SOUTHWESTERN MICHIGAN COLLEGEDIVISION OF ADVANCED TECHNOLOGIES

Dowagiac, MichiganCOURSE SYLLABUS

Fall Semester/Session 2011

COURSE TITLE: GTAW (TIG Welding) ICOURSE NO.: WELD162SECTION NO.: 1424

DAYS AND TIMES: Lecture: TR 8:10 – 9:10am Lab: TR 9:20am – 12:30pm

CREDITS/CONTACTS: Credit Hours: 2Lecture hours/weekly: 1 (Room 122, NAC)Laboratory hours/weekly: 3 (Room 227, M-TEC)Weekly Contact Hours: 4

FINAL EXAMINFORMATION:

Refer to the Final Exam Schedule posted on SMC Wired for time and location of final exam.

INSTRUCTOR: Name Mr. Nathan KrambOffice: Room 207, M-TECPhone Number: 269-687-5653Email: nkramb01@swmich.edu

OFFICE HOURS:

M 12:25 – 1:25pmT 4:00 – 5:00pmW 8:00 – 9:00amR 2:00 – 4:00pm

PREREQUISITE: Minimum grade of C in WELD 159, concurrent enrollment allowed; and READ 100 or satisfactory test score, concurrent enrollment allowed.

COURSE DESCRIPTION: This course covers the application of the gas tungsten arc welding process for flat and horizontal positions.

COURSE OUTCOMES: Students successfully completing WELD 162 will be able to:

1. Safely set-up, adjust, operate, and properly shutdown an electric arc welding machine for the Gas Tungsten Arc Welding (GTAW) process.

2. Demonstrate the ability to interpret drawings, sketches or Weld Procedure Specifications (WPS) into the proper completed weldments.

3. Demonstrate a basic knowledge of GTAW process theory, shielding gases, filler metals, base metal identification, and weld metallurgy.

4. Demonstrate welding, cutting, and welding laboratory safety skills; perform safety inspections of equipment and accessories.

5. Successfully complete a groove weld in the flat (1G) position. (Carbon, Stainless and Aluminum) (WPS-T001, WPS-T005, WPS-T009)

6. Successfully complete a groove weld in the horizontal (2G) position. (Carbon and Stainless) (WPS-T002, WPS-T006)

7. Successfully complete a fillet weld in the flat (1F) and horizontal (2F) position (Carbon, Stainless and Aluminum) (WPS-T003, WPS-T004, WPS-T007, WPS-T008, WPS-T010, WPS-T011)

8. Successfully demonstrate how to inspect a completed weld or cut, identify the causes of discontinuities or defects, and make the necessary corrections or repairs

TEXTBOOK: REQUIRED: Hobart, EW369 GTAW Gas Tungsten Arc Welding

Hobart, Welding Procedures and Qualifications

Hobart, Discontinuities & Defects

Lincoln: The Procedure Handbook of Arc Welding

OPTIONAL: n/aADDITIONAL REQUIRED RESOURCES:

WELD Voucher, Slip-Joint pliers

METHOD OF INSTRUCTION: Welding Technology will use classroom lecture/discussion, audio-visual materials, written assignments, and welding projects. Welding Procedure Specifications (WPS), Visual Inspection Criteria and Weld Test Records will be used.

EVALUATION METHOD: Upon completion of this course, the student will demonstrate achievement of the course objectives by obtaining a final minimum grade of 73%, as measured by quizzes, laboratory projects, the final examination and attendance. The final grade for this course will be made up of the following percentages:

Written Quizzes 25 %Written Final Exam 25 %Weld Projects 50 % 100%

Students who participate in unsafe activities, exhibit unacceptable behaviors or misuse tools/equipment, could lose up to 20% of their final grade, will be asked to leave the classroom, and must meet with the Dean of Advanced Technologies before being allowed to return.

Written quizzes and projects must be completed the semester they are assigned.

GRADING SCALE: The following grading scale will be in effect for this course:

93 – 100% = A 73 – 76% = C90 – 92% = A- 70 – 72% = C-87 – 89% = B+ 67 - 69% = D+83 – 86% = B 63 – 66% = D80 – 82% = B- 60 – 62% = D-77 – 79% = C+ Below 60% = F

ATTENDANCE POLICY: ATTENDANCE IS REQUIRED FOR CLASSROOM AND LAB. It is the responsibility of each student to complete the time required for the course in which they are enrolled. When a student completes the total hours of

lecture/lab, lab projects and quizzes/tests required for the specific course, they have completed the course.

TESTING POLICY: Students are expected to take all examinations as scheduled. Students who are ill must contact the instructor within the following week and make up the examination within two weeks of the original testing date. The instructor reserves the right to determine whether a make-up test will be given and the format of the testing method.

NOTICE: Representative student work will be used as a part of SMC’s on-going curriculum assessment program.

OTHER COURSEEXPECTATIONS:

PROJECT EVALUATION:

SAFETY AND EQUIPMENT REQUIREMENTS FOR CLASS:

1. Approved safety glasses.2. Approved ear protection.3. Leather apron and sleeves or approved welding jacket.4. Approved welding gloves.5. Approved welding hat or skullcap.6. Clothing should made of non-flammable material and be free of oil and

grease. Pants must be full length, without cuffs.7. Leather shoes or work boots.8. Pliers (either slip joint or vise grip).9. Wire cutting pliers (for wire welding).10. Scribe and/or soapstone.

Upon entry to the weld laboratory, all students should note the location of safety items such as extinguishers; fire blankets, and is aware of the location of the nearest exits. No welding should be performed unless ventilation hood systems in the welding booths are functioning properly.

All students will be required to sit through a safety orientation before being allowed to participate in welding activities. Upon completion of the orientation, students will sign a checklist signifying that they have received and understand the safety requirements for the class.

A $30 Welding Voucher Fee is required for each student upon entry to the weld lab. This voucher is used for welding supplies and consumables such as welding rod and wire, contact tips, tungsten, welding gases, and weld material to be used in the laboratory. The voucher is purchased at the bookstore and is given to your instructor before you will be allowed to participate in the welding class.

All projects will be inspected by the instructor to determine if the weld is full size, full length and free of defects that would render the weld unsound. To ensure that students attain expected welding skills, assigned projects will be redone until they are acceptable.

ACCEPTABLE USE OF PERSONAL COMMUNICATION TECHNOLOGY:

All phones, iPods, Black Berries, palm pilots, pagers, laptops and other technological devices including devices capable of taking photographs must be turned off or placed on vibrate mode and may not be brought our during class.. If you are expecting or receiving an urgent call, you are required to leave the classroom before answering. Violation of this policy will result in your removal from the classroom for the class period. Multiple violations of this policy will be referred to the appropriate dean for disciplinary action. Further details or ramifications of violations maybe found elsewhere in this syllabus. The instructor has the right to modify this policy to meet the needs

of your course.

HONESTY POLICY: Cheating or plagiarizing will absolutely not be tolerated at Southwestern Michigan College. Any student found cheating or plagiarizing material in any manner may be assigned a failing semester/session grade in this course. A second such incident while at SMC could result in suspension or expulsion from the institution. A student found in violation of this section of the syllabus will not be allowed to drop this course. Additional detail regarding cheating and/or plagiarism may be found elsewhere in this syllabus. For more detailed information consult the SMC Student Code of Conduct.

CLASSROOM BEHAVIOR: Students are expected to assist in maintaining a classroom environment that is conducive to learning. In order to assure that all students have the opportunity to gain from time spent in class; students are prohibited from engaging in any form of distraction. Inappropriate behavior in the classroom shall result, minimally, in a request to leave class.

NOTICE: Information in this syllabus was, to the best knowledge of the instructor, considered correct and complete when distributed for use at the beginning of the semester. The instructor, however, reserves the right, acting within the policies and procedures of Southwestern Michigan College, to make changes in course content or instructional techniques.

COURSE OUTLINE

WEEK 1 Discussion of Welding, Cutting, and Welding Laboratory Safety

WEEK 2 Discussion of Weld Nomenclature

WEEK 3 Discussion of GTAW Process Theory, Shielding Gasses and Filler Metals

WEEK 4 Discussion of Weld Quality, Size, and Profiles

WEEK 5 Discussion of Equipment Set-up and Maintenance

WEEK 6 Discussion of Weld Inspection, Discontinuities/Defects, and Repair

WEEK 7 Weld Projects Due

WEEK 8 WRITTEN FINAL EXAM – COMPREHESIVE

COURSE ASSIGNMENTS

BIBLIOGRAPHY

SAFETY RULES

Southwestern Michigan College

Welding Technology

1. Know where safety equipment is located.

2. Notify instructor of any injuries - immediately.

3. Notify instructor of any equipment damage – immediately.

4. Never use a new piece of equipment without instruction.

5. Never repair a piece of equipment without instruction.

6. If you are unsure about an assigned project or use of equipment – ask instructor.

7. Check equipment condition before use, and make sure welding environment is safe.

8. Keep combustibles out of the welding areas.

9. Always wear non-flammable, protective clothing and shoes suitable for the welding to be done.

10. Safety glasses must be worn under your welding helmet, and whenever you are in welding laboratory.

11. Make sure helmet has correct lens shade for the process being used.

12. Always handle welding material with proper gloves and pliers.

13. Always wear hearing protection and a face shield when grinding.

14. Always turn equipment off when leaving booth, and hang electrode holder in the brackets provided.

15. Never use electrode holders as chipping hammer, or tighten with pliers. (Use proper equipment.)

16. Never change polarity, amperage or voltage settings while equipment is in use.

17. Never open a welding machine cabinet when the machine is operating.

18. Make sure ground clamp is secure and tight on worktable.

19. Make sure fume exhaust is working properly before welding.

20. Never stand in front of the gauges when opening a cylinder. Stand aside and slowly open cylinder valves.

21. When cylinders are not in use, the cylinder valve should be closed and the diaphragm screw should be released.

22. Always clean up your work area when you are done.

VISUAL INSPECTIONWELD BEAD EVALUATION CRITERIA

Southwestern Michigan CollegeWelding Technology

Objective: To provide standardized visual inspection criteria for weld beads, in all positions, joint types and weld processes.

Cracks:A weld shall be acceptable by visual inspection if it shows that the weld has no cracks, otherwise it shall be considered as having failed.

Arc Strikes:Arc strikes outside the weld area shall be considered as the weld having failed.

Fusion:A weld shall be acceptable by visual inspection if it shows that there is complete fusion between weld metal and base metal, along the total length of weld bead, otherwise it shall be considered as having failed.

Slag Inclusions:A weld shall be acceptable by visual inspection if there are no slag inclusions, otherwise it shall be considered as having failed.

Joint Penetration:The root of the weld shall be acceptable by visual inspection if there is no evidence of incomplete joint penetration, otherwise it shall be considered as having failed.

Root Reinforcement shall be flush with the surface of the base metal minimum, to 1/8” maximum.

Face Reinforcement shall be flush to the surface of the base metal minimum, to 1/8” maximum.

Reinforcement:A weld shall be acceptable by visual inspection if the face and root reinforcement does not exceed the specified dimension, and shows a gradual transition to the surface of the base metal. Any reinforcement must blend smoothly into the plate, pipe or previous weld surface, with transition areas free from edge weld undercut, otherwise it shall be considered as having failed.

Porosity:A weld shall be acceptable by visual inspection if porosity does not exceed 1/32” maximum diameter and has no more than the combined total of 1/8”, in any one square inch of weld, otherwise it shall be considered as having failed.

Undercut:A weld shall be acceptable by visual inspection if undercut does not exceed the lesser of 10% of the base metal thickness or 1/32” deep, and has no more than the combined total of 1/2” of undercut in any 6 inches of weld, otherwise it shall be considered as having failed.

Crater:A crater shall be acceptable by visual inspection if the cross section is completely filled, otherwise it shall be considered as having failed.

WELDING LABORATORY / CLASS TIME LOG Southwestern Michigan College

Welding Technology

NAME_________________________ CLASS_______________________

Date Time In Time Out Total Hrs. Description of Time Use

       

       

       

       

       

       

       

       

       

       

       

       

       

       

       

       

       

       

       

SAFETY ORIENTATION AND CLASS ATTENDANCE REQUIREMENTSSouthwestern Michigan College

Welding Technology

I HAVE RECEIVED THE SAFETY ORIENTATION AND THE CLASS ATTENDANCE REQUIREMENTS.

I UNDERSTAND AND AGREE TO FOLLOW THESE REQUIREMENTS.

CLASS: WELD 162

PRINTED NAME: ________________________________________________

SIGNATURE: ____________________________________________________

DATE: __________________________________________________________