Portland Community College | Portland, Oregon

Course Number:
WLD 217
Course Title:
Diesel Welding
Credit Hours:
3
Lecture Hours:
0
Lecture/Lab Hours:
60
Lab Hours:
0
Special Fee:
$18.00

Course Description

Develops knowledge and skills in welding required of a diesel mechanic. Focuses on maintenance and repair applications using FCAW, GMAW, SMAW, CAC-A, OAW, TB, PAC and OAC processes. Prerequisites: 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, videotapes, and lab demonstrations of technical skills.  Course outcomes will include: theoretical concepts, layout, fabrication, welding, oxy-fuel cutting and safety. 

Intended Outcomes for the course

Upon completion of the course students should be able to:

  • Function safely in the PCC Welding lab.
  • Operate oxy-fuel welding and cutting systems in accordance to industry standards.
  • Operate a Plasma Arc Cutting (PAC) hand held system in accordance to industry standards.
  • Operate a Carbon Arc Cutting - Air (CAC-A) system in accordance to industry standards.
  • Weld common joints using SMAW, GMAW, FCAW processes to industry standards.
  • Apply visual examination principles and practices in accordance to industry standards

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 and welding tests.

Course Content (Themes, Concepts, Issues and Skills)

Function safely in the PCC Welding lab.

  • Understand and practice personal safety by using proper protective gear
  • Understand and practice power tool safety
  • Understand and practice equipment safety for welding and oxy-fuel cutting systems
  • Understand and maintain a safe work area
    • Recognize and report dangerous electrical and air/gas hose connections
    • Understand and practice fire prevention

Operate oxy-fuel welding and cutting systems in accordance to industry standards.

  • Demonstrate correct setup and shutdown procedures
  • Adjust gas pressures in accordance with pressure chart recommendations.
  • Demonstrate welds on 16 gauge mild steel 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 pressures in accordance with pressure chart recommendations.
    •  Demonstrate braze welds on 16 gauge mild steel in the following positions:
      •      Flat position bead plate
      •      Horizontal position lap joint
      •      Braze weld on cast iron
  • Oxy-fuel hand held cutting torch
    •  Demonstrate correct setup and shutdown procedures
    •  Adjust gas pressures in accordance with pressure chart recommendations
    •  Demonstrate straight cuts in cutting plate to nominal size
  • Oxy-fuel semiautomatic track torch
    •  Demonstrate correct setup and shutdown procedures
    •  Adjust gas pressures in accordance with pressure chart recommendations    
    •  Demonstrate bevel and straight cuts        

Operate a Plasma Arc Cutting (PAC) hand held system in accordance to industry standards.

  • 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
    • Torch angle
    • Amperage setting
    • Air pressure
    • Travel speed.
  • Demonstrate correct PAC cutting techniques on steel 

Operate an Carbon Arc Cutting - Air (CAC-A) system in accordance to industry standards.

  • 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

Weld common joints using SMAW, GMAW, FCAW processes to industry standards.

  • 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
  • Demonstrate correct starting and stopping techniques with E7018 electrodes
  • Demonstrate welds in the following positions:
    • Surfacing beads in the flat position with E7018
    • Tee joint in the horizontal position with E7018
  • SMAW on Cast Iron
    • Explain need for preheat, inter pass 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
  • Demonstrate correct starting and stopping techniques with short arc
  • Demonstrate welds in the following positions using GMAW short arc:
    • Flat position Bead Plate with short arc
    • Horizontal position Lap Joint with short arc
    • Horizontal position T-Joint with spray arc
  • Demonstrate correct starting and stopping techniques with FCAW     
  • Demonstrate welds in the following positions using FCAW:
    • Flat position Bead Plate.
    • Horizontal position T-Joint

Apply visual examination principles and practices in accordance to industry standards.

  • Evaluate welds using appropriate welding inspection tools
  • Assess weld discontinuities causes and corrections