Portland Community College | Portland, Oregon

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This is a competency-based course utilizing a lecture/lab format. This course includes classroom discussions, video tapes, and lab demonstrations covering technical skills. Course competencies will include; theoretical concepts, layout, fabrication, welding, oxyfuel cutting, safety and environmental awareness, communication, applied Math and Science and human relations.

At the beginning of the course, the course syllabus will identify the methods used to evaluate student progress and the criteria for assigning a course grade. The student will be evaluated on his/her ability to demonstrate the development of course competencies. The methods of evaluation may include one or more of the following: oral or written examinations, quizzes, written assignments, welding tests, safe work habits, task performance, and work relations.

SAFETY AND ENVIRONMENTAL AWARENESS COMPETENCIES

Student will understand and practice personal safety

• Understand the importance of personal health and fitness
• Use proper protective gear
• Understand situation awareness
• Use correct manual lifting techniques

Student will understand and practice tool safety

• Use hand tool safely
• Use power tool safely

Student will understand and practice equipment safety

• Demonstrate safety procedures required in the use of a welding machines and cutting systems.

Student will understand and maintain a safe work area.

• Maintain a clean and clutter free floor
• Understand the importance of adequate lighting 
• Recognize objects that might fall
• Recognize and report dangerous electrical and air/gas hose connections
• Understand the importance of space management in regards to safety
• Understand and practice fire prevention

Student will understand aspects of the welding industry that effect the environment (environmental awareness)

• Identify hazardous materials
• Identify the purpose of a Material Safety Data Sheets (MSDS) and where MSDS sheets are kept.
• Understand the effects of hazardous materials and welding fumes on the atmosphere
• Understand correct procedures when working in or around containers or vessels

GMAW/FCAW COMPETENCIES

Use correct terminology.

• Define terms used in the GMAW/FCAW processes.

Equipment identification, setup, shut down, and principles of operation for GMAW/FCAW.

• Power source and wire feeder identification and adjustment.
• Welding lead, regulator/flow meter, connections, inspection, and use.
• Electrode identification, characteristics, and use.
• Shielding gas identification, characteristics, and use.

Know essential variables of GMAW/FCAW.

• Demonstrate the effects of the following variables: voltage, wire feed speed, travel speed electrode angle, electrode extension, and shielding gas.

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.

Welding Exercises

• Demonstrate correct starting and stopping techniques.
• Given a schematic diagram with welding specifications, perform the following welding projects.
• Demonstrate correct welding techniques for tee joints in the vertical and overhead.
• Demonstrate correct welding techniques in butt joints in the horizontal, vertical and overhead position.

QUALIFICATION PROCEDURES/CODE REQUIREMENTS COMPETENCIES

Use correct terminology.

• Define terms used in welder qualification/certification.
• Identify weld defects.
• Identify defect causes and corrective measures.

Know code requirements.

• Interpret code for allowable limits of discontinuities.
• Examine weld profiles to determine acceptability.

Understand Certification Procedures.

• Explain test coupon preparation.
• Follow preheat requirements.
• Adhere to "hold points".

Evaluate weld.

• Examine shop test to determine acceptability.
• Complete bend test to determine acceptability.
• Confirm acceptability with instructor.

OXYGEN FUEL GAS CUTTING COMPETENCIES

Oxyfuel hand held cutting torch

• Demonstrate correct set-up shut-down 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 set-up and shut-down procedures.
• Adjust gas pressure in accordance with pressure chart recommendations.
• Demonstrate bevel and straight cuts.

GRINDING COMPETENCIES

Pedestal Grinders and Portable Hand Grinders

• Identify the major components of the grinders.
• Explain safe operational procedures for the grinders.
• Demonstrate the safe operation of the grinders.

HORIZONTAL BAND SAW COMPETENCIES

Horizontal Band Saw

• Identify major components of the saw.
• Explain safe operational procedures for the saw.
• Demonstrate the safe operation of the saw. 

 Apply math and science concepts to the welding related process 

Math Science

• Measuring with fractions
• Reducing common fractions
• Expressing common fractions in higher terms
• Ability to read a tape measure 

• GMAW/FCAW welding with various welding electrodes.
• As-Deposited Composition of various wire welding electrodes.
• Mechanical Properties of various wire and stick welding electrodes
• Operating Range for GMAW/FCAW
• Fluxes for FCAW Electrode
• Impact Toughness of FCAW/GMAW Weld Metal
• Arc Stability and Slag Removal
• Arc Length for FCAW/GMAW
• Possibility of Hydrogen-Assisted Cracking with wire weld metals
• Significance of the Volt-Ampere Curve for FCAW
• Duty Cycle Calculation

HUMAN RELATION COMPETENCIES

Student will develop team work skills.

• Work constructively in teams.
• Share equal responsibilities and duties within a team.
• Develop team tactics in problem solving

Student will interact productively with co-workers.

• Work constructively with a partner.

Students will interact productively with supervisors

• Follow directions in a positive manner.
• Relay relative information back to the instructor for further direction.

PERSONAL MANAGEMENT COMPETENCIES

Students will utilize time productively.

• Track training hours on time cards.
• Allocate time to complete all assignments.
• Be prepared for class
• Be personally responsible for attendance.

Student will maintain clean and orderly work stations and shop area.

• Keep assigned station clean and clutter free
• Participate in general shop clean up
• Inspect lab area for cleanliness
• Keep all tools and equipment clean

Student will demonstrate pride in workmanship

• Perform projects in accordance to specifications and procedures
• Use all tools and equipment correctly

COMMUNICATION COMPETENCIES

Student will develop working knowledge of the vocabulary and symbols used in the welding industry.

• Demonstrate spelling skills with emphasis on industry vocabulary.
• Use correct vocabulary terms
• Identify common welding symbols

Student will develop technical writing skills

• Prepare welding procedure specification form.

Student will develop verbal communication skills>

• Participate in classroom discussions
• Formulate questions