new jasper high school · 2019. 11. 22. · with oxy-fuel cutting and welding process, arc welding...

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Jasper High School

Welding I & Welding II

Robert Fancher, CTE Trades Building Room 105

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Jasper High School Welding I & II

General Syllabus

I. BASIC COURSE INFORMATION:

A. Course Description:

Welding I&II – A progressive instruction of the principles of welding and applications of

equipment used in oxy-fuel and arc welding, including welding and cutting safety, oxy-

fuel welding and cutting, plasma cutting, basic, intermediate and advanced arc welding

processes and basic metallurgy.

B. Intended Audience: High School 10 – 12 Grade

C. Instructor: Robert E. Fancher Office Location: Rm. 106 (New Trades Building) Conference Hour: 1:40 – 2:28 Phone: (409) 382-1086 Ext: 086 E-mail Address: [email protected]

II. INTENDED STUDENT OUTCOMES:

A. Core Objectives Required for this Course

1. Critical Thinking: to include creative thinking, innovation, inquiry, and

analysis, evaluation and synthesis of information

2. Communication: to include effective development, interpretation and

expression of ideas through written, oral and visual communication

3. Empirical and Quantitative Skills: to include the manipulation and analysis

of numerical data or observable facts resulting in informed conclusions

4. Teamwork: to include the ability to consider different points of view and to

work effectively with others to support a shared purpose or goal

5. Personal Responsibility: to include the ability to connect choices, actions

and consequences to ethical decision-making

6. Social Responsibility: to include intercultural competence, knowledge of civic

responsibility, and the ability to engage effectively in regional, national, and

global communities

B. Course Learning Outcomes for all Students

Demonstrate safety procedures associated with all oxy-fuel and arc processes;

perform basic, intermediate and advanced welds using oxy-fuel and arc welding

equipment, plasma cutting equipment; and identify ferrous and nonferrous

metals.

III. ASSESSMENT MEASURES

mailto:[email protected]

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A. Assessments for the Core Objectives:

1. Critical Thinking: Students will be given a job related scenario and ask to

answer questions on how best to plan for and complete the job.

2. Communication: Students will be required to effectively communicate with

instructors and fellow students throughout the course. Assignments will be given

to aid in facilitating communications.

3. Empirical and Quantitative Skills: Students will be required throughout the

course to develop their skills in mathematical calculations of material

requirements, and appropriate measurements.

4. Teamwork: Students will be given a group project to design, develop a

material list, and complete the project.

5. Social Responsibility & Personal Responsibility: Students will be required to develop a contract between themselves and the instructor stating what is required of them to be successful in the course.

B. Assessments for Course Learning Outcomes 1. Students will be observed demonstrating all safety procedures associated

with oxy-fuel cutting and welding process, arc welding processes and plasma cutting process.

2. Students will be observed for performance on all welds using oxy-fuel, arc welding and plasma cutting equipment and processes.

3. Students will be required to identify ferrous and nonferrous metals

IV. INSTRUCTIONAL PROCEDURES:

1. Lecture will be provided in the classroom and individually based on the student’s current assignment.

2. Lab test will be given based on the expected progress at the time of the test. (See Attachment A)

V. COURSE REQUIREMENTS AND POLICIES:

A. TEXTBOOKS AND RECOMMENDED READING Will be provided per course requirements: Instructional Materials Service; Trade and Industrial Education

B. WRITTEN TESTS – (Appropriate due dates, schedules, deadlines)

Written tests will be completed in class.

C. READING ASSIGNMENTS: Student will read material as assigned by instructor.

D. WRITING ASSIGNMENTS:

Writing assignments will be assigned as needed in the course.

E. REQUIRED TOOLS AND SUPPLIES: See Attachment B for a list of required and optional tools.

F. DRESS CODE: See Attachment B for the required Dress Code.

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VI. Course Policies – This course conforms to the policies of Jasper High School as stated in the Jasper High School Handbook.

A. Academic Assistance – If you have a disability (as cited in Section 504 of the Rehabilitation Act of 1973 or Title II of the Americans with Disabilities Act of 1990) that may affect your participation in this class, you should see your designated counselor.

B. Attendance – Attendance is required as per Jasper High School Policy and will be

recorded daily. VII. EVALUATION AND GRADING:

A. Grading Criteria 1. A participation grade will be assessed daily for shop exercises (a maximum

of 3 daily grades per week will be recorded) - - Students will be required to dress in the proper attire and safety equipment in order to participate in shop exercises. (See Attachment B) - Students that do not participate in the shop exercises will receive a zero for their participation grade. - Grades will be assessed based on the students overall participation in assigned activities.

2. A minimum of 3 test will be assessed each grading period. 3. All cutting and welding tests will be graded as outlined in Attachment A. 4. Accommodations and modifications will be made as needed.

VIII. SYLLABUS MODIFICATION:

The instructor may modify the provisions of the syllabus and lesson plan to meet individual class needs by informing the class in advance as to the changes being made.

Safety Rules and Guidelines

1. Students will be required to wear their student ID at all times, except in the shop area. 2. Students will be seated before the tardy bell rings. 3. Students will not be allowed to eat in the classroom or shop area. Students electing to

stay outside the class to finish their food will be counted tardy. Water, in a clear plastic water bottle, will be allowed.

4. Students will not be allowed to use or charge their cell phones during class, unless the instructor permits the use for instructional purposes.

5. Students will remain in their desks at all times except when consulting with the instructor. 6. Talking between students will be held to a minimum. 7. Each student will bring a pen or a pencil, notebook and paper to class daily. 8. No student will be allowed to leave the classroom or shop area without permission of the

instructor or a written note from the front office. 9. No students will be allowed in the instructors office. 10. Students are expected to participate in class and lab exercises. Failure to do so will

result in a participation grade of zero.

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11. Students will be expected to maintain their tools and clean their work areas daily. Students will inspect their tools prior to use; only tools that are in good working order will be used.

12. Proper safety equipment and attire will be used/worn at all times in the shop area. Students not in the proper protective equipment will return to the classroom and will receive a zero for their participation grade.

13. No jewelry will be worn in the shop area. 14. Horseplay will not be allowed in either the classroom or shop area. 15. No headphones/ear buds will be allowed for use in the classroom or shop area. 16. All safety rule violations will be reported to the instructor. 17. No Profanity will be used. 18. All equipment will be turned to the off position when not in use. 19. Students will abide by all additional rules written in the student handbook.

Punishment for infractions:

1st Offence: Warning

2nd Offence: Written Report / Misconduct Report, Parent Notified

3rd Offence: Sent to the Office with Misconduct Reports

Marketing/Sales Plan

Standard Repairs and Fabrication

Periodically throughout the year, the Jasper High School Welding Program will perform

repairs to equipment and small fabrication jobs. The cost of each job performed will be

assessed and billed in relation to the time and/or materials needed for completion. Materials will

be calculated to the nearest foot and tabulated at the current replacement cost value. Hours will

be calculated by the sum of the total class periods required for completion at a rate of $10.00

per class period. No students will be required to stay after school hours to complete a job.

Special Requested Projects

Special projects (BBQ pits/cookers, fire pits, walk/drive through gates, large fabrication

jobs, etc.) will be assessed on a case-by-case basis. These projects will be evaluated on

complexity and time requirements. Such project may be scheduled in blocks at different times

throughout the year and/or postponed until time permits. The cost of these projects will be

determined by the cost of materials and the market value of the item requested.

Note: The goal of the program is to produce industry ready welders. In an effort to facilitate this

goal, the training of students in industry standard welds (AWS, API) is the first priority. While the

knowledge and skills acquired in fabrication and repairs are important, all projects and repairs

will be subsequent to reaching our goal.

Certification List

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State Based Industry Certifications Available:

AWS D1.1 Structural Steel

AWS D9.1 Sheet Metal

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Jasper High School Dual Credit

General Syllabus

Welding Safety, Tools, and Equipment (WLDG 1323)

Credit: 3 semester credit hours (3 hours lecture)

Prerequisite/Co-requisite: None

Course Description An introduction to welding careers and safety practice, including welding safety, OSHA and the

hazardous communication act, Material Safety Data Sheets (MSDS), basic mathematics,

measuring systems, shop operations, use and care of precision measuring tools, and the use and

care of hand and power tools. Introduction to various types of welding and oxy-fuel cutting

equipment and processes, basic welding and cutting gases, fluxes, rods, electrodes, symbols, and

blueprints.

Required Textbook and Materials 1. Modern Welding by Althouse, Turnquist, Bowditch 2013

a. ISBN number is 978-1-60525-795-2

2. Notebook.

3. Black/Blue ink pen or Number 2 pencil

Course Objectives Upon completion of this course, the student will be able to:

1. Discuss the different types of welding.

2. Explain welding safety practices, involving Material Safety Data Sheets, the Hazardous

Communications Act, and OSHA. List hazards associated with welding equipment and

processes. Identify hazards associated with gasses, fluxes, electrodes, equipment and

interpret an MSDS.

3. Use and maintain tools and equipment while practicing welding shop safety.

4. Name the different welding processes and explain the operation of each.

Course Outline Upon completion of this course, the student will be able to

A. Career paths of a welder

• Specific reasons for interest in a specific welding career • Career paths by certifications

B. Welding safety practices, OSHA and the Hazardous Communications Act, and

MSDS.

• Welding safety procedures • Hazards associated with basic welding gases, fluxes, and electrodes • Proper personal protective equipment (PPE)

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• OSHA and the Hazardous Communications Act • Material Safety Data Sheets (MSDS)

C. Hazards associated with welding and oxyfuel cutting equipment and processes.

• Dangers of fumes produced while welding or cutting • Dangers of fire and explosions • Ventilation systems and fresh air supply

D. List the dangers and safety procedures when handing an oxyfuel welding/cutting rig.

• Dangers of high pressure gas cylinders • Safety devises of high pressure gas cylinder and the safe handling procedures of high pressure cylinders

• Safety devises of high pressure cylinder regulators • Reverse flow check valves and flashback arrestor • Proper procedure the start-up, light and shut-down an oxyfuel torch system

F. Use and maintain tools and equipment

• Proper use of angle grinders, die grinders, saws, clamps, jack stands, etc. • Proper maintenance and storage of shop tools

E. Basic shop math as it pertains to the welding industry

• Various measuring instruments and their application in the welding industry • Add, subtract, multiply, and divide fractions • Markings on a tape measure • Fabrication tools

Grade Scale • 90 – 100 A • 80 – 89 B • 70 – 79 C • 60 – 69 D • 0 – 59 F

Course Evaluation Final grades will be calculated according to the following criteria:

Activity Percentage

Assignments 30%

TEST 70%

Late Penalties will be assessed on all work turned in late.

Average a grade on all test and assignments of at least 70%.

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Course Requirements 1. Complete all tests.

2. Use general shop safety procedures.

3. Complete reading assignments.

4. Identify gasses, fluxes, electrodes, equipment and interpret an MSDS.

Attendance Policy I. Students are allowed to miss two days without penalty; each additional day will result in

the student’s grade being dropped by a letter grade.

Example: 1 days absent = If student has an A average no penalty

2 days absent = A drops to a B

3 days absent = B drops to a C

4 days absent = C drops to a D (student must retake class)

5 days absent = D drops to a F (student must retake class)

II. Absences are counted for unexcused, excused and coming to class late.

III. 2 tardies = 1 absence

A. Tardy- arriving within 15 minutes after class begins or leaving before the end of class.

B. More than 15 minutes late you will be counted absent.

C. If you go to sleep in class you will be counted absent.

IV. Excused absences. Only given to allow students to make up missed work.

A. Will be given for documented Injury or Illness. Doctor’s excuse required showing

proof. Will count toward total days missed.

B. Will be given for documented Death in immediate family. Will count toward total

days missed.

C. Approved LIT school functions; e.g. SkillsUSA, SGA etc. Will not count toward total

days missed

D. It is the student’s responsibility to obtain from the instructor any handouts or

assignments for classes missed. Lectures will not be repeated.

V. If you wish to drop, you are responsible for the drop process. I will not initiate the drop, no

matter how many absences or zeroes you have; that is, if you stop coming to class and do not

drop, you will earn an “F” in the course. Students are only allowed to drop 6 times in their

college career.

Classroom Policies 1. No electronic devices of any kind (cell phones, I-pod, headphone, etc.) will be tolerated in the

classrooms or labs. If you are seen using any electronic device you will be asked to leave the

class for the day.

2. No food or drink will be allowed in the classroom.

3. No derogatory or foul language will be tolerated.

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4. Zero tolerance policy for sexual harassment.

5. Zero tolerance policy of racial or ethnic discrimination.

6. Be considerate of others in the classroom. Remember they paid for the class just like you.

Disabilities Statement The Americans with Disabilities Act of 1992 and Section 504 of the Rehabilitation Act of 1973

are federal anti-discrimination statutes that provide comprehensive civil rights for persons with

disabilities. Among other things, these statutes require that all students with documented

disabilities be guaranteed a learning environment that provides for reasonable accommodations

for their disabilities. If you believe you have a disability requiring an accommodation, please

contact the Special Populations Coordinator at (409) 880-1737 or visit the office in Student

Services, Cecil Beeson Building.

Student Code of Conduct Statement It is the responsibility of all registered Lamar Institute of Technology students to access, read,

understand and abide by all published policies, regulations, and procedures listed in the LIT

Catalog and Student Handbook. The LIT Catalog and Student Handbook may be accessed at

www.lit.edu or obtained in print upon request at the Student Services Office.

Course Schedule Week Topic Reference

1&2 Course introduction and policies Syllabi

Safety in the Welding Shop Chapter 1

The Welding shop Chapter 32

• Lecture • Test

_______________________________________________________________________

3 Shielded Metal Arc Welding Equipment Chapter 5

Pages 117-137

Shielded Metal Arc Welding Chapter 6


________________________________________________________________________

4 Oxyfuel Gas Welding Equipment and Supplies Chapter 11

Oxyfuel Gas Welding Chapter 12


_________________________________________________________________________

5 Oxyfuel Gas Cutting Equipment and Supplies Chapter 13

Oxyfuel Gas Cutting Chapter 14

• Lecture • Lab: Chapter Exercises • Test

_________________________________________________________________________

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6 Getting and holding a Job in the welding Chapter 33

Industry Chapter 34

Technical Data

• Project: As Assigned • Test

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Welding I & II Student’s Name: ___________________________________________________(Print legibly)

I hereby acknowledge receipt of Mr. Robert Fancher, Welding I & II guidelines. I have read the guidelines and agree to abide by the standards, policies and procedures defined or referenced in this document.

Please sign and date this receipt and return to Mr. Robert Fancher. ________________________________________ __________________________________ Parent Name Parent Signature _______________________________________ ___________________________________ Parent Email Address Parent Cell Phone # _______________________________________ ___________________________________ Student Name Student Signature ------------------------------------------------------------------------------------------------------------------- cut Student’s Name: ___________________________________________________(Print legibly)

I hereby acknowledge receipt of Mr. Robert Fancher, Welding I & II guidelines. I have to read the guidelines and agree to abide by the standards, policies and procedures defined or referenced in this document.

Please sign and date this receipt and return to Mr. Robert Fancher. ________________________________________ __________________________________ Parent Name Parent Signature _______________________________________ ___________________________________ Parent Email Address Parent Cell Phone # _______________________________________ ___________________________________ Student Name Student Signature

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Attachment A

Objective:

During this course, students should be able to repeatedly produce the following welds with 80 to 90% accuracy, and in some cases near 100% accuracy. 100% accuracy is an abnormal achievement for welding and will generally not be met consecutively. All welds will be graded to American Welding Society (AWS) or American Petroleum Institute (API) standards. In maintaining the self-paced nature of this course all students may not complete all welds on this list; however with proper instruction students should have the ability to catch up in future classes.

Self-paced:

Students are expected to spend class time practicing on their assigned weld until the instructor signs off, and instructs them on the next weld in the sequence. Upon successful completion of one instructor approved weld, students will be asked to stencil their test material and produce one (or two depending on the joint fitment) weld of equal or higher quality. Once this requirement is met the instructor will sign off and the student advances to the next weld in sequence. Only with instructor approval will a student begin a new weld before completing the previous weld.

Welds Required:

See Attachment C

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Attachment B

WELDING SUPPLIES:

List of Supplies Required For Welding Classes: 8. 100% cotton welding shirt (starched and pressed recommended) (with flaps over the

pockets) 9. Denim pants or work pants, no shorts (starched and pressed recommended) Pants

are to be free of rips, tears and frays. 10. All-cloth welding cap 11. Leather work boots (no low quarter boots or tennis shoes) (Replace as needed) 12. Safety Glasses (safety glasses are to be clear and ANSI Z87 shatter resistant) 13. Combination lock 14. Writing tools (paper and pencil or pen)

(Optional) List of Supplies for Welding Classes: Gloves (all leather) (Replace as needed) Oxy-acetylene cutting goggles (No glasses or round lenses) Welding Hood Pliers 12” (slip-joint or channel lock) Chipping hammer Shoe Handle Wire brush (Replace each semester) 25’ Tape measure Rectangular Soap Stone Holder Striker (Multi flint style preferred) Welding leather sleeves Hearing Protection (ear plugs or ear muffs)

DRESS CODE FOR All WELDING CLASSES:

During class sessions, all welding students will wear: 7. 100% cotton welding shirt (starched and pressed recommended) (with flaps over the

pockets) (Approximate replacement of shirts each year)

8. Denim pants or work pants, no shorts (starched and pressed recommended) Pants are to be free of rips, tears and frays.

9. All-cloth welding cap

10. Leather work boots (no low quarter boots or tennis shoes) (Replace as needed)

11. Clear ANSI Z87 Safety glasses 12. Hearing Protection

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Attachment C

Bead Pad E6010 Below

70% 70-80% 80-90% 90-100%

Bead Pad E7018 Below

70% 70-80% 80-90% 90-100%

Flat Butt Joint E6010 Below

70% 70-80% 80-90% 90-100%

Flat Butt Joint E7018 Below

70% 70-80% 80-90% 90-100%

Horizontal “T” Joint Single Pass E6010 Below

70% 70-80% 80-90% 90-100%

Horizontal “T” Joint Triple Pass E6010 Below

70% 70-80% 80-90% 90-100%

Horizontal “T” Joint Single Pass E7018 Below

70% 70-80% 80-90% 90-100%

Horizontal “T” Joint Triple Pass E7018 Below

70% 70-80% 80-90% 90-100%

Vertical “T” Joint Single Pass E6010 Below

70% 70-80% 80-90% 90-100%

Vertical “T” Joint Triple Pass Stringers

E6010

Below

70% 70-80% 80-90% 90-100%

Vertical “T” Joint Triple Pass Weave

E6010

Below

70% 70-80% 80-90% 90-100%

Vertical “T” Joint Single Pass E7018 Below

70% 70-80% 80-90% 90-100%


E7018

Below

70% 70-80% 80-90% 90-100%

Vertical “T” Joint Triple Pass Weave

E7018

Below

70% 70-80% 80-90% 90-100%

Overhead “T” Joint Single Pass E6010 Below

70% 70-80% 80-90% 90-100%

Name: ________________________________________________________

Class Period: ___________________________________________________

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Overhead “T” Joint Triple Pass E6010 Below

70% 70-80% 80-90% 90-100%

Overhead “T” Joint Single Pass E7018 Below

70% 70-80% 80-90% 90-100%

Overhead “T” Joint Triple Pass E7018 Below

70% 70-80% 80-90% 90-100%

Flat Butt Joint .035 Hard wire Below

70% 70-80% 80- 90% 90-100%

Horizontal Butt Joint .035 Hard Wire Below

70% 70-80% 80- 90% 90-100%

Vertical Butt Joint .035 Hard Wire Below

70% 70-80% 80- 90% 90-100%

Horizontal “T” Joint Single Pass .035

Hard Wire

Below

70% 70-80% 80- 90% 90-100%

Vertical “T” Joint Single Pass .035 Hard

Wire

Below

70% 70-80% 80- 90% 90-100%


.035 Hard Wire

Below

70% 70-80% 80- 90% 90-100%

Overhead “T” Joint Single Pass .035

Hard Wire

Below

70% 70-80% 80- 90% 90-100%

Overhead “T” Joint Triple Pass Stringers

.035 Hard Wire

Below

70% 70-80% 80- 90% 90-100%

Flat V-Groove (1G) 6010 Root, Hot

pass, Fillers, and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%

Flat V-Groove (1G) 6010 Root & Hot

pass, Weaved Fillers and Cap

Below

70% 70-80% 80-90% 90-100%


pass, 7018 Fillers and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%


pass, 7018 Weaved Fillers and Cap

Below

70% 70-80% 80-90% 90-100%

Horizontal (2G) V-Groove 6010 Root &

Hot pass, 6010 Stringers Filler & 3 Bead

Cap

Below

70% 70-80% 80-90% 90-100%

Horizontal (2G) V-Groove 6010 Root &

Hot pass, 7018 Stringers Filler & 3 Bead

Cap

Below

70% 70-80% 80-90% 90-100%

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3G Plate 6010 Root, Hot pass, Fillers,

and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%

3G Plate 6010 Root & Hot pass,

Weaved Fillers and Cap

Below

70% 70-80% 80-90% 90-100%

3G Plate 6010 Root & Hot pass, 7018

Fillers and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%

4G Plate 6010 Root, Hot pass, Fillers,

and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%


Fillers and 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%

1G Pipe 6010 Root & Hot pass, 6010

Stringers Filler & 3 Bead Cap

Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%



Below

70% 70-80% 80-90% 90-100%

5G Pipe 6010 Root, Hot pass, Fillers,

and 3 Bead Cap Below

70% 70-80% 80- 90% 90-100%


Weaved Fillers and Cap Below

70% 70-80% 80- 90% 90-100%


Fillers and 3 Bead Cap Below

70% 70-80% 80- 90% 90-100%

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70% 70-80% 80- 90% 90-100%


Stringers Filler & 3 Bead Cap Below

70% 70-80% 80- 90% 90-100%



70% 70-80% 80- 90% 90-100%


Stringers Filler & 3 Bead Cap Below

70% 70-80% 80- 90% 90-100%



70% 70-80% 80- 90% 90-100%

GTAW Flat Butt Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Horizontal Butt Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Vertical Butt Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Overhead Butt Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Horizontal T-Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Vertical T-Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Overhead T-Joint Steel Below

70% 70-80% 80-90% 90-100%

GTAW Flat Butt Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Horizontal Butt Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Vertical Butt Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Overhead Butt Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Horizontal T-Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Vertical T-Joint Aluminum Below

70% 70-80% 80-90% 90-100%

GTAW Overhead T-Joint Aluminum Below

70% 70-80% 80-90% 90-100%

new jasper high school · 2019. 11. 22. · with oxy-fuel cutting and welding process, arc welding...

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