Lesson 1 - Fundamentals of Welding

Topics:

Metals; Common and production welding processes; Kinds of welds and welded joints; Weld parts; Fusion; Penetration; Joint design and fitup

Learning Objectives:
– Describe fusion welding, resistance welding, filler rods, and electrodes.
– Compare the oxyfuel and arc welding processes and compare the SMAW, GMAW, and GTAW processes.
– Describe and sketch the following kinds of joints-butt, lap, tee, corner, and edge.
– Describe the following kinds of welds-groove, fillet, plug, slot, spot, and seam.
– Name and locate the parts of a weld.
– Discuss basic considerations in joint design and fitup.


Lesson 2 - Welding Safety

Topics:

Fire and explosion hazards; Burns; Fumes and gases; Respiratory, eye, face, and hearing protection; Protective clothing; Handling cylinders; Shock

Learning Objectives:
– Explain the importance of good housekeeping in an area where welding is taking place.
– List at least three precautions to take to avoid fires and explosions when welding.
– Describe two methods of protecting yourself against the fumes and gases associated with welding.
– Describe the personal protective equipment required when welding.
– Explain the precautions to take when using and handling cylinders and regulators.


Lesson 3 - Oxyfuel Welding Equipment

Topics:

Gas pressure regulators; Check valves; Hoses, torches, and tips; Filler rods; Protective gear; Preparing to weld; Making the weld; Shutdown

Learning Objectives:
– Briefly describe the oxyfuel welding process and the components of an oxyfuel welding outfit, including the lighting device.
– Discuss safety precautions and personal protective gear required for working with oxyfuel equipment.
– List the steps involved in preparing to weld.
– Compare the neutral, carburizing, and oxidizing flames.
– List the steps in safely shutting down an oxyfuel welding system.


Lesson 4 - Arc Welding Equipment

Topics:

Welding with electricity; Constant current, voltage power sources; Welding machines, cables, electrodes, and electrode holders; Safety

Learning Objectives:
– List similarities and dissimilarities between oxyfuel welding and arc welding.
– Describe the electric welding circuit, including choice of ac or dc, dc polarity, and power sources.
– Discuss welding machine ratings in terms of amperage and duty cycle and describe features and uses of transformer, generator, rectifier, and inverter
   welding machines.
– Discuss welding cable considerations and describe the electrodes and electrode holders used for SMAW, GMAW, and GTAW processes.
– Discuss the personal safety gear and precautions necessary for arc welding and explain how arc welding accessories are used.


Lesson 5 - Welding Techniques

Topics:

Selecting a process; Welding positions; Oxyfuel, SMAW, GMAW, and GTAW procedures

Learning Objectives:
– Explain what considerations affect the selection of a welding process.
– Describe the four welding positions.
– Explain why overhead welds are difficult to make and tell how to make them.
– Describe the preparation required for oxyfuel welding, SMAW, GMAW, and GTAW processes.
– Describe the procedures involved in oxyfuel welding, SMAW, GMAW, and GTAW processes.


Lesson 6 - Avoiding Weld Faults

Topics:

Common weld problems; Poor fitup; Shape problems; Internal defects; Effects of heat; Expansion and contraction; Identifying metals

Learning Objectives:
– Describe the effects of electrode selection, current, arc length, and travel speed on arc welding procedures.
– Describe common causes of arc blow, a hard-to-start arc, and spatter, and explain why proper fitup is important.
– Define the terms overlap, undercut, blowhole, and inclusion and explain the causes of each.
– Explain how expansion and contraction can be controlled when welding.
– Name and describe the various tests used to identify metals.