Sam Houston State University Department of Agricultural Sciences and Engineering Technology Agricultural Engineering Technology Program Presents the

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1 Sam Houston State University Department of Agricultural Sciences and Engineering Technology Agricultural Engineering Technology Program Presents the SHSU Welding/ Metal Fabrication Contest Date: May 13, 2016 Start Time: 8 a.m. to completion and awards Where: Harrell Agricultural Engineering Technology Center, Sam Houston State University, 2224 Avenue M, Huntsville, TX Registration: Registration cost are $80 per team of (4) Texas FFA Members. Registration can be found at One team per school is allowed to register. Registration is first come, first serve. Registration is limited to 30 schools total. Registration will begin March 1, 2016 at 8 a.m. and close on May 1, 2016 at 5 p.m. Late registration will begin May 1, 2016 at 5:01 p.m. and conclude May 7, 2016 at 5 p.m. Late registration cost are $160 per team. Awards: Banners will be awarded to the top 10 winning teams along with any donated prizes/scholarships that become available from business and industry. Additionally, the top 10 individuals will also be recognized. Overview: This event will test both the technical and welding/ metal fabrication skills of students. A team of four members must demonstrate their knowledge about and their ability to perform skills associated with various welding and metal fabrication technologies. During this event, members will complete a 100 question written exam and demonstrate hands-on performance skills. Purpose: Technological advances and the constant shortage of skilled workers in the welding/ metal fabrication industry in the U.S. continue to plague many companies and local and national economies. Students entering the workforce need a strong knowledge base and the ability to comprehend the interaction of complex processes and systems in the welding and metal fabrication industry. Students with these skills and abilities are more competitive in the job

2 market, receive financial rewards, and are selected for advancement over their peers. An agricultural mechanics education is comprised of strong technical content and complimented by the development of practical, hands-on skills. Each welding and metal fabrication skill has been developed in a response to a problem or need encountered in the workplace. The SHSU Welding/ Metal Fabrication Contest recognizes students with these important competencies which are critical to the modern workplace Contest Format/ Rules: A. Team Make-Up This will be a team contest. A team will consist of (4) Texas FFA members, grades Team ranking is determined by combining the scores of the top three students from each team and dropping the team member with the lowest combined score. B. Required Equipment, Supplies, and Personal Protection Equipment (PPE) Each team member will be required to bring the following tools/supplies/equipment to include: Proper PPE (eye protection must be in accordance with ANSI Z.87.1 standards and ear protection) for the SMAW, GMAW/FCAW, Oxygen/Fuel Cutting & Plasma Cutting Processes, chipping hammer, steel wire brush, appropriate layout tools (compass, steel ruler, steel square, tape measure, pipe wrap, soapstone, white paint pen, etc.) Students will be working with material that includes pipe up to 12 ID, plate, c-channel, I-beam, and or rod. Right angle grinders will not be allowed in Students will be required to wear ear and eye protection at all times throughout the welding/ metal fabrication skill activities. Additionally, students must wear leather gloves when welding and/or cutting on both hands. Because of rotating time schedules throughout the various skills activities, sharing of tools and equipment between team members will not be allowed. C. Clothing Each team member shall furnish and wear clothing appropriate for welding/ metal fabrication skills. This clothing shall be made of 100% cotton or other fire resistant material. No frays or holes in clothing shall be tolerated and students will be excluded from the welding and metal fabrications skills if they are found wearing clothing with these hazards. Long sleeves must be worn when welding and/or cutting. D. Other materials Each team member must have a clean, transparent plastic compliant clipboard, two sharpened No. 2 pencils, and an electronic scientific or graphing calculator. Calculators used in the event should be battery operated and silent. Each team member must also provide (1) Scantron 882-ES or equivalent scan sheet for the exam portion of the contest.

3 E. Contest Format The contest will consist of two sections: (1) exam and (2) Welding and Metal Fabrication Skills. 1. Exam a one hour, 100 point exam about welding theory, facts, technical information interpretation, welding symbols, electrode identification and selection, gas facts and selection, material costs, etc. 2. Welding and Metal Fabrication Skills students will complete 4 rotations (15 minutes each) that consist of hands on activities to include: SMAW, GMAW, Oxygen/Acetylene Cutting, and a Blue Print/Technical Drawing Interpretation/ Layout Activity. F. Scoring (maximum points possible) Written Examination (per member) Individual Skills (per member, 4 at 100 points each) 100 points 400 points Total Points (maximum) Individual Team 500 points 1,500 points * The team member with the lowest total score will be dropped from the overall team score. Therefore, the team score will consist of only the top three team members total scores from the exam and the individual skill activities. G. Tiebreakers Ties for teams will be broken as follows: 1. Team with the highest total overall individual skill activity scores. 2. If still tied, the team with the highest total overall individual exam scores. 3. If still tied, the team with the highest total alternate score (the 4 th team member with the lowest score not included in the original team score) will win. 4. If still tied, a coin toss will determine the winning team.

4 Welding and Metal Fabrication Skills for 2016 SMAW The SMAW project will require the student to perform two welds (1G Flat-no backer plate & 1F Flat) using an E /8 diameter electrode on ¼ thick mild steel plate (No bevel on plate). Students will be using a Lincoln Electric Precision TIG 225 welding machine to perform the SMAW process. The student will have 15 minutes to complete this portion of the contest. GMAW The GMAW project will require the student to perform one weld (2F) using ER-70S electrode, solid core wire,.035 diameter, 75% Argon/25% CO2 shield gas with a Lincoln Electric Power MIG 255 GMAW welding machine. The project will consist of 2 ID schedule 40 mild steel pipe being welded to ¼ mild steel plate. There will be no bevel the pipe. The student will have 15 minutes to complete this portion of the contest. Oxygen/Acetylene Cutting The Oxygen/Acetylene Cutting project will require the student to perform a bevel cut, a pierce cut, and a normal cut on 3/8 mild steel plate. Additionally, students will be required to layout the location of the cuts based upon a drawing with precise dimensions. Students will use Harris torches utilizing both oxygen and acetylene gases. The student will have 15 minutes to complete this portion of the contest. Blue Print/Technical Drawing Interpretation and Layout Activity The Blue Print/Technical Drawing Interpretation and Layout Activity will require the student to examine and interpret: a set of blue prints/ technical drawings, identify elements of weld symbols, identify dimensions, interpret material selection, identify materials as indicated in blue prints/ technical drawings, and layout features of a blue print/ technical drawing on various materials (i.e. pipe, plate, c channel, I beam, angle, etc.) using soapstone, paint pen (white), compass, protractor, center punch and ball peen hammer, or any other appropriate layout tool. The focus will on either pipe or plate. The student will have 15 minutes to complete this portion of the contest. Skill Evaluation: Welds and cuts will be visually examined and scored in 2016 by a Certified Welding Inspector utilizing a grading rubric.

5 Reference Materials: Textbooks Chasan, R. (2009). Practical problems in mathematics for welders. (5 th edition). Delmar Cengage Learning. ISBN # Herren, R. V. (2015). Agricultural mechanics: Fundamentals and applications (7 th edition). Cengage Learning. ISBN # Hoffman, D. J., Dahle, K. R., Fisher, D. J. (2012). Welding. Pearson Education/ Prentice Hall. ISBN # John Deere Publishing. (2016). Fundamentals of service: Welding. (8 th edition). ISBN # J.F. Lincoln Arc Welding Foundation (2008). How to read shop drawings with special reference to arc welding. James F. Lincoln Arc Welding Foundation, Cleveland, OH. Jeffus, L. (2012). Welding: Principles and applications. (7 th edition). Delmar Cengage Learning. ISBN# Jeffus, L. (2011). Metal fabrication technology for agriculture. (2 nd edition). Delmar Cengage Learning. ISBN# Squires, W. T. (2001). Arc welding. American Association for Vocational Instructional Materials. ISBN # Online Resources Instructional Material Service, Power, Structural, and Technical Systems Curriculum related to welding and metal fabrication James F. Lincoln Arc Welding Foundation. Time Slot Assignments for Teams: Teams will be assigned alphabetically, at the conclusion of registration, to a two hour time frame to complete both the exam and the individual skill activities. A wait list will be established for teams who do not make the normal registration. In the event a team who originally registers drops out, the first team on the waitlist will be invited in their place. The same process will be used for any other teams that drop out.