10412110Metalworking for Heavy Duty Applications
Course Information
Description
This course focuses on welding and metal cutting safety as it applies to heavy-duty applications. Students setup and use welding and cutting equipment to weld and cut a variety of types and thicknesses of materials commonly used in heavy-duty applications. Emphasis will be placed on cutting metal with oxy-fuel and plasma arc methods. Welding techniques and procedures for SMAW and GMAW will also be included. In addition, students will have the opportunity to demonstrate layout procedures and complete fabrication projects. Students will also learn various methods of extracting broken threaded fasteners.
Total Credits
2
Course Competencies
  1. Demonstrate safe work habits while performing metalworking repairs or working in a metalworking environment
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Use required eye protection for welding and machine shop
    Demonstrate welding safety procedures
    Use the grinder and drill press safety
    Protect tools, equipment and manuals
    Maintain clean and organized work areas
    Demonstrate conservative use of shop supplies

  2. Perform precision measuring utilizing standard and metric micrometers as well as standard and metric dial calipers
    Assessment Strategies
    Skill Demonstration
    Criteria
    Measure with a steel rule to within the print specifications
    Measure with a micrometer - English and Metric to within the print specifications
    Measure with a dial caliper to within the print specifications
    Measure with a dial indicator to within the print specifications
    Layout project to within tolerance specified on print handout

  3. Use a drill press
    Assessment Strategies
    Skill Demonstration
    Criteria
    Follow safety procedures when using drill press
    Select proper drill bit per application including using a tap drill chart
    Calculate the RPM and set the drill press speed
    Set up and drill stock per print

  4. Determine the need for drill bit sharpening and demonstrate the ability to sharpen it
    Assessment Strategies
    Skill Demonstration
    Criteria
    Identify drill bits that need sharpening
    Grind a drill bit with appropriate angles
    Drill hole in steel to verify bit was ground properly

  5. Use taps and dies to perform threading
    Assessment Strategies
    Skill Demonstration
    Criteria
    Determine appropriate drill bit size needed for tapping threads
    Determine percentage of thread engagement as per drill bit size
    New threaded fasteners should thread in by hand
    Identify thread sizes
    Tap stock per print
    Identify parts of a thread
    Use threading terminology
    Identify tap drill size per tap
    Perform a threading operation to print specifications
    Perform a thread restoration using a thread file
    Cut new threads internally
    Cut new threads externally

  6. Remove broken fasteners using a variety of methods
    Assessment Strategies
    Skill Demonstration
    Criteria
    Demonstrate safe work habits
    Identify the various methods used
    Select correct size drill bit
    Fasteners are removed with no damage
    Threads are cleaned using a thread chaser
    Use a torch safely when heating bolt (fire blanket may be necessary)
    Use welder safely when welding nut to broken fastener

  7. Repair threads using thread chasers and Heli-Coils
    Assessment Strategies
    Skill Demonstration
    Criteria
    Demonstrate safe work habits
    Use drill bit and tap in Heli-Coil kit (per instructions)

  8. Lay out a metal project from the blueprint
    Assessment Strategies
    Skill Demonstration
    Criteria
    Read blueprint accurately
    Follow blueprint written instructions
    Project meets tolerances as specified by the instructor

  9. Perform various weld joints using the GMAW welding process
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Follow Gas Metal Arc Welding safety standards
    Explain GMAW set-up procedure
    Set up MIG welding machine
    Use a welding calculator to determine proper voltage and wire feed
    Use welder settings on welder or welder operator's manual
    Calculate the wire feed speed of an unknown wire feeder
    Use welding terminology
    Set up MIG welding machine
    Perform all welds on specified material
    Weld bead is appropriate width
    Weld bead is appropriate height
    Welding has appropriate amount of spatter for selected electrode
    Assess the quality of the weld

  10. Perform various weld joints using the SMAW welding process
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Follow Shielded Metal Arc Welding safety standards
    Set up power source
    Weld bead is appropriate width
    Weld bead appropriate height
    Welding has appropriate amount of spatter for selected electrode
    Welding is performed on specified metal
    Use a variety of welding rods
    Perform selected welds in the horizontal positions
    Perform selected welds in the vertical positions
    Weld passes a face bend test on butt welds
    Identify characteristics of power supply set-up
    Identify manipulation techniques for electrodes
    Use welding terminology
    Assess the quality of the weld

  11. Perform plasma cutting
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Follow plasma arc cutting safety standards
    Identify basic plasma arc cutting functions
    Identify plasma arc cutting safety standards
    Set up plasma arc cutting machine
    Perform a plasma cut on ½ inch steel

  12. Use an oxy-acetylene torch
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Follow oxy-acetylene cutting safety standards
    Safely set up, light, adjust to a neutral flame and shut down torch in proper sequence
    Select correct tip size for application
    Select correct oxygen and acetylene line pressure for tip size
    Perform cutting
    Use cutting terminology

  13. Perform oxy-acetylene brazing
    Assessment Strategies
    Skill Demonstration
    Criteria
    Wear PPE (Personal Protective Equipment)
    Follow oxy-acetylene brazing safety standards
    Select correct tip size for application
    Select correct oxygen and acetylene line pressure for the tip size
    Perform brazing as specified by the instructor
    Use welding terminology
    Assess quality of the braze

  14. Solder copper tubing
    Assessment Strategies
    Skill Demonstration
    Criteria
    Follow blueprint
    Use tubing cutter to cut pieces to length per blueprint
    Clean tubing externally
    Clean fittings internally
    Apply flux
    Heat to temperature that will facilitate capillary action
    Apply solder as per size of tubing
    Clean solder joint
    Pressure test to check for leaks

  15. Use metal working tools
    Assessment Strategies
    Skill Demonstration
    Criteria
    Select tools to correspond with task
    Use a variety of tools appropriate to the task and metal working industry (handheld grinders, cut off tools, band saws, files, hacksaws, etc.)
    Use the appropriate saw blade
    Perform basic hand metal cutting operations appropriately
    Tool selection and use contributes to efficient completion of task or project