PCC/ CCOG / WLD

Course Content and Outcome Guide for WLD 217

Course Number:
WLD 217
Course Title:
Diesel Welding
Credit Hours:
3
Lecture Hours:
0
Lecture/Lab Hours:
60
Lab Hours:
0
Special Fee:
 

Course Description

Develops knowledge and skills in welding required of a diesel mechanic. Focuses on maintenance and repair applications using S.M.A.W., O.A.W., and O.A.C. processes. Department permission required. Audit available.

Addendum to Course Description

This is an outcome based course utilizing a lecture/lab format. This course includes classroom discussions, video tapes, and lab demonstrations covering technical skills. Course outcomes will include the following: theoretical concepts, layout, fabrication, welding, cutting, safety, environmental awareness, communication, computations and human relations.  

Intended Outcomes for the course

  • Function safely in the PCC Welding Lab
  • Demonstrate professional work ethics (habits)
  • Apply math and science concepts related to welding processes
  • Operate oxy-fuel portable and track cutting systems in accordance with industry standards.
  • Operate a PAC (Plasma Arc Cutting) hand held system
  • Operate an CAC-A (Carbon Arc Cutting - Air) system
  • Weld common joints using SMAW, GMAW, FCAW processes
  • Perform TB (Torch Brazing) using the oxy-acetylene system
  • Repair cracks in Cast Iron using S.M.A.W.    

Outcome Assessment Strategies

The student will be assessed on his/her ability to demonstrate the development of course outcomes. The methods of assessment may include one or more of the following: oral or written examinations, quizzes, written assignments, visual inspection techniques, safe work habits, task performance and work relations.

Course Content (Themes, Concepts, Issues and Skills)

Apply math and science concepts related to welding processes

  • Practice measuring with fractions
  • Explain how to reduce common fractions
  • Explain expressing common fractions in higher terms
  • Identify the metallurgical concepts in welding cast iron

Function safely in the PCC Welding Lab

  • Students will understand and practice personal safety by using proper protective gear
  • Students will understand and practice hand and power tool safety
  • Students will understand and practice equipment safety
  • Students will understand and maintain a safe work area
  • Maintain a clean and clutter-free floor
  • Recognize and report dangerous electrical and air/gas  hose connections
  • Understand and practice fire prevention
  • Identify the purpose of a Material Safety Data Sheets (MSDS)
  • Locate MSDS

OAW ( OXY-ACETYLENE WELDING), OAC (OXY-ACETYLENE CUTTING ), TB (TORCH BRAZING)

  • Demonstrate correct setup and shutdown procedures
  • Adjust gas pressure in accordance with pressure chart recommendations.
  • Demonstrate welds on 16 gauge in the following positions:
    • Flat position bead plate without filler metal.
    •     Flat position bead plate with filler metal. 
    •     Horizontal position T joint
    •     Horizontal position Lap joint  
  • Torch Brazing
    •  Demonstrate correct setup and shutdown procedures for torch brazing.
    •  Adjust gas pressure in accordance with pressure chart recommendations.
    •  Demonstrate braze welds on 16 gauge in toe following positions:
      •      Flat position bead plate
      •      Horizontal position lap joint
      •      Demonstrate braze weld on cast iron casting
  • Oxyfuel hand held cutting torch.
    •  Demonstrate correct setup and shutdown procedures.
    •  Adjust gas pressure in accordance with pressure chart recommendations.
    •  Demonstrate straight cuts in cutting plate to nominal size.
  • Oxyfuel semiautomatic track torch.
    •  Demonstrate correct setup and shutdown procedures.
    •  Adjust gas pressure in accordance with pressure chart recommendations.    
    •  Demonstrate bevel and straight cuts.        
  • Material Preparation
    • Layout material per specification.
    • Use the oxyfuel cutting process cut material to specified dimensions.
    • Grind material to using appropriate tools to meet project specifications.
    • Assemble weld project as per specification.

SMAW

  • Define common terms.
  • Identify equipment and components.
  • Demonstrate setup, machine adjustments and shut down procedures.
  • Describe the importance of welding leads and their connections and inspection techniques.
  • Identify electrodes and describe their arc characteristics, and use.
  • Explain process variables and demonstrate the effects of:
    • Current
    • Travel speed  
    • Electrode angle
    • Arc length

Welding Exercises

  • Demonstrate correct starting and stopping techniques with the 6011 and 7018 electrodes.
  • Demonstrate welds in the following positions:
    • Surfacing beads in the flat position with 6011 positions.
    • Tee joint in the horizontal position with 6011
    • Tee joint in the horizontal position with 7018
  • SMAW on Cast Iron
    • Explain need for preheat, interpass temperature and post heat.
    • Demonstrate SMAW using Ni-rod on cast iron
  • GMAW
    • Define common terms.
    • Identify equipment and components.
    • Demonstrate setup, machine adjustments and shut down procedures

Describe the importance of welding leads and their connections and inspection techniques.

  • Identify electrodes and describe their arc characteristics, and use.
  • Explain process variables and demonstrate the effects of:
    • Voltage
    • Wire feed speed (WFS)
    • Travel speed  
    • Gun angle
    • Stick out
    • Shielding Gas

Welding Exercises

  • Demonstrate correct starting and stopping techniques with short arc and spray arc.
  • Demonstrate welds in the following positions using short arc and spray arc:
    • Flat position Bead Plate with short arc
    • Horizontal position Lap Joint with short arc
    • Horizontal position T-Joint with spray arc

FCAW  

  • Define common terms.
  • Identify equipment and components.
  • Demonstrate setup, machine adjustments and shut down procedures
  • Describe the importance of welding leads and their connections and inspection techniques.
  • Identify electrodes and describe their arc characteristics, and use.
  • Explain process variables and demonstrate the effects of:
    • Voltage
    • Wire feed speed (WFS)
    • Travel speed  
    • Gun angle
    • Stick out
    • Shielding gas

Welding Exercises

  • Demonstrate correct starting and stopping techniques with FCAW.      
  • Demonstrate welds in the following positions using FCAW:
    • Flat position Bead Plate.
    • Horizontal position T-Joint

CARBON ARC CUTTING - AIR (CAC-A)

  • Demonstrate correct setup and shutdown procedures.
  • Adjust current and air pressure for size of electrode being used. 
  • Explain CAC-A electrode shapes and their uses.
  • Demonstrate the effects of the following variables: electrode angle, amperage setting, air pressure, and travel speed.
  • Demonstrate correct CAC-A gouging techniques on steel.

PLASMA ARC CUTTING (PAC)

  • Demonstrate correct setup and shutdown procedures.
  • Explain how safety interlocks function as they relate to associated tip parts
  • Adjust current and air pressure for material being cut 
  • Demonstrate the effects of the following variables:
    • Stand Off
    • Electrode angle
    • Amperage setting
    • Air pressure
    • Travel speed.
  • Demonstrate correct PAC cutting techniques on steel.