Welding 240: Qualification Syllabus Spring 2014

Transcription

1 Welding 240: Qualification Syllabus Spring 2014 WLD 240 Credit(s): 2 Weekly Hrs: Lecture 0/Lab 4 COURSE INTRODUCTION: Qualification with groove welds qualifies for both groove and fillet welds so an emphasis is placed on plate and pipe groove weld tests. The processes covered are Shielded Metal Arc Welding (SMAW), Gas Metallic Arc Welding (GMAW) and Flux-Cored Arc Welding (FCAW). All positions of welding will be performed in these processes. Serves as a final preparation for students for American Welding Society (AWS) and ASME certification tests administered in the lab. Prerequisites/Co-requisites: WLD 100 Introduction to Welding & Industrial Safety; WLD 110 Welding Symbols and Blueprint Reading; WLD 120 Thermal Cutting and Welding; WLD 140 Shielded Metal Arc Welding; WLD 150 Fabrication and Rigging; WLD 160 Gas Metal Arc Welding/Flux Cored Arc Welding; WLD 170 Metallurgy; WLD 180 Gas Tungsten Arc Welding; WLD 220 Weld Inspection and Testing Lab fees: $159 (Lab fee includes one attempt at 4 available all-position tests) INSTRUCTOR: Gary Gouin Office: T23 Office Hours: Any time by appointment. Office Phone: ext. 365 (I recommend calling my cell #) Cell Phone: Address: garyg@gogebice.edu Required Texts and Supplies REQUIRED: Title: Welding Skills [Hardcover], Author: Moniz, Miller, Publisher: ATP ISBN-10: ISBN-13: Edition: 4 th, (Current Edition) REQUIRED: RECOMMENDED: Ipad, Android or Windows tablet.

2 COURSE OVERVIEW: A. Prepare raw materials for welding qualification testing Class: 0 Lab: 4 B. Site welding procedure specifications in preparation for testing Class: 0 Lab: 1 C. Efficiently operate welding equipment to complete weld tests Class: 0 Lab: 3 D. Pass 2G weld qualification test on beveled plate Class: 0 Lab: 4 E. Pass 3G weld qualification test on beveled plate Class: 0 Lab: 4 F. Pass 4G weld qualification test on beveled plate Class: 0 Lab: 4 G. (Optional) Pass 2G weld qualification test on beveled pipe Class: 0 Lab: 4 H. (Optional) Pass 5G weld qualification test on beveled pipe Class: 0 Lab: 4 I. Visually inspect welded coupons in preparation for bend test Class: 0 Lab: 1 J. Prepare welded coupons and perform guided bend test procedures Class: 0 Lab: 3 PERFORMANCE OBJECTIVES: TOTAL Class: 0 Lab: 32 WARNING READ CAREFULLY! You are required to complete your qualification as an all-position plate or pipe welder by passing a combination test consisting of two plate welding positions (TEST A: 3G and 4G plate). TEST B: 2G and 5G pipe, Test C: 6G pipe) are available per individual student progress. Mandatory testing must be started prior to the withdrawal deadline. If you do not, your instructor will withdraw you for lack of progress! Note: This Syllabus does not have a copy of the FCAW plate test procedure but the instructor has the option to administer such test in lieu of the SMAW plate test. You must achieve qualification in accordance with the acceptance criteria of the American Welding Society (AWS): D1.1, Structural Welding Code Steel. Choices for qualification testing are given below. If you complete your testing early, your remaining assignments will be designed for you by your instructor. Additional testing may be available from the instructor at an additional cost. Performance Objectives: Meet the challenges of industry driven qualifications. Demonstrate knowledge of WPS s, WPQR s and subsequent test records in accordance to the appropriate welding code. Successfully complete qualification testing on plate or pipe according to CODE and WPS specifications. (SEE ATTACHED SPECIFICATION SHEET OBJECTIVES)

3 Code: Process: Current: Positions: Material: Filler Metal: Fit-Up: Technique: 3/8-inch Thick Limited Plate Certification American Welding Society (AWS): D1.1, Structural Welding Code Steel. Shielded Metal Arc Welding, or Flux Core Arc Welding DCEP (DCRP) 3G (vertical up) and 4G (overhead) ASTM A-36 or equivalent steel plate 3/8-inch thick with 1/4" x 1" backing bar SMAW: E-7018 electrodes 1/8 diam., FCAW: E71T diam. 1/4" root opening No root face 45º included groove angle No grinding of any weld passes Interpass cleaning by hand brush Visual Acceptance Criteria: 1. The finished weld shall exhibit a neat, uniform workman-like appearance. 2. No reinforcement >1/8"...AWS D1.1: paragraph (3) Reinforcement includes both convexity, and weld metal extending beyond the edges of the groove. 3. No undercut >1/32" (4) 4. No arc strikes No underfill at craters (2) 6. No Patching on cover pass(es). Beads must be sequential from one side of the joint to the other. See drawing below as an EXAMPLE ONLY. Specimens: Inspector will designate specimen locations per welding code specifications: One 1-1/2" wide x 3/8" thick guided bend root specimen One 1-1/2" wide x 3/8" thick guided bend face specimen Guided Bend Acceptance Criteria: 1. No discontinuity >1/8" in any direction... AWS D1.1: paragraph (1) 2. 3/8" maximum accumulation of flaws >1/32" (2) 3. 1/4" maximum corner crack, if not fusion related (3) Qualification: Welder is qualified to weld in all positions with all SMAW electrodes on a maximum thickness of 3/4" plate. Other qualifications also apply, and are given in AWS D1.1: 2010 Table 4.10

4 6-inch Schedule 80 Pipe Certification Code: ASME SECTION IX 2010 Process: Shielded Metal Arc Welding (SEE FOOTNOTE BELOW) Current: DCEP (DCRP) Positions: 2G (horizontal) and 5G (vertical up) Material: API 5L, Grade B or equivalent steel pipe 0.562" ( 9/16") thick welded open root without backing ring Filler Metal: E-6010 size 3/32 electrodes for root pass E-6010 size 3/32 electrodes for "hot" pass E-7018 size 3/32 electrodes for filler and cap passes Fit-Up: 0"-1/8" root opening 0"-1/8" root face 60º included groove angle Technique: Grinding of root pass permitted ONLY AFTER INSPECTOR APPROVAL, but no grinding of any further weld passes. Interpass cleaning by power brush. Visual Acceptance Criteria: As per ASME QW194, and AWS D No reinforcement >1/8"... AWS D1.1: paragraph (3) 2. No undercut >1/32" (4) 3. No arc strikes No underfill at craters (2) 5. No inadequate joint penetration at root (5) 6. Concave root permitted, if total weld thickness base metal (6) 7. No root concavity > 1/16" (6a) 8. No melt-through > 1/8" (6b) Specimens: Four 1" wide guided bend specimens taken at 1:30 o'clock, 4:30 o'clock, 7:30 o'clock, and 10:30 o'clock. Guided Bend Acceptance Criteria: 1. No discontinuity >1/8" in any direction... AWS D1.1: paragraph (1) 2. 3/8" maximum accumulation of flaws >1/32" (2) 3. 1/4" maximum corner crack, if not fusion related (3) Qualification: Welder is qualified to weld in all positions with all SMAW electrodes on 3/16"- unlimited thickness pipe and 4"-unlimited diameter pipe. Other qualifications apply. FOOT NOTE: GTAW/SMAW Combination test may be performed per instructor s discretion.

5 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. Returning Graded Assignments: The Instructor will attempt to return all grades promptly. 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 by visiting 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 50% reduction penalty will be placed towards any makeup work that is voluntarily turned in for the time missed. 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. Granting permission for time already missed will not be allowed with the exception of circumstances such as documented illness, or emergencies. Requests for excused leave of absence 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.

6 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 $248,063 to provide access and support to 160 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 Section 504 of the Rehabilitation Act, please contact the Office of Disability Services, located in office T105E of the ACES Center, call x 271, or daylej@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

7 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 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. EMPSET (Employability Assessment) (5-10 pts): Each week you will have the opportunity to gain up to an additional 10 points towards your grade by having your lab performance evaluated. Your EMPSET score is based on multiple factors including: safety, attendance, participation in team activities, quality of work, productivity, and housekeeping/shop conduct.

8 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. Lab Point Skill Builder Value Week 1 (introduction) 10 Week 2 10 Week 3 10 Week 4 10 Week 5 10 Week 6 10 Week 7 (Review) 10 Week 8 MID TERM 25 Week 9 10 Week Week Week Week Week Week 15 (Review) N/A Week 16 FINAL 25 TOTAL POINTS POSSIBLE 180

9 Grade Percentile Scale