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WLD 253 SMAW Certification Practice 3/8" Mild Steel (E6011)

WLD 253 SMAW Certification Practice 3/8 Mild Steel (E6011)Chapter 19, Welding Codes, Standards, and Costs Chapter 20, Testing and Inspection of Welds Chapter 21, Welder Certification

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WLD 253 SMAW Certification Practice

3/8" Mild Steel (E6011)

WLD 253 9/16/05 NSF-ATE Project - Advanced Materials Joining for Tomorrow’s Manufacturing Workforce

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Index Syllabus

3-9

Visual Inspection Criteria

10-17

Math On Metal 18-20

Science on Steel 21-27

Worksheets: • Quality Control and Performance

Qualification

28-32

Craftsmanship Expectations for Welding Projects

33

Information Sheets: • Plate Fit-up • Root Pass Inspection and Inter Pass

Cleaning • Bend Test Procedures

34-3536

37-41

Welding Projects 42-45

Information Sheets • 3/8” Test Plate Information • Testing Procedures • Helpful Hints

46-4849-51

52

Final Exam Information

53-56

Grading Rubric for the Practical Exam

57

Assessment Breakdown for the Course

58

Supplemental Videos See Welding Resource Room

This project was supported, in part, by the

National Science Foundation Opinions expressed are those of the authors And not necessarily those of the Foundation

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Portland Community College Welding Technology 17705 NW Springville Road Lec/Lab Course Syllabus Portland, OR 97229 Building Location Welding lecture: Bldg. 2, Rm. 132a/b Welding lab: Bldg. 2, Rm. 131 Phone (503) 614-7226 Time & Days Morning Shift 7am to 12:50 pm Monday through Thursday Afternoon Shift 10 am to 3:50 pm Monday through Thursday Evening Shift 4pm to 9:50 pm Monday through Thursday Instructors Connie Christopher Office Bldg. 2 Rm. 232c, Phone (503) 614-7502 Scott Judy Office Bldg. 2 Rm. 232, Phone (503) 614-7600 Matthew Scott Office Bldg. 2 Rm. 233b, Phone (503) 614-7601 Danny Merrick Office Bldg. 2 Rm. 232d, Phone (503) 614-7603 Introductory Statement Weld 253 SMAW Certification Practice 3/8" Mild Steel (E6011) is a course to prepare the student for the American Welding Society Mild Steel Welding Certification test(s) using SMAW mild steel electrodes in the vertical and overhead positions. The goal of this course is to develop the skills needed to pass a 3/8 inch groove weld plate test using the E6011 electrode. When the student has demonstrated this skill level through successful completion of two consecutive sets of shop tests, s/he will be given the option to take a qualification test that will be sent to an independent test lab for certification. This option is not required for the successful completion of this course and is at an additional cost to the student. This course uses a lecture/lab format that includes classroom discussions and lab demonstrations. Topics covered will include safety, uses, nomenclature, equipment operation and set-up and shutdown procedures for the oxyacetylene cutting and shielded metal arc welding. This is an outcome-based course that will allow the student to work at his/her own pace. The student will be required to follow all safety regulations and complete common cutting and welding projects in accordance with industry standards. The student is expected to complete all the exercises within this training packet

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INTENDED OUTCOMES FOR THE COURSE

Function safely in the PCC Welding Shop. • Understand and practice personal safety by using proper protective gear. • Understand and practice hand and power tool safety. • Understand and practice equipment safety for welding and oxy fuel cutting systems. • Understand and maintain a safe work area. Recognize and report dangerous electrical and air/gas hose connections. Understand and practice fire prevention. • Access and explain the importance Material Safety Data Sheets (MSDS). Demonstrate professional work ethics • Track training hours on time card. • Perform projects in accordance to specifications and procedures. • Follow directions in a positive manner. • Manage time productively. • Respects equipment and others. • Demonstrate skill in problem solving and decision-making. • Maintain quality workmanship standards. Prepare material to industry standards using the band saw; oxyfuel portable and track cutting systems and grinders • Identify major components of the saw. • Explain safe operational procedures for the saw.

• Demonstrate the safe operation of the saw. • Demonstrate correct setup and shutdown procedures for the hand cutting and track cutting

systems. • Perform oxyfuel cutting with guided practice. • Identify the major components of the grinders. • Explain safe operational procedures for the grinders. • Demonstrate the safe operation of the grinders. Interpret drawing and symbols to accurately layout, prepare and assemble weld joints • Interpret lines, symbols and verbiage on project drawing. • Layout material per drawing specifications. • Use the oxyfuel cutting process to cut material to specified dimensions. • Grind material to meet specifications. • Assemble weld project per specification.

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Weld test assembly with the E6011 to code quality standards in the vertical and overhead positions • Use correct terminology. Define terms used in the SMAW process. • Equipment identification, setup, shut down, and principles of operation for SMAW. Power source identification and adjustment. Welding lead, connections, inspection, and use. Electrode identification, characteristics, and use. • Know essential variables of SMAW by demonstrating the effects of the following variables:

current, travel speed, electrode angle and arc length. • Demonstrate correct welding techniques with the E6011. Starting and stopping. Overlapping welds. Follow welding procedure. • Demonstrate correct welding techniques in the following joints: Vertical Position - Single v-groove weld. Overhead Position - Single v-groove weld. • Demonstrate visual examination principles and practices in accordance AWS D1.1 Structural

Steel Code. Develop knowledge of AWS D1.1 requirements in qualification procedures.

Use Welding Procedure Specification to set up and weld qualification coupons. Develop knowledge and skills of the welder qualification procedures on 3/8” plate

coupons using E6010. Utilize welding code to reference weld profile inspection criteria. Prepare and bend test plates in accordance with AWS D1.1. Evaluate Bend test samples in accordance with AWS D1.1 to determine acceptability. Attendance Policy Students are expected to attend all class meetings for which they are scheduled. Repeated absence will effect the student’s grade. Students are responsible to officially withdraw from a class when s/she stops attending. If a student has excessive absences and fails to withdraw, a grade of F will be assigned. Students who do not attend or stop attending class(es) and fail to personally drop within the refund period, will be responsible for all tuition and fees. Full-time students (12 credits ) are required to attend class daily for the entire class period. Part-time students are required to schedule their days and hours of attendance with their instructor. Class dates are established at the beginning of the course. Absence from a scheduled class does not entitle a student to extend their course end date. STUDENTS MAY ATTEND SCHEDULED HOURS ONLY THERE ARE NO MAKE UP HOURS. YOUR INSTRUCTOR MUST APPROVE ANY CHANGE IN COURSE SCHEDULE.

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Course Assignments Reading

Welding Principles and Applications by Larry Jeffus. Chapter 19, Welding Codes, Standards, and Costs Chapter 20, Testing and Inspection of Welds Chapter 21, Welder Certification

ANSI/AWS D1.1 Structural Welding Code, Performance Qualification Work Sheets

Quality Control Performance Qualification

Welding Projects

3G Certification Preparation 4G Certification Preparation Bend Test Procedures

Final Exam

Closed Book Test Timeline Open-entry, open-exit instructional format allows the student to work at his/her own pace. It’s the student’s responsibility to complete all assignments in a timely manner within your pre-scheduled time. See your instructor for assistance. Outcome Assessment Policy The student will be assessed on his/her ability to demonstrate the achievement of course outcomes. The methods of assessment may include one or more of the following: oral or written examinations, quizzes, written assignments, visual inspection techniques, welding tests, safe work habits, task performance and work relations. Grading criteria

The student's assessment will be based on the following criteria: 20% of grade is based on Safe work habits and shop practices 20% of grade is based on Completion of written and reading assignments 20% of grade is based on demonstrating professional work ethics 40% of grade is based on completion of welding exercises

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Grading Scale 90 - 100% A – Superior Honor grade indicating excellence. Earned as a result of a combination of some

or all of the following as outlined in the course training packet. Superior examination scores, consistently accurate and prompt completion of assignments, ability of to deal resourcefully with abstract ideas, superior mastery of pertinent skills, and excellence attendance. Probable success in a field relating to the subject or probable continued success in sequential courses.

80 - 89% B - Above average Honor grade indicating competence. Earned as a result of a combination of some

or all of the following as outlined in the course training packet. High examination scores, accurate and prompt completion of assignments, ability to deal with abstract ideas, commendable mastery of pertinent skills and excellent attendance.

Probable continued success in sequential courses.

70 - 79% C – Average Standard college grade indicating successful performance earned as a result of a combination of some or all of the following as outlined in the course training packet. Satisfactory examination scores, generally accurate and prompt completion of assignments, ability to deal with abstract ideas, fair mastery of pertinent skills and regular attendance. Sufficient evidence of ability to warrant entering sequential courses.

60 - 69% D – Substandard Substandard but receiving college credit. Substandard grade indicating that the

student has met only minimum requirements as outlined in the course training packet. Earned as a result of some or all of the following: low examination scores, generally inaccurate, incomplete or late assignments, inadequate grasp of abstract ideas, barely acceptable mastery of pertinent skills, irregular attendance, insufficient evidence of ability to make advisable the enrollment in sequential courses. Does not satisfy requirements for entry into course where prerequisite are specified.

0 - 59% F – Failure Non-passing grade indicating failure to meet minimum requirements as outlined

in the course training packet. Earned as a result of some or all of the following: non-passing examination scores, inaccurate, incomplete or late assignments, failure to cope with abstract ideas, inadequate mastery of pertinent skills, repeated absences from class. Does not satisfy requirements for entry into course where prerequisites are specified.

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Pass Acceptable performance A grade of “P” represents satisfactory achievement that would have been graded “C” or better on the grading scale, but is given instead of a letter grade. By the end of the eighth (8th) week of class (or equivalent) students shall choose the graded or pass option. By the end of the eighth (8th) week of class or equivalent), students may rescind an earlier request of the pass option.

No Pass No Pass Unacceptable performance or does not satisfy requirements for entry into courses where prerequisites are specified. This grade may be used in situations where an instructor considers the “F” grade to be inappropriate. The NP mark is disregarded in the computation of the grade point average.

CIPR Course In Progress Re-register A mark used to only for designated classes. To receive credit, a student must

reregister because of equipment usage is required. This may include course in modular or self-paced programs. This mark may also be used in skill-based course to indicate that the student has not attained the skills required to advance to the next level. If the course is not completed within a year, the “CIPR” changes to an “AUD” (Audit) on the transcript unless the course was repeated and a grade earned.

AUD Audit Some courses may allow the students to attend a course without receiving a grade

or credit for the course. Tuition must be paid, and instructor permission must be obtained during the first three weeks of class (or equivalent). Instructors are expected to state on their course handouts any specific audit requirements. Does not satisfy requirements for entry into courses where prerequisites are specified.

Repeated Courses Courses with grades of “D,” “F,” “NP,” or “CIP,” and “CIPR,” may be repeated

for a higher grade. All grades earned will appear on the transcript. The first earned grade of “C” or “P” or better will count in the accumulated credit total. The first grade of “C” or better will be used for the GPA calculation.

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SPECIAL If you have a special limitation or disability, which requires special assistance NOTE: please notify your instructor. IMPORTANT:

Grades will no longer be mailed to you automatically. You may request a copy by calling: T.R.A.I.L. at 977-5000 and select Option 4. Or you can access your grades on the World Wide Web at https://banweb.pcc.edu/.

Notice: All projects must be completed in the PCC Welding Lab within your course time.

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Visual Inspection Criteria For

Welding Certification Tests This section will familiarize the student with inspection criteria that will be applied to the evaluation of their projects. PCC Welding Department utilizes the visual inspection requirements set forth under the Welder Qualification Section in AWS D1.1 Code. The following criteria are gathered from this source.

Summary of Visual Inspection Criteria for Welder Qualification

A. The test must be complete. The full length (6”) of the test plate will be visually inspected. Use your run off tabs throughout the test to insure quality results at the start and finish at both ends of the plates. All craters shall be filled to the full cross section of the weld.

B. Reinforcement layer (cover pass) height shall be Flush to 1/8” (3 mm) above the

plate.

C. A reinforcement layer higher that 1/8” (3 mm) will not be accepted.

D. Weld width cannot exceed ¼” wider than original groove opening.

E. Weld shall merge smoothly with the base metal.

F. Weld must be free of porosity, slag inclusions, and/or cold lap.

G. Undercut shall not exceed 1/32 in. (1 mm).

H. Arc strikes outside of the weld area are NOT acceptable.

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Undercut Is a condition where the base metal has been melted away during the welding operation and there is insufficient filler metal deposited to adequately fill the resulting depression. These grooves vary in depth and length. Undercut can be present at a weld-to-weld junction or a weld to base metal junction (toe of weld). Undercut causes a stress concentration point (stress riser) that is a potential starting point for weld cracking.

Causes: Improper welding technique Arc length too long

Oscillation too abrupt, not spending enough time on the sides of the puddle. Amperage too high Base material too hot Travel speed too fast Maximum undercut allowed is 1/32” in depth for welder qualification tests.

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Cracks Cracks are caused by stresses in the immediate area that exceed the strength of weld metal or base metal (tensile strength). Cracks are a major concern because of their ends, which are generally sharp and jagged. With increased stress, the crack can then propagate (travel) in the weld or base metal causing catastrophic (total) failure.

Maximum Cracks Allowed: None

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Porosity Cavity type discontinuities caused by gas trapped during weld solidification. Due to its spherical shape, porosity is considered the least detrimental discontinuity.

Causes: Loss of shielding gas Base metal contamination (oils, grease, water) Too long of an arc.

Visual porosity is unacceptable for a Welder qualification test

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Overlap (Also known as: Cold Lap, Roll Over or Cold Roll) Is the protrusion of weld metal beyond the weld toe or root. Due to its linearity and relatively sharp end condition, over lap represents a significant weld discontinuity. None Allowed

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Slag Inclusions Slag is a nonmetallic by product of the welding process. If slag is not cleaned out thoroughly prior to depositing the next pass it can be trapped. Or, if the previous weld(s) have poor weld profile slag can become trapped in the crevices when welded over. Improper cleaning, improper electrode manipulation or poor bead placement most often causes slag inclusions. Slag Inclusion

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Weld Profile Reinforcement Minimum: Flush with base metal Maximum: 1/8” high Bead Contour Smooth transition from bead to bead and weld metal to base metal.

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Math

on

Metal The Welding Fabrication Industry needs qualified welder fabricators who can deal with a variety of situations on the job. This portion of the training packet explores mathematics as it relates to industry requirements.

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Conversion between Celsius and Fahrenheit—WLD 253

Name: ________________________________ Date: _______________________

(Refer to the Solving formulas and Order of Operations to remember how to substitute numbers into formulas and calculate a solution) F = Fahrenheit C = Celsius Formulas to use: F = 9/5 C + 32 C = (F – 32) ÷ 1.8 or C = 5/9 (F – 32) Convert the following Celsius values to Fahrenheit temperatures: Example: C = 200° F = 9/5 (200) + 32 F = 360 + 32 F = 392

1. C = 0° 2. C = 10° 3. C = 20° 4. C = 30° 5. C = 100° 6. C = 250°

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Convert the following Fahrenheit values to Celsius (metric) temperatures:

Example: F = 1000° C = (1000 – 32) ÷ 1.8 OR C = 5/9(1000-32) C = 968 ÷ 1.8 C = 5/9(968) C = 537.78 degrees C = 537.78 degrees 7. F = 400° (max. interpass temp.) 8. F = 200° (preheat plates) 9. F = 1600° (kindling temp)

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Science

on

Steel The Welding Fabrication Industry needs qualified welder fabricators who can deal with a variety of situations on the job. This portion of the training packet explores science as it relates to industry requirements.

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Mild Steel E6011 Certification Contents of this Packet

- Introduction - Importance of Code Qualification - Why Mechanical Properties Testing? - AWS D1.1 Structural Welding Code – Steel - Significance of Bend Testing - Effect of the E6011 vs. E7018 Electrodes on Bend Test Results - Tensile Testing and Charpy V-Notch Impact Testing

Introduction This packet covers the welder certification using E6011 cellulosic electrodes (for WLD-253), and E7018 low-hydrogen electrodes (for WLD-254) on mild steel plate per AWS D1.1 Structural Welding Code – Steel. Although the E6011 and E7018 electrodes operate differently (as discussed in previous science packets), the testing required for welder qualification per AWS D1.1 are similar. E6011 is primarily an AC, deep-penetrating, all-position electrode, which uses cellulose to provide gaseous shielding. This allows the welder to have a clear view of the keyhole in open root welding. E7018 is a lime-based, iron-powder, low-hydrogen electrode, which provides a slag as the primary source of shielding and high deposition rate. Importance of Code Qualification In all industries, there are applicable codes and standards to assure the quality, reproducibility, and adequacy of welded joints. Depending upon the application, a welded joint may need certain mechanical properties; for example, welds on bridges must pass tests for strength, tensile ductility, bend ductility, and Charpy impact toughness. These codes are based on many years of experience. Changes to codes are ongoing to reflect the dynamic changes that taking place in the industry. There are many welding codes to ensure quality welding. For example, the following is a list of only a few typical industries and governing codes for welding quality.

Pressure Vessels ASME Boiler and Pressure Vessel Code (Vol. IX – Welding Qualifications

Pipe and Pipe Lines API Standard 1104; Standard for Welding Pipelines and Related Facilities

Pressure Piping ASME Code for Pressure Piping B31 All Steel Structures AWS D1.1 Structural Welding Code – Steel Buildings AISC Specification for Structural Steel

Buildings Bridges AASHTO/AWS D1.5; Bridge Welding Code Ships ABS Rules for Building and Classing Steel

Vessels Sheet Metal AWS D9.1; Sheet Metal Welding Code Automotive Frames ANSI/AWS D8.8; Specification for

Automotive Frame Weld Quality Aircraft MIL-STD-1595A; Qualification of Aircraft,

Missile, and Aerospace Fusion Welders

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Why Mechanical Properties Testing? In all codes for welded structures and pipe, various degrees of mechanical testing are performed to assure the quality and integrity of the structure. This includes both procedure qualification and welder qualification. For example, the procedure qualification for steel structures in accordance with the AWS D1.5 Bridge Welding Code–Steel requires that certain welds undergo all-weld-metal tensile testing, transverse-to-weld tensile testing, side bend testing, Charpy v-notch (CVN) impact testing as well as non-destructive testing. Mechanical testing is very important because it ensures that the welding procedure, welder qualification, consumables, and the resulting metallurgy of the weld and heat-affected zone are acceptable in accordance to code requirements. Although the procedure qualification per AWS D1.1 requires tensile tests, bend tests, CVN impact tests, and others, the primary test for welder qualification is the bend test. This is because bend testing is the single most comprehensive screening test for workmanship and welder competence. AWS D1.1 Structural Welding Code – Steel When a structure is going to be built, the owner and contractor agree on the appropriate welding code, which will be needed to govern the acceptability or rejection of structural welds being fabricated. AWS D1.1 Structural Welding Code – Steel is devised to provide welded joints with acceptable strength, ductility, and CVN impact toughness for the intended application, such as a building, general construction, motorized vehicle, etc. AWS D1.1 provides a minimum level of weld quality that must be achieved. AWS D1.1 provides both procedure qualification requirements and welder qualification and certification requirements. The qualification and certification tests for welders are specially designed to determine the welder’s ability to produce sound welds routinely. To achieve these quality standards, the welder qualification and certification provide the means to ensure acceptable welds. Significance of Bend Testing Of all the tests prescribed by different welding codes, the bend test provides the best and most reliable measure of ductility of the entire weld joint, including the weld metal, heat-affected zone, and unaffected base metal. Welder qualification tests in AWS D1.1 always specify bend testing of welded joints. This is because the bend test is extremely sensitive to all types of metallurgical problems associated with welding. For example, weld joints which have inadequate ductility and fail the requirements of the bend test may be due to: (a) hydrogen assisted cracking, (b) microfissuring due internal solidification cracking, (c) excessive slag inclusions, (d) excessive porosity, (e) wrong filler metal, causing embrittlement, (e) wrong welding parameters, causing embrittlement, and (f) other metallurgical factors affecting the ductility of the weld joint.

There are three types of bend tests, (1) side bend, (2) face bend, and (3) root bend. Side bend tests are generally required for welds that are greater than 3/8-inch thick for AWS D1.1 and over ½-inch thick for API-1104. For example, a 2-inch thick butt joint deposited by single-pass electroslag welding could not be tested by face or root bend testing because the thickness is too great for practical testing. However, a 2-inch thick butt joint can be machined to several 3/8-inch thicknesses and tested by side bending.

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So, face and root bending are used to test the ductility of butt joints that are thinner than 3/8-inch. Whether face bends, root bends, or both face and root bends specimens are required depends upon the code used. In AWS D1.1 Structural Welding Code, both face and root bends are required in most cases. The root bend test determines the adequacy of the root preparation and soundness of the root portion of the weld joint. This is particularly important in open root welding applications. Similarly, the face bend test determines the adequacy of the weld metal deposited on the face of the joint. These specimens must be able to withstand bending strains that are produced when a plunger forces a 3/8-inch thick welded specimen into a guided bend fixture. The plunger, having a specified bend radius, forces the welded bend specimen into a die in order to endure a specified amount of bending (or plastic deformation), that is required by the code for structural applications. From Table 1, the plunger radius and plunger thickness increase with increasing yield strength of the base metal being tested. Bending becomes more difficult with increasing yield strength, because ductility decreases as the strength of the steel increases. Thus, AWS D1.1 permits the bend radius required for welder qualification to increase with increasing yield strength, as shown in Table 1.

Table 1 Specified Bending Parameters for Guided Bend Test for Steel Welds

in accordance with AWS D1.1 Structural Welding Code - Steel Yield Strength Of Base Metal

Plunger Thickness

Plunger Radius

Interior Die Opening

Die Radius

50,000psi and less Over 50,000psi to 90,000psi 90,000psi and greater

1 ½” 2” 2 ½”

¾” 1” 1 ¼”

2 3/8” 2 7/8” 3 3/8”

1 3/16” 1 7/16” 1 11/16”

Furthermore, the bend test for steel welds is very sensitive to the presence of diffusible hydrogen in the weld. Even if non-destructive testing shows a welded steel to be crack-free, the bend test can activate the hydrogen cracking mechanism in steel welds which are susceptible to hydrogen cracking. Thus, there are many metallurgical causes for lack of adequate ductility in a welded structure, and the bend test is best suited to separate the “good” welds from the “bad” welds. Effect of the E6011 vs E7018 Electrodes on Bend Test Results Although the bend testing procedure for weld joints deposited by E6011 and E7018 electrodes are similar, the electrode composition can greatly affect the results of the bend test. The reason for the difference in bending performance is the hydrogen content of the electrodes. Because E6011 is a high-hydrogen electrode, the chances of passing the bend test are reduced in the as-welded condition, due to hydrogen-assisted cracking. Hydrogen-assisted cracking can occur during the bend test and reduce ductility so much that the bend test fails to meet minimum requirements. Since bending stresses and high hydrogen content can initiate hydrogen-assisted cracking in the weld and heat-affected zone, the welds deposited with cellulosic electrodes are much more susceptible to failing the bend test than similar welds deposited with low-hydrogen E7018 electrodes. To prevent bend failures, cellulosic electrodes should only be used to weld low-carbon mild steels because reduced carbon and alloy content reduce the susceptibility to

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hydrogen-assisted cracking. However, whenever cellulosic electrodes must be used with higher carbon, higher strength steels, then preheating is vitally necessary to prevent hydrogen-assisted cracking and to pass the bend test. Some codes allow bend test specimens to be baked prior to welding. If this practice is permitted, bend specimens have a much better chance to pass the bend test because baking allows hydrogen to diffuse out of the specimen. However, most codes which deal with fracture-critical applications do not allow baking of any test specimens prior to testing. For example, AWS D1.5 Bridge Welding Code forbids baking of any test specimens prior to testing. That is, welded specimens must be tested in the as-welded condition. In this way, the test results will truly reflect the anticipated performance in the field. Tensile Testing and Charpy V-Notch Impact Testing For welder qualification in accordance with AWS D1.1, tensile testing and Charpy v-notch (CVN) testing of the test weld are not required. However, in other codes, these tests are also used for welder qualification (in addition to bend testing).

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Science on Steel Questions—WLD 253

Name: _____________________________ Date: ________________________ Read each question carefully and answer the following questions with complete sentences using the material in the Science on Steel section. 1. What are codes primarily based upon? 2. List 5 welding codes that are in use today.

A. B. C. D. E.

3. Explain why mechanical testing is used today.

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4. List 7 reasons why bend tests fail 5. If a metal has a yield strength of 65,000psi, what size plunger should be used?

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Quality Control—WLD 253 Name: _________________________ Date: _______________________ Directions: Review Chapters 19- 21 in Welding Principles and Applications and utilize that information to complete the questions on this work sheet. Answer the questions using complete sentences, and do not hesitate to reference other sections in the text to find an answer.

1. What are Codes and Standards? 2. Explain the difference between a welding qualification test and a procedure qualification test.

3. What is the difference between Qualifying and Certifying?

4. Why are welding procedures established?

5. How does a welding procedure specification (WPS) and a procedure qualification record (PQR) differ from one another?

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6. What might influence the selection of a particular code or specification for welding?

7. Who should witness the test welding being performed by a tentative WPS?

8. Define essential variables as it applies to welding procedure.

9. How do welding procedures and pre-qualified procedures differ?

10. What is the difference between a discontinuity and a defect?

11. List five types of destructive tests.

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12. Define tolerance as it applies to mechanical drawings?

13. Define: • Preheat - • Interpass Temperature – • Post Heat -

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Performance Qualification—WLD 253 Name: ________________________ Date: _____________________ Directions Reference the AWS D1.1 Structural Steel Welding Code and utilize the index to locate the information to complete the questions on this work sheet. List the section where the answer is obtained in the code. Answer the questions using complete sentences, and do not hesitate to reference other sections in the text to find an answer

1. What are the dimensions for a structural fillet weld break and macro etch test plate in accordance with AWS D1.1?

2. What is the difference among a qualified welder, welding operator, and a tack welder?

3. What are the dimensions for a test plate of limited thickness (all position) test in accordance with AWS D1.1?

4. How is a fillet weld test inspected?

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5. When a 3/8" groove weld test has passed the visual inspection test and it is going to

be x-rayed, what portion of the test will be examined on the radiograph?

6. A welder originally passed a qualification test with an E6011; is s/he qualified to weld with an E7018? Why or Why not?

7. What are the acceptance criteria for both visual and mechanical testing for a fillet weld test?

8. What are the acceptances criteria for both visual and radiographic testing on a 3/8" groove-welding test?

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Craftsmanship Expectations for Welding Projects The student should complete the following tasks prior to welding.

1. Thoroughly read each drawing. 2. Make a cutting list for each project. Cut at least two project assemblies of metal at

a time. This will save a great amount of time. 3. Assemble the welding projects per drawing specifications. 4. Review the Welding Procedure portion of the prints to review welding parameter

information. 5. See the instructor for the evaluation.

Factors for grading welding projects are based on the following criteria: Metal Preparation Project Layout Post Weld Clean-up Oxyacetylene Cut quality Accurate (+/- 1/16”) Remove Slag/Spatter Grind all cut surfaces clean Limit waste Remove sharp edges

Example of a high quality weld

Weld Quality per AWS D1.1Welder Qualification

VT Criteria Cover Pass Reinforcement (groove welds) Flush to 1/8”

Fillet Weld Size See specification on drawing Undercut 1/32” deep

Weld Contour Smooth Transition Penetration N/A

Cracks None Allowed Arc Strikes None Allowed

Fusion Complete Fusion Required Porosity None Allowed

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Plate Fit-up

The plate preparation and fit-up process is an incredibly important part in the welding process that is many times over looked. The following steps will insure proper fit up is obtained which is the first step in a high quality weld. Prepare plate with the track burner and grind the welded surfaces clean prior to fitting up the plates.

Use Vise-Grips (11R’s) to clamp the back strap to the beveled plate. Ensure that there is no gap between the two plates.

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Plate Fit-up Space the two beveled plates apart by ¼” using a spacer gage. Use the Vise Grip’s to clamp the plates together. Again, ensure that there is no gap between the back strap and the two beveled plate.

A ¼” spacer should fit at all points in the root of the joint. An excessively wide or too narrow of a root opening will reduce weld quality.

Place your project in the desired position per the requirements on the project drawing.

3G (Vertical Position)

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Root Pass Inspection and Inter Pass Cleaning

In according with AWS D1.1, “the root of the weld shall be inspected and there shall be no evidence of cracks, incomplete fusion, or inadequate joint penetration.” If one of these items is present the weld will be unacceptable.

Inter pass cleaning is a must! At PCC, inter pass cleaning shall be completed with hand tools only. This emphasizes the need for students to develop their welding skills.

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Bend Test Procedure For 3/8” Test Plate

Bend tests are used to determine the ductility and soundness of a weld joint. The test will allow the welder to determine if she or he has obtained fusion in the weld joint. Use the following procedure in preparing and bending your coupons.

1. Reference AWS D1.1 Structural Welding Code to determine the dimensional layout of the bend coupons (use this diagram for all positions).

2. Flush back up strip off of the plate at the flushing station. See requirements on

drawing below.

3. Layout four 1 1/2” wide coupons and cut using the track burner. Do Not Bend

coupons greater than 1 1/2” wide they will not fit in the bend jig.

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4. Allow coupon to air cool. Do Not Quench!

5. Grind coupon’s smooth, ensuring grinding marks are going with the length of the

coupons and all edges are rounded.

6. Request permission from your instructor to use the bend test machine. 7. CAUTION: Keep hands and fingers clear when operating equipment.

Watts Bend Test Machine 8. Ensure guard is in the correct position. The coupons sometimes eject out the

end of the machine rapidly. Guard

9. Place coupon in the machine taking care not to position your hands/fingers in the

way. Locate weld in the center of the die. Bend one coupon (from each plate) to test the face and one to test the root.

10. Actuate the machine by the lever on the topside and stand away from the end

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where the coupon will exit.

11. Inspect the convex surface of the bend specimen for fusion type defects. Reference AWS D1.1 Structural Welding Code for Acceptance Criteria for Bend Tests.

Four bend samples are shown above. Left to right are: face bend, root bend, side bend and a face bend.

The bend samples shown above are different in the radius that they were bent. This is a requirement set forth by the code that is being referenced. Be sure to check the code to determine what is required.

Inspection by instructor Instructors signature: ___________________________ Date: _______________ Students signature: __________________________

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E6010 Butt Joint- Single Vee (3G) Project #1 Welding Sequence E6011-- Root Pass Single pass technique ensuring the weld metal is fusing into all three

pieces E6011—Fill Use split bead technique with stringer beads ensuring even fill. E6011—Finish Beads Use step technique. ______________________________________________________________________________

Successful completion of this project will require the student to complete two welds that meet both visual testing requirements and bend test requirements set forth in AWS D1.1 Structural Steel Welding Code.

VT Criteria Project #1 Project #2 Reinforcement

Undercut Bead Contour

Cracks Arc Strikes

Fusion Porosity

Bend Test Grade Date

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E6010 Butt Joint- Single Vee (4G) Project #2 Welding Sequence E6011-- Root Pass Single pass technique ensuring the weld metal is fusing into all three

pieces E6011—Fill Use split bead technique with stringer beads ensuring even fill. E6011—Finish Beads Use step technique. ______________________________________________________________________________

High quality root pass

An example of a high quality cover pass.

Successful completion of this project will require the student to complete two welds that meet both visual testing requirements and bend test requirements set forth in AWS D1.1 Structural Steel Welding Code.

VT Criteria Project #1 Project #2 Reinforcement

Undercut Bead Contour

Cracks Arc Strikes

Fusion Porosity

Bend Test Grade Date

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3/8" Test Plate Preparation (Practical Final Shop Test or Certification Test)

This section details the steps the student must take to complete the Practical Final Shop Test or the Welding Certification Test. . Permission to test is issued at your request, by your instructor, upon successful completion of two consecutive sets of shop tests. All shop tests must meet visual inspection and bend test criteria set forth in AWS D1.1 prior to testing. Complete Certification Information Form below and check it for accuracy. All tests are submitted for x-ray or bend test examination in accordance with AWS D1.1 Structural Steel code unless otherwise specified. Take the test form to PCC Business Office and pay the test fee. Return test form and receipt to the Tool Room and your test plates will be issued.

Welding Performance Qualification ___________________________________________________ _________________________ Last Name First Name MI Social Security # ______________________________________________________________________________ Street City State Zip Phone Number Original ______ Re-take ______ Test Plate Cost $_______________ Type of Test ____________________ City Card Cost $_______________ Material ____________________ Total Cost $_______________ Thickness ____________________ Date __________________ Process ____________________ ________________________________________ PCC Instructor Signature: Electrode Size______ Type______ _____________________________________ Position ____________________ Student Signature: Account Number M910

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3/8” Test Plate Fit-Up READ ALL INSTRUCTIONS CAREFULLY BEFORE YOU BEGIN. REMEBER, THE 3/8" PLATE TEST ASSEMBLY IS DIFFERENT FROM THE 1" TEST. SEE YOUR INSTRUCTOR IF YOU HAVE ANY QUESTIONS. STEP 1: Cut material with Track Burner

• Cutting List : 4 pieces 3/8" x 3" x 7 ½” • Cutting procedure:

1. Cut stock in half. (2 @ 6 x 7 ½” plates). 2. Bevel two 7 ½” sides @ 22 ½º.

3. Cut 6 x 7 ½” plates in half, resulting in 4 plates 3 x 7 ½”. STEP 2: Clean material.

• Grind all surfaces in the area to be welded until free of mill scale. Surfaces to be cleaned include; all beveled surfaces, ½” front and back of plate adjacent to each bevel and one side of each back up strip.

• CAUTION: Clean material only. Excessive grinding will effect the quality of your fit up.

INSPECTION:

Inspection by instructor Instructors signature: ___________________________ Date: _______________ Students signature: __________________________

STEP 3: Assemble groove joint.

• Root Opening = ¼” • Use Clamps or fixturing device to ensure “tight” fit-up (See information sheets in this

training packet). • Adjust plate position as needed to ensure proper root opening. • Ensure that there is NO gap between the beveled plates and the back up strip surface. • Tack the assembly together with 1" tack welds at the ends where the plates meet the back

up strip. • Do not tack weld on the backside of the test plate per code requirements.

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STEP 4: Attach strong backs.

• Strong backs are used to control distortion of the plates during welding. • Position strong backs on the backside of the groove assembly 3/16" in from the ends of

the plates. • Tack the strong backs across the ends of the plates. Weld only on the outside of the

strong back. • DO NOT weld on the plate side (inside) of the strong backs.

• Review “Welder Qualification” AWS D1.1 Structural Steel Code.

STEP 5: INSPECTION #1 ( See your instructor ): Test Plate Assembly

• Have your plates inspected for proper assembly and stamped for testing. • Store test plates in designated locker. • Review the testing procedures. The test examines your ability to weld in compliance with

the specific acceptance criteria and your ability to comprehend and follow testing procedures.

• Violation of testing procedures will constitute automatic failure of your test.

Inspection by instructor: Instructors signature: ____________________________ Date: ______________ Student signature: ____________________________

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TESTING PROCEDURES

For 3/8” Plates

STEP 1: Read entire procedure before you start your testing. You have three class periods to complete testing. STEP 2: Notify your instructor that you are going to begin your test. STEP 3: Obtain the 200 and 300-degree temp sticks from the tool room. STEP 4: Using a torch preheat the test plates to 200 degrees. STEP 5: Position the test plates at your welding station. The plate stamped 3G is positioned vertical. The plate stamped 4G is positioned overhead. STEP 6: INSPECTION #2 ( See your instructor ): Test Plate Position

Have your instructor inspect the proper positioning of the test plates. Test plates must remain in position throughout the test. DO NOT MOVE THE TESTS. Tests must be cleaned and inspected in position. No grinding is allowed on the test.

Inspection by instructor: Instructors signature: ____________________________ Date: _______________ Student signature: ____________________________

STEP 7: Complete the root passes in both positions. STEP 8: INSPECTION #3 ( See your instructor ): Root Pass Inspection. Have your instructor inspect the root passes.

Inspection by instructor: Instructors signature: ____________________________ Date: _______________ Student signature: ____________________________

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STEP 9: Complete welding the V groove until the weld is within 1/16” to 1/8” of the base material.

CAUTION: Control your inter pass temperature. Use the 300-degree temp stick to monitor maximum heat input in the test material. DO NOT weld on the test plate if it is over 300 degrees.

STEP 10: INSPECTION #4 ( See your instructor ): Flush Layer Inspection

Inspection by instructor: Instructors signature: ____________________________ Date: _______________ Student signature: ____________________________

STEP 11: Complete the finish beads (cover pass) on both plates. STEP 12: INSPECTION #5 ( See your instructor ): Final Visual Inspection

See your instructor for visual inspection. Both tests must pass visual inspection criteria to be submitted for x-ray or bend test examination. See visual inspection criteria below.

SUMMARY OF VISUAL INSPECTION CRITERIA A. The test must be complete. The full length of the test plate will be visually inspected. Use your run off tabs throughout the test to insure quality results at the start and finish ends of the plates.

B. Reinforcement layer (cover pass) height must be at least 1/32” and not more than 1/8” above the plate. C. Weld contour must be smooth and uniform.

D. Weld must be free of undercut, porosity, slag inclusions, and/or over lap.

E. Arc strikes outside of the weld area are NOT acceptable.

Inspection by instructor: Instructors signature: ____________________________ Date: _______________ Student signature: ____________________________

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STEP 13: Remove plates from position and allow to air cool. DO NOT quench test plates in water at Anytime.

STEP 14: Remove strong backs and use the band saw to cut ¼” off each end. Remember

that a minimum of 7 inches must be sent to the test lab. DO NOT REMOVE THE BACK UP STRIP !!!

STEP 15: File all saw cut edges smooth for safe handling of test plates.

STEP 16: Turn in finished plates to the tool room. STEP 17: LAB INSPECTION #6 X-ray or bend test examination

Tests are submitted to the testing lab for x-ray or bend test examination. Results are usually received approximately two weeks after the tests are submitted.

Testing Procedure Sign Off

Inspection by instructor: Instructors signature: ___________________________ Date: _______________ Student signature: ___________________________

Passed Root inspection Failed Visual

Passed Visual Fillets Failed Visual

Passed Visual Cover Failed Visual All forms and packet must be returned to instructor before plates will be sent to the inspection lab. Support Technicians Signature: __________________________________________

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Helpful Hints 1. Be prepared to feel confident during your test. You need to have demonstrated

consistency during your practice tests. Repeat the practice tests as many times as necessary to ensure confidence and consistent performance.

2. Be comfortable !!! Plan your test on a day that you know you will be at your best, well

rested and able to concentrate. Check your clothing, to be certain you are protected from any stray sparks. Nothing breaks your concentration faster than getting burned or catching on fire!

3. Check the condition of your cover lenses; make sure that you can see clearly. 4. Bring a flashlight so you may thoroughly inspect your inter pass cleaning. Clean the weld

thoroughly. Make sure your slag hammer and wire brush are in good condition. 5. Plan the weld carefully to avoid having to patch up low spots. Decide before you strike

the arc the size and location of the bead you are about to run. If the weld fill becomes uneven, fix it immediately by filling in the low areas, don't wait until the flush layer or cover pass.

6. Notify your fellow students in your area that you are testing; ask their cooperation in

avoiding any banging or movement of the booth area while you are welding. 7. Above all don't panic! Relax and take your time. Don't hold your breath! If at any time

you become uncomfortable stop and reposition. 8. If you can not see STOP. If you feel you are loosing control of the puddle STOP. 9. Do not over heat the plates. Allow the plates to air cool to 200 degrees before you

attempt to weld the cover passes. 10. See your instructor at anytime if you have a concern. Take a break as needed.

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Final Exam Part One This portion of the final exam is a closed book test. Consult with your instructor to determine items that you may need to review. Complete the exam and write all answers on the answer sheet provided. Once completed, return the exam and answer sheet to your instructor. Part Two This portion of the exam is a practical test where you will fabricate and weld out a 3/8” plate test according to the attached Welding Procedure Specification and blueprint. The evaluation of this portion of the exam will be based on the attached rubric.

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Welding Procedure Specification AWS D1.1 Job No.:

WPS Number: Rev. Number Original Date: PQR Number: Prequalified

Title: Shielded Metal Arc—Groove with Carbon Steel Backing Welding Process: Shielded Metal Arc Type: Manual Mode: Prepared by: Date: Approved by: Date:

PREHEAT Preheat Temp. Min. 60° Interpass Temp. Min: 60° F Max: 400°F

JOINT DESIGN Type: Single Groove B-L2a Single or Double Weld: Single Backing : Yes Backing Material: Carbon Steel Root Opening-R: 1/4” Land-L: 0-1/8” Radius (J-U): N/A

BASE METALS Metal Specification: A36 Type or Grade: Grade A Group 1 Plate Thickness: 3/8” Thickness Groove: 3/8” Fillet: All Diameter (Pipe) 24” and up Wall 1/8” and u

FILLER METALS Classification: E6011 Specification No. AWS 5.1

SHIELDING Gas: N/A Composition: N/A Flow Rate: N/A Gas Cup Size: N/A Electrode-Flux (Class): N/A Flux: N/A

TECHNIQUE/ OTHER Stringer or Weave Beads Multipass or Single pass per side Single or Multiple Electrodes Contact Tube to Work Distance: N/A Peening: None on root or cover Initial Cleaning: All areas to be welded shall be cleaned for oil, grease, paint, etc., for at least two (2) inches from the toes of the weld Interpass Cleaning: Remove all oxides and slag with a clean wire brush and/or chipping hammer Notes: 1. A stringer or slight weave may be used as required to provide proper bead shape and side wall wetting. 2. Initial and interpass cleaning shall be accomplished by wire brushing, chipping, and no grinding. 3. Welder shall accomplish a visual inspection of previously deposited weld metal, prior to depositing the next bead.

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POSITION Position of Groove or Fillet: 1G, 2G, 3G, 4G, 1F, 2F, 3F, 4F Vertical Progression: Up

POSTWELD HEAT TREATMENT Temperature Range: Time:

4. Welding electrode shall be stored in dry area and located in close proximity to the work area. 5. Preheating shall be accomplished using oxy-fuel torches. 6. Weld shall be allowed to cool slowly, keeping air drafts to a minimum.

Filler Metals Current Pass or Weld

Layer(s) Process Class Dia.

Type and

Polarity

Amps or wire feed

speed Volts

Travel Speed (IPM)

All SMAW E6011 1/8” DCEP 90-170A 19-27 2-4

Joint Details

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Grading Rubric for the Practical Exam – WLD 253 Name: ____________________________ Date: _____________________ Hold Points Hold Points are mandatory points in the fabrication process which require the inspector to

check your work. You will have the following hold points.

Points Hold Point Instructor’s Evaluation 5 points Blueprint Interpretation and Material Cut List 5 points = 0 errors, all parts labeled and sized correctly 3 points = 1 error in part sizing and/or identification 2 points = 2 errors or more rework required (max points) ________ 10 points Material Layout and Cutting (Tolerances +/- 1/16”) 10 points Layout and cutting to +/-1/16” Smoothness of cut edge to 1/32”

7 points Layout and cutting to +/- 1/8”

Smoothness of cut edge to 1/16” 5 points (Rework Required max points)

Layout and cutting to +/-3/16” Smoothness of cut edge to 3/32” ________ 10 points Fit-up and Tack weld (Tolerances +/- 1/16”) 10 points

Tolerances +/- 1/16” Straight and square to +/-1/16” 7 Points

Tolerances +/- 1/8” Straight and square to +/-1/8”

5 Points (Rework Required—Max points ) Tolerances +/- 3/16”

Straight and square to +/-3/16” _________ 15 points Weld Quality Subtract 1 point for each weld discontinuity,

incorrect weld size and incorrect spacing sequence. _________ 28 points Minimum points acceptable. This equates to the minimum

to AWS D1.1 Code. Total Points _________

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Assessment Breakdown for Course—WLD 253

Percentage 20% Safe work habits and shop practices ________ 20% Student consistently wears apparel and operates equipment safely 18% - 14% Instructor reminds student s to wear safety apparel and/or

operate equipment safely 12% - 10% Instructor needs to consistently remind the student to wear

safety apparel and/or operate equipment safely

20% Completion of reading and writing assignments _________ On time vs. late Complete and accurate responses Graded on a point basis 20% demonstrating professional work ethics _________ Track training hours on time card Perform projects in accordance to specifications and procedures Follow directions in a positive manner Manage time productively (time on task) Respects equipment and others Demonstrate skill in problem solving and decision making 40% of grade is based on completion of welding exercises _________

Complete all projects to industry standards See project grading criteria TOTAL _________ COURSE GRADE _________