Chabot College
Fall 2010
Course Outline for Welding Technology 66
WELDING INSPECTION AND TESTING
Catalog Description:
66 - Welding Inspection and Testing
(May be repeated 3 times)
2 units
Theory and practical application of inspection testing using destructive and non-destructive methods
(dye penetration method, magnetic particle, radiographic, ultrasonic, and metallographic inspection),
AWS (American Welding Society) welding codes and specification, analysis of joint configuration, wire
and electrodes selections, tensile strength, bend and hardness testing. Strongly recommended:
Welding Technology 65B or Industrial Technology 74. 1 hour lecture, 3 hours laboratory.
[Typical contact hours: lecture 17.5, laboratory 52.5]
Prerequisite Skills:
None
Expected Outcomes for Students:
Upon completion of the course, the student should be able to:
1. properly describe, identify, and set welding equipment according to manufacturer
requirements, relevance and functionality;
2. handle welding and shop equipment in a safe manner;
3. demonstrate proper usage of welding power supply;
4. properly identify metals and metal alloys’ weld-ability;
5. understand and interpret metallurgical transformation in welds and welding heat affected area;
6. correctly identify and use electrodes, flux-core wires and welding consumables;
7. read, understand and apply; blueprints, welding symbols, and shop sketches;
8. perform mathematical calculation from blue prints and welding symbol dimensions;
9. identify OSHA hazardous material and apply safety norms in shop environment;
10. list requirements and duties of a welding inspector;
11. perform welding destructive tests, record test data, and write critiques for test results;
12. explain existing non-destructive testing systems, state their limitations and optimum
applications;
13. locate, recognize and explain possible reasons for observed weld discontinuities and defects
and suggest specific correctional procedures to be employed;
14. perform welds tests according to procedures used by certified test laboratory.
Course Content (Lecture):
1. Welding power supplies and their application
2. Metallurgical welding related transform and their relevance to the welding industry
3. Welding techniques applied to perform welds in 1G, 2G 3G, 4G, 1F,2F 3F, and 4F welding
positions
4. The weld-ability of metals and their alloys
5. Welding procedure qualifications in accordance with AWS
6. OSHA industrial safety requirements regulations
7. Metallurgical aspects of welding testing
8. Technical math application and methods of weld cost calculation
9. Equipment and shop maintenance
Chabot College
Course Outline for Welding Technology 66, Page 2
Fall 2010
10.
11.
12.
13.
Welding certification preparation
Welding inspection concepts and practices (destructive, non-destructive)
State procedures welders qualifications
Writing and recording report testing data according with AWS requirements
Course Content (Laboratory):
1. Welding power supplies selection and settings related to their application
2. Metallurgical welding related transformations and their relevance to the welding industry
3. Welding practice on plates and profiles applying 3G, 4G, 3F, and 4F welding positions
4. Demonstration and practice of weld-ability of similar and dissimilar metals and their alloys
5. Indentify and reason related metallurgical and non-metallurgical welding discontinuities and
defects ascertaining proper control related techniques in order to satisfy AWS testing
required standards
6. Identify and apply appropriate procedures for the elimination of hazardous materials according
to the OSHA material safety data sheet
7. Observation of welding metallurgical microstructure on tested welding specimens and of
structural modification in HAZ (heat affected zone)
8. Assessing the various layouts and fitting designs on welding costs including technical math
calculations
9. Perform Equipment and shop maintenance
10. AWS welding performance test in processes in 3G, 4G, 3F, and 4F welding positions
11. Performance of destructive and nondestructive tests using plasma and fuel cutting practice
and shop related equipment
12. Collective and individual observation and participation of complete inspection processes
13. Inspection report writing and record keeping of performed welding specimens in compliance
with AWS requirements
Methods of Presentation:
1.
2.
3.
4.
5.
6.
Lectures
Videos
Demonstrations
Models
Destructive tests specimens models
AWS technical testing rapports adds
Methods of Evaluating Student Progress:
1. Typical Assignments
Complete a GMAW process welding practice test on a 1” plate in 3G position. Prepare out of
it two welding test specimens and execute the respective destructive tests (one face up, one
face down). Inspect the tested specimens, critiques the test results, record test data and write
an objective report with your technical finding.
a. Obtain 1 in. plate and oxyacetylene cut and bevel along the longest side at 30 degree
angle two 7 in. by 4 in. plates
b. Obtain 232 tubular flux core wire
c. Set the power supply on DC straight polarity (with 20.5 volts, 150 inch/minute wire speed)
d. Set up and tack plates at each end tack plates in the vertical position (make sure that it is
connected to the work connection)
e. Perform a root pass followed by a hot pass
f. Chip the slag from the weld brush and inspect
Chabot College
Course Outline for Welding Technology 66, Page 3
Fall 2010
g.
h.
i.
j.
k.
l.
Perform the rest of the passes as many as necessary
Chip the slag from the weld brush and inspect
Submit the welds for instructor inspection
Practice until will produce consistently sound welds
Cut two 1 &1/2 in. testing specimens across the practiced welds and perform two bending
tests one face up and the second face down
Inspect and discuss the results with your instructor
2. Methods of Evaluating Student Progress
a. Class participation
b. Performance of laboratory tasks, assignments, and projects
c. Homework assignments
d. Student projects and laboratory written reports
e. Quizzes
f. Midterm examination
g. Final examination
Textbook(s) (Typical):
Weld Inspection and Testing, American Welding Society, 2007
Special Student Materials:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Welding protective clothing
Welding gloves
Welding goggles
Welding helmet
Welding safety glasses
Welding jacket
Welding boots
Pure tungsten 3/32 rod
2% thorium oxide tungsten 3/32 rod
DR
Weld 66 course outline
Revised: Sept2009