Chemistry Course Syllabus

Welding Technology Course Syllabus Assignment Code 13207 Spearfish High School 2015-2016 Mrs. Kristi McCoy, Instructor [email protected] (605) 717-1212 (W) (605) 892-6152 (H)

Welding Technology Course Description

1 Credit Grade Level: 10, 11, 12 Full year elective with 90 min classes every other day. There is a high demand for motivated and creative individuals in the welding field. This course offers students the basics of welding in a hands-on environment. The students will be taught the basics of AC/DC, MIG, and Oxy-Acetylene Gas welding. Semester 1 will be spent learning how to use the equipment and how to properly weld metal to metal. Safety training will be a part of all training exercises within each lecture. Semester 2 will be spent learning how to draw plans and fabricating individual student projects. Materials/Textbook Information

*Reference Books* The Art of Welding, by William Galvery, Industrial Press 2014 The Art of Sculpture Welding by Kristi McCoy, Indutrial Press, 2015 Modern Welding, complete coverage of welding field in one easy-to-use volume., by Althouse, Tunquist, and Bowditch., The Goodheart-Wilcox Co., Inc., 1970. Metals and How to Weld Them., by T.B. Jefferson., Welding Engineer Publications. Inc., 1990

*Required Supplies* (Supplies can be purchased through the school resale program or from a local hardware store.) -Shop coveralls (non insulated), or a suitable long sleeve shirt and denim jeans. -Safety glasses or goggles. ($4.00) -10’ tape measure or longer. -Metal Scribe ($7.50) (Optional) -Welding Cap or hat (Optional) -Thick leather gloves ($8 – $12 or supply your own) -Pencil or Pen. -$15 Supply fee per semester- The supply fee will go towards metal used for small required projects, welded joints, wasted steel used on projects, and miscellaneous supplies. NOTE: Scholarships are available through the guidance office for students who need help with funding for this class.

1 Learning Objectives

SMAW -Identify a good bead when stick welding -Be able to properly set the welder for any given thickness of steel -Identify different electrodes and understand the number identification system -Be able to troubleshoot problems with the welder -Be able to weld the four basic welded joints using a stick welder -Be able to use the welder safety -Be aware of what safety attire should be worn while stick welding. -Be able to weld a steel project together using the SMAW process. GMAW -Identify a good bead when MIG welding -Be able to properly set the welder for any given thickness of steel -Understand how the wire is fed through the liner and how the current is transferred to the electrode when MIG welding. -Be able to troubleshoot problems with the welder and the MIG gun. -Be able to weld the four basic welded joints using a MIG welder. -Be able to use the welder safely -Be aware of what safety attire should be worn while MIG welding -Be able to weld a steel project together using the GMAW process Oxy/Acetylene Welding -Identify a good bead when gas welding -Be able to properly set the regulators on the Oxygen and Acetylene cylinders to the proper pressure settings for the thickness of steel being welded. -Demonstrate how to start up and properly shut down the Oxy/Acetylene station -Demonstrate how to clean a dirty tip. -Be able to gas weld the 4 basic welded joints. -Use the proper safety attire while gas welding -Understand the dangers of high pressure cylinders and use proper safety precautions while using the oxyacetylene equipment. -Be able to weld a steel project together using the Gas welding process Drills -Be able to identify safety hazards while using the drill press -Be able to drill holes in steel using a drill press or hand drill safely and accurately -Be able to properly measure and locate the center of hole locations. -Use a scribe to mark center point locations and a punch to mark the center before drilling -Use a milling machine to drill holes. Plasma Cutting -Understand the safety hazards associated with using a plasma cutter. -Be able to use a straight edge to cut smooth, even, precise cuts with a plasma cutter. -Use the plasma cutter safely. -Use a circle cutting attachment to produce a smooth perfectly round circle with the plasma cutter. -Be able to troubleshoot problems that may occur while using the plasma cutter. -Understand how to properly set the plasma cutter for the thickness of steel being used. -Be able to free hand cut silhouettes with the plasma cutter. Cutting Torch Be able to properly set the regulators on the Oxygen and Acetylene cylinders to the

2 proper pressure settings for the thickness of steel being cut. -Demonstrate how to start up and properly shut down the Oxy/Acetylene station -Demonstrate how to clean a dirty cutting torch tip. -Be able to cut steel with a cutting torch free hand, with a straight edge, and with a circle cutting guide. -Use the proper safety attire while using the cutting torch.

-Understand the dangers of high pressure cylinders and use proper safety precautions while using the oxyacetylene equipment. -Use a flint and steel striker.

Saws -Be knowledgeable of the different safety precautions that should be taken while using different saws found in the welding shop environment. -Be able to cut safely and accurately with a metal band saw, cold cut saw, and abrasive cut-off saw. -Understand how to set up different part stops to make duplicate parts the same length accurately. Grinders -Demonstrate the safe and proper use of die grinders, stationary grinders, angle grinders, stationary wire wheels and wire wheels on angle grinders. -Know the proper procedure for changing out the discs as they are depleted. -Understand the dangers of grinders and consider the safety of others while in use. Specialty tools -Demonstrate the proper use of the various wrought iron benders. -Demonstrate the use of various 90 degree bending tools. -Be able to roll a steel ring. -Understand the use of a metal break, metal shear, and hydraulic pipe bender. -Know the the proper use and importance of tools such as pliers, c-clamp locking pliers, squares, punches, chipping hammers, metal hammers, metal files, various metal clamps, straight edge guides, and levels. Miscellaneous -Locate job opportunities in the welding field. -Identify welding symbols and be able to read welding blueprints. -Be able to cost estimate steel projects -Be able to properly identify prefabricated steel products such as square tubing and pipe. Laptop, Internet, and Class Rules and Procedures

No Internet or e-mailing will be allowed without permission from the instructor. No computer games are allowed in my classroom at any time of the day or school year. 1 hour of detention will be given for getting caught breaking this rule.

Homework Procedures

Contact me at [email protected] for assignments if you have missed a class period.

Assessment Plan

3 Student Evaluation Process for Spearfish Credit 1st Semester Weighting Policy 2nd Semester Weighting Policy 35% Projects 60% Projects 35% Lab points 40% Lab Points 15% Questions 15% Welded Joints

Points Distribution for Semester I -300 chapter questions -150 quizzes -200 practice joints/projects

-200 small metal project -20 pts. Per day Lab Points. (0/20 for absences) Lost points may be accumulated during open shop hours and other class periods with prior approval. (These figures are estimates and will vary slightly)

Point Distribution for Semester II: -10 pts. Per day Lab Points. (0/20 for absences) Lost points may be accumulated during open shop hours and other class periods with prior approval. -200 + pts. For individual projects must be earned by the end of the semester. Point values for projects will be given according to project size and student abilities.

Letter grades are determined by the SHS grading scale outlined below: 96-100 A 76-78 C 92-95 A- 73-75 C- 89.91 B+ 69-72 D+ 86-88 B 65-68 D 83-85 B- 60-64 D- 79-82 C+

Grade Rounding Policy & Semester Tests: Semester tests will be given on the scheduled test date. They will be weighted at 20% of a student’s final grade. This score will be added to the student’s semester accumulative score. .5 % or higher grades will be rounded up. Example: 94.5% will be rounded to 95%. 94.49 will be treated as 94%.

Make Up Work

Testing Policy: No talking, No cheating. Tests will be collected and given no credit if either offence is violated. Makeup work: Missing assignments should be turned in within one week of missing a scheduled

4 assignment. General Information

Classroom Rules: 1. No horseplay (Pushing, hitting, etc...) Detention Immediately for this violation. 2. No THROWING THINGS EVER. 3. No talking while myself or another student is talking during lectures. 4. Come and get me for help but be patient if you have to wait. 5. Be polite, courteous, and respectful to everyone in the classroom and their belongings.

General Safety Policies: 1. All students must wear clothing suitable to the activity (shop coats, aprons, or old clothes.) ABSOLUTELY No shorts, sandals, or short sleeves in the welding areas. You will not be allowed to weld without proper attire. 2. Students must remove or securely fasten neckties, jewelry, loose clothing, long hair, etc. 3. Students must wear approved safety eye protection at all times while in a laboratory, except in safe areas as designated by the instructor. Students who wear glasses must have attached side protectors or safety glasses over the top of their original eye glasses. No exceptions. 4. Students must at all times have permission from the instructor to work in the laboratory. 5. A running machine must never be left unattended. 6. Accident reports must be filled out on all injuries and on near injuries as well. 7. All material and equipment damage must be reported. 8. No student may use any machine on which he/she has not been properly instructed. 9. The work area and work surfaces should be kept clean of scraps, liquids, and unnecessary equipment. 10. No horseplay or roughhousing is allowed in the laboratory or shop. 11. Anyone caught abusing the equipment, or intentionally trying to harm another student in any way will be dismissed from this class immediately. 12. Even though the school has a no hat policy, students may wear their hats in the welding area to protect your hair from flying sparks and soot that will inevitably be flying around. Please leave the room into the hallway without your hat. 13. Wear proper ear protection. Plugs will be supplied by the school. Ask instructor for location of dispenser. 14. Nametag ID’s should not be worn while in the shop area. If you must leave during class, your nametag should be worn

General Outline

I. Welding Safety A. Eye Protection B. Hearing safety C. Burns D. Equipment safety II. Oxy-Acetylene A. On/Off B. Gas Welding C. Cutting Torch III. Plasma Cutter A. Use B. Repair C. Safety IV. AC/DC Welding

5 A. AC Welding 1. 6013 Rod, 6011 Penetrating Rod 2. Amperage Settings and Equipment Parts 3. Safety 4. Strong Welds/Weak Welds B. DC Welding 1. 7018 or 6013 Rod 2. Amperage Settings and Equipment Parts 3. Safety 4. Strong/Weak Welds V. MIG Welding/Wire Feed A. Equipment Parts 1. Changing the wire. 2. Fixing a stuck tip. 3. Troubleshooting when gun does not work. 4. Gas difuser, tip, tip cover, ground clamp, nozzel gel, welding debri inside tip cover. B. Welder Settings 1. Wire Feed (Speed) 2. Amperage (Heat) C. Safety D. Strong/Week Welds E. Gas VI. Brazing A. Rod B. Torch Settings C. Usage VII. Band Saw A. Parts B. Usage C. Safety VIII. Grinders A. Small Hand B. Large Hand C. Wire Wheel D. Grinding Wheel IX. Cold Cut Saw/Chop Saw A. Parts B. Usage C. Safety X. Drills A. Hand Drill B. Bits C. Drill Press and vice XI. Blueprint Reading. A. Symbols B. Linetypes. C. Orthographic Views D. CAD XII. Math. A. Fractions B. Weight of metal/Cost XIII. Milling Machine A. Drilling B. Machining XIV. Benders and Specialty Tools

6 A. Wrought iron benders B. Circle rollers C. Pipe bender D. Iron worker

WELDING MODULES: 1. AC Electrode Welding 2. MIG Welding 3. Gas Welding 4. Oxy/Acetylene Cutting 5. Benders and Specialized Equipment 6. Saws and Milling Machine 7. Drills 8. Brazing 9. DC Electrode Welding 10. TIG Welding 11. Blueprint Reading. 12. Steel Identification 13. Welding symbols and blueprint reading 14. Math for Metalworkers. **Some or all of these modules may be used**

Course Standards IWT1.1 Identify and demonstrate the proper industry safety standards. IWT2.1 Demonstrate mathematical skills related to work assignments. IWT2.2 Read and demonstrate understanding of welding terms and definitions from ANSI/AWS A3.0, Standard Welding Terms and Definition. IWT2.3 Complete a job assignment given verbal and written work assignments. IWT3.1 Read and sketch drawings. IWT3.2 Identify basic weld symbols. IWT 3.3 Identify lines and joints. IWT4.1 Identify and explain the use of oxyfuel cutting equipment. IWT4.2 Prepare layouts for cutting individual parts. IWT4.3 Perform cuts using oxyfuel gas-cutting process. IWT4.4 Use weld-washing techniques. IWT5.1 Prepare base metal for various welding processes. IWT6.1 Identify and understand SMAW equipment and setup. IWT6.2 Identify and understand Shielded Metal Arc electrodes. IWT6.3 Demonstrate knowledge of Shielded Metal Arc Welding (SMAW) process. IWT7.1 Identify and demonstrate knowledge of quality control of the welding process. IWT8.1 Research career opportunities in the manufacturing fields.

Assessment Plan

Grade Scale Description of Work A 92-100% Consistently demonstrates an exceptional level of quality and effort.

7 Having all work in on time and completed to exceed expectations. Mastery in evaluating, synthesizing, and applying the knowledge. B 83-91% Consistently demonstrates proficient knowledge with a good effort and quality of work. All assignments are complete and on time. Demonstrates the ability to evaluate, analyze, synthesize and apply the principles. C 73-82% Demonstrates proficient knowledge and the ability to apply knowledge. Work shows average effort. A few assignments may be missed or late. D 60-72% Work shows minimal effort and some assignments are late. Demonstrates a basic understanding of recalling or comprehending knowledge F Below – 60% Understanding is below basic. Work is of poor quality and does not meet standards or expectations.

Supply Fees and Classroom Policy

In order to offer students the opportunity to build unique and individualized projects, students will incur a bill through the use of metal and other resale items that they may purchase for their safety and to build their projects, along with a $15.00 metal supply fee each semester. This fee pays for metal used to build required small projects which the students take home when complete, miscellaneous supplies for projects, and covers the cost of wasted metal incurred during project construction. Each student is responsible for paying off their account balance at the end of each nine weeks. If any student cannot afford any part of this class, they need to inform the instructor prior to building a project or accepting supplies from our resale account. In this case, alternate projects are available to the student at no cost or they can pursue financial assistance through our school’s scholarship program available through the guidance office to help pay for metal and other supplies. Please contact the instructor or the guidance office for funding assistance.

If you agree to follow this policy, sign below and return this portion of the syllabus to the instructor. If you have any questions, contact Mrs. McCoy via e-mail at: [email protected].

Student printed name ______

8 Student signature______

Parent printed name______Parent or Guardian signature ______