WIS343 METAL FABRICATION 02/26/1990 08:51 AM D1 406 Lines Agriculture Mechanization/Engineering and Technical Support Services Metal Fabrication (15-45 days) This unit deals with the metal fabrication industry. Topics include career opportunities, basic metallurgy, types of metal fabrication, mathematics used in metal fabrication, and welding. Objectives To acquaint students with employment information and career opportunities in the metal fabrication industry To emphasize to students the need to follow safety practices and procedures associated with all types of welding and metalwork To provide students with instruction and practice in identifying common metals To develop student understanding of how to prepare metal for welding To provide students with instruction on how to weld machinery and equipment in all positions To develop student ability to set up and adjust welders To prepare students to apply welding skills to jobs and projects To assist students with design and assembly of a laboratory project Competencies At the conclusion of this unit, students will be able to explain current employment information such as job descriptions, job availability, personal and educational requirements, working conditions, opportunity for advancement, and other factors relative to potential employment in the metal fabrication industry and relate it to their personal needs and aspirations; understand and apply good safety habits in the laboratory; identify different metals used in various metalworking processes; prepare metal for welding; use welding techniques on agricultural machinery and equipment; set up and adjust arc and gas welders; apply welding skills to jobs and projects; and design and assemble a shop project. Subject Matter (Basic skills integration areas are shown in brackets following title.) Careers - Current and future employment needs - Job descriptions - Training requirements - Working conditions - Opportunities for advancement - Other factors Welding - Definition - Historical background - Welding processes Metallurgy [Science] - Mechanical properties - Classifications of carbon steels - Alloy steels - Spark testing of metals - Effects of heat on metal Welding vocabulary Arc welding machines [Mathematics] - Electrical background information - Welding circuit - Arc welding equipment Gloves Helmets, shields, goggles Cables, clamps Ventilation systems - Electrodes American Welding Society classification system Amperage selection Conserving and storing - Welding operations Machine and laboratory setups Striking an arc Electrode angle Arc length Laying stringer beads Padding Safety - Welding types Butt weld Fillet weld Corner weld Lap weld Groove weld Gas welding [Science] - Process description - Useable gases - Oxyacetylene equipment Tanks Regulators Hoses Torches Welding tips Spark lighter Welding goggles - Setup of welding outfit - Lighting torch and flame adjustments - Flame types - Torch shutdown - Welding processes Carrying a puddle Beads with a rod Flange weld Brazing Flame cutting - Gas welding safety Welding positions - Horizontal - Vertical - Overhead - Protective cautions Cast-iron welding [Science] - Process description - Electrode types - Metal identification - Metal preparation - Welding techniques - Controlled cooling Thick section welding - Metal preparation - Welding technique Metallic arc welding [Science] - Process description - Machine setup - Welder operation - Machine maintenance Gas tungsten inert welding - Process description - Machine setup - Welder operation - Machine maintenance Product planning [Mathematics] - Ideas for product design - Working drawings - Bill of materials and procurement Motivational Activities Take a field trip to a welding repair shop, a welder manufacturer, or a factory that has an on-site welding operation. Post bulletin board displays featuring topics on welding. View films, filmstrips, and videotapes about welding. Learning Activities Participate in a Supervised Agricultural Experience program. Identify and run beads made with a short arc, long arc, high amperage, and low amperage. Weld metals of different thicknesses in the flat, horizontal, and vertical position. Construct welding projects. Identify common metals using a spark test. Weld pipe in any axis. Remove a nut from a rusted bolt. Collect, label, and display specimens of steels and steel alloys and identify the electrodes to use with them. Perform brazing exercises on different metals and alloys. Demonstrate a 60-degree groove joint exercise. Complete a lap on a "T" joint on metal 3/16'' or less in thickness. Repair a broken piece of agricultural equipment, agricultural machinery, or hard-surface-worn machine and equipment parts. Instructional Materials Textbooks and References General Metals by John L. Feirer. 5th ed. New York: McGraw-Hill, 1980. Mechanics in Agriculture by Lloyd J. Phipps. 3rd ed. Danville, IL: Interstate, 1983. Metals and How to Weld Them by Theodore B. Jefferson and Gorham Woods. 2nd ed. Cleveland: James F. Lincoln Arc Welding Foundation, 1972. Metals Handbook. 11 vols. Metals Park, OH: American Society for Metals International, 1983. Modern Welding by Andrew D. Athouse and Carl H. Turnquist. South Holland, IL: Goodheart-Willcox, 1984. The Oxyacetylene Handbook. New York: Linde Division, Union Carbide, 1976. The Oxyacetylene Welders' Handbook by Theodore B. Jefferson. 7th ed. Lake Zurich, IL: Jefferson Publishing, 1972. Print Reading for Welders by J.W. Giachino and H.J. Baukema. 2nd ed. Homewood, IL: American Technical Publishing, 1978. Procedure Handbook of Arc Welding. 12th ed. Cleveland: James F. Lincoln Arc Welding Foundation, n.d. Welding Handbook. 6 vols. 6th ed. Metals Park, OH: American Society of Metals International, 1982. Welding Practices and Procedures by Richard H. Carr and Robert L. O'Con. Englewood Cliffs, NJ: Prentice Hall, 1983. Bulletins and Pamphlets The following is available from Airco Welding Products. Recommended Safe Practices in Welding and Cutting The following is available from Allstate. Instruction Manual and Catalogue The following is available from the American Welding Society. Safety in Welding and Cutting. AN51Z49.1. The following are available from Handy and Harman. The Brazing Book. 1980. Fundamentals of Silver Brazing. Bulletin 666. The following is available from Hobart Brothers Technical School. Recommendations for Teaching Welding The following are available from James F. Lincoln Arc Welding Foundation. Aids to Excellent Machine Design in Welded Steel Arc Welding - Basic Manual of Instruction The following are available from Union Carbide Corporation. How to Do Heliarc Welding of Pipe How to Do TIG Welding Linde-Gases and Welding Products Oxyacetylene Welding and Cutting for the Beginner Precautions and Safe Practices for Welding and Cutting. Form 52529. The following is available from the Miller Electric Manufacturing Company. Principles of Arc Welding The following is available from the Stellite Division. Stellite Hard Facing Products The following is available from the Stoody Company. Stoody Farm Hard-surfacing Handbook The following are available from Vocational Agriculture Services. Metal Inert Gas (MIG) Welding. U3037. Oxyacetylene Welding and Cutting. U3001a. Safety in the Shop. U3022a. Shielded Metal-Arc Welding. U3004a. Tungsten Inert Gas (TIG) Welding. U3036a. Periodicals Applied Science and Technology Index Welding-Brazing-Soldering Digest Welding Design and Fabrication Welding Journal Computer Software The following are available from Hobar Publications. Arc Welding. Apple, IBM. Arc Welding and Related Review. Apple, IBM, TRS, Commodore, Macintosh.. Oxyacetylene and Related Review. Apple, IBM, TRS, Commodore, Macintosh. The following is available from Midwest Agribusiness Services, Inc. Agri-Quiz: Welding. Apple, IBM. The following is available from Hobar Publications. Vocational Competency Management Program: Metals. Apple, IBM. Welding Electrodes Identification. Apple. Welding Equipment Safety and Operations. Apple, IBM, TRS. Laboratory Resources The following is available from American Technical Publishers, Inc. Welding Skills and Practices. 1985. The following is available from Hobar Publications. Metals and Welding. 170 (Manual). 1987. The following is available from Vector Publications. Arc Welding: A Self-Instruction Guide. Volumes I and II. 1967. Films, Videotapes, and Slides The following are available from the Bureau of Audio Visual Instruction. Arc Welding Methods. 08516 (16mm film, color, 27 minutes). Miller Electric Manufacturing, 1972. Fundamentals of Manual Shielded Arc Welding Techniques. 03979 (16mm film, color, 44 minutes). Airco Welding, 1971. Short Circuiting Metal Transfer - A Gas Metal Arc Welding Process. 08308 (16mm film, color, 25 minutes). Miller Electric Manufacturing, 1974. The following are available from Teaching Aids, Inc. Arc Welding. P-0963 (Five filmstrips with cassettes, instructor's guide, and reproducible masters). Welding Safety. B-515 (Two filmstrips with cassettes and study guides). The following are available from Vocational Agriculture Services. Care and Maintenance of Arc Welding Equipment. F470 (56-frame filmstrip). Equipment Safe Practices. F455a (93-frame filmstrip). Equipment Setting Up. F456a ( 57-frame filmstrip). Lighting and Adjusting the Flame. F471 (42-frame filmstrip). The following are available from Vocational Education Productions. Basic Arc Welding Safety. 6-047-100V2 (VHS videotape, 10 minutes). Welding. 6-066-123V2 (VHS videotape). The following are available from Vocational Media Associates. Arc Welding. 30987-93 (Five-part filmstrip with program guide). Welding Vocabulary Skills. 31065-93 (Three-part filmstrip with program guide). Equipment and Facilities Alternating current, direct current, and automatic welders Oxyacetylene tanks and setups 220-volt wiring in shop Ventilation system