WELD 2333 LESSON PLANS Instructional Resources NCCER Welding Level 1 Trainee Guide, Paperback, 4th Edition, ISBN-13: 978-0-13-609969-7 Lincoln Electric “Arc Welding Safety” video MODULE 29101 – WELDING SAFETY NCCER Welding Level 2 Trainee Guide, Paperback, 4th Edition, ISBN-13: 978-0-13-609970-3 MODULE 29207 - GTAW Equipment and filler metals NCCER Welding Level 3 Trainee Guide, Paperback, 4th Edition, ISBN-13: 978-0-13-213512-2 MODULE 29304-10 - GTAW – Carbon Steel Pipe MODULE 29305-10 – GTAW –– Stainless Steel Pipe The Lincoln Electric Company (http://www.lincolnelectric.com/en-us/educationcenter/Pages/education-login-or-register.aspx) http://www.lincolnelectric.com/en-us/education-center/weldingsafety/Pages/weldingsafety.aspx “No Teacher Left Behind” (http://www.lincolnelectric.com/assets/US/EN/literature/ed122.pdf) o GTAW Overview http://www.lincolnelectric.com/en-us/support/welding-how-to/Pages/tig-weldingaluminum-detail.aspx Other EASB GMAW SAW and GTAW Filler Metal http://www.esabna.com/euweb/awtc/lesson6_10.htm EASB FCAW Filler Metal http://www.esabna.com/euweb/awtc/lesson7_1.htm WPS numbering https://www.mcaa.org/ncpwb/home/ncpwb-technical-resources/welding-procedurespecifications-wpss/ https://www.wpsamerica.com/welding_software_demo1.php o GTAW WELDING PROCEDURE SPECIFICATION WELD 2333 LESSON PLANS Materials, Equipment, and Supplies WELD 2333 ADVANCED GTAW LAB WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 MATERIALS ** WPS selected for final proficiency assessment CARBON STEEL PIPE (ALL POSITIONS) CARBON STEEL TUBE (ALL POSITIONS) ASSESSMENT: BASE MATERIALS (Per Student) CONSUMABLES (Per Student) (1) 8"L, 6"NPS (XXS) COUPON w/4 GROOVES ER70S-6 (8) 5"L, 2" (0.220"t) TUBE COUPON ER70S-6 ER70S-6 304SS PIPE (ALL POSITIONS) (1) 8"L, 6"NPS (XXS) COUPON w/4 GROOVES ER308 304SS TUBE(ALL POSITIONS) (8) 5"L, 2" (0.220"t) TUBE COUPON ER308 ASSESSMENT: ALUMINIUM PIPE (ALL POSITIONS) ASSESSMENT: 14 DISSIMILAR METAL WELDS 15 Proficiency Assessment ER308 (1) 8"L, 6"NPS (XXS) COUPON w/4 GROOVES ER6063 WELD 2333 LESSON PLANS WEEK 1 & 2 OBJECTIVE: The objective of the first two weeks’ lesson is review welding safety, setting up equipment for GTAW process and selecting the correct consumables for pipe welding. LECTURE: Syllabus Lincoln Electric “Arc Welding Safety” video Review MODULE 29101 – WELDING SAFETY Review MODULE 29207-09 - GTAW Equipment and filler metals EASB GMAW SAW and GTAW Filler Metal ** WPS selected for final proficiency assessment** Student will be assigned by the instructor the type of weld that they will write a WPS later in the semester. They can start researching this now. The assignment can change each semester and there will be different ones for each student at the discretion of the instructor. LAB: Perform GTAW on 8” long 6”NPS XXS carbon steel pipe with four grooves in different positions with ER70S-6 WELD 2333 LESSON PLANS Flat groove position 1G (rotated) Horizontal groove position 2G Vertical groove position 5G All position groove 6G All position groove 6GR (T, K, & Y Joints) WELD 2333 LESSON PLANS Flat fillet position 1F (rotated) Horizontal fillet position 2F Overhead fillet position 4F Fillet multiple position 6F Horizontal fillet position 2FR (rotated) Vertical fillet position 5F (fixed position) WELD 2333 LESSON PLANS WEEK 3 & 4 OBJECTIVE: The objective of these two weeks’ lesson is to review GTAW process of pipe welding and practice the process in the lab. Instructor will demonstrate correct gun work angles and travel positions for non-rotated welding. LECTURE: LAB: Review MODULE 29304-10 – GAS TUNGSTEN ARC WELDING (GTAW) – CARBON STEEL PIPE Perform GTAW on 5” long 2”NPS (0.220”th) carbon steel pipe in different positions with ER70S-6 WELD 2333 LESSON PLANS WEEK 5 OBJECTIVE: The objective of this week’s lesson is to review the basic GTAW principles for testing. The lab will continue to practice different weld positions and multi-pass techniques for groove welds LECTURE: LAB: Review for Exam #1 ASSESSMENT: QUALIFICATION PIPE: Perform GTAW in 2G position, 6” NPS Carbon Steel pipe with ER70S-6 Acceptance Criteria Uniform rippled appearance on bead face Craters and restarts filled to full cross section of weld Acceptable weld profile in accordance with the ASME Boiler and Pressure Vessel Code – Section IX Smooth transition with complete fusion at the toes of the weld • Complete uniform root reinforcement at least flush with the inside of the pipe to a maximum of 1⁄8" No porosity, overlap, inclusions, cracks, or excessive undercut Smooth transition and complete fusion at toe of weld Proper PPE used and safety procedures followed WELD 2333 LESSON PLANS WEEK 6 & 7 OBJECTIVE: The objective of these two weeks’ lesson is to assess the comprehension of the GTAW principles for pipe welding and begin to introduce pipe welding on stainless steel LECTURE: Exam #1 Review MODULE 29305-10 – GAS TUNGSTEN ARC WELDING (GTAW) – STAINLESS STEEL PIPE and discuss heat requirements for working with stainless steel alloys. LAB: Perform GTAW on 8” long 6”NPS XXS stainless steel pipe with four grooves in different positions with ER308 WELD 2333 LESSON PLANS WEEK 8 & 9 OBJECTIVE: The objective of these two weeks’ lesson is to cover pipe welding on stainless steel alloys. The students will practice multi-pass pipe welds in various positions, rotated and non-rotated. LECTURE: Continue MODULE 29305-10 – GAS TUNGSTEN ARC WELDING (GTAW) – STAINLESS STEEL PIPE LAB: Perform GTAW on 5” long 2”NPS (0220 th) stainless steel tube in different positions with ER308. WEEK 10 OBJECTIVE: The objective of this week’s lesson is to review WPS requirements and demonstrate the ability to weld a stainless steel pipe in a 5G position. LECTURE: Review process of creating a WPS. LAB: ASSESSMENT: QUALIFICATION PIPE: GTAW in 5G position, 6” NPS Stainless Steel pipe with ER 308. Acceptance Criteria Uniform rippled appearance on bead face Craters and restarts filled to full cross section of weld Acceptable weld profile in accordance with the ASME Boiler and Pressure Vessel Code – Section IX Smooth transition with complete fusion at the toes of the weld • Complete uniform root reinforcement at least flush with the inside of the pipe to a maximum of 1⁄8" No porosity, overlap, inclusions, cracks, or excessive undercut Smooth transition and complete fusion at toe of weld Proper PPE used and safety procedures followed WELD 2333 LESSON PLANS WEEK 11 & 12 OBJECTIVE: The objective this week’s lesson is to review the GTAW process of pipe welding on stainless steel piping. The student will be introduced and practice the process of pipe welding on aluminum piping with different positions and multi-pass welds. LECTURE: Review for Exam #2 TIG Welding Aluminum LAB: Perform GTAW on 8” long 6”NPS XXS aluminum pipe with four grooves in different positions with ER6063 WELD 2333 LESSON PLANS WEEK 13 OBJECTIVE: The objective of this week’s lesson is to review and assess GTAW on stainless steel for testing. The students will be demonstrating their ability to make a GTAW pipe weld on aluminum piping. LECTURE: Exam #2 A Guide to Aluminum Welding LAB: ASSESSMENT: ASSESSMENT: QUALIFICATION PIPE: Perform GTAW in 6G position, 6” (XXS) NPS Aluminum pipe with ER308 Acceptance Criteria Uniform rippled appearance on bead face Craters and restarts filled to full cross section of weld Acceptable weld profile in accordance with the ASME Boiler and Pressure Vessel Code – Section IX Smooth transition with complete fusion at the toes of the weld • Complete uniform root reinforcement at least flush with the inside of the pipe to a maximum of 1⁄8" No porosity, overlap, inclusions, cracks, or excessive undercut Smooth transition and complete fusion at toe of weld Proper PPE used and safety procedures followed WELD 2333 LESSON PLANS WEEK 14 OBJECTIVE: The objective of this week’s lesson is to review any advanced GTAW applications and practice making welds with various pipe materials and rods. LECTURE: Discuss dissimilar metal welding. LAB: Introduce and practice dissimilar metal welds. WEEK 15 OBJECTIVE: The objective of this week’s lesson is to complete a WPS for pipe welding and demonstrate the actual pipe weld in an advanced position. LAB: *Proficiency Assessment* Qualification PIPE Student's choice: GTAW, any position per written WPS** Submit a welding procedure specification (WPS) with the type of weld and procedure selected at the beginning of the term.
