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0-2333 WELD LESSON PLANS

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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)
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

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
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

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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.
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