2010 Prince Edward Island Department of Education and Early Childhood Development P.O. Box 2000, Charlottetown Prince Edward Island Canada, C1A 7N8 Tel. (902) 368-4600 Fax. (902) 368-4622 http://www.gov.pe.ca/eecd/ Welding Technology Gas Tungsten Arc Welding (GTAW) (WEL801E) Course Description Gas tungsten arc welding is a precise method of welding various types of metal. GTAW is a process widely used in the welding fabrication industry. During this course students will learn to identify, describe, and safely use the equipment and tools required to perform GTAW welds in a variety of positions on various types of metal. Classroom Component—Suggested time: 19 hours This component of the curriculum is required to teach the knowledge and skills associated with the learning outcomes of the curriculum. Skill Development Component—Suggested time: 91 hours This component of the curriculum is required by the student to apply the knowledge and develop the skills related to the learning outcomes of the curriculum. SCO - Identifies the Specific Curriculum Outcome (SCO) Column 1 SCO - Delineations Describes what the students are expected to know, be able to do, and value in order to achieve the SCO. The teacher is responsible for the planning and facilitation of learning as well as the assessment of each SCO - Delineation. Column 3 Teacher Lessons / Demonstrations Provides suggestions for developing and delivering the content for student learning. Student Activities / Assessments Provides suggestions for creating meaningful activities to allow the student to achieve the SCO. Column 2 Student Knowledge, Abilities and Competencies Provides clarity to the SCO by describing the knowledge, abilities, and competencies that the students develop. This column is designed to indicate the depth and breadth of the SCO. It is not necessary to use all of these suggestions or that all of the students be engaged in the same learning activity. Column 4 Resources Lists a variety of resources that support the teaching and learning related to the SCO. These resources are suggested to support the teacher in developing an effective instructional package for delivery to the students. 1 CURRICULUM OUTCOMES Module 1: Materials Handling (~10 hours Classroom Component) 28. Students will be able to apply safe procedures for handling materials. Students will be expected to 28.1 identify safe procedures for handling and storing materials 28.2 determine weight and centre of gravity of loads 28.3 describe the effect that sling angles have on safe lifting 28.4 identify the load limits of commonly used wire rope slings and synthetic slings 28.5 describe the causes and effects of shock loading on rigging 28.6 identify relevant Occupational Health and Safety Regulations 28.7 identify and use hand signals for crane operations 28.8 describe safe procedures for lifting, hoisting, and moving loads 28.9 describe the purpose and use of knots 28.10 describe the care and use of wire rope, synthetic rope, and chains 28.11 describe the correct use of plate clamps 28.12 describe the correct procedure for applying cable clips Module 2: Introduction to GTAW Process (~2 hours Classroom Component) 29. Students will be able to apply safe work practices and procedures when using GTAW. Students will be expected to 29.1 describe the GTAW process and applications 29.2 explain the advantages and disadvantages of the GTAW process 29.3 explain hazards and protective measures associated with GTAW 29.4 identify the basic components of a GTAW work station 29.5 describe types of GTAW power sources 29.6 identify welding currents used in GTAW (a) AC current (b) DC current (c) High frequency current 29.7 describe the torch assembly 29.8 describe gas regulators and flowmeters 2 CAREER AND TECHNICAL EDUCATION CURRICULUM CURRICULUM OUTCOMES Module 3: GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) 30. Students will be able to select GTAW electrodes, filler metals, and gases. Students will be expected to 30.1 identify the function of the electrode in GTAW 30.2 identify electrodes by AWS designations and explain their applications 30.3 explain and demonstrate the care and preparation of electrodes 30.4 identify the function of the filler metals in GTAW 30.5 identify filler metals by AWS and CSA designations and explain their applications 30.6 identify types and purpose of consumable inserts 30.7 explain the care and handling of filler metals 30.8 describe the types and applications of shielding gases used in GTAW 30.9 describe the advantages and disadvantages of various types of shielding gases Module 4: GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) 31. Students will be able to maintain and troubleshoot GTAW equipment. Students will be expected to 31.1 diagnose power source output current problems and demonstrate corrective measures 31.2 diagnose GTAW torch and cable assembly problems and demonstrate corrective measures 31.3 explain the care and handling of GTAW equipment and components 31.4 diagnose shielding gas coverage problems and demonstrate corrective measures Module 5: GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. Students will be expected to 32.1 strike an arc using the touch start or lift start and high frequency methods 32.2 demonstrate the ability to weld stringer beads in the flat position on mild steel gauge plate 32.3 prepare joints for GTAW on mild steel gauge plate 32.4 demonstrate the ability to weld fillet welds in the 1F position on mild steel gauge plate 32.5 demonstrate the ability to weld fillet welds in the 2F position on mild steel gauge plate 32.6 demonstrate the ability to weld fillet welds in the 3F position on mild steel gauge plate CAREER AND TECHNICAL EDUCATION CURRICULUM 3 4 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) Materials Handling (~10 hours Classroom Component) Introduction Handling materials of various sizes, shapes, and weights is a common practice in the welding trade. An apprentice must be aware of all rules and regulations governing the handing of materials and be able to follow procedures to ensure their own safety and the safety of those working with them. Specific Curriculum Outcome 28. Students will be able to apply safe procedures for handling materials. SCO - Delineations Students will be expected to 28.1 28.2 28.3 28.4 28.5 28.6 28.7 28.8 28.9 28.10 28.11 28.12 identify safe procedures for handling and storing materials determine weight and centre of gravity of loads describe the effect that sling angles have on safe lifting identify the load limits of commonly used wire rope slings and synthetic slings describe the causes and effects of shock loading on rigging identify relevant Occupational Health and Safety Regulations identify and use hand signals for crane operations describe safe procedures for lifting, hoisting, and moving loads describe the purpose and use of knots describe the care and use of wire rope, synthetic rope, and chains describe the correct use of plate clamps describe the correct procedure for applying cable clips Assessment Strategies Paper/Pencil Self/Peer-Assessments Skills Performance Teacher Observation Career Portfolio Resources Alberta Module 120101j, Materials Handling National Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - Welder StudentsAchieve (http://sas.edu.pe.ca) CAREER AND TECHNICAL EDUCATION CURRICULUM 5 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: General Safety • Demonstrate an uderstanding of the standard personal protective equipment (PPE) required in the welding trade: - head protection - eye protection - ear protection - foot protection - limb and body protection • Demonstrate an ability to maintain a clean work environment. • Describe proper procedures for lifting and carrying loads. • Demonstrate an ability to follow lifting and carrying procedures. • Demonstrate an ability to store materials and supplies in a safe manner. 28.1 identify safe procedures for handling and storing materials 28.2 determine weight and centre of gravity of loads 28.3 describe the effect that sling angles have on safe lifting 6 Topic: Weight • Locate lifting and rigging information. • Calculate the weight of an object to be lifted. • Define “centre of gravity”. • Describe the effect of lifting an unstable load when the centre of gravity is not located directly below the hook. • Demonstrate an understanding of proper lifting and hoisting procedures. Topic: Sling Angle • Define “sling angle”. • Describe the rated capacity of a sling. • Describe the effect that sling angle has on the weight distribution across the legs. • Demonstrate knowledge of the sling stress formula. • Calculate the sling stress and determine the appropriate slings required to lift loads. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. Teacher Lessons / Demonstrations Resources Topic: General Safety • Review safety practices for the welding facility. • Have on display examples of all of the PPE that welders are expected to wear. • Review emergency exit plans. Texts / Teacher Resources Alberta Module 120101j Materials Handling pp. 2-9 Topic: Weight • Create visuals (overheads or slideshow) of images in the ILM to explain centre of gravity. Topic: Sling Angle • Create visuals (overheads or slideshow) of images in the ILM to explain sling angle. Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Numeracy • Develop a math-enhanced lesson on calculating the weight of structural shapes. • Develop a math-enhanced lesson on determining the amount of tension on a sling. • Refer to “Fractions” module (WEL701A) for an example of a mathenhanced lesson. Student Activities / Assessments • • Determine the centre of gravity for structural shapes. Practise safe work habits and proper housekeeping while working on shop projects. Literacy • Free Writing: Use as a pre-reading strategy. Write for 3 min. on experiences you have had related to general safety. Numeracy • Calculate the weight of structural shapes. • Calculate the amount of tension on a sling. CAREER AND TECHNICAL EDUCATION CURRICULUM 7 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Slings • Describe advantages of wire rope slings. • Define “working load limit”. • Calculate the working load limit of a wire rope. • Describe the advantages of synthetic slings. • Identify the configurations of synthetic web slings. • Demonstrtate an understanding of manufacturers’ specifications for web slings. 28.4 identify the load limits of commonly used wire rope slings and synthetic slings 28.5 describe the causes and effects of shock loading on rigging Topic: Shock Loading • Describe the actual working load of a wire rope. • Define “shock loading”. • Describe how to avoid shock loading. identify relevant Occupational Health and Safety Regulations Topic: Occupational Health and Safety • Reference sections of the P.E.I. Occupational Health and Safety Act that apply to rigging equipment. • Interpret Occupational Health and Safety Regulations. 28.6 8 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. Teacher Lessons / Demonstrations Resources Topic: Slings • Have on display examples of a variety of wire rope and synthetic slings. • Demonstrate how to read and interpret sling manufacturers’ tables and charts related to working load limits of wire ropes. Texts / Teacher Resources Alberta Module 120101j Materials Handling pp. 10-14 Topic: Shock Loading • Discuss the ways to avoid shock loading. Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder Topic: Occupational Health and Safety • Review the content in the ILM and share with students the P.E.I. Occupational Health and Safety Regulations related to rigging. StudentsAchieve (SAS) Numeracy • Develop a math-enhanced lesson related to calculating the working load limit of wire ropes. Student Activities / Assessments • • Component ID: Identify a variety of slings and wire ropes. Select the appropriate sling or wire rope for lifting operations. Literacy • Say Something (p.13 of Materials Handling ILM): Take time to model the strategy with a student or colleague and review the rules that will make for a successful Say Something. It is a good idea to post these rules so everyone can see them and be reminded of them during the activity: - With your partner, decide who will say something first. - When you say something, you should make a prediction, ask a question, clarify something you had misunderstood, or make a connection. - If you cannot do one or more of the above things, then you need to reread. CAREER AND TECHNICAL EDUCATION CURRICULUM 9 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. SCO - Delineations Students will be expected to 28.7 identify and use hand signals for crane operations 28.8 describe safe procedures for lifting, hoisting, and moving loads 28.9 describe the purpose and use of knots 10 Student Knowledge, Abilities, and Competencies Topic: Hand Signals • Describe the role of the signal person. • Demonstrate an understanding of common hand signals. Topic: Lifting, Hoisting and Moving • Define “softeners” and describe their function. • Describe the types of stress and abuse that are applied to slings. • Demonstrate an ability to perform visual inspections of rope and slings. • Describe the function of the tag line. • Describe factors that can cause an uneven loading on sling legs. • Identify the following sling arrangements: - single vertical hitch - bridal hitch (two and three leg) - single basket hitch - double basket hitch - double wrap basket hitch - single choker hitch - double choker hitch - double wrap choker hitch • Describe the function of spreader beams. • State the importance of levelling a crane. • Describe procedures for levelling a crane • Describe factors that affect the lifting of any load. • Define “load radius deflection”. • Describe precautions to follow when hoisting and carrying a load. Topic: Knots • Define “knot”, “bend”, “hitch” and “splice”. • Describe the effect that knots, bends, hitches, and splices have on rope strength. • Demonstrate an understanding of the purpose and function of each of the knots, bends, hitches, and splices listed below: - bowline, bowline on a bight, running bowline, self-centring bowline - figure of eight (or figure eight) - clove hitch, round turn and two half-hitches - timber hitch - sheet bend, carrick bend - cat’s-paw • Demonstrate an ability to tie each of the knots, bends, hitches, and splices listed above. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. Teacher Lessons / Demonstrations Topic: Hand Signals • Create for display in the welding facility a visual of the hand signals for crane operation. Topic: Lifting, Hoisting, and Moving • Review general safety rules regarding the hoisting and lifting of items in the welding facility. • Demonstrate the application of softeners. • Demonstrate the application of the various sling arrangements. • Create a slideshow to highlight the various types of sling arrangements. • Create a slideshow to help describe the process of levelling a crane. Resources Texts / Teacher Resources Alberta Module 120101j Materials Handling pp. 15-26 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Topic: Knots • Create visuals from the ILM (overheads or slideshow) to identify the difference between knots, bends, hitches, and splices. • Demonstrate how to tie each of the knots, bends, hitches, and splices listed in column 2. Literacy • Anticipation Guide: Use as a pre-reading strategy. Develop questions around the safe application and purpose of common knots, bends, hitches, and splices CBL • Arrange for students to visit an industry where numerous hoisting, lifting and jacking operations are performed (e.g., Georgetown Shipyard). • Arrange for students to visit a work site that involves the use of a crane and have them witness a real application of hand signals. • Arrange for a local crane operator to bring a crane to the school so students can use hand signals to direct the crane through a series of movements. Student Activities / Assessments • • • • • Role-play sets of crane operations with students as a class and in small groups. Practise hoisting and lifting a load using a variety of sling arrangements and using softeners when necessary. Label diagrams related to load radius. Tie each of the knots, bends, hitches, and splices listed in column 2. Use the correct knots, bends, hitches, and splices when handing materials in the shop Literacy • Free Writing: Use as a pre-reading strategy. Have students write for 3 min. on a experience you had in which you had to rely on a rope or a knot to perform a task. CAREER AND TECHNICAL EDUCATION CURRICULUM 11 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. SCO - Delineations Students will be expected to 28.10 describe the proper care and use of wire rope, synthetic rope, and chains 28.11 describe the correct use of plate clamps 28.12 describe the correct procedure for applying cable clips Student Knowledge, Abilities, and Competencies Topic: Care of Rope and Chains • Explain how a wire rope is constructed. • Explain the difference between an independent wire rope core and a fibre core. • Define “lay”. • Define “lay length”. • Describe the construction of a right lay regular lay wire rope. • Explain the difference between regular lay and lang lay rope. • Interpret wire rope classification tables. • Measure the size of a wire rope. • Define seizing and describe its function. • Describe precautions to take when installing new wire rope. • Describe the advantages of synthetic rope over natural fibre rope. • Demonstrate an understanding of the properties and uses of common ropes. • Describe factors that can reduce the breaking strength of a rope. • State safety factors to consider when lifting objects. • State safety factors to consider when lifting people. • Demonstrate an understanding of the advantages and disadvantages of lifting and hoisting using chains. • Identify grade 8 alloy (grade T) chain. • Describe the process of heat treating. • Demonstrate an ability to perform visual inspections of chains. Topic: Plate Clamps and Cable Clips • Describe the function of plate clamps. • Describe how to ensure the proper function of the plate clamps. • • • • 12 Describe the function of wire rope clips. Identify the two main types of wire rope clips. Demonstrate the abililty to correctly install both types of wire rope clips. Interpret manufacturers specifications on the use and installation of wire rope clips. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 1 Materials Handling (~10 hours Classroom Component) SCO 28. Students will be able to apply safe procedures for handling materials. Teacher Lessons / Demonstrations Topic: Care of Rope and Chains • Have on hand samples of right and left lay and right and left lang lay ropes for students to inspect. • Demonstrate how to seize a wire rope. • Demonstrate proper handling of wire rope. • Demonstrate the proper method of inspecting a chain. Topic: Plate Clamps and Cable Clips • Demonstrate the application of plate clamps and cable clips. • Demonstrate the proper method of inspecting plate clamps and cable clips. Resources Texts / Teacher Resources Alberta Module 120101j Materials Handling pp. 27-47 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Student Activities / Assessments • • • • Seize wire ropes. Set up an inspection schedule for chains, wire ropes, plate clamps and cable clips used in the welding facility. Replace a worn or damaged link in a chain. Use plate clamps and cable clips when necessary while performing hoisting and lifting operations. CAREER AND TECHNICAL EDUCATION CURRICULUM 13 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) 14 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) Introduction to GTAW Process (~2 hours Classroom Component) Introduction GTAW is a welding process which is used on a variety of metals where the utmost in weld quality is desired. Prior to performing a weld, an apprentice is required to select the specified welding process for the job. Being familiar with GTAW and the consumables used with it will allow the apprentice to make appropriate choices. Specific Curriculum Outcome 29. Students will be able to apply safe work practices and procedures when using GTAW. SCO - Delineations Students will be expected to 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 describe the GTAW process and applications explain the advantages and disadvantages of the GTAW process explain hazards and protective measures associated with GTAW identify the basic components of a GTAW work station describe types of GTAW power sources identify welding currents used in GTAW (a) AC current (b) DC current (c) high frequency current describe the torch assembly describe gas regulators and flowmeters Assessment Strategies Paper/Pencil Self/Peer-Assessments Skills Performance Teacher Observation Career Portfolio Resources Alberta Module 120202a, Introduction to GTAW Process National Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - Welder StudentsAchieve (http://sas.edu.pe.ca) CAREER AND TECHNICAL EDUCATION CURRICULUM 15 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: GTAW Process • Describe the GTAW process. • State applications of GTAW. • Describe the GTAW spot welding process. • State advantages and disadvantages of GTAW spot welding. • Describe hot and cold wire GTAW. • State advantages and disadvantages of hot and cold wire GTAW. 29.1 describe the GTAW process and applications 29.2 explain the advantages and disadvantages of the GTAW process 29.3 16 explain hazards and protective measures associated with GTAW Topic: Hazards • Apply and describe safety measures to be taken with GTAW in reference to: - electrical shock - eye, face, and hearing protection (PPE) - fire prevention - ventilation. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. Teacher Lessons / Demonstrations Resources Topic: GTAW Process • Discuss the GTAW process, its application, and its advantages and disadvantages. Texts / Teacher Resources Alberta Module 120102a Introduction to GTAW Process pp. 2-10 Topic: Hazards • Review the general safety regulations for the welding facility. • Demonstrate the application of the PPE required for GTAW. • Review fire safety regulations for the welding facility. Literacy Anticipation Guide: Use as a pre-reading strategy. Allow students to make assumptions about the GTAW process based on what they already know about other welding processes. Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Student Activities / Assessments • Label diagrams of the GTAW process. Literacy Summarizing: Use as a post-reading strategy. Use a graphic organizer similar to the example to help illustrate the advantages and disadvantages of GTAW. Compare and Contrast: Use as a post-reading strategy. Compare the process of GTAW to other welding processes (SMAW, GMAW, FCAW, OAW). CAREER AND TECHNICAL EDUCATION CURRICULUM 17 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. SCO - Delineations Students will be expected to 29.4 identify the basic components of a GTAW work station 29.5 describe types of GTAW power sources 29.6 identify welding currents used in GTAW: (a) AC Current (b) DC Current (c) High Frequency Current 18 Student Knowledge, Abilities, and Competencies Topic: GTAW Outfit and Power Sources • Identify the components of a GTAW work station. • Describe optional accessories that may be part of the GTAW work station. • Describe the process of pulsed GTAW and discuss its advantages. • • • • • Describe factors that affect the type of power source required. Describe the types of power sources available. Define “drooping”. State the classifications of power sources. Describe the features and controls built into a full function GTAW power source. Topic: Welding Currents • Define “amperage” and “voltage”. • State the welding currents used for GTAW. • Describe the resulting welding characteristics unique to each current type and polarity. • Describe the function and process of each of the following welding currents: - direct current electrode negative (DCEN) - direct current electrode positive (DCEP) - alternating current • Define “arc rectification”. • Define “DC component”. • List features that help with arc starting and arc stability. • Describe the principles of operation and discuss the advantages and disadvantages of the following: - high-frequency current - high voltage injection - AC square wave output - AC unbalanced and balanced wave control • Identify proper welding current for a variety of metals. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. Teacher Lessons / Demonstrations Topic: GTAW Outfit and Power Sources • Display all the components of a GTAW outfit. • Demonstrate how to set the power source to perform GTAW welds. Topic: Welding Currents • Create a slideshow of the graphics from the ILM to help illustrate the effects of welding current. Literacy Materials related to outcome 29.6 (pp. 20-27) in this module may be difficult for students to read. Help students understand how to read the text by modelling reading strategies. • Resources Texts / Teacher Resources Alberta Module 120102a Introduction to GTAW Process pp. 11-27 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Think Aloud and Say Something: Use as during-reading strategies. Take time when doing the Think Aloud to reflect on how it is you yourself make meaning when reading challenging trade-related text, and how you relate the topic to prior topics covered (e.g., SMAW and GMAW equipment). Take time to model the Say Something strategy with a student or colleague and review the rules that will make for a successful activity. It is a good idea to post these rules so everyone can see them and be reminded of them during the activity: - With your partner, decide who will say something first. - When you say something, you should make a prediction, ask a question, clarify something you had misunderstood, or make a connection. - If you cannot do one or more of the above things, then you need to reread. CAREER AND TECHNICAL EDUCATION CURRICULUM 19 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Torches • Describe the characteristics of both air-cooled and water-cooled torches. • Describe how GTAW torches are rated. • Identify the components of both an air-cooled and water-cooled torch. • Describe the function of each of the following components: - torch cap - torch body - collet body and electrode collet - gas nozzles - gas lenses • Assemble a GTAW torch with the correct equipment to perform a weld. 29.7 describe the torch assembly 29.8 describe gas regulators and flowmeters 20 Topic: Regulators and Flowmeters • Describe the function of a regulator. • Describe the function of a flowmeter. • Discuss points to consider when selecting a regulator and/or flowmeter. • Describe the function and characteristics of shielding gas hoses. • Describe the function of the solenid valves. • Read and interpret WHMIS MSDS on compressed gas cylinders. • Demonstrate an ability to assemble the gas cylinder valve and regulators. • Demonstrate an ability to adjust gas flow rate to required working rate. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 2 Introduction to GTAW Process (~2 hours Classroom Component) SCO 29. Students will be able to apply safe work practices and procedures when using GTAW. Teacher Lessons / Demonstrations Resources Topic: Torches • Make an overhead of figure 32. • Demonstrate how to disassemble a torch body. Texts / Teacher Resources Alberta Module 120102a Introduction to GTAW Process pp. 28-44 Topic: Regulators and Flowmeters • Review the set-up and operation of regulators and flowmeters. • Create visuals from the ILM. Student Activities / Assessments • • Assemble a GTAW air-cooled torch body. Label diagrams of GTAW torches. Literacy • Free Writing: Use as a pre-reading strategy. Write for 3 min. on experiences you have had working with torches, regulators, and flowmeters. CAREER AND TECHNICAL EDUCATION CURRICULUM Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Alberta ILM Graphics CD Welding Period 2 21 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) 22 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) Introduction A welder apprentice must develop a solid working knowledge of the electrodes, filler metals, and shielding gases used in all welding processes. This knowledge enables the apprentice to ensure that projects and welds conform to acceptable standards, and will help them to troubleshoot problems related to the welding process. Specific Curriculum Outcome 30. Students will be able to select GTAW electrodes, filler metals, and gases. SCO - Delineations Students will be expected to 30.1 30.2 30.3 30.4 30.5 30.6 30.7 30.8 30.9 identify the function of the electrode in GTAW identify electrodes by AWS designations and explain their applications explain and demonstrate the care and preparation of electrodes identify the function of the filler metals in GTAW identify filler metals by AWS and CSA designations and explain their applications identify types and purpose of consumable inserts explain the care and handling of filler metals describe the types and applications of shielding gases used in GTAW describe the advantages and disadvantages of various types of shielding gases Assessment Strategies Paper/Pencil Self/Peer-Assessments Skills Performance Teacher Observation Career Portfolio Resources Alberta Module 120202b, GTAW Electrodes, Filler Metals and Shielding Gases National Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - Welder StudentsAchieve (http://sas.edu.pe.ca) CAREER AND TECHNICAL EDUCATION CURRICULUM 23 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to 30.1 identify the function of the electrode in GTAW Topic: GTAW Electrodes • Describe the function of the electrode used for GTAW. • State the characteristics of tungsten that make it an effective electrode. • State the four alloying elements used to create tungsten alloys. 30.2 identify electrodes by AWS designations and explain their applications • • • • • 30.3 24 explain and demonstrate the care and preparation of electrodes Interpret AWS specifications for identifying GTAW electrodes. State factors to consider when selecting a tungsten electrode. Describe the function and intended use of common GTAW electrodes. Identify the finish on the electrode. Interpret data related to electrode selection from manufacturers’ tables and specifications. Topic: Care and Preparation • Describe the purpose of preparing electrodes. • State the application of tapered ends. • State the application of balled ends. • Describe the three methods of preparing electrodes. • Explain why grinding marks should be longitudinal. • Discuss how to keep an electrode in good condition when welding. • Practise safe work habits when handling and preparing electrodes. • Describe factors that influence electrode end conditions. • Predict potential problems based on the condition of the electrode. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. Teacher Lessons / Demonstrations Topic: GTAW Electrodes • Have a variety of common GTAW electrodes for display and for circulation through the class. • Review the AWS standards for the classification of GTAW electrodes. Topic: Care and Preparation • Create a slideshow using images from the graphics CD to help illustrate the various types of electrode preparation. • Demonstrate how to properly prepare an electrode. • Demonstrate how to inspect and recondition an electrode. Resources Texts / Teacher Resources Alberta Module 120102b GTAW Electrodes, Filler Metals, and Shielding Gases pp. 2-13 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder Student Activities / Assessments StudentsAchieve (SAS) • • • Alberta ILM Graphics CD Welding Period 2 Prepare GTAW electrodes for shop projects. Recondition GTAW electrodes. Select the appropriate GTAW electrode for shop projects. Literacy • Free Writing: Use as a pre-reading strategy. Write for 3 min. on experiences you have had identifying and working with welding electrodes. CAREER AND TECHNICAL EDUCATION CURRICULUM 25 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Filler Metals • Identify various forms of filler metals. • Describe factors to consider when selecting a filler metal. 30.4 identify the function of the filler metals in GTAW 30.5 identify filler metals by AWS and CSA designations and explain their applications • • • Describe AWS and CSA designations. Interpret specification tables related to filler metals for GTAW. Explain the characteristics of commonly used filler metals. 30.6 identify types and purpose of consumable inserts • • Describe advantages of using consumable inserts. Identify various forms of consumable inserts and state their intended function. 30.7 explain the care and handling of filler metals • Practise proper care and handling of filler metals. 26 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. Teacher Lessons / Demonstrations Topic: Filler Metals and Consumable Inserts • Have a variety of common GTAW filler metals for display and for circulation through the class. • Review the AWS standards for the classification of GTAW filler metals. • Demonstrate the application of a consumable insert and joint preparation. • Discuss the care and handling of GTAW filler metals. Student Activities / Assessments • • • Component ID: Identity a variety of filler metals and electrodes used with GTAW. Prepare joints for consumable inserts. Demonstrate proper care and handling of GTAW filler metals and electrodes. CAREER AND TECHNICAL EDUCATION CURRICULUM Resources Texts / Teacher Resources Alberta Module 120102b GTAW Electrodes, Filler Metals, and Shielding Gases pp. 14-22 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) 27 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Shielding Gases • Define terms related to shielding gases. • Interpret WHMIS information. • Explain the function of the shielding gas. • State the general application of each of the following shielding gases used for GTAW: - argon - helium - nitrogen - argon helium - argon hydrogen • Demonstrate an ability to regulate shielding gas flow rates. 30.8 describe the types and applications of shielding gases used in GTAW 30.9 describe the advantages and disadvantages of various types of shielding gases 28 Topic: Advantages and Disadvantages • Demonstrate an understanding of the advantages of various shielding gases. • Demonstrate an understanding of the disadvantages of various shielding gases. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 3 GTAW Electrodes, Filler Metals, and Shielding Gases (~4 hours Classroom Component) SCO 30. Students will be able to select GTAW electrodes, filler metals, and gases. Teacher Lessons / Demonstrations Resources Topic: Shielding Gases • Review the terms related to shielding gases. • Review the function and characteristics of shielding gases, and relate the content back to experiences the students would have had working with shielding gases in GMAW welding. Topic: Advantages and Disadvantages • Discuss table 4 and table 5 in the ILM (pp. 27-28). Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder Student Activities / Assessments • • Identify shielding gas problems from sample welds. Copy and complete a chart similar to the example below. Gas Characteristics / Applications Cost Texts / Teacher Resources Alberta Module 120102b GTAW Electrodes, Filler Metals, and Shielding Gases pp. 23-28 StudentsAchieve (SAS) Metals Literacy Summarizing: Use as a post-reading strategy. Use a graphic organizer similar to the example shown to help illustrate the advantages and disadvantages of GTAW. CAREER AND TECHNICAL EDUCATION CURRICULUM 29 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) 30 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) Introduction Keeping welding equipment running smoothly not only results in better quality welds, but also improves efficiency, which helps reduce the high cost of equipment down time. The more knowledgeable apprentices are about the function, operation, and maintenance of GTAW equipment, the better prepared they are to set welding parameters, diagnose problems, and take preventative steps to avoid future problems. Specific Curriculum Outcome 31. Students will be able to maintain and troubleshoot GTAW equipment. SCO - Delineations Students will be expected to 31.1 31.2 31.3 31.4 diagnose power source output current problems and demonstrate corrective measures diagnose GTAW torch and cable assembly problems and demonstrate corrective measures explain the care and handling of GTAW equipment and components diagnose shielding gas coverage problems and demonstrate corrective measures Assessment Strategies Paper/Pencil Self/Peer-Assessments Skills Performance Teacher Observation Career Portfolio Resources Alberta Module 120102c, GTAW Equipment Maintenance & Troubleshooting National Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - Welder StudentsAchieve (http://sas.edu.pe.ca) CAREER AND TECHNICAL EDUCATION CURRICULUM 31 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 4 GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) SCO 31. Students will be able to maintain and troubleshoot GTAW equipment. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Power Sources • Describe factors to consider when setting up and maintaining GTAW power sources: - location and hookup of the welding power source - torch assembly - shielding gas and gas control system - work lead - high-frequency current system - shut-down procedures • Interpret manufacturers’ information related to GTAW equipment maintenance. 31.1 diagnose power source output current problems and demonstate corrective measures 31.2 diagnose GTAW torch and cable assembly problems and demonstrate corrective measures 32 Topic: Torch and Cable Assemblies • Describe factors to consider when setting up and maintaining GTAW torch and cable assemblies: - torch handle and head - air-cooled GTAW torches - gas control valves - cable covers - nozzles - collet and collet body - gas lens - electrode condition • Interpret manufacturers’ information related to GTAW torches and cable assemblies. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 4 GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) SCO 31. Students will be able to maintain and troubleshoot GTAW equipment. Teacher Lessons / Demonstrations Topic: Power Sources • Demonstrate the proper assembly and adjustment of a GTAW set-up. Topic: Torch and Cable Assemblies • Demonstrate proper care, handling, and inspection of GTAW torch and cable assemblies. CBL • Guest Speaker: Invite a service person and salesperson from a local machine supplier to speak to the class about equipment maintenance. Resources Texts / Teacher Resources Alberta Module 120102c GTAW Equipment Maintenance and Troubleshooting pp. 2-18 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Student Activities / Assessments • • • Identify the components of the GTAW set-up. Correctly set up and adjust a GTAW set-up. Develop a routine maintenance schedule. Literacy • Free Writing: Use as a pre-reading strategy. Write for 3 min. on the value of and experiences you have had with equipment maintenance and troubleshooting. CAREER AND TECHNICAL EDUCATION CURRICULUM 33 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 4 GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) SCO 31. Students will be able to maintain and troubleshoot GTAW equipment. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Care and Handling • Demonstrate an understanding of the proper care and handling of the following components of the GTAW outfit: - regulator/flowmeter unit - hoses - remote control switches - cooling systems 31.3 explain the care and handling of GTAW equipment and components 31.4 diagnose shielding gas coverage problems and demonstrate corrective measures 34 Topic: Shielding Gases • Describe the following common problems related to shielding gases: - inadequate gas flow - excessive gas flow - incorrect gas selection • Describe the three categories of weld faults. - process - electrical - mechanical • Demonstrate an ability to diagnose GTAW weld faults related to the categories above. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 4 GTAW Equipment Maintenance and Troubleshooting (~3 hours Classroom Component) SCO 31. Students will be able to maintain and troubleshoot GTAW equipment. Teacher Lessons / Demonstrations Resources Topic: Care and Handling • Review the proper handling procedures and safety regulations related to a GTAW outfit. Texts / Teacher Resources Alberta Module 120102c GTAW Equipment Maintenance and Troubleshooting pp. 19-26 Topic: Shielding Gases • Review the tables on pp. 24-26 of the ILM. Literacy • Anticipation Guide: Use as a pre-reading strategy. The questions or statements made should relate to trouble shooting welding equipment with regard to process, electrical and mechanical problems. Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Student Activities / Assessments • • Identify various weld faults related to mechanical, process, and electrical problems. Implement a routine maintenance schedule. CAREER AND TECHNICAL EDUCATION CURRICULUM 35 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) 36 CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) Introduction A welder apprentice must be able to perform GTAW welds to an acceptable standard. This module is a hands-on, practical module that will develop students’ ability to perform GTAW welds on mild steel plate. Specific Curriculum Outcome 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. SCO - Delineations Students will be expected to 32.1 32.2 32.3 32.4 32.5 32.6 strike an arc using the touch start or lift start and high-frequency methods demonstrate the ability to weld stringer beads in the flat position on mild steel gauge plate prepare joints for GTAW on mild steel gauge plate demonstrate the ability to weld fillet welds in the 1F position on mild steel gauge plate demonstrate the ability to weld fillet welds in the 2F position on mild steel gauge plate demonstrate the ability to weld fillet welds in the 3F position on mild steel gauge plate Assessment Strategies Paper/Pencil Self/Peer-Assessments Skills Performance Teacher Observation Career Portfolio Resources Alberta Module 120102d, GTAW Welds on Mild Steel National Occupational Analysis (NOA), Human Resources and Skills Development Canada (HRSDC): Occupational Analyses Series - Welder StudentsAchieve (http://sas.edu.pe.ca) CAREER AND TECHNICAL EDUCATION CURRICULUM 37 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 5 GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) SCO 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to Topic: Starting the Arc • Demonstrate an understanding of the factors to consider when assessing the value of any welding technique. • Describe and practise safety procedures related to GTAW processes. • Define the terms identified on pp. 3-4 of ILM 120202d. • Interpret welding procedure specifications. • Create welding procedure specifications. • Perform welding techniques used for GTAW. • Demonstrate the ability to start the arc by means of - scratch start - high frequency start - lift start. 32.1 38 strike an arc using the touch start or lift start and high frequency methods CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 5 GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) SCO 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. Teacher Lessons / Demonstrations Topic: Starting the Arc • Create a slideshow to illustrate the proper method of starting the arc. • Demonstrate proper starting techniques. Student Activities / Assessments • • Create a Welding Procedure Specification (WPS) for eacj shop project. Have the students fold a piece of blank paper in half. Label the top half “scratch start” the bottom half “high-frequency start,” and the back “lift start”. Have students practice both methods of striking an arc by using a pencil or a felt tip marker. The marks left on the paper will help determine students’ understanding of both methods. Observe each student for proper technique and arc length. Resources Texts / Teacher Resources Alberta Module 120102d GTAW Welds on Mild Steel pp. 2-10 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Literacy • Summarizing: Use as a post-reading strategy after you have read the exercise. CAREER AND TECHNICAL EDUCATION CURRICULUM 39 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 5 GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) SCO 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. SCO - Delineations Student Knowledge, Abilities, and Competencies Students will be expected to • 32.2 demonstrate the ability to weld stringer beads in the flat position on mild steel gauge plate 32.3 prepare joints for GTAW on mild steel gauge plate 32.4 demonstrate the ability to weld fillet welds in the 1F position on mild steel gauge plate 32.5 demonstrate the ability to weld fillet welds in the 2F position on mild steel gauge plate 32.6 demonstrate the ability to weld fillet welds in the 3F position on mild steel gauge plate 40 For each of the exercises in the ILM that relate to outcomes 32.2–32.6 demonstrate the ability to - select/prepare and identify correct materials - prepare work area - interpret welding parameters - evaluate the quality of the final weld. CAREER AND TECHNICAL EDUCATION CURRICULUM WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) - MODULE 5 GTAW Welds on Mild Steel (~18 of 91 hours Skill Development Component) SCO 32. Students will be able to place stringer beads in the flat position, prepare joints for GTAW, and perform welds in the 1F, 2F, and 3F positions. Teacher Lessons / Demonstrations • • • Review and demonstrate proper safety procedures. Demonstrate set-up of GTAW welding parameters. Perform a class demonstration for each of the exercises. Student Activities / Assessments Complete each of the exercises in the ILM. Literacy • Summarizing: Use as a post-reading strategy after you have read the exercise. Resources Texts / Teacher Resources Alberta Module 120102d GTAW Welds on Mild Steel pp. 11-29 Software / Databases NOA, HRSDC: Occupational Analyses Series - Welder StudentsAchieve (SAS) Enrichment / Research Activities • Participate in Skills Canada competitions. CAREER AND TECHNICAL EDUCATION CURRICULUM 41 WEL801E - GAS TUNGSTEN ARC WELDING (GTAW) 42 CAREER AND TECHNICAL EDUCATION CURRICULUM