WLD101 - Fundamentals Welding Processes

Outline info
Semester
School
Last revision date 2017-09-15 11:46:02.98
Last review date 2017-09-15 11:46:02.981


Subject Title
Fundamentals Welding Processes

Subject Description
This subject is designed for individuals who are interested in welding and have little or no previous experience. Instruction is given on the correct use of Oxy Fuel Cutting and SMAW (Shielded Metal Arc Welding).

Credit Status
This is one credit toward the Canadian Welding Bureau (CWB) Welding Qualification Recognition of Achievement

Learning Outcomes
Upon successful completion of this subject the student will be able to:

  1. Demonstrate safe performance of oxy-fuel cutting and brazing.
  2. Perform SMAW welding in the flat, horizontal, vertical and overhead positions.
  3. Explain and understand the five major metal working processes (Oxy-fuel Cutting, SMAW, GMAW, GTAW, and Plasma). 

Cheating and Plagiarism
Each student should be aware of the College's policy regarding Cheating and Plagiarism. Seneca's Academic Policy will be strictly enforced.

To support academic honesty at Seneca College, all work submitted by students may be reviewed for authenticity and originality, utilizing software tools and third party services. Please visit the Academic Honesty site on http://library.senecacollege.ca for further information regarding cheating and plagiarism policies and procedures.

Discrimination/Harassment
All students and employees have the right to study and work in an environment that is free from discrimination and/or harassment. Language or activities that defeat this objective violate the College Policy on Discrimination/Harassment and shall not be tolerated. Information and assistance are available from the Student Conduct Office at student.conduct@senecacollege.ca.

Accommodation for Students with Disabilities
The College will provide reasonable accommodation to students with disabilities in order to promote academic success. If you require accommodation, contact the Counselling and Disabilities Services Office at ext. 22900 to initiate the process for documenting, assessing and implementing your individual accommodation needs.

Prerequisite(s)
 None

Topic Outline
THEORY

  • Welding in the Industry
  • Welding Processes
  • Welding Health and Safety
  • Measurement in Welding
  • Assemble/Disassemble Oxy Fuel Equipment
  • Types of Flame Adjustment
  • Fumes In Welding
  • Equipment Care and Maintenance
  • Grinders and Safety
THEORY
  • Health and Safety/WHMIS
  • Assemble and Disassemble Oxy Fuel Equipment
  • Cutting of Containers, Tanks and Piping
  • Cylinders - Care and Types
  • Equipment Care and Maintenance
PRACTICAL
  • Types of Gases
  • Oxy Fuel Cutting Project
  • Cutting Circles, Holes, and Bevels
THEORY
  • Oxy Fuel Cutting & Welding Techniques
  • Oxy Fuel Cutting Diagnosis
  • Non Fusion Welding Principles
  • Motten Flow and Heat
  • Terminology
  • Joint Design, Preparation
  • Thin Materials
PRACTICAL
  • Oxy Fuel Cutting & Fitting
  • Oxy Fuel Cutting Pipe
  • Grinding
  • Oxy Fuel Non-Fusion Welds-Brazing
PRACTICAL
  • Non Fusion Welds-Brazing on Various Joint Types and Metals
THEORY
  • Shielded Metal Arc Welding
  • Principles
  • Safety Procedures
PRACTICAL
  • SMAW: Flat Position
  • 1/4" Plate
  • Running Weld Bead
THEORY
  • Welding Fundamentals
  • Types of Machines and Polarity
  • Types of Weld Joints
  • Techniques
PRACTICAL
  • Continue Weld Bead
  • Practice Stops and Starts
  • Padding Plate
THEORY
  • Safety Precautions
  • Electrode Selection & Classification System
  • Weld Problems Flat Position
  • Controlling Distortion
PRACTICAL
  • Welding Tee Joints: 1/4" Plate
  • Multi Pass Welding
THEORY
  • Use of Various Rod  Types and Sizes
  • Low Hydrogen Rods
  • Iron Power
PRACTICAL
  • Welding with Various Electrodes
THEORY
  • Electrode Manipulation Techniques
  • Magnetism, Arc Blow and your Work Lead
  • Weaving Techniques
  • Whipping Techniques
PRACTICAL
  • Practical Welding with Various Electrodes
  • Weaving
  • Whipping
THEORY
  • SMAW Metallurgy
  • Weld Faults
  • Horizontal Welding
PRACTICAL
  • Continue Welding Tee Joints
  • Weld Bead in the Horizontal Position
THEORY
  • SMAW Testing Techniques
  • Destructive and Non-Destructive Methods
  • Stress Relieving
  • Preheating and Postheating
  • Vertical Position
  • Apprenticeship Program
  • Governing Bodies and Codes
PRACTICAL
  • SMAW Tee Joint- Horizontal and Vertical Positions
  • 1/4" Plate, 1/8" Rods
THEORY
  • Welding Fabrication
  • Hardsurfacing
  • Overhead Position
  • Safety Precautions
PRACTICAL
  • MIG & TIG Welding
  • Demo and Tryout
  • Overhead Welding (SMAW)
THEORY
  • Identifying Metals
  • Metal Fabrication
  • Summary of Processes
PRACTICAL
  • Arc Welding Various Thicknesses
  • Welding Plate to Pipe
  • Cutting with the Arc

Mode of Instruction
Students learn through classroom instruction and practice.

Prescribed Texts
Module 1 Welding Health & Safety,   Gooderham Institute (CWB)   ISBN 889-000-155-183
Blueprint Reading for Welders; Julius C. Blair; Schoolcraft Publishing ISBN 000-613-000-B

Reference Material
Shielded Metal Arc Welding Basic,  Hobart Institute of Technology  (CWB)  ISBN 0-00431-002-B

Required Supplies
CSA Approved Safety Glasses with side shields
CSA Approved Work Boots
Leather Welding Gloves

Promotion Policy

Grading Policy
A+ 90%  to  100%
A 80%  to  89%
B+ 75%  to  79%
B 70%  to  74%
C+ 65%  to  69%
C 60%  to  64%
D+ 55%  to  59%
D 50%  to  54%
F 0%    to  49% (Not a Pass)
OR
EXC Excellent
SAT Satisfactory
UNSAT Unsatisfactory

For further information, see a copy of the Academic Policy, available online (http://www.senecacollege.ca/academic-policy) or at Seneca's Registrar's Offices.


Modes of Evaluation

Assignments

  • Assignments are due at the beginning of the class on which they are due.
  • A late penalty of 10% per day is assessed for late assignments, including those not handed in at the beginning of class when due.
  • Material will not be accepted after one week following the due date and/or when the marked material is returned to students, whichever comes first.
  • Assignments are to be prepared by computer.

Absenteeism and Exams
  • Students should be aware that absenteeism almost guarantees an inability to achieve satisfactory grades.
  • Students who are absent for an examination due to an emergency (e.g., motor vehicle accident, hospitalization or death in the family) may provide official documentation within five days of the missed exam and be provided a deferred exam at a later date.  Official documentation includes a death notice or an original doctor’s certificate identifying the date, length of time expected absence and the specific reason for the absence.  Examinations missed without official documentation and approval result in a grade of zero.
  • There are no deferred options for missed tests.  The value of missed tests, at the discretion of the Faculty, will be added to other evaluation components

English Proficiency
  • All written work should demonstrate the following characteristics for clarity and conciseness:
-writing is consistent with the rules of English grammar
-spelling and punctuation are correct
-sentences are structured correctly
-main ideas are supported with specific, relevant examples and reasons
-work flows logically through supporting statements/paragraphs
-work is arranged in correct format (e.g., as a report, essay)
-up to 10% of the final grade may be deducted on all work if the above English competencies are not met.

Format for Assignments
  • Students must use the standard, APA style for quoting sources.   Help is available at:  http://library.senecacollege.ca

LAB COURSES
Laboratory Attendance

The laboratory component is essential and therefore it is strongly recommended  that you attend all labs.  Any missed labs must be supported with a legal document with three days of the lab.  Any student who fails to attend 2 scheduled laboratory classes for a 7 week subject and more than 3 laboratory classes for a 14 week subject will not pass the subject.    

Laboratory Safety
Students are required to review and understand the safety procedures and guidelines outlined on the first class and sign the sheet to this effect before beginning work in the laboratory.  Students must also wear a lab coat and safety glasses when conducting experiments.
A student who arrives without the proper safety equipment will not be permitted to participant in the lab but will be asked to leave the class.  The student will receive no grade for the lab missed.


Grading is based on the following marking scheme:
Quizzes 30%
Practical Test 40%
Final exam 30%

MINIMUM PERFORMANCE FOR GRADUATION
No student will be eligible to graduate with a Seneca College certificate or diploma if, in more than 30% of the subjects required for graduation, the student has received a "D" grade.

Other Evaluation Considerations
The student is expected to comply with the Safety Rules for working in the laboratory, sign the safety contract, and WILL NOT UNDER ANY CIRCUMSTANCES WEAR CONTACT LENSES in the laboratory.  The student will know where all safety equipment is located in the laboratory and will be familiar with WHMIS concepts and signage.

PLEASE RETAIN THIS SUBJECT OUTLINE FOR POSSIBLE FUTURE USE IN SUPPORT OF CREDIT APPLICATIONS AT OTHER EDUCATIONAL INSTITUTIONS     

Approved by: Denis Gravelle, Sharon Estok