Module 120104cPercent and Ratiopp.

PEI Department of Education and Early Childhood Development—Applied Mathematics (MAT801A)

Software / DatabasesStudentsAchieve (SAS)

Edu Wel801B

Documents

Transcript of Edu Wel801B