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,  oxy-fuel cutting and safety.  Historical and contemporary imagery and process will be introduced through slide/lecture presentations, films, sketchbook and research assignments will support the three-dimensional projects.  Three projects completed during the term will address sculptural form.  Projects will be concluded with a class critique/review process.Due to the substantive lecture/discussion, research and homework components of this course, it will meet the General Education Policy requirements.

• Function safely in the PCC Welding Lab
• Demonstrate professional work ethics ( habits )
• Apply math and science concepts related to the welding processes
• Operate oxy-fuel portable and track cutting systems
• Demonstrate OAW techniques
• Demonstrate SMAW techniques
• Safely operate grinding equipment
• Demonstrate GMAW techniques
• Demonstrate GTAW techniques
• Demonstrate PAC techniques
• Complete three sculptures

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 and  task performance.

• Students will understand and practice personal safety
  • Use proper protective gear
  • Understand situation awareness
  • Use correct manual lifting techniques
  • Students will understand and practice tool safety
  • Use hand tools safely
  • Use power tools safely
• Students will understand and practice equipment safety
• Demonstrate safety procedures required in the use of welding machines and cutting systems.

• 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 the importance of space management in regards to safety
  • Practice fire prevention techniques
• Students will understand aspects of the welding industry that effect the environment
  • 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

OAW ( Oxy -Acetylene Welding ) and OAC ( Oxy-Acetylene Cutting )

• Demonstrate correct setup and shutdown procedures. for the Oxy-fuel welding torch.
• 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

Oxy-fuel cutting

• Demonstrate correct setup and shutdown procedures.
• Adjust gas pressure in accordance with pressure chart recommendations.
• Demonstrate straight cuts in cutting plate to nominal size.

SHIELDED METAL ARC WELDING

• Identify major components of the SMAW machines
• Demonstrate how to set controls on a constant current power source
• Demonstrate the safe use of a constant current power source.
• Explain AWS electrode classification system. of electrode identification

Welding Exercises

• Demonstrate correct starting and stopping techniques
• Demonstrate correct arc length, travel speed, and electrode angles for the 7024 electrode in the flat and horizontal welding positions.

GRINDING

• Identify the major components of the grinders.
• Explains the safe operational procedures for grinders.
• Demonstrate the safe operation of the grinders
• Explain grinding and sanding techniques.
• Apply correct techniques in finishing materials.

GMAW

• Define terms used in the GMAW process.
• Equipment identification, setup, shut down, and principles of operation for GMAW
• Power source identification and adjustment.
• Welding lead, connections, inspection, and use.
• Electrode identification, characteristics, and use
• Shielding gas types and characteristics.
• Know essential variables of GMAW.

Demonstrate the effects of the following variables

• Voltage
• Wire feed speed (WFS)
• Travel speed
• Electrode angle
• Stick out

GMAW practice welds

• Demonstrate correct starting and stopping techniques with short circuit transfer.
• Demonstrate correct welding techniques in surfacing beads in the flat positions.
• Demonstrate correct welding techniques for tee joints in the horizontal positions
• Demonstrate correct welding techniques in lap joints in the horizontal position.

GTAW 

• Define terms used in the GTAW process.
• Equipment identification, setup, shut down, and principles of operation for GTAW.
• Power source identification and adjustment
• Torch assembly
• Tungsten electrode identification, characteristics, and use
• Shielding gas types and characteristics.
• Filler composition
• Material preparation
• Know essential variables  of GTAW

Demonstrate the effects of the following variables

• Amperage
• Polarity
• Travel speed
• Electrode angle
• Stick out
• Adjust shielding gas cfm

GTAW practice welds

• Demonstrate correct starting and stopping techniques
• Demonstrate correct welding techniques in surfacing beads in the flat positions
• Demonstrate correct welding techniques for tee joints in the horizontal positions
• Demonstrate correct welding techniques in lap joints in the horizontal position.

SCULPTURE OUTCOMES
Identify the elements (line, shape, mass, light, value, color, texture and space) in sculpture Identify the principles of design (unity and variety, balance, emphasis and  focal point, proportion and scale, and rhythm) and their relationship to sculpture.

• Demonstrate an ability to use terminology during critiques and in the research assignment
• Develop a familiarity with the historical and contemporary perspectives of sculpture
• Compile Design Sketches.
• Create preliminary drawings in preparation for sculpture construction.

Research Assignment.
Ten synopses of sculpture related articles or ten drawings of metal sculpture will be compiled in a sketchbook/journal to satisfy this assignment The study of sculptors and their work will develop critical models Three sculpture design problems which demonstrate the ability to solve aesthetic and structural design problems.
Relief Sculpture:

• Understand bas-relief and haut-relief.
• Create variety with positive and negative space
• Develop depth by using overlapping, tiering, diminishing size, and/or perspective.

Tools and techniques covered:

• Cutting and welding mild steel with Oxyfuel torch
• Bending metal with the brake.
• Use of grinders

Enclosed Form Sculpture:

Create a freestanding, 3-dimensional sculpture. Tools and techniques covered: Cutting mild steel using the plasma arc Weld using the SMAW and/or GMAW process.
Use of air tools; cutting wheel and die grinders.

Found Object Sculpture:
Using a variety of metals objects to create a sculpture. Tools and techniques covered: Operate chop saw and other cutting machines Weld using the SMAW, GMAW and/or GTAW process Oxyacetylene welding and brazing.   Critique and Sculpture Presentations Develop critical skills necessary to evaluate sculpture Explore artistic intent. Discuss aesthetic and structural solutions.