Portland Community College | Portland, Oregon

This is an outcome-based course utilizing a lecture/lab format. This course includes classroom discussions, videos, and lab demonstrations covering technical skills. Course outcomes will include theoretical concepts, lay out, fabrication, welding and  safety.  This course is part of a program designed to meet some requirements of the Federal Aviation Administration (FAA) for certification of Aviation Mechanics. Lecture/discussion/demonstration sessions and lab projects, supported by written instructional materials, will present to the student background knowledge needed at entry level for related aviation maintenance employment, and needed to perform the written, oral, and practical tests which are required for FAA certification of Aviation Mechanics. For this course to be creditable toward the FAA authorized CERTIFICATE OF COMPLETION, the total hours recorded for the course must not be less than 90% of the hours offered during the course. Material missed by students during allowed absence will be made available to them in one or more ways, as selected by the instructor.
 

Upon successful completion of the course students should be able to:

• Function safely in the PCC Welding Shop.

• Operate oxy-fuel portable welding units and manifold system in accordance with industry standards.

• Interpret drawing and symbols to accurately lay out a project.

• Weld/braze common joints with the Oxy-fuel welding equipment.

• Weld common joints using Gas Tungsten Arc Welding.

• Demonstrate visual examination principles and practices.

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 and welding tests. Evaluation levels will be at least those defined in FAR Part 147 Appendices and in this Course Content Guide. A letter grade of “C” or higher is required for this course to be creditable toward the FAA authorized CERTIFICATE OF COMPLETION.
 

Function safely in the PCC Welding Shop. -Level 3

• 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 portable welding units and manifold system - Level 2

• Demonstrate correct setup and shutdown procedures for the portable welding tanks and manifold system

• Perform oxy-fuel welding practice

Interpret blueprints to accurately lay out, prepare, and assemble weld joints – Level 2

• Interpret lines, symbols, views and notes
• Lay out material per specifications
• Use the oxy-fuel cutting process to cut material to specified dimensions
• Assemble project per specifications

Weld/braze common joints with the with the Oxy-fuel welding process - Level 2

• Develop a working knowledge of the vocabulary used in the welding industry

• Use correct terminology

• Define terms used in the Oxy-fuel process

• Equipment identification, setup, shut down, and adjustment of equipment to settings called for in the Oxy-fuel welding process

  • Oxy-fuel hose connections, inspection, and proper use

  • Filler rod identification and classification, characteristics, and use

• Describe essential variables of tip size to regulating Oxy-fuel settings on regulators

• Demonstrate how to adjust travel speed and amount of heat for thickness of material, and weld bead size

• Demonstrate correct welding techniques with the Oxy-fuel welding process and torch brazing

  • Starting and stopping

  • Follow welding procedure
• Demonstrate correct welding techniques in the following joints:

• Flat Position:

  • Bead Plate

  • Lap Joint

  • Outside Corner Joint

• Demonstrate Braze joints

• Flat position

  • Lap joint

Weld common joints using the Gas Tungsten Arc Welding process. - Level 2

• Use correct terminology

  • Define terms used in the GTAW process

• Equipment identification, setup, shut down, and principles of operation for GTAW

  • Power source identification and adjustment

  • Electrode identification, characteristics, preparation and use

• Know essential variables, of GTAW by demonstrating the effects of the following variables: current, travel speed, torch angle, arc length, gas flow and importance of tungsten preparation.

• Demonstrate correct welding techniques with the GTAW process

  • Starting and stopping

  • Bead placement

  • Follow welding procedure

• Demonstrate correct welding techniques in the following joints

  • Flat Position:

    • Fuse weld a flat position edge joint

    • Fuse weld a flat position corner joint

    • Bead Plate

    • T-Joint (optional)

Demonstrate visual examination principles and practices - Level 3
 

Upon successful completion of this course, the student will have satisfactorily accomplished the following goals and objectives that are required by the Aviation Maintenance Technology Subject Area Committee and required by the FAA. The level designation that follows the objective is defined in the following manner by the Federal Aviation Administration:
(l) LEVEL 1 requires:
(a) Knowledge of general principles, but no practical application.
(b) No development of manipulative skill.
(c) Instruction by lecture, demonstration, and discussion.
(2) LEVEL 2 requires:
(a) Knowledge of general principles and limited practical application.
(b) Development of sufficient manipulative skill to perform basic operations.
(c) Instruction by lecture, demonstration, discussion, and limited practical application.
(3) LEVEL 3 requires:
(a) Knowledge of general principles and performance of a high degree of practical application.
(b) Development of sufficient manipulative skill to simulate return to service.
(c) Instruction by lecture, demonstration, discussion, and a high degree of practical application.
Weld magnesium and titanium. - Level 1

• The method of cleaning magnesium in preparation for welding.

• The main function of a flux while welding magnesium.

• The types of gases to use when gas-welding magnesium.

• The use of butt joints when gas-welding magnesium.

  Solder stainless steel. - Level 1

• The use of silver soldering as a method of bonding metals.

• The preparation of stainless steel for soldering.

• The methods of cleaning material after soldering.

  Fabricate tubular structures. - Level 1

• The types of tubing splices.

• The proper welding sequence to use when welding fuselage tubes.

• The characteristics of a welded tubing joint.

• The protection of the interior of tubular steel that is to be closed by welding.

• The methods used to control distortion of steel tube structures during welding repairs.

• The preparation of tube ends for welding.

  Solder, braze, gas-, and arc-weld steel (in part). - Level 2

• Use cleaning operations to prepare sheet steel for welding.

• Adjust oxyacetylene welding torch to produce the type flame needed to weld a specified material.

• Select and use filler rod.

• Describe the effect of excessive heat on metal.

• Operate a portable welding set.

• Select the correct size welding torch tip.

• The precautions regarding welding over a previously brazed or soldered joint.

• Sweat-solder a lap joint.

• Normalize a steel part after welding.

• Identify steel parts considered to be repairable by welding.

• The preheating required prior to welding.

  Weld aluminum and stainless steel. - Level 1

• Use a filler rod when welding aluminum with oxyacetylene.

• Use flux when welding aluminum.

• The purpose and effect of using inert gas to shield the arc in certain types of welding