Welding 100: Introduction to Welding and Industrial Safety Syllabus Fall 2015

Transcription

1 Welding 100: Introduction to Welding and Industrial Safety Syllabus Fall 2015 WLD 100 Credit(s): 2 Weekly Hrs: Lecture 1/Lab 2 COURSE INTRODUCTION: Introduction to Welding will cover the welding processes used in industries. Students will gain fundamentals of theory and techniques pertaining to: arc welding and thermal cutting processes, lab orientation, equipment set-up, electrode types, and consumable requirements for specific welding processes and applications. Requirements for use of industrial welding codes to develop welding procedures and welder qualifications are introduced. Students are also introduced to individual and work force safety and health practices through: Occupational Safety and Health Administration (OSHA), Mining Safety and Health Administration (MHSA), and The American National Standards Institute (ANSI), as well as subsequent regulations pertaining to welding industry and manufacturing careers. Prerequisites/Co-requisites: None Lab Fees: $950 (includes welder s kit) INSTRUCTOR: Gary Gouin Office: T-23 Office Hours: Any time by appointment. Office Phone: ext. 365 Cell Phone: (906) Address: garyg@gogebic.edu Required Texts and Supplies REQUIRED: Title: Welding Skills [Hardcover], Author: B.J. Moniz, R.T. Miller, Publisher: American Technical Publishers (ATP), ISBN-10: ISBN-13: Edition: 5th, (Current Edition)

2 REQUIRED: Welder s Equipment List: Welder s job bag PART PART NUMBER QTY. UNIT PRICE FINAL PRICE Miller Arc Armor Performance Pak includes: Bag, hood, cotton jacket, two pr. gloves, safety glasses $ $ Reusable Ear Plugs, Red Banded (Radian) 23NRR, RB pk. $8.00 $8.00 Safety Glasses RAD pr $2.50 $2.50 Miller Welding Sleeves MIL pr $33.00 $33.00 Heavy Welding Gloves RAD pr. $5.00 $5.00 Welding cap or dude rag CMX8000-L 2 $2.50 $5.00 Tungsten Electrodes, 2% Ceriated, size 3/32" RAD pk. $26.00 $26.00 Grinding wheels, 4 1/2" x 7/8" arbor RAD $2.00 $20.00 Wire wheels, 4 1/2", knotted RAD $15.00 $30.00 Flap Discs, 4 1/2" RAD $7.00 $21.00 Cut-off Wheels, 4 1/2" RAD $3.00 $6.00 Striker RAD $2.00 $2.00 Wire Hand Brush RAD $3.00 $ ½ Angle Grinder, (Milwaukee) 7.0A MET $70.00 $70.00 Fillet Weld Gauges, (Anchor) 100-NFG-7 1 $12.00 $12.00 Chipping Hammer (Radnor) RAD $8.00 $8.00 Tip Cleaners, (US Forge) # $6.00 $6.00 Tri-Square, 3 piece, (Oshlun) MTM-CS 1 $15.00 $15.00 Magnetic Torpedo Level, (Empire) 9-Inch em $10.00 $10.00 Tungsten Carbide Scriber and Magnet, (General Tools) 88CM 1 $5.00 $5.00 Round Soapstone Holder with Refills, (Hobart) $6.00 $6.00 Magnetic Welding Holder, 50-lb. (TEKTON) $7.00 $7.00 Welder's Pencil, Red (MARKAL) $2.00 $2.00 Tape Measure, 25 ft. (Stanley) $11.00 $ " Stanley Adjustable Wrench S29J710SWTCAT16 1 $20.00 $ " Irwin Locking Pliers VIS302L3 1 $13.00 $13.00 Pen Flashlight RAYBRSLEDPEN-BA 1 $5.00 $5.00 Welding Pliers RAD $10.00 $10.00 APPROXIMATE TOTAL $ Steel toed, leather work boots ($40-$150 retail NOT INCLUDED) All listed prices are approximate retail value. Cost may vary depending on clothing size, style, brand availability and market prices. RECOMMENDED: Heavy Denim work pants or coveralls; Ipad, Android or Windows tablet.

3 COURSE OVERVIEW: Major Divisions (Topics Covered, Including Class/Laboratory Hours) A) Welding Safety Class: 2 Lab: 4 B) Shop Orientation and Equipment Class: 2 Lab: 4 C) Welding Theory Class: 2 Lab: 4 D) Welding Processes Class: 2 Lab: 4 E) Welding Equipment Class: 2 Lab: 4 F) Welding Joints and Positions Class: 2 Lab: 4 G) Common welding flaws and defects Class: 2 Lab: 4 H) Introduction to Welding Codes Class: 2 Lab: 4 TOTAL Class: 16 Lab: 32 Performance Objectives: 1. Given verbal work assignment instructions and the required materials, equipment and tools, the trainee will carry out a job assignment. 2. Demonstrates proper safe operation practices in the work area. 3. Perform safety inspections and make minor repairs to SMAW equipment and accessories. 4. Demonstrates proper use and inspection of ventilation equipment. 5. Demonstrates proper Hot Zone operations. 6. Sets up and operates SMAW operations on carbon steel. Learning Outcomes: a. Understand, communicate and mitigate common safety hazards related to welding processes and careers. b. Relate the roles of AWS, OSHA, and other professional organizations within the welding industry. c. Inspect and safely operate equipment found in the welding shop. d. Analyze AWS welding processes and their applications. e. Identify, set-up and assemble welding equipment for individual welding processes. f. Classify parts of fillet and groove welds and apply terminology to lab work being performed. g. Identify welding joints and positions for pipe and plate welding. h. Examine work performed, recognize and troubleshoot common welding discontinuities. i. Summarize common welding codes and their applications in industry. INSTRUCTOR RESPONSIBILITIES Fairness and Equality: Each student will be treated fairly and equally. The Instructor makes every effort to ensure all rules, policies, and assignments are appropriate for the course and apply equally and fairly to each student. The Instructor reserves the ability to reconsider any element of the course on a case-by-case basis or with the entire class, and will consider the fairness to all students when exceptions or changes are granted.

4 Returning Graded Assignments: The Instructor will attempt to return all grades promptly. I will aim to post grades within 3 weeks after the assignment deadline unless other circumstances come about. If no urgent situation hindered grading, then starting 3 weeks after the deadline, each student will earn 3 additional bonus points on the essay for each calendar day until scores are made available. Organization and Flexibility: I will work hard to keep the course on schedule and avoid making changes during the semester. However, changes are occasionally necessary to adapt to lab availability or other circumstances. As a result, please be patient when there are changes to the course during the semester. I will make every effort to highlight any changes with you. PROCEDURES AND POLICIES Attendance: Demanding careers in the welding profession require you to be on location before the start of your work day. It is highly recommended that you practice time management by arriving five to ten minutes prior to the start of each class. Gogebic Community College s attendance policy can be viewed at the following link: The instructor will keep an accurate attendance record of all students for both the class and lab portions of the course. Arriving five or more minutes late constitutes an unexcused absence. Additionally, voluntarily leaving (being unaccounted for) before the scheduled end of a class/lab will be considered an unexcused absence for the entire period. Excessive absences will be reported to the Dean of Students. Excessive absences incurred by veterans receiving educational benefits will be reported to the Veterans' Administration as will those of students attending college under other programs requiring attendance reporting to the sponsoring agency. Absences exceeding 1/16th of total class hours will be considered excessive. Out of a 16 week semester, 1/16 total hours equals one class or lab session. Each unexcused absence will result in a zero grade entry for that class. Additionally, a grade level reduction penalty will be placed towards the final grade for each unexcused absence. The instructor will not work with or get caught up any student who has unexcused absences. All absences will be unexcused unless prior arrangements are agreed upon by the student and instructor in advance of a class or lab. Telling the instructor you are going to be gone does not constitute an excuse for being absent. Requests for excused absences for time already missed will not be granted with the exception of circumstances such as a documented illness, or emergency(s). Requests for excused absence(s) will be done in person during scheduled office hours. The instructor reserves the right to refuse claims of illness unless a letter is provided by the student s medical professional. Class Work: A one hour period of study/research is required for each class session. It is essential for you to plan adequate study time into your weekly schedule. Late homework will only be accepted for full grade during the first two weeks of classes. No exceptions. Please plan ahead. It is your responsibility to turn in any due assignments on time or ahead of time. Students will deliver any late work to the instructor during scheduled office hours (NOT

5 DURING CLASS). The reduced credit for late work will be a 1 percent reduction from your grade for each hour late. That penalty time begins immediately upon completion of the respective class in which the work was due. The maximum consequence per day is a 15 percent reduction. Lab Work: Prerequisite lab modules must be completed in their designated order before progressing on to additional work. It is the responsibility of the student to have all lab modules completed within two weeks of the end of the semester. Communication Policy: You are responsible for checking your twice a week or when directed to do so by the instructor. If you do not have personal access to your , computer labs at GCC are available for your use. You are always welcome to me with questions about the course, but I ask that you attempt to find the answers on your own. I will make every effort to reply within a reasonable time frame. I encourage you to or contact your classmates if you require a more immediate response. Guidelines: 1. Make every attempt to find your answer. 2. Contact at least one classmate first. 3. Use professionalism: be respectful, concise, and formal (avoid casual IM language). 4. You may not submit homework via without instructor permission. Feel free to contact my office phone or cell phone on matters that require more urgent attention. I also accept text messages but on a limited, casual basis. DO NOT text me if you are going to be late or are missing a class. Academic Support and Advising: The ACES Center on campus provides students with learning support services to promote their success at GCC. ACES provides advising, tutoring, and testing services for students. Please visit the ACES Center for tutoring schedules or to make an appointment for any approved testing service. TRIO - Student Support Services (SSS) is a 100% federally funded TRiO program authorized by the U.S. Department of Education. Each year, the SSS program at Gogebic Community College is awarded funding to provide access and support to students. In order to be eligible for the SSS program, students must meet one or more of the following criteria: First Generation Status: A student, neither of whose parents have completed a fouryear college degree (baccalaureate degree). In the event that one parent supports the student, eligibility will be determined based on the supporting parent's degree status. Income: A student who meets current TAXABLE income guidelines as defined by the U.S. Department of Education. Please contact an SSS staff member concerning income guidelines for eligibility. Documented Disability: A student with a documented disability that limits her/his ability to participate in college. Students are also encouraged to access disability related accommodations. ADA Accommodations for Students with Disabilities: If you believe that you need academic accommodations for a disability that qualifies under the Americans with Disabilities Act and

6 Section 504 of the Rehabilitation Act, please contact the Office of Disability Services, located in office T105C of the ACES Center, call (906) x 237, or jessicaln@gogebic.edu to discuss your needs and the process for requesting accommodations. This office is responsible for coordinating disability-related academic accommodations and will issue students with verification letters as appropriate. Since accommodations may require early planning and generally are not provided retroactively, please contact the office as soon as possible. NOTE: As your instructor, I m happy to provide you every opportunity to succeed and provide whatever resources you may need regardless of your status with our ADA office. GCC Policy on Dishonesty and Cheating: The GCC student handbook explains, Dishonesty of any kind, including plagiarism, cheating on examinations or any assigned work, may be dealt with in any manner deemed suitable by the instructor, including the recording of a failing grade for the course. Cheating on examinations may also result in the student appearing before the Conduct Committee and possible suspension from school if circumstances warrant. Academic dishonesty includes any attempt by a student to submit someone else s work as his/her own. Examples include a student: Performing lab work such as welds or cutting for another student, submitting an assignment as original work that was created by another person, using someone else s work without proper permission and citation. Regardless of whether the academic dishonesty was intentional or not, the same penalty will be applied. Team Work: The purpose of team work is to combine the individual strengths of you and your peers into an employable pool of skilled workers. Some assignments may be assigned as group work. Conference Requirement: Conferences will be required. The purpose of having conversations with the instructors is to provide students with a direct opportunity to ask questions and discuss individual and group strengths and challenges. Limits of Confidentiality: Most communication between students and the instructor will be treated as confidential. However, if you communicate something that violates procedures or policies or that seriously threatens the safety of you or others; I am legally and ethically required to report it to the college administration and/or the proper authorities. If you feel you still need to share that information with me, please understand I will report it. Examples include: Violations of drug, tobacco or alcohol policies That someone is seriously hurting or abusing you That you plan to seriously hurt or abuse yourself or someone else Something that presents a serious threat to your safety or the safety of your classmates COURSE ASSIGNMENTS Class Assignments (10 pts): A weekly class assignment will be given to prepare and reinforce your development in the welding lab. Each assignment will be graded and converted to 10 points which are entered into your score chart.

7 Skill Builders (10 pts): Each week will include a lab module in which you will perform the required skill to a set of predefined standards. Your work will be graded and converted to 10 points which are entered into your score chart. Extra Credit (5 to 30 points): There are options for extra credit, and if necessary, you can complete all options to reach 30 extra credit points. No student may earn more than 30 points of extra credit. Grading: (This Chart DOES NOT Include Extra Credit Options) Class/Lecture Assignment Point Value Lab Skill Builder Point Value Week 1:Module 1 Chapters 1&2 Orientation/Safety 10 Lab Week 1:Module 2 AWS Safety Welding Safety (2) 10 Lab Week 2:Module 3 & Organizations Lab Orientation & 10 Lab Week 2:Module 3 Procedures (1) Lab Orientation & 10 Lab Week 3:Module 4 Procedures (2) Welding Hardware/ 10 Lab Week 3:Module 5 Equipment (1) Welding Hardware/ 10 Lab Week 4: (Review) Equipment (2) Welding 10 Lab Week 4: MIDTERM Processes (1&2) MID TERM 25 Lab 100.MT 25 Week 5:Module 7 Welding Theory 10 Lab 100.8a 10 Week 5:Module 8 Weld Joints & 10 (1F,2F) Lab 100.8b 10 Week 6:Module 9 Positions (1) Weld Joints & 10 (3F,4F) Lab 100.9a 10 Week 6:Module 10 Positions (2) Intro. to QC 10 (1F,2F) Lab 100.9b 10 Week 7:Module 10 (Flaws&Defects 1) Intro. to QC 10 (3F,4F) Lab a 10 Week 7:Module 11 (Flaws&Defects 2) Intro. to Welding 10 (1F,2F) Lab b 10 Week 8: (Review) Codes (1) Intro. to Welding (3F,4F) (FINAL) Week 8: FINAL Codes(2) &Review FINAL 25 FINAL 25 TOTAL POINTS POSSIBLE = 360

8 Grade Percentile Scale Grade Points Scale 465 to 500 A 450 to 464 A- 435 to 449 B+ 415 to 434 B 400 to 414 B- 385 to 399 C+ 365 to 384 C 350 to 364 C- 335 to 349 D+ 315 to 334 D 300 to 314 D- 0 to 299 F