SkillsUSA Welding Fabrication Competition Update – 2021

State Welding Fabrication Winners: Congratulations on your accomplishments thus far. Please review these guidelines for the national competition in June. Now is the time to plan and practice your build. Your team will have 6.5 hours to complete your project. Keep in mind your team & project will be judged throughout your 6.5 hours. Manage your time wisely. As we enter another unprecedented year, and as many of you are already aware the national contest will be held virtually this year at each team’s convenient location. These are unique circumstances that require creative solutions and we need all participants’ commitment to a fair and successful competition. The Welding Fabrication committee thanks you in advance for your efforts and patience. To compete this year your team will need to secure a designated proctor (Certified Welding Inspector is required!), competition area, fabrication tools, GMAW and GTAW equipment, material and consumables, recording devices, create a YouTube channel and have content posted for the committee to review. Instructors’: Your role will be heavily loaded on the front end to prepare your competitors and the contest. During the competition it is required that you have a very limited role so as to not influence the performance of the competitors. Please assist your team in creating a YouTube channel; this will be where your recorded contest will be uploaded. You will need to familiarize the proctor with this channel as they will be responsible for uploading content for your team. Format your name as follows: ### SkillsUSA Welding Fabrication 2021. The number you enter at the beginning of the name is your team number provided to you. Number TBD once it is known which schools will be participating in the national contest. You will need to break your video into clips to post to YouTube. Each clip should have a number designation at the end of the name. ex: ###SkillsUSA Welding Fabrication 2021 (1). The numbers need to be in order and overlap the clip before and after it so as to show no break in the video. Proctor: A CWI is required for this role so that standards of safety, procedures and required information for quality is maintained across all the remote contests. The CWI shall be familiar with the contest update, the reference sheet of responsibilities and the proctors check sheet of contest requirements (provided at a later date). The proctor will provide their valid CWI credentials, allow competitors to execute all their requirements, document any requirements submitted by the competitors and document each stop point for evaluation by the judges. The proctor shall remain impartial. Should a situation arise, such as equipment malfunction, where the competitors require assistance so the competition may continue the proctor will provide specific notes to the judges. Contest Requirements: This year your team will be fabricating “dip tanks”. This is the standard project all competitors will build. Your fabricated dip tanks will be supporting the efforts of Sleep in Heavenly Peace a non-profit whose mission is to provide less fortunate children with a bed to sleep on. This organization operates with volunteers who construct and deliver wooden bunk beds to those children and families in need. The dip tanks that you all build will be used to stain the long rail boards for the beds. In addition, teams will still be required to brainstorm and design a project. A project theme is provided below with guidelines. Prints for this project theme will be required and will be graded as they have been in the past as part of your overall grade. The project your team will design is for the purpose of supporting a humanitarian cause. This project will be built and donated in a future contest.

In 2022 the SkillsUSA national conference will be moving to Atlanta, Georgia. Since this will be our first appearance there and we still want to focus on projects that support a humanitarian cause, the national Welding Fabrication Committee would like to do a project to give back to the city of Atlanta. An issue that Atlanta could use assistance with is helping the homeless. Atlanta has a large number of homeless people that sleep in the streets and under overpasses. You can help this cause by designing a project that can be built in 2022 and donated to the homeless to give them some form of shelter and minimize the need to sleep on the streets. Please research Atlanta homeless and design a project that will provide shelter. The following information is intended to help you prepare for your fabrication build. Be prepared for changes; these are common in the fabrication environment. Plan for stop points during your build; judges will need to inspect welds and other fabrication factors. If you are meticulously going through this update it may become clear what changes may be implemented, where stops points could be and what aspects of the build will impact your score the most. Best of luck!

• Standard Fabrication Project: Dip Tanks and Sawhorse (All teams will be fabricating this for the June 2021 contest) – Bring 11x17 copies of the print for

your team to work from NOTE: Dip Tank Drawings to be provided at a later date.

• Material List your team will need to supply to build DIP TANKS:

o Qty. 1 –4’ x 8’ 3/16” A36 sheet o Qty. 1 – 20’ 1” x 1.5” x .120” tube o Qty. 1 – 4’ x 8’ 16ga 304 SS sheet

▪ Tank to be: 6-1/2”deep x 9” wide x 84” long w/1-1/4”outward facing lip ▪ Outsourcing or pre-forming the “U” shaped channel is permitted however all other

forming (including channel end caps) must be done during the competition by the competitors. (Details of the tank TBD and have purposely been left off the print for now)

o Qty. 1 – 1/2” Stainless Steel Ball Valve (ex: Amazon B082945LWT)

o Qty. 4 – 5/16 x 2-1/4” Square Lock Pins (ex: Tractor Supply Co. part number: 22KITA084)

o Qty. 4 – 5/16” x 2-1/4” Bolts o Qty. 8 – 5/16” washers. o Qty. 8 – 1/4" x 1-1/2” Bolts o Qty. 8 – 1/4" Nuts o Qty. 16 – 1/4" Washers

• Welding Consumables your team will need to supply to build DIP TANKS:

o .035” ER70S-6 GMAW Weld Wire

o 3/32” 308 SS TIG Rod o 1/16” 308 SS TIG Rod

• Minimum Project Requirements: only (2) weld processes this year!

o 8 Individual GMAW Welds of 6” or greater (vertical welds not required) o 6 Individual GTAW Welds of 6” or greater (vertical welds not required) o 5 Individual OFC Cuts of 6” or greater

• Performance Qualification Record (PQR)

Your team is to prepare a PQR that will be submitted for grading. It is to be based on samples you have completed prior to the contest. A picture of the samples with each sample marked with each variable tested needs to be submitted with your PQR.

o Attached with the contest update will be a template PQR to be used by your team ▪ This template can also be downloaded from the AWS website.

https://app.aws.org/technical/samples/PQR.doc o Some criteria on the PQR will not apply

▪ Write “NA” in blanks that do not apply ▪ For any blank “Company Name, By, Test Conducted By or Manufacturer/Contractor”

only put your team number!

• Welding Procedure Specification (WPS) Your team is to prepare a WPS based on the best results from your PQR samples. You will need to follow this WPS during your contest. You are expected to have a copy in your work area and all variables should meet the WPS. The proctor will verify you are following the WPS throughout the contest.

o Attached with the contest update will be a template WPS to be used by your team ▪ This template can also be downloaded from the AWS website.

https://app.aws.org/technical/samples/WPS.doc Some criteria on the WPS will not apply

▪ Write “NA” in blanks that do not apply ▪ For any blank “Company Name, By, Test Conducted By or Manufacturer/Contractor”

only put your team number!

The following link will help you to better understand the importance of these documents: https://www.aws.org/resources/detail/wps-and-pqr-demystified

• Project Theme for Prints: Shelter for the homeless

(Team prints will be graded on this concept)

• Guidelines for Design:

o Designed for outdoor use o Must allow for a roof to be added o Must allow for at least 1 person to lay down and off the ground o Max height 6’ o Consider your design to be modular and could be connected to another teams shelter o Consider what a homeless person may need to use this structure for other than just shelter o Construction can be with or without a skeletal frame o Consider weather conditions in Atlanta o Consider materials that are commonly discarded or of low cost that could be incorporated into

you design o May incorporate any material, but there must be enough metal fabrication for the national contest o Metal material can not be over $300

• Blue Print Requirements:

o One set of prints on 11” x 17”paper printed in the Landscape mode (for grading) ▪ In addition a USB type drive containing prints in PDF format is required

• USB drive will not be returned • Drives must only contain prints for project theme

o No bindings or covers o Title block in lower right hand corner titled with your Team ###. o No school name or competitor names on the print o Max of 10 pages – You must have overall dimensions of the finished project included within the

drawings you submit. o All Welds MUST have appropriate weld symbols included to show where the required welds

and weld processes will be used on the parts. o All vertical welds shall be noted o A blueprint can be neatly hand drawn if the team does not have access to design software.

▪ An electronically scanned pdf copy is still required for all prints. o All prints MUST be created by the team. o Do NOT roll up paper copies

• Proposal for Future Projects o Propose a project that is worthy of being a national project

▪ Prepare a hard copy of your proposal to be turned in with your prints with the following headings

• “Proposal for Future Projects” • Sub-heading is to be a brief description of the project

▪ Think of projects that can improve communities in some way ▪ Provide as much information as possible to describe the project ▪ No guarantees your project will be chosen

• Judging Overview:

Category Points Judging Detail

SAFETY 30 Each safety infraction will be a 10pt deduction. Disqualification after 30pt deduction!

GMAW 150 8 required welds will be judged on joint fit-up, size, contour and appearance. Judging is based on: AWS D1.1 Structural Welding Code-Steel.

GTAW 150 6 required welds will be judged on joint fit-up, size, contour and appearance

PERFORMANCE QUALIFICATION RECORD (PQR)

60 Perform test samples to determine the best results for welding this project. Label each sample with parameters used. Provide a picture of these test samples to the proctor. Using the provided PQR template fill the document out and provide to the proctor.

WELDING PROCEDURE SPECIFICATION (WPS)

60 Prepare your WPS based on the results of your PQR. The WPS is to be used during your contest and the proctor will verify you are within parameters throughout the contest.

OFC 100 5 required cuts will be judged on angle, appearance, dimension, bottom edges slag free and cuts free of chipping marks (Cuts must be judged prior to any cleaning, grinding, etc)

TEAMWORK 100 Students will be judged on equal participation, team communication and ability to work together

FABRICATION 100 5 critical dimensions will be judged for accuracy. Overall appearance and functionality is also scored

WELD DRAWINGS 65 Minimum requirements for Blueprint: Title Block, Proper Critical Dimensions, No Tolerances, Proper Welding Symbols, Proper Finishing Symbols, Proper Views to Fabricate the project, Proper Sub Assembly Drawings

PROPOSAL 35

Your team is to present (1) proposal for a project that you believe is worthy of being fabricated at national’s. It must support humanity in some way. Plan for a 5min video recorded proposal during your contest time.

▪ Your team is to group together while the contest proctor records your presentation.

▪ Provide as much information as possible to describe the project ▪ Explain how this project would support humanity ▪ Explain why there is a need ▪ IF you have contact information for someone with direct experience with this

need and that person wants to be contacted please provide that. Their information will only be used by the Welding Fabrication committee to make contact.

PROFESSIONAL DEVELOPMENT TEST

50 Based on SkillsUSA Framework. Will be questions on Personal Skills, Workplace skills and Technical skills. This will be administered by SkillsUSA and not the Welding Fab committee.

WRITTEN TEST 100 The 3 individual test scores will be averaged for your team's total score

• Contest Area:

o 20’x20’ (maximum) taped off weld booth o Install weld curtains as needed (ensure cameras have adequate visibility of contest as required) o No identifying school or team information visible to the cameras (ie. Banners, flags, posters,

etc…) o All work must be performed within the contest area in view of both cameras at all times.

• Items that must be supplied by Teams:

o All Personal Protective Equipment o Full welding jackets or half jackets w/ bib are REQUIRED! - Sleeves only or uniform shirts are

NOT ACCEPTABLE as a jacket) o Hearing and/or ear protection o Welding helmet with appropriate filter plate/lens and protective cover plate/lens in a flip or slide

front. Auto darkening shields are permissible o Spare spatter and filter lenses/plates for arc welding helmet and oxyacetylene goggles o Blueprints – See “Blueprint requirements” o Teams may use personal hand tools. o Grading Templates

• Tools supplied by Teams:

o Welding Machines ▪ Welder (GMAW) capable of 200amp output or greater

o With consumables ▪ Welder (GTAW) capable of 200amp output or greater

o With consumables o Environmental Equipment

▪ 1 Environmental Extraction Unit per team o OFC Kit o Bill of Materials o Hand Drill o Drill Press and/or hand drill

▪ 5/16” drill bit ▪ 1/4” drill bit ▪ Hole saw (sized to match drain valve purchased) ▪ Step bits and additional quantities of all bits is permitted

o Two 4 ½” grinders with preferred cutting, grinding and sanding disks o Oxyacetylene goggles o Grinding face shields o Any hand tools may be used.

• Other tools: (suggested)

o Heat Sink Blocks (qty. 2-4)

• Safety:

o Safety glasses must be worn at all times o Hearing protection must be worn at all times o Gloves must be worn while handling material

▪ Removing gloves is permitted for layout (print reading, marking, measuring) purposes o Face shields must be worn while grinding

o Helmets or oxyacetylene goggles must be worn while cutting o Welding jackets must be worn while welding

▪ (Full welding jackets or half jackets w/ bib are REQUIRED! ▪ Sleeves only or your uniform shirt are NOT ACCEPTABLE as a jacket

• The committee is requiring this at all remote sites for the 2021 contest so that we maintain consistency with our requirements at in-person contests.

▪ Competitors may remove their long sleeve uniform shirt while wearing a welding jacket (must have cotton T shirt on underneath)

▪ While not welding competitors must have long sleeves on and rolled down at all times • You will be working in tight quarters and by the nature of your work you are

constantly exposed to sharp material and hot parts – long sleeves minimize the risk of injury

o Grinding sparks on the welding equipment and/or other people will result in a deduction in points

o Environmental equipment must be used at all times when welding. Points will be deducted for improper use.

• Other Information:

o Dip Tanks will be donated to SHP. o Teams are not permitted to use any power tools, or additional metal material.

▪ Decimal / Fraction conversion cards are permitted ▪ (1) Hand drill and/or a basic drill press is permitted.

o Premade templates are required however they will only be used by the proctor to aid in grading. o Possession or use of any electronic communication devices are not allowed in the contest

area at any time (except those used by the proctor). o Cell phones may not be substituted for calculators!

• Possible changes AFTER 2021

o Some of your 6.5hrs may be spent working with mixed teams. ▪ The focus will be on teamwork ▪ As an entry-level fabricator chances are while at your first job you will be working with

complete strangers and the idea of mixing teams is to expose you to this factor and evaluate your ability to work with people you do not already have a relationship with.

o You may be provided with a complete Welding Procedure Specification and graded on how well your team follows it.

▪ This is being considered since following a WPS is often required at fabrication companies.

o Standard tool boards with supplied tools may be in place. ▪ Personal tools may be prohibited ▪ This is to reduce safety hazards in your competition area ▪ This also reduces your burdens and costs of traveling to the competition

Instructor Responsibilities

Competition Prep & Proctor Support

Proctor Responsibilities

Verify, Monitor, Record & Collect Information

* Collect Grading Templates, Written Tests, Prints, Proposal, (2) WPS and (2)

PQR's

* Brainstorm a Concept for a Homeless

Shelter

* Copy PDF Format of Prints onto SkillsUSA

Server

* Take Test 6ft Apart from Each Competitor

* Deliver Dip Tanks to SHP

* Volunteer to Help SHP (optional, but recommended)

Proctor SupportCompetition Prep

* Acquire Filler Metals and Electrodes

* Prepare Equipment for Competition

* Prepare a 20' x 20' Competition Area

(taped off)

* Prepare Adequate Ventilation

* Prepare Competitors Using Contest Update

* Assist Competitiors with creating their YouTube channel

* Make Fabrication Prints for Shelter

Student Prep

* Assist Competitors w/ Delivering Dip Tanks to SHP & Volunteering

* During Competition Disconnect from Competitors by Staying in

Designated Area* Assist Competitors in Making Grading Templates

* Be Available for the Proctor incase Technical Issues Arise w/

Cameras or Other Remote Requirements

* Acquire Material for Fabrication

Reference Sheet of Responsibilities

After Competition

* Verify Grading Templates are Adequate

* Verify Competitors Have Proper Safety Equipment & Clothing

* Monitor Time of Contest

* Monitor Safety During Contest

* Monitor Interference from Anyone Person Watching Contest

* Make Required Views, Pictures, and Measurements at Stop Points

* Monitor Written Test

After Competition

* Take Final Views, Pictures, and Measurements

* Prepare Grading Templates

* Fabricate Dip Tanks from Provided Prints

* Follow Sequence of Operation

* Complete (2) WPS and (2) PQR's

* Bring Tools & PPE* Install Proposal File onto SkillsUSA Server

in PDF Format

* Operate Moveable Camera

* Ensure Stop Points for Grading

* No one Except Proctor is to Have Access to This Material

* Send Materials to Welding Fabrication Committee as Required

Fabrication Project Designed Project Proposal Written Tests

* Propose a Future Project

After Competition

Competitors Responsibilities

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WELDING FABRICATION

Sample of PROCEDURE QUALIFICATION RECORD (PQR) 1. Procedure Qualification or 2. Procedure Verification

COMPANY NAME BY PQR No. DATE PQR REV. No. REV. DATE SUPPORTING WPS Nos. WELDING PROCESS(ES) TYPE Manual, Semi-Automatic, Automatic, Robotic

JOINTS JOINT TYPE BACKING BACKING MATERIAL (TYPE) GROOVE ANGLE ROOT OPENING RADIUS (U or J) ROOT FACE BACKGOUGING (YES or NO) BACKGOUGING METHOD

Sketches, production drawings, welding symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the root spacing details of the weld groove may be specified.

BASE METAL(S) M-No. GROUP No. OR TO M-No. GROUP No. SPECIFICATION TYPE AND GRADE TO SPECIFICATION TYPE AND GRADE THICKNESS RANGE OF BASE METAL GROOVE FILLET PIPE DIA. RANGE GROOVE FILLET OTHER

FILLER METALS FILLER METAL F-No. OTHER AWS CLASSIFICATION AWS SPECIFICATION WELD METAL ANALYSIS A-No. OTHER FILLER METAL SIZE ELECTRODE-FLUX (CLASS) FLUX TRADE NAME CONSUMABLE INSERT OTHER

POSITIONS POSITION(S) OF GROOVE WELD PROGRESSION POSITION(S) OF FILLET

PREHEAT PREHEAT TEMPERATURE INTERPASS TEMPERATURE

POSTWELD HEAT TREATMENT TEMPERATURE TIME

Joint Details

Sample PQR Form (continued) PQR NUMBER (Page 2)

SHIELDING

SHIELDING BACKING TRAILING GAS(ES) COMPOSITION FLOW RATE FLUX Yes No FLUX TYPE / TRADE NAME

ELECTRICAL CHARACTERISTICS & WELDING PARAMETERS CURRENT TYPE AND POLARITY PULSING (YES OR NO) CURRENT (RANGE) VOLTAGE (RANGE) WIRE FEED SPEED (RANGE) TRAVEL SPEED (RANGE) TUNGSTEN ELECTRODE SIZE AND TYPE PULSING PARAMETERS OTHER

OTHER VARIABLES CUP OR NOZZLE SIZE COLLET BODY or GAS LENS CLEANING METHOD TECHNIQUE Stringer or Weave NUMBER OF ELECTRODES NUMBER OF PASSES PER SIDE OTHER

TEST RESULTS VISUAL TEST RESULTS

TENSILE TESTS

Specimen No. Width Thickness Area

Results Failure Type and Location

Yield Load

Yield Strength

Tensile Load

Tensile Strength

GUIDED BEND TESTS Type and Figure Number Results

WELDER’S NAME: ID or SS No.

TESTS CONDUCTED BY: LAB TEST No.

We the undersigned certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of AWS D18.3.

MANUFACTURER OR CONTRACTOR

DATE BY Please Print Signature

Sample of WELDING PROCEDURE SPECIFICATION (WPS) COMPANY NAME BY

WPS No. DATE

WPS REV. No. REV. DATE

SUPPORTING PQR Nos.

WELDING PROCESS(ES) TYPE Manual, Semi-Automatic, Automatic, Robotic

JOINTS

JOINT TYPE

BACKING

BACKING MATERIAL (TYPE)

GROOVE ANGLE

ROOT OPENING RADIUS (U or J)

ROOT FACE

BACKGOUGING (YES or NO)

BACKGOUGING METHOD

Sketches, production drawings, welding symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the root spacing details of the weld groove may be specified.

BASE METAL(S) M-No. GROUP No. OR TO M-No. GROUP No. SPECIFICATION TYPE AND GRADE TO SPECIFICATION TYPE AND GRADE THICKNESS RANGE OF BASE METAL GROOVE FILLET DEPOSITED METAL GROOVE FILLET PIPE DIA. RANGE GROOVE FILLET OTHER

FILLER METALS FILLER METAL F-No. OTHER AWS CLASSIFICATION AWS SPECIFICATION WELD METAL ANALYSIS A-No. OTHER FILLER METAL SIZE ELECTRODE-FLUX (CLASS) FLUX TRADE NAME CONSUMABLE INSERT OTHER

Joint Details

Sample WPS Form (continued) WPS NUMBER (PAGE 2)

POSITIONS

POSITION(S) OF GROOVE WELD PROGRESSION

POSITION(S) OF FILLET

PREHEAT

PREHEAT TEMP. (MINIMUM) INTERPASS TEMP. (MAXIMUM)

PREHEAT MAINTENANCE

CONTINUOUS OR SPECIAL HEATING OR MAINTENANCE

POSTWELD HEAT TREATMENT

TEMPERATURE TIME

SHIELDING

SHIELDING BACKING TRAILING

GAS(ES)

COMPOSITION

FLOW RATE

FLUX Yes No FLUX TYPE / TRADE NAME

ELECTRICAL CHARACTERISTICS

CURRENT TYPE AND POLARITY PULSING (YES OR NO)

CURRENT (RANGE) VOLTAGE (RANGE)

WIRE FEED SPEED (RANGE)

TUNGSTEN ELECTRODE SIZE AND TYPE

PULSING PARAMETERS

OTHER

OTHER VARIABLES

CUP OR NOZZLE SIZE COLLET BODY OR GAS LENS

CLEANING METHOD

NUMBER OF ELECTRODES

OTHER

WELDING PARAMETERS

LAYERS PROCESS FILLER METAL ELECTRICAL TRAVEL

SPEED RANGE Class Diameter Type &

Polarity Current Range

Voltage Range