DOCUMENT RESUME ED 271 557 CE 044 642 AUTHOR Fortney, Clarence; Gregory, Mike TITLE Introduction to Welding. INSTITUTION Mid-America Vocational Curriculum Consortium, Stillwater, Okla. PUB DATE 84 NOTE 449p.; Some pages use colored paper. AVAILABLE FROMMid-America Vocational Curriculum Consortium, 1500 West Seventh Avenue, Stillwater, OK 74074 (Catalog No. 600101--$24.00). PUB TYPE Guides - Classroom Use - Guides (For Teachers) (052) EDRS PRICE MF01 Plus Postage. PC Not Available from EDRS. DESCRIPTORS Competency Based Education; Employment Opportunities; *Equipment Utilization; First Aid; Hand Tools; Job Application; Machine Tools; Mathematics Skills; Measurement Techniques; *Metallurgy; *Metals; Safety; Secondary Education; *Trade and Industrial Education; *Welding ABSTRACT This curriculum guide provides six units of instruction on basic welding. Addressed in the individual units of instruction are the following topics: employment opportunities for welders, welding safety and first aid, welding tools and equipment, basic metals and metallurgy, basic math and measuring, and procedures for applying for a welding job. Each unit contains some or all of the following: performance objectives, suggested activities for teachers and students, information sheets, assignment sheets, job sheets, visual aids, tests, and answers to the tests. (MN) *********************************************************************** * Reproductions supplied by EDRS are the best thatcan be made * * from the original document. * *********************************************************************** 11 ION TO WELDING Written by Clarence Fortney and Mike Gregory Edited by Dan Fulkerson Developed by the Mid-America Vocational Curriculum Consortium, Inc. Board of Directors Larry Barnhardt, North Dakota, Chairman James Dasher, Arkansas, Vice Chairman Les Abel, Kansas, Parliamentarian Wiley Lewis, Colorado John Van Ast, Iowa David Poston, Louisiana Harley Schlichting, Missouri Merle Rudebusch, Nebraska U.S. DEPARTMENT OF EDUCATION "PERMISSION TO Y MICROFICHEREPR FIODUCE ONTHLIS 0 e of EduCidarial Research and Improvement Bob Patton, Oklahoma MATERIAL INM EDCATIONAL RESOURCES SINFORMATION GRANTED BY CENTEERIC) Larry Lyngstad, South Dakota HAS BEEN This document has been reproduced as Pat Lindley, Texas received from the person or organization originating it. Ann Benson, Executive Director O Minor changes have been made to improve reproduction Quality RESOURCES Pointsol wawa opinionsstatedinthisdocu- TO THEEDUCATIONAL ment dO not necessarily represent official CENTER (ERICV OERI position or policy INFORMATION t' 1984 by the Mid-America Vocational Curriculum Consortium, Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from the publisher Printed in the United States of America by the Oklahoma State Department of Vocational-Technical Education Stillwater, Oklahoma 74074 s Mid-America Vocational Curriculum Consortium, Inc. 1500 West Seventh Stillwater, Oklahoma 74074 3 Introduction to Welding TABLE OF CONTENTS Unit I: Welding Orientation 1 Unit II: Welding Safety and First Aid 31 Unit III: Welding Tools and Equipment 111 Unit IV: Basic Metals and Metallurgy 193 Unit V: Basic Math and Measuring 289 Unit VI: Applying for a Welding Job 439 4 iii FOREWORD Because their classroom experience helps them to accurately identify needs in existing cur- riculum, outstanding instructors from each of the MAVCC member states serve 09 a MAVCC Resource Committee. Charged with planning and approving materials, the Resource Commit- tee also includes selected representatives from industry whose input helps direct learning objectives toward actual jobgetting skills that industry needs. The instructor-industry input is nowhere more apparent than in Introduction to Welding. Both groups demanded that welding safety be properly introduced and repeatedly accented. Both instructors and industry representatives pinpointed needs for better student skills in math and metallurgy. Industry wanted students to have a better appreciation for the world of work, and an emphasis on the fact that along with the monetary rewards of a job goes an equal amount of basic responsibility. And preparing and interviewing for a welding job is so different from job interviewing in other occupations that industry wanted materials that more realistically reflected the actual procedure. So the committee process has made Introduction to Welding much more than a simple ori- entation for students planning welding careers. It is a text that both instructors and students will continue to use as a "reference" for a multitude of other welding activities both in training and in the real world. Instructional materials in this publication are written in terms of student performance, and the criterion-referenced tests provide for uniform measurement of student progress. The com- petency-based format should free welding instructors to spend more time in planning other classroom and shop activities to personalize the learning process and better motivate stu- dents in their learning endeavors. Department of Labor projections indicate that the demand for welders will increase beyond the average for other trades during the 1980's. Introduction to Welding presents the fundamen- tals for students willing to meet the challenge and advance their careers in an industry that rewards talent with good pay and better lives. Larry Barnhardt, Chairman Board of Directors Mid-America Vocational Curriculum Consortium v 0I"' PREFACE In its Dictionary of Occupational Titles, the Department of Labor suggests that a Combina- tion Welder should be able "... tofabricate or repair...according to layouts, blueprints,... [with a] variety of arc and gas welding equipment." There are other requirements, but those brief remarks are enough to merit a well-rounded training program, and MAVCC has attempted to provide curriculum equal to the ambitious task. Introduction to Welding is the first book in MAVCC's new seven-text welding series. The six others are: Oxyacetylene Welding and Cutting; SMAW, Shielded Metal Arc Welding; GTAW, Gas Tungsten Arc Welding; GMAW, Gas Metal Arc Welding and FCAW, Flux-Cored Arc Welding; Shielded Metal Arc Pipe Welding; and Welding Blueprint Reading and Layout. Introduction to Welding is basic to each of the other books in the series, but beyond that point, text selection provides instructors with an impressive flexibility for planning local pro- grams to fit local needs. Whether it's an Ag program dedicated to basic skills in oxyacetylene and stick, or a long- range program designed to produce a multi-skilled combination welder, MAVCC's is the combi- nation series that can best accomplish the task. Ann Benson Executive Director Mid-America Vocational Curriculum Consortium .vii ....,%., 6 ACKNOWLEDGEMENTS Appreciation is extended to the many individuals and companies who contributed their time, talent, and materials to the successful development of Introduction to Welding. The Resource Committee that planned and approved the text deserves a special thank you. That committee includes: Ron Carpenter, Twin Lakes Vo-Tech, Harrison, Arkansas Patrick Muiville, Pike's Peak Community Col;ege, Colorado Springs, Colorado Rick Cowman, Des Moines Area Community College, Ankeny, Iowa Kennith Lutz, North East Kansas Area Vo-Tech, Atchison. Kansas Ker neth Powers, Vocational Curriculum Development and Research Center, Natchitoches, Louisiana Joe E. H. Templien, Mid-Plains Community College, North Platte, Nebraska Jerry Swaim, West County Technical High School, Chesterfield, Missouri Roger Sorensen, North Dakota Stata Industrial School, Mandan, North Dakota Ted Dorton, Francis Tuttle AVTS, a(lahoma City, Oklahoma Paul Marrs, Western Dakota Vo-Tech Institute, Rapid City, South Dakota Dee Gober, fvlonahans High School, Monahans, Texas Dale Majors, Majors Welding Supply and Equipment Company, Greeley, Colorado Jim Coote, Lincoln Electric Company, Wichita, Kansas Harold R. Kretchmar, Phillips Petroleum Company, Bartlesville, Oklahoma Ray Suenram, Oklahoma Gas and Electric Company, Edmond, Oklahoma Rick Sullivan, Teacher Education, T&I, Central State University Edmond, Oklahoma Stephen C. Saunders, Robberson Steel Company, Oklahoma City, Oklahoma David R. Thomas, Lincoln Electric Company, Oklahoma City, Oklahoma Jane Vesper, Presto Welding Supply Company, Oklahoma City, Oklahoma Verlin Hart, Oklahoma State Department of Vo-Tech Education, Stillwater, Oklahorr a Walon Holt, Oklahoma State Department of Vo-Tech Education, Stillwater, Oklahoma Floyd Silvers, Welding, Metallurgy, and Testing Consultant, Tulsa, Oklahoma Several manufacturers and suppliers of welding tools, equipment, and materials have contrib- uted illustrations and other valuable materials that assisted significantly in the development process. In cases where it is appropriate, their names are noted throughout the text, and many materials published by those manufacturers and suppliers appear as references for instruc- tors who wish to enhance their programs. We extend a special acknowledgement to the American Welding Society whose publications were frequently referenced for the sake of technical accuracy. Appreciation is also extended to the artists Robert Randall and Regina Beaney of the Graph- ics Division, Oklahoma State Department oc Vocational-Technical Education, for their hard work with the project, and to members of the Oklahoma State Vo-Tech Print Shop for their excellent service in printing the text.