Lesson 1 - Welding Ferrous Metals


Fusion welding; Fluxes; Flame characteristics; Temperature control; Welding common mild steels, stainless steel, cast iron, and wrought iron

Learning Objectives:
– Explain how oxyfuel welding joins metals and how it differs from arc welding.
– Explain how braze welding and torch brazing are different from oxyfuel welding and from each other.
– Discuss the purposes for using flux and characteristics that make a flux suitable for an application.
– Compare the appearance and general uses of the carburizing flame, neutral flame, and oxidizing flame.
– Explain why preheating and postheating are used.
– List important considerations in welding common mild steels, stainless steel, and cast and wrought iron.

Lesson 2 - Welding Nonferrous Metals


Joint preparation; Welding aluminum, copper, brass, bronze, lead, nickel, and magnesium

Learning Objectives:
– Discuss characteristics of aluminum that are important in welding.
– Explain how to use aluminum alloy designations.
– Describe procedures used in aluminum joint preparation and in aluminum welding.
– Discuss characteristics of copper and copper alloys that are important in welding.
– Discuss procedures for welding copper, brass, and bronze.
– Discuss procedures for welding lead, nickel, and magnesium.
– Summarize general standard procedures for making optimum welds.

Lesson 3 - Oxygen Cutting


Oxygen cutting process, torch, and tips; Cutting safety; Cutting bevels; Piercing holes; Cutting circles; Removing rivets; Gouging; Scarfing

Learning Objectives:
– Explain the similarities and differences between oxyfuel cutting and oxyfuel welding.
– Describe the equipment and safety precautions necessary for torch cutting and list standard steps in the torch cutting operation.
– Describe special equipment or methods used in cutting bevels, piercing holes, cutting circles, and cutting away rivets.
– Explain why gouging, scarfing, and washing are used.
– Explain methods used on metals that are otherwise difficult to cut.

Lesson 4 - Brazing and Soldering


Filler alloys and fluxes; Brazing and braze welding cast, malleable iron, aluminum, and steel; Safety; Soldering; Kinds of solder; Soldering tools

Learning Objectives:
– Compare and contrast brazing, braze welding, and oxyfuel fusion welding.
– Describe the materials and procedures used in brazing and braze welding.
– Explain important special considerations in braze welding cast and malleable iron, brazing aluminum, and brazing stainless steel.
– List the safety precautions necessary for brazing and braze welding operations.
– Explain how soldering differs from brazing and describe the materials and procedures used in soldering.

Lesson 5 - Surfacing Techniques


Thermal spraying; Hard facing; Flame spraying; Surfacing materials; Preparation; Safety

Learning Objectives:
– Define hard face welding and thermal spraying as used for surfacing purposes and discuss general uses of each.
– Discuss advantages and disadvantages of detonation-gun, plasma, and electric arc thermal spraying and explain how each is done.
– Describe the processes of torch hard facing and flame spraying.
– Name several common surfacing materials and discuss one or more characteristics of each.
– List the steps, including those for surface preparation, in repairing a shaft by means of thermal spraying.
– Discuss the safety precautions necessary to prevent or minimize hazards from surfacing processes.