welding technology

MINISTRY OF EDUCATION, MALAYSIA

December Edition2012

MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULUM

MODULE INFORMATIONMODULE:INTRODUCTION TO WELDING TECHNOLOGY

CODE:MWT 101

LEVEL :1 SEMESTER 1

CREDIT UNIT:2.0

CONTACT HOUR:FACE TO FACE : 6.0 HOURS / WEEK

NON FACE TO FACE :

MODULE TYPE:VOCATIONAL

PRE-REQUISITE:-

CORE REQUISITE:-

MODULE OUTCOMES:

At the end of the course, the students should be able to:-

1. Describe History of welding

2. Describe basic of welding technology

3. Identify SMAW equipment

4. Set up SMAW equipment and accessories

5. Carry out padding/buttering

6. Weld carbon steel plate of thickness range 6-9 mm in 2F positionMODULE DESCRIPTION:

This unit identifies the competence required to equip students with a technical understanding of the definition of welding; history of welding, master chart of welding and allied processes and identifying and setting up SMAW equipment and accessories. Competence also required for setting up SMAW equipment and accessories by selecting, assembling and checking assembled set so that the components/parts is securely connected, safe and ready for operation to perform padding and buttering and weld carbon steel plates in 2F position.

CONTENT AND LEARNING STANDARDS

COURSE:WELDING TECHNOLOGY

MODULE:INTRODUCTION TO WELDING TECHNOLOGY

CODE:MWT 101

CONTENT STANDARD

LEARNING STANDARD

PERFORMANCE CRITERIA

1. DESCRIBE HISTORY OF WELDING

1.1 Describe the history of metalworking and welding.

1.2 Describe the importance of welding and its applications1.1.1 Explain the history of metalworking and welding.

1.1.2 Identify early developments in welding.

1.1.3 Explain the developments of modern welding.

1.2.1 Give details of the mission of welding in the industrial process.

1.2.2 Describe the importance of welding and its applications




CODE:MWT 101

CONTENT STANDARD

LEARNING STANDARD

PERFORMANCE CRITERIA

2. DESCRIBE BASIC OF WELDING TECHNOLOGY

2.1 Describe welding technology

2.2 Describe the master chart of welding processes and allied processes.

2.3 Identify the source of energy for various welding processes

2.1.1 Define welding technology according to BS/AWS standards.

2.2.1 Identify and describe the various welding processes according to the master chart of welding processes and allied processes.

2.2.2 Identify and describe the classification of welding processes according to master chart of welding processes and allied processes

2.3.1 Describe the source of energy to produce heat for welding.

2.3.2 Identify welding power sources transformer, rectifier, generator and inverter.




CODE:MWT 101

CONTENT STANDARDLEARNING STANDARDPERFORMANCE CRITERIA

3. IDENTIFY SMAW EQUIPMENT

3.1 Identify the process required

3.2 Identify and choose the parts and accessories for SMAW welding

3.1.1 Apply safety precaution related to handling and operating of welding equipment in accordance to Standard Operation Procedures.

3.1.2 Identify main type of arc welding processes such as SMAW, GTAW, GMAW, FCAW, SAW, Plasma Welding according to BS/AWS code and standards.

3.1.3 Define principles of arc welding according to BS/AWS code and stantards.

3.1.4 Identify equipment and accessories for SMAW, GTAW, GMAW, FCAW, SAW, OAW, OAB and PAW according to BS/AWS standards.

3.1.5 Identify type of consumables according to BS/AWS code and standards.

3.1.6 Describe basic electricity related to arc welding.

3.2.1 Describe SMAW processes, equipment, accessories and consumables in accordance to BS/AWS code and standard.

3.2.2 Prepare parts and accessories for SMAW in accordance to AWS/BS standard and welding procedures.

3.2.3 Practise safety, consciousness, cautious and proper working etiquette in compliance with work safety requirements according to Occupational Safety and Health Act.




CODE:MWT 101


4. SET UP SMAW EQUIPMENT AND ACCESSORIES

4.1 Select parts and accessories for SMAW process

4.2 Fix parts and accessories

4.3 Check assembled SMAW equipment

4.1.1 Apply safety precaution related to handling and operating equipment according to Occupational Safety and Health Act.

4.1.2 Describe SMAW process in accordance to AWS/BS codes and standards.

4.1.3 Identify type of welding machine transformer (AC), rectifier (AC/DC) and motor driven generator or diesel / petrol driven generator (DC).

4.1.4 Identify parts and accessories for SMAW process.

4.2.1 Apply safety precaution related connecting parts and accessories according to Occupational Safety and Health Act.

4.2.2 Identify and apply correct procedure of assembling and install SMAW parts and accesories according to Standards Operational Procedures.

4.3.1 Check electrical installation related to welding according to manufacturer manual instruction.

4.3.2 Apply correct method of checking polarity related to welding equipment according to Standard Operational Procedure.

4.3.3 Conduct voltage and current testing according to Standard Operational Procedure.

4.3.4 Use voltage and amperage testing meters according to Standard Operational Procedure.




CODE:MWT 101


5. CARRY OUT PADDING / BUTTERING

5.1 Select material required

5.2 Prepare material

5.3 Set welding current

5.4 Choose welding electrode

5.5 Striking the arc and perform short beads and stringer beads

5.6 Perform buttering and padding process.

5.7 Inspect weldment after welding5.1.1 Identify type of material and properties required for welding work.

5.2.1 Interpret welding drawing for metal preparation.

5.2.2 Prepare material surface for required welding process.

5.2.3 Select jigs and fixtures suitable for welding work.

5.2.4 Identify types of measuring and marking tools.

5.2.5 Measure and mark material according to welding work requirement.

5.2.6 Operate cutting equipment according to Standard Operational Procedures

5.2.7 Apply safety precaution related to handling cutting machine and marking tools according to Occupational Safety and Health Act.

5.3.1 Apply safety precaution related to handling electrical equipment according to Occupational Safety and Health Act.

5.3.2 Set welding current according to AWS/BS code and standards.

5.4.1 Identify types of electrode classification according to AWS/BS code and standards.

5.4.2 Identify correct electrode required for welding process according to AWS/BS codes and standards.

5.4.3 Explain the importance of electrode storage according to factory recommandation.

5.5.1 Apply safety precaution related to welding process according to Occupational Safety and Health Act

5.5.2 Define and set welding current, arc length, electrode angle and travel speed according to AWS/BS standard.

5.5.3 Arrange parent metal to position according to welding work instructional.

5.5.4 Apply correct method of striking the arc according AWS/BS welding procedure.

5.5.5 Produce intermittent short beads and stringer beads using correct welding technique according to AWS/BS standards and welding procedures.

5.6.1 Apply safety precaution related to welding process according to Occupational Safety and Health Act

5.6.2 Arrange parent metal to position according to welding instructional.

5.6.3 Set correct welding current, arc length, electrode angle and travel speed according to AWS/BS welding procedure.

5.6.4 Produce stringer beads using correct welding technique for buttering/padding in down hand/flat position welding according to AWS/BS welding procedure.

5.7.1 Identify and inspect surface defects according to AWS/BS codes and standards




CODE:MWT 101


6. WELD CARBON STEEL PLATE OF THICKNESS RANGE 6-9 MM. IN 2F POSITION

6.1 Identify and select parent metal

6.2 Make edge preparation

6.3 Set welding current

6.4 Identify and select welding electrode

6.5 Align and tack weld plates

6.6 Carry out welding using E6010/E6013/E7016/E7018

6.7 Check weldment after welding6.1.1 Identify type of carbon steel and basic properties required for specific welding process.

6.2.1 Interpret welding drawing for intended welding process.

6.2.2 Describe purpose for edge preparation for welding joint

6.2.3 Identify type and size of butt and fillet joints according to BS/AWS codes and standards.

6.2.4 Measure and mark material for welding work.

6.2.5 Use cutting tools and equipment according to standard operational procedures.

6.3.1 Apply safety precaution related to handling of electrical equipment according to Occupational Safety and Health Act.

6.3.2 Set welding current and amperage according to BS/AWS welding procedure.

6.4.1 Identify types and classification of common electrodes according to BS/AWS codes and standards.

6.4.2 Choose correct electrode required for welding work according to BS/AWS codes and standards.

6.4.3 Apply correct procedure for storage electrodes according to manufacturer recommendation.

6.5.1 Select and use jigs and fixtures for welding process.

6.5.2 Apply correct technique to align weld metal.

6.5.3 Tacks weld plate according to BS/AWS welding procedure.

6.3.1 Adhere to safety precaution during welding process according to Occupational Safety and Health Act

6.3.2 Use correct type and classification of electrodes for intended welding process.

6.3.3 Set parent metal to required position according to BS/AWS codes

6.3.4 Apply correct welding technique in weld T or lap joint in 2F horizontal position according to BS/AWS welding procedure.

6.3.5 Maintain correct welding current, arc length, electrode angle and travel speed according to BS/AWS welding procedure.

6.7.1 Inspect surface defect according to welding instruction/procedure and meet the BS/AWS specified welding standard.

6.7.2 Practice safety consciousness, cautious, alertness and patience in accordance to BS/AWS welding procedure.

Last Edited03 06 Dec 2012

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