Welding and Metal Fabrication

• Identify Personal Protective Equipment 
• Demonstrate appropriate PPE use 
• Explain the importance of SDS in the shop 
• Follow shop safety rules 
• Maintain a clean work area/shop 
• Locate Emergency shut-offs in shop 
• Explain the importance of a GFCI 
• 100% on written safety test 

• Identify classes of fires
• Locate fire extinguishers and blankets in shop
• Identify types of extinguishers
• Explain the process of extinguishing certain fires
• Obtain 100% on written safety test

• Describe procedures for dealing with various injuries.
• Explain the dangers bloodborne pathogens
• 100% on written safety test

• List 7 hazards that exist in the welding shop 
• Demonstrate precautions taken to reduce electrical hazards  
• Examine work areas for potential trip and fall hazards  
• Explain how to prevent injuries from hot objects (quench the piece, use soapstone to write HOT, perform a ½ hour cool down)  

• Research job opportunities in Welding and Metal Fabrication
• List job requirements for entry-level employment in Welding and Metal Fabrication

9.2.2 Employability Skills

• Demonstrate good attendance
• Adhering to shop rules
• Demonstrate Professionalism
  • Dress code
  • Readiness
  • Hygiene

9.3.1 Hand Tool Identification 

• Identify common hand tools 
  • Measuring/Marking Tools 
  • Slag Picks 
  • Wire Brushes 
  • Hammers, Punches, and Chisels  
  • Squares  
  • Clamps 
• Explain hand tool uses 
• Explain the advantage of using hand tools over power tools for certain tasks 

9.3.2 Safe Hand Tool Use

• Explain the importance of the appropriate tool for the job 
• Explain the dangers of using a damaged tool 
• Explain the importance of keeping tools sharp and clean 
• Sharpen an edge tool 
• Demonstrate safe use of hand tools 
• 100% on Written Safety Test 

9.4.1 Abrasive Tool Identification 

• List and explain the use of various abrasive tools: 
  • Handheld grinding machine  
  • Pedestal Grinder 
  • Cutting wheels 
  • Grinding Wheels  
  • Sanding discs  
• Identify parts and functions of common grinding machines 
• Selects proper Abrasives for specific tasks  
• Choose and use abrasive equipment Safely  

9.4.2 Abrasive Tool Safety Precautions 

• Inspect tool for safe operation 
• List safety rules that apply to Abrasive  tools 
• Demonstrate setup of proper use of abrasive tooling use 
• 100% on written and performance safety tests 

9.4.3 Abrasive Tool Operation

• Identify various Grinding wheels, discs, and sanding discs  
• Demonstrate how to safely change: 
  • Grinding Wheels  
  • Cutting Discs  
  • Sanding discs  
• Demonstrate proper setup for different operations 
• Demonstrate safe use through shop projects 

9.5.1 Principles of Shielded Metal Arc 

• Define Shielded Metal Arc Welding  

• Identify the main differences from other processes 

• Determine when it is appropriate to use Shielded Metal arc welding  

9.5.2 Equipment Setup

• List common parts associated with Shielded Metal Arc Welding   

• List safety rules that apply to Shielded Metal Arc  

• describes process for dealing with damaged equipment 

• Performs a safety ground check  

• Identify appropriate PPE required in SMAW cladding  

• Set-up work station including checking for and removing burnables in the 35 foot hotwork boundary  

• Determine appropriate amperage needed for specific task 

• Strike an arc successfully  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Produce welds with proper toe to crown weld placement  

9.6.1 Principles of Gas Metal Arc Welding

• Define Gas Metal Arc Welding  

• Identify the main differences from other processes 

• Identify when it is appropriate to use Gas Metal arc welding  

9.6.2 Equipment Setup

• List all parts associated with Gas Metal Arc Welding   

• List safety rules that apply to Gas Metal Arc Welding 

• Describe process for dealing with damaged equipment 

• Perform a safety ground check  

• Identify appropriate PPE required in SMAW cladding  

• Check for and removes burnables in the 35 foot hotwork boundary   

• Determine the appropriate amperage needed for specific task 

• Run a bead while maintaining arc distance and travel speed  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Produce welds with proper toe to crown weld placement  

9.7.1 Plasma Arc Cutting Principles 

• Describe the plasma arc cutting process 

• Contrast the differences between Plasma arc cutting and Oxy fuel cutting  

• Identify and use proper PPE for Plasma arc cutting  

9.7.2 Equipment Setup

• Describe the equipment needed to operate Plasma Arc cutting  

• Demonstrate proper identification and inspection of torch parts  

• Develop a list of cutting procedures for carbon steel depending on thickness.  

• Identify tooling needed to layout cuts  

• Properly layout lines needed to make a cut.  

• Demonstrate safe and proper cutting techniques 

• Perform 90 degree cut and restart cut in mild steel 

• Make a bevel cut on mild steel 

9.8.1 Oxy-Fuel Parts 

• List the parts that make up an oxy-fuel setup  

• Explain the functions of all the parts  

• Demonstrate knowledge of parts that make up an oxy-fuel setup  

• 100% on written safety test  

9.8.2 Oxy-Fuel Safety Precautions  

• List safe procedural storage of oxy fuel equipment 

• Demonstrate proper inspections of all parts  

• Demonstrate proper setup of oxy-fuel equipment 

• Successfully disassemble and store equipment  

9.8.3 Oxy-Fuel Set-Up

• List hazards that exist with oxy fuel equipment 

• Recognize hot work procedures for oxy fuel use 

• Identify different types of flames 

• Interpret Oxy-fuel Operating Procedures  

• Demonstrate safe setup and lighting of Oxy Fuel flames   

• Perform shut down of equipment 

• Identify tooling needed to layout cuts  

• Properly layout lines needed to make a cut.  

• Demonstrate safe and proper cutting techniques 

• Perform 90 degree cut and restart cut in mild steel 

• Make a bevel cut on mild steel 

9.9.1 Measuring

• Identifying measurements with 1/16 accuracy  

• Adding measurements (fractions) 

• Subtracting measurements (fractions) 

• Finding center (division) 

• Identify the process of calculating board footage 

• Calculate perimeter and area of regular and irregularly shaped rooms 

• Calculate the volume of a variety of shapes 

• Convert measurements (Fractions to Decimals) 

9.9.2 Welding Math

• Adding measurements (fractions) 

• Subtracting measurements (fractions) 

• Finding center (division) 

• Identify the process of calculating board footage 

• Calculate perimeter and area of regular and irregularly shaped rooms 

• Calculate the volume of a variety of shapes 

• Convert measurements (Fractions to Decimals) 

9.10.1  Construct Projects  

• Measuring 

• Layout 

• Hand Tools 

• Stationary Machines 

• Common Weld Joints 

• Project Completeness  

• Proficiency will be determined by scoring a 3 or greater on individual project/production proficiency scales in the following areas: 
  • Measuring 
  • Layout 
  • Hand Tools 
  • Cutting 
  • Common Weld Joints 
  • Project Completion 
• Demonstrate behavior expected for career employability 

• 9.10.2 Welding Portfolio

• Uploading evidence of proficiencies completing project to portfolio 

• Update the Competency Checklist 

• Shop Rules
  • Horseplay
  • Dress code
• Housekeeping
  • Material Handling and Storage
• SDS
• Emergency Shut-off
• Electrical Safety
  • GFCI

• Identify Personal Protective Equipment
• Demonstrate appropriate PPE use
• Explain the importance of SDS in the shop
• Follow shop safety rules
• Maintain a clean work area/shop
• Locate Emergency shut-offs in shop
• Explain the importance of a GFCI
• 100% on written safety test

• Identify Personal Protective Equipment 
  • Welding Helmet 
  • Gloves 
  • Jacket 
  • High Top Leather Boots 
  • Safety Glasses 
• Hearing Protection 
• Demonstrate appropriate PPE use 
• Explain uses of different shade lenses  
  • Cutting 
  • Welding 
  • General Shop Equipment 

• Classes of Fires
• Fire Triangle
• Extinguisher Use
• Fire Blankets
• Fire Alarms / Evacuations

• Identify classes of fires
• Locate fire extinguishers and blankets in shop
• Identify types of extinguishers
• Explain the process of extinguishing certain fires
• 100% on written safety test

• Injury Protocols
• AED/First Aid locations
• Eye Wash Station
• Bloodborne Pathogens

• Describe procedures for dealing with various injuries
• Explain the dangers bloodborne pathogens
• Appropriate contact person
• 100% on written safety test
   

• Complete OSHA-10 - 1910 General Industry safety training.  

• Obtain OSHA-10 - 1910 General Industry certification 

• Recall the basic PPE from flat SMAW welding 

• Evaluate the need for added PPE in out of position welding vs flat welding  

• Inspect PPE for damage  

• Use PPE properly  

• List the four basic fillet weld positions 

• Explain work angle and travel angle  

• Construct a list of of angles for each position  

10.2.3 Fillet Weld Joint Types 

• List the 3 types of fillet weld joints  

• Discuss bead planning patterns  

• Compare the differences in concave and convex weld profiles 

• Identify defects that occur for out of position welding  

10.2.4 Fillet weld performance qualification 

• Identify the material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Weld a 2F/3F/4F to requirements, ( 2F/4F-?” fillet weld minimum) (3F fillet weld- ½ minimum fillet)  

10.3.1 Information Location

• Locate page numbers and title from Title block. 

• Identify revision numbers 

• Identify proper pages. 

• Locate appropriate drawings for each task 

10.3.2 Interpreting Information

• Interpret weld symbols from drawing. 

• Preform proper welds from drawing information 

• Draft drawings to specific scale. 

• Analyze and create from Blueprints. 

• Interpret prints to direct others. 

10.4.1 Plasma Track Burner

• Identify parts of a track cart 

• Select proper travel speeds for material thickness 

• Set proper air pressure for material 

• Explain the reason for proper bevel 

• Identify the proper parts to obtain accurate bevel 

• Evaluate cut quality 

• Explain gas use for different metals 

• Modify equipment for gouging and angle cuts. 

• Test for proper outcomes with different metal and gas combinations. 

• Choose proper feeds for cutting 

• Create different bevels for weld fit-up 

• Improve cut surface for welding 

10.5.1 GMAW Equipment

• Identify steps for setting up equipment 

• Select different processes 

• Interpret erratic arc 

10.5.2. T-joint Angles

• Explain what is a fillet weld. 

• Identify proper bead discontinuities. 

• Inspect weld beads for correct angles 

10.5.3 Out of position welding (GMAW)

• Explain best practices for out of position welding. 

• Discuss ways to minimize weld defects 

• Identify solution for erratic welding arc (high level) 

10.6.1 Oxy-Fuel Setup

• Demonstrate proper setup of equipment for safe operation. 

• Safely demonstrate torch operation 

• Evaluate kerf pattern to obtain acceptable cut 

• 100% on written safety for handling of Oxy acetylene gasses and equipment 

10.6.2 Oxy-Fuel Beveling

• Using torch manually cut Clean Bevel at 22.5 degrees 

• Perform a manual 45 degree bevel 

10.6.3 Oxy-Fuel Piercing 

• Preform proper torch pierce in material 

• Cut hole to proper size 

• Cope and notch material for proper fit of angle iron 

10.7.1 Setup of Welding 

• Set up a welding machine in a booth properly 

• Identify quality ground location 

• Identify proper polarity for weld process 

10.7.2 Electric Principals

• Explain how current flows 

• Describe amperage in welding 

• Explain resistance in welding 

• Explain Direct current (DCEP, DCEN) 

• Explain alternating Current (AC) 

• Adding Measurements(fractions) 

• Subtracting fractions(fractions) 

• Calculate material length 

• Calculate area of shapes 

• Find center(Division) 

• Check accuracy of wire feeder 

• Identify lines of drawerings 

• Hidden 

• Center 

• Edge 

• Create rough sketch of Project with measurements 

• Demonstrate proper layout of shop projects 

• Analyze layout for errors 

• Layout steel for minimal waste 

• Name the purpose of a welding procedure specification  

• List information found on a Welding Procedure Specification  

• Setup a machine per the requirements of a welding procedure  

• Explain Preheat and Interpass temperature  

• Demonstrate preheat 

• Measure interpass temperature  

• Identify the Joules formula 

• Demonstrate knowledge of multiplication and division 

• Perform calculations on weldments ½” thick or less.  

10.10.1  Construct Projects  

• Measuring 

• Layout 

• Hand Tools 

• Stationary Machines 

• Common Weld Joints 

• Project Completeness  

• Proficiency will be determined by scoring a 3 or greater on individual project/production proficiency scales in the following areas: 

  • Measuring 

  • Layout 

  • Hand Tools 

  • Cutting 

  • Common Weld Joints 

  • Project Completion 

• Demonstrate behavior expected for career employability 

• Uploading evidence of proficiencies completing project to portfolio 

• Update the Competency Checklist 

11.1.1    Review of safe work habits: 

• Hand Tools  
• Personal Safety 
• Job-Site Safety 
• SDS 
• Other 

• Demonstrate safe practices. 
• Evaluate construction site work areas for potential hazards. 
• Explain the consequences of unsafe working conditions in construction. 
• Demonstrate the safe handling of hand tools. 
• Advocate for your personal safety. 
• Score 100% on the written Safety Test and hands-on assessment as new tools and equipment are introduced. 

11.1.2    Review of Fire Safety Procedures 

Locate: 

• Fire alarms 
• Fire extinguishers 
• Eye wash stations 
• Power shut offs 
• Fire exits 
• Hot work
• Other 

• Locate fire alarms, fire extinguishers, eye wash stations, and power shut-offs. 

• Identify types of fires. 

• Describe the fire triangle. 

• Explain the protocol for extinguishing fires. 

• Score 100% on the written safety test. 

• Identify appropriate practices for administering first aid. 
• Explain the procedures for dealing with various injuries on outside production. 
• Explain the dangers of blood borne pathogens. 

11.1.4     Personal Protective Equipment  

• Hard hat 
• Safety glasses 
• Hearing protection 
• Respirators/Dust Masks 
• Safety shoes 
• Gloves 
• Other 

• Identify common types of PPE 
• Select appropriate PPE 
• Demonstrate appropriate use of PPE 

11.1.5   Ladder and Scaffold Safety 

• Step ladders 
• Extension ladders 
• Pipe staging 
• Ladder jacks 
• Other  

• Identify common types of ladders and scaffolds. 
• Inspect equipment for damage or defects. 
• Set-up ladders and scaffolding in the school setting and on the job site safely. 
• Appropriately utilize safe practices while using equipment. 
• 100% on written and performance safety tests. 

11.1.6 Fall Protection Systems 

• Personal fall arrest system 
  • Connector 
  • 5-point harness 
  • Anchor Point 
• Guard rails  
• Safety nets 

• Identify components of each fall protection system. 
• Describe the process of setting up fall protection systems. 
• Setup and use a personal fall arrest system. 

• Identify safe lifting practices. 
• Demonstrate safe lifting practices.  

11.2.1 P.P.E. For SMAW  

• Describe a variety P.P.E. for SMAW 

• Demonstrate the use of P.P.E. appropriately for the given tasks 

11.2.2 Common Groove Weld Types

• List 4 groove joints 

• Discuss the reason for an open root vs. closed root 

• Sketch weld a symbol for each of the 4 groove joints listed. 

• Select one weld joint to build  

• Construct the weld joint as a shop project 

• Define when a multi pass groove weld would be necessary 

• Explain why it's critical to place weld beads in the correct pattern in a multi pass groove weld. 

• Sketch a numbered bead pattern layout for a 20 pass single V-groove weld. 

• Discuss the importance of bead planning 

• Evaluate a multi-pass groove weld that was not welded in the correct order 

• Construct a multi-pass groove weld with proper bead placement 

11.2.4 SMAW Groove Weld Certifications

• State 2 common groove weld tests 

• Describe why a welder would benefit from being certified 

• Interpret the reason for different thicknesses of testing materials 

• Compare the qualities of the 2 weld tests 

• Complete D1.1 single V groove weld test 

11.3.1 Hand Tools

• Identify common welding shop hand tools and describe their purpose or function: 
  • Wrenches 
  • Saws 
  • Files 
  • Hand taps/dies (threading) 
  • Hammers 
  • Clamps 
  • Vises 
  • Pliers 
  • Screwdrivers 

11.3.2 Hand Tool Use and Care

• Select the appropriate hand tool for a specific application  

• Demonstrate the proper safe use and care of each hand tool during a performance assessment 

• Identify common shop power tools and describe their purpose or function: 
  • Drills 
  • Saws 
  • Grinders/Sanders 
  • Metal Forming tools 

11.3.4 Power Tool Use and Care

• Select the appropriate power tool for a specific application  

• Demonstrate the proper safe use and care of each power tool during a performance assessment 

11.3.5 Welding Equipment 

• Identify common shop Equipment and describe their purpose or function: 
  • Drill Press 
  • Bandsaws 
  • Grinders/Sanders 
  • Benders 
  • Ironworkers 
  • Shears 
  • Lifting and moving  
• Demonstrate the proper safe use and care of each piece of welding equipment during a performance assessment. 

• Utilize square and leveling tools properly 

• Identify angles and degrees properly 

• Measure to a 1/16th of an inch 

11.4.1 GMAW Equipment

• Identify steps for setting up equipment 

• Select the appropriate process for a specific job.  

• Interpret erratic arc 
   

11.4.2 T-joint Angles

• Identify what is a fillet weld. 

• Identify proper bead discontinuities. 

• Inspect weld beads for correct angles 

• Identify best practices for out of position welding. 

• Discuss ways to minimize weld defects 

• Evaluate solutions for erratic welding arc 

11.5.1 Safety Procedures

• List the safety items needed for welding  

• Perform inspections on all parts of equipment 

• Gather all necessary safety gear needed 

11.5.2 Basic Tools Needed

• List tools needed(temp sticks, slag pick, wire brush, ect.)  

• Gather tools required 

• Inspect tools for damage  

11.5.3 Material

• Identify factors of material cleanliness  

• Prepare metal to acceptable standards  

• Ensure material being welded is the correct material  

• Ensure all pieces are per the drawing specification  

11.5.4 Weld Machine Settings

• Research the procedure for weld machine settings 

• Set  the machine to the appropriate weld mode 

• Adjust machine accordingly for voltage  

11.6.1 The Principles of Gas Tungsten Arc Welding 

• Define Gas Tungsten Arc Welding 

• Identify the main differences from other processes.  

• Determine where Gas Tungsten Arc Welding is used the most in industry and why  

11.6.2 Equipment Setup

• List all parts associated with Gas Tungsten Arc Welding   

• List safety rules that apply to Gas Tungsten Arc Welding  

• Make minor repairs if needed or tells the instructor of deficient conditions  

• Perform a safety ground check  

11.6.3 Equipment Use

• List all PPE required while using this process  

• Sharpen Tungsten properly  

• Use correct collet for tungsten 

• Set Gas to the appropriate setting  

• determines appropriate amperage needed for specific task 

• Perform a success bead without the use of wire maintaining a consistent weld bead 

• Produce welds with proper toe to crown weld placement  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Produce welds with proper toe to crown weld placement before testing 

11.7.1 Material Classification

• Identify the differences between pipes and tubes during a performance assessment 

• Identify sizes and classification of pipe and tubular metals 

11.7.2 Process Positions

• Identify the positions for both groove and fillet welds on a written assessment 

• Explain the different groove positions for pipe welding 

• Demonstrate the technique used  for uphill and downhill welding on a practical assessment 

• Weld an open root pipe joint using 6010 electrodes in the 2g position 

• Weld a closed root pipe joint using 7018 electrodes in the 2g position 

• Weld an open root pipe joint using the GTAW process in the 1g rotated position 

• Weld an open root pipe joint using the GTAW process in the 2g position 

• Weld an open root pipe joint using the GMAW process in the 1G and 2G position 

11.8.1 Equipment and Accessories Used in FCAW

• Perform safety inspections of FCAW equipment and accessories 

• Make minor external repairs to FCAW

• Identify all of the parts of an arc welding outfit and its functions 

• Describe potential electrical hazards 

• 100% on written safety test 

11.8.3 Voltage and Wire Speed Settings

• Describe voltage and wire speed settings 

• Proper set up of a FCAW machine relative to the material being welded 

• Demonstration of knowledge with both a written and hands on assessment 

• Perform safety inspections of FCAW equipment and accessories 

• Make minor external repairs to FCAW equipment and accessories 

• Set up for FCAW operations on carbon steel 

• Operate FCAW equipment on carbon steel 

• Make fillet weld in all positions on carbon steel 

• Make groove welds, in all positions, on carbon steel 

• Recall the basic PPE from flat GMAW welding 

• Contrast the need for added PPE in out of position welding vs flat welding  

• Evaluate PPE for damage  

• Wear PPE correctly  

• List the four basic groove weld positions 

• Explain work angle and travel angle  

• Construct a list of angles for each position  

• List the different types of groove joint configurations  

• Discuss bead planning patterns  

• Compare concave and convex welds 

• Discuss the defects that occur for out of position welding  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Performs a success weld, 1G/2G to requirements to AWS standards  

11.9.1 Reasons for Testing

• Define weld flaws and weld defects  

• List criteria used in testing  

• Determine the code that governs the standards being upheld  

• Distinguish acceptable and rejectable defects  

11.9.2 Types of Nondestructive Tests 

• List the major testing types 

• Describe surface flaw and internal flaw 

• Compare testing types with flaws they detect.  

• Formulate a conclusion the importance of testing  

• Determine what type of testing is to be performed  

• Make a list of flaws you are looking for 

• Gather equipment needed (fillet gauge, undercut gauge, measuring device, lighting)  

• Perform a visual inspection on a T weld 

11.10.1 Construct Projects  

• Measuring 
• Layout 
• Hand Tools 
• Stationary Machines 
• Common Weld Joints 
• Project Completeness  

• Proficiency will be determined by scoring a 3 or greater on individual project/production proficiency scales in the following areas: 
  • Measuring 
  • Layout 
  • Hand Tools 
  • Cutting 
  • Common Weld Joints 
  • Project Completion 
• Demonstrate behavior expected for career employability 

11.10.2  Welding Portfolio

• Uploading evidence of proficiencies completing project to portfolio 

• Update the Competency Checklist 

12.1.1 Hazard Identification

• Model safe practices 
• Describe potential safety risks of: 
  • Crush points 
  • Pinch points 
  • Burns 
  • Eye injuries 
  • Electrocution 
  • Entanglements 
  • Welding Fumes/Respiratory injuries     
  • Lifting injuries 
  • Compressed Gasses 
• Demonstrate knowledge of proper personal protective equipment 
• Prepare a list of safety rules for welding shop 
• Proper storage of gas cylinders 
• 100% on written safety test 

12.1.2 Safety Data Sheets

• Identify Safety Data Sheets layout and format 

• Locate the Safety Data Sheets in welding shop 

• 100% on written safety test 

• 100% on written safety test 
• Demonstrate proper ‘hot zone’ operation 
• Locate: 
  • Fire alarms 
  • Fire extinguishers 
  • Eye wash stations 
  • Power shut offs 
  • Fire exits 

12.1.4 Personal Protective Equipment

• 100% on safety test 
• Wear appropriate safety clothing and equipment: 
  • Eye Protection 
  • Welding Helmet 
  • Jacket 
  • Gloves 
  • Safety Shoes 
• Select proper lens shade for specific welding and cutting operations 
• Describe dangers of arc flash and damage ultraviolet rays can do to the eyes

12.2.1 Hand Tool Identification

• Identify common welding shop hand tools and describe their purpose or function: 
  • Wrenches 
  • Saws 
  • Files 
  • Hand taps/dies (threading) 
  • Hammers 
  • Clamps 
  • Vises 
  • Pliers 
  • Screwdrivers 

12.2.2 Hand Tool Use

• Select the appropriate hand tool for a specific application  

• Demonstrate the proper safe use and care of each hand tool during a performance assessment 

• Identify common shop power tools and describe their purpose or function: 
  • Drills 
  • Saws 
  • Grinders/Sanders 
  • Metal Forming tools 

12.2.4 Power Tool Use

• Select the appropriate power tool for a specific application  

• Demonstrate the proper safe use and care of each power tool during a performance assessment 

12.2.5 Angle Grinders

• Demonstrate ability to change wheels on an angle grinder safely 

• Demonstrate proper use of an angle grinder 

• Utilize proper angle grinder maintenance  

• Use grinder properly for weld preparation and to remove mill scale 

• Make a cut safely with  a cut off wheel 

• Remove a weld properly using hard discs and flap discs 

• Identify common shop Equipment and describe their purpose or function: 
  • Drill Press 
  • Bandsaws 
  • Grinders/Sanders 
  • Benders 
  • Ironworkers 
  • Shears 
  • Lifting and moving 

12.3.1 Views and Isometric Drawings

• List the names of the views used in orthographic projection 

• Describe characteristics of an isometric drawing 

12.3.2 The ANSI-AWS Welding Symbols

• Identify basic types of welds indicated on the ANSI/AWS weld symbol 

• Know arrow side and other side 

12.3.3 Weld sizes and other information

• Locate information on the weld symbol to determine: 
  • Size of root opening 
  • The groove angle 
  • Desired size 
  • Contour 
  • Finish of the weld 

12.3.4 Measuring

• Adding Measurements(fractions) 

• Subtracting fractions(fractions) 

• Calculate material length 

• Calculate area of shapes 

• Find center(Division) 

• Check accuracy of wire feeder 

12.3.5 Layout

• Demonstrate proper layout of shop projects 

• Analyze layout for errors 

12.4.1 Equipment and Accessories

• Perform safety inspections of SMAW equipment and accessories 

• Perform minor external repairs to SMAW equipment and accessories 

12.4.2 PPE and Hazard Identification

• Identify all of the parts of an arc welding outfit and its functions 

• Describe potential electrical hazards 

• 100% on written safety test 

• Identify polarities and how they work within a welding circuit, shown with both a written and hands on assessment 

• Perform safety inspections of SMAW equipment and accessories 

• Makes minor external repairs to SMAW equipment and accessories 

• Sets up for SMAW operations on carbon steel 

• Operates SMAW equipment on carbon steel 

• Makes fillet weld in all positions on carbon steel 

• Makes groove welds, in all positions, on carbon steel 

• Passes SMAW welder performance qualification test 

• Recall the basic PPE from flat SMAW welding 

• Contrast the need for added PPE in out of position welding vs flat welding  

• Evaluate PPE for damage  

• Wear PPE correctly  

• List the four basic groove weld positions 

• Explain work angle and travel angle  

• Construct a list of angles for each position  

• List the different types of groove joint configurations  

• Discuss bead planning patterns  

• Compare concave and convex welds 

• Discuss the defects that occur for out of position welding  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Weld a 1G/2G/3G/4G to requirements to AWS standards  

12.5.1 Equipment and Accessories Used in GMAW

• Perform safety inspections of GMAW equipment and accessories 

• Make minor external repairs to GMAW equipment and accessories 

12.5.2 Components of an arc welding outfit and potential hazards

• Identify all of the parts of an arc welding outfit and its functions 

• Describe potential electrical hazards 

• 100% on written safety test 

• Describe voltage and wire speed settings 

• Proper set up of a GMAW machine relative to the material being welded 

• Demonstration of knowledge with both a written and hands on assessment 

• Perform safety inspections of GMAW equipment and accessories 

• Make minor external repairs to GMAW equipment and accessories 

• Set up for GMAW operations on carbon steel 

• Operate GMAW equipment on carbon steel 

• Make fillet weld in all positions on carbon steel 

• Make groove welds, in all positions, on carbon steel 

• Pass AWS GMAW Welder Qualification Tests in the 2F/1G/2G/3G/4G positions 

• Recall the basic PPE from flat SMAW welding 

• Contrast the need for added PPE in out of position welding vs flat welding  

• Evaluate PPE for damage  

• Wear PPE correctly  

• List the four basic groove weld positions 

• Explain work angle and travel angle  

• Construct a list of angles for each position  

• List the different types of groove joint configurations  

• Discuss bead planning patterns  

• Compare concave and convex welds 

• Discuss the defects that occur for out of position welding  

• Identify material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepare carbon steel for welding 

• Successfully weld a 1G/2G/3G/4G to requirements to AWS standards  

12.6.1 Equipment and Supplies

• Perform safety inspections of GTAW equipment and accessories 

• Make minor external repairs GTAW equipment and accessories 

12.6.2 Principles of GTAW

• Set up for GTAW operations on carbon steel 

• Operate GTAW equipment on carbon steel 

• Make fillet weld in all positions on carbon steel 

• Make groove welds, in all positions, on carbon steel 

• Pass GTAW welder performance qualification test 

• Identify the parts of a GTAW torch 

• Operate assembly and break down of a GTAW torch 

12.6.4 Safety Inspections and Precautions 

• Identify visible issues with GTAW machinery 

• Make minor repairs to GTAW equipment and accessories 

12.6.5 Use of GTAW Equipment 

• List all PPE required while using this process  

• Sharpens Tungsten properly  

• Uses correct collet for tungsten 

• Set Gas to the appropriate setting  

• determines appropriate amperage needed for specific task 

• Perform a successful bead without the use of wire maintaining a consistent weld bead 

• Produces welds with proper toe to crown weld placement  

• Identify material needed for testing 

• Prepare carbon steel for welding 

• Produce welds with proper bead size, appearance and weld placement before testing 

• Perform GTAW fillet welds in the 1F and 2F positions according to AWS standards 

12.7.1 PAC Safety Precautions

• Demonstrate proper setup of PAC equipment 

• Identify proper PPE used with  PAC 

• Describe potential electrical hazards with PAC 

12.7.2 PAC Equipment Set-Up 

• Demonstrate proper setup of PAC equipment 

12.7.3 PAC Process

• Demonstrate safe and proper cutting techniques 

• Perform 90 degree cut and restart cut in mild steel 

• Make a bevel cut on mild steel 

• Layout pattern and cut to specifications 

12.7.4 OFC equipment and supplies

• Identify the parts of a OFC setup 

• Replace consumables on a OFC torch 

• Demonstrate safe and proper cutting techniques 

• Perform 90 degree cut and restart cut in mild steel 

• Make a bevel cut on mild steel 

• Layout pattern and cut to specifications 

12.8.1 Material Classification

• Identify the differences between pipes and tubes during a performance assessment 

• Identify sizes and classification of pipe and tubular metals 

12.8.2 Pipe Welding Positions

• Identify the positions for both groove and fillet welds on a written assessment 

• Explain the different groove positions for pipe welding 

12.8.3 Pipe Welding Techniques 

• Uphill  

• Downhill 

• Demonstrate the technique used for uphill and downhill welding on a practical assessment 

12.8.4 SMAW Pipe Welding 

• Weld an open root pipe joint using 6010 electrodes in the 2g position 

• Weld a closed root pipe joint using 7018 electrodes in the 2g position 

• Weld filler passes and cover pass using 7018 in the 5g position 

• Weld an open root pipe joint using the GTAW process in the 1g rotated position 

• Weld an open root pipe joint using the GTAW process in the 2g position 

• Weld an open root pipe joint using the GTAW process in the 5g position 

• Weld an open root pipe joint using the GMAW process in the 1G and 2G position 

• Weld an open root pipe joint using the GMAW process in the 5G and 6G position 

12.9.1 Importance of Passing Welder Certification 

• Define what welder certification is  

• Explain how certification is important to welding 

• Demonstrate knowledge of the certification process  

• Develop a list of skills needed to successfully pass certification  

12.9.2 Advanced Welding Procedures

• Recall the steps from 10.9.1 

• Gather temp sticks for preheat and interpass  

• Set up machine in accordance with the welding procedure 

• Calculate Joules formula  

12.9.3 Performance needed to pass a certification 

• Have a prior successful performance of  10.5 Gas Metal arc Fillet Welds  

• Have a prior successful performance 11.4 Gas Metal arc Groove Welds  

• Knowledge of the 3G position 

• Prepare steel  for qualification test 

• Fitup test to testing tolerances 

• Perform welding in accordance to procedure  

• Successfully pass 3G qualification bend test  

• List methods of destructive testing  

• Define vocabulary used in destructive testing 

• Compare the types of destructive testing methods 

• Recall the procedure of 9.4 Introduction to Abrasive Equipment

• Demonstrate proper PPE and hot work requirements 

• Layout specimens for a guided bend test 

• Cut pieces per layout on the bandsaw 

• Identify face a root pieces 

• Perform a bend test  

• Perform a final visual examination 

• Define weld flaws and weld defects  

• List criteria used in testing  

• Determine the code that governs the standards being upheld  

• Distinguish acceptable and rejectable defects  

• List the major testing types 

• Describe surface flaw and internal flaw 

• Compare testing types with flaws they detect.  

• Formulate a conclusion the importance of testing  

• Determine what type of testing is to be performed  

• Make a list of flaws you are looking for 

• Gather equipment needed (fillet gauge, undercut gauge, measuring device, lighting)  

• Perform a visual inspection on a T weld  

12.10.1 Principles of Gas Metal Arc Welding Spray

• Define Gas Metal Arc Welding  

• Identify the main differences from other processes 

• Describe when it is appropriate to use Gas Metal Arc Spray Welding  

• Select the two positions Spray welding can be performed in 

12.10.2 Equipment Setup

• Lists all parts associated with Gas Metal Arc Spray Welding   

• Performs safety inspection of all equipment and accessories 

•  Makes minor repairs if needed or tells the instructor of deficient conditions  

• Performs a safety ground check  

• Identifies appropriate PPE required in this process  

• Identifies the hot work boundaries   

• determines appropriate amperage needed for specific task 

• Runs a bead in the Flat position while maintaining arc distance and travel speed  

• Identifies material needed for testing 

• Interpret the requirements of testing procedure (Amperage, wire feed, preheat) 

• Prepares carbon steel for welding 

• Can successfully produce proper toe to crown placement before testing.  

12.11.1 Construct Projects  

• Measuring 

• Layout 

• Hand Tools 

• Stationary Machines 

• Common Weld Joints 

• Project Completeness  

• Proficiency will be determined by scoring a 3 or greater on individual project/production proficiency scales in the following areas: 
  • Measuring 
  • Layout 
  • Hand Tools 
  • Cutting 
  • Common Weld Joints 
  • Project Completion 
• Demonstrate behavior expected for career employability 

12.11.2 Welding Portfolio  

• Uploading evidence of proficiencies completing project to portfolio 

• Update the Competency Checklist