Portland Community College | Portland, Oregon

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.  

• 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.    

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.

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.