Lesson 1 - Shielded Metal Arc Welding

Topics:

Welding current; Arc length; Welding machines; Polarity; Tools and accessories; Electrodes; Setup and operation; Personal protection

Learning Objectives:
– Explain how the shielded metal arc welding process works.
– Tell what provides the shield in shielded metal arc welding.
– Define arc length and explain its importance.
– List factors to consider when selecting an electrode.
– Describe the personal protective equipment necessary for welding.


Lesson 2 - Selecting Electrodes for SMAW

Topics:

Electrode identification; Current ranges; Electrode coverings; Handling, storing, and conserving electrodes

Learning Objectives:
– Explain the factors involved in selecting SMAW electrodes.
– Explain how to identify different welding electrodes.
– Give examples of several kinds of electrode coverings and tell when each is used.
– Describe correct procedures for handling, storing, and conserving electrodes.


Lesson 3 - Gas Metal Arc Welding

Topics:

GMAW vs SMAW; Metal-transfer methods; Shielding gases; Electrode wire; Equipment and accessories; Gun operation; Safety

Learning Objectives:
– Name and describe the three basic types of metal transfer for GMAW.
– Name the most common shielding gases used in GMAW and tell what factors influence their selection.
– List factors that affect the selection of an electrode for GMAW.
– Describe GMAW gun operation.


Lesson 4 - Gas Tungsten Arc Welding

Topics:

GTAW process, equipment, current, torches, and electrodes; Shielding gases; Filler metals; Adding filler metal; Spot welding; Safety

Learning Objectives:
– List the advantages of GTAW over other welding processes.
– Describe the equipment and supplies needed for GTAW.
– Explain the purpose of the electrode in GTAW and tell how this differs from other types of welding.
– Properly select shielding gases and filler metals for GTAW.
– Describe how to use GTAW to weld common metals.


Lesson 5 - Other Welding Processes

Topics:

Resistance, flash, percussion, flux-cored arc, submerged arc, plasma arc, stud, electron beam, laser beam, friction, and ultrasonic welding

Learning Objectives:
– Describe resistance spot welding and resistance seam welding.
– Define flash welding, upset welding, and percussion welding, and tell how they differ.
– Explain how submerged arc welding and plasma arc welding differ from other arc welding methods.
– Describe the three forms of friction welding.
– Describe two advantages of ultrasonic welding.


Lesson 6 - Preheating and Postheating

Topics:

Stress; Changes in properties; When to preheat and postheat; Preheating equipment and methods; Spot preheating; Postheating methods

Learning Objectives:
– Describe the effects of uneven or rapid heating and cooling on base metals and weld beads.
– Define the heat-affected zone and tell what changes can occur there during welding.
– Explain the benefit of preheating and when it should be used.
– List several factors in welding jobs that make postheating advisable.
– Describe methods and materials for preheating and postheating.


Lesson 7 - Welding Ferrous Metals

Topics:

Ferrous metal identification; Edge preparation; Welding cast iron, carbon steel, and alloy steel

Learning Objectives:
– Define ferrous metals and describe their characteristics, including weldability.
– Explain cleaning and edge preparation required prior to welding ferrous metals.
– Name the welding processes and practices that are used for different types and thicknesses of ferrous metals.
– List several different electrode types and their advantages for welding ferrous metals.
– Explain specific procedures to use when welding alloy steels.


Lesson 8 - Welding Nonferrous Metals

Topics:

Nonferrous metal identification; Edge preparation; Cleaning; Welding aluminum, stainless steel, nickel, and copper

Learning Objectives:
– Name the special properties of several nonferrous metals and explain how these properties affect welding preparations and procedures.
– Describe some of the methods of identifying different nonferrous metals.
– Compare seven arc cutting processes used for edge preparation of nonferrous metals.
– Explain proper methods of cleaning nonferrous metals prior to welding.
– Identify the welding processes that are suitable for nonferrous metals.


Lesson 9 - Pipe Welding

Topics:

Piping systems and joints; Codes; Pipe materials; Repair safety; Arc, oxyfuel welding processes; Types of welding joints; Edge preparation and fitup

Learning Objectives:
– Compare the advantages of welded pipe joints to bolted or screwed connections.
– Discuss pipe welding codes and what they cover.
– List the welding processes used for joining pipe and their advantages and disadvantages.
– Identify some special methods and accessories that are used in pipe welding as opposed to flat welding.
– Give examples of the uses of preheating and postheating in pipe welding.


Lesson 10 - Hard Facing and Rebuilding

Topics:

Surfacing alloys; Base metals; Preheating; Surface bonding; Oxyacetylene, manual arc, and automatic hard facing; Thermal spraying

Learning Objectives:
– List several purposes of hard facing and rebuilding.
– Identify the different types of surfacing alloys and their particular uses.
– Describe effective cross-checking and explain why it is desirable.
– Explain the special techniques used in hard facing and tell why they are necessary.
– Name the welding processes used in hard facing and tell why they are adapted to this work.