Table of Contents
Task D-13 Welds using shielded metal arc welding (SMAW) process
Task Descriptor
SMAW is a commonly used process for joining most ferrous and some non-ferrous metals. Even though it is one of the slowest of the welding processes, it is readily available, easily accessible, very reliable, versatile and portable, and therefore it is widely used.
D-13.01 - Selects SMAW equipment and consumables
D-13.01 - Selects SMAW equipment and consumables
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| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-13.01.01P |
select power source |
power source is selected according to application and primary power supply availability |
| D-13.01.02P |
select electrode type and diameter |
electrode type and diameter are selected according to base metal thickness and composition, joint type and position, and WPS/WPDS to ensure fusion and avoid weld discontinuities |
| D-13.01.03P |
select components |
components are selected according to application |
Range of Variables
- power source [constant current (CC) capable] includes: inverters, rectifiers, generators, transformers
- components include: work lead clamps, electrode holders, cables, remote controls
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-13.01.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using SMAW equipment |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-13.01.02L |
demonstrate knowledge of SMAW processes, equipment, components consumables, and their characteristics, applications and operation |
describe fundamentals of SMAW process |
| identify power sources, and describe their characteristics and applications |
| identify SMAW equipment, components and consumables, and describe their characteristics and applications |
| describe storage requirements for SMAW electrodes |
| identify SMAW electrodes, and describe their classifications, characteristics, flux coating composition, and applications |
| identify components, and describe their characteristics and applications |
| describe operating principles of SMAW equipment |
| interpret and apply welding symbols and information pertaining to SMAW equipment, components and consumables found on drawings and specifications |
| D-13.01.03L |
demonstrate knowledge of training and qualification requirements for SMAW |
identify training and qualification requirements for SMAW |
| identify training and certification requirements and limitations pertaining to setting up primary wiring for SMAW equipment |
| D-13.01.04L |
demonstrate knowledge of regulatory requirements pertaining to SMAW equipment, components and consumables |
identify codes, standards and regulations pertaining to SMAW equipment, components and consumables |
Range of Variables
- components include: work lead clamps, electrode holders, cables, remote controls
- power source [constant current (CC) capable] includes: inverters, rectifiers, generators, transformers
- classifications include: American Welding Society (AWS), Canadian Standards Association (CSA), American Society of Mechanical Engineers (ASME), (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition, fast freezing, fast fill, freeze fill
- flux coating composition includes: rutile (titania), cellulose, low-hydrogen (basic), iron-powder
D-13.02 - Sets up SMAW equipment
D-13.02 - Sets up SMAW equipment
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| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-13.02.01P |
identify damage and defects in SMAW equipment and components |
damage and defects in SMAW equipment and components are identified |
| D-13.02.02P |
select machine settings on power source |
machine settings on power source are selected according to SMAW process |
| D-13.02.03P |
set required current type |
required current type is set by adjusting selector switch or connecting cables (leads) to appropriate terminals |
| D-13.02.04P |
connect electrode holders (stingers) and work lead clamps to cables |
electrode holders (stingers) and work lead clamps are connected to cables |
| D-13.02.05P |
attach work lead clamp to base metal |
work lead clamp is attached to base metal to complete circuit |
| D-13.02.06P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode and position |
Range of Variables
- components include: work lead clamps, electrode holders, cables, remote controls
- power source (CC capable) includes: inverters, rectifiers, generators, transformers
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-13.02.01L |
demonstrate knowledge of SMAW processes, equipment, components and their characteristics, applications and operation |
describe fundamentals of SMAW process |
| identify power sources, and describe their characteristics and applications |
| identify SMAW equipment and components and describe their characteristics and applications |
| describe operating principles of SMAW equipment |
| describe procedures to refuel and perform general maintenance checks of engine-driven power sources |
Range of Variables
- components include: work lead clamps, electrode holders, cables, remote controls
- power source (CC capable) includes: inverters, rectifiers, generators, transformers
D-13.03 - Sets operating parameters for SMAW equipment
D-13.03 - Sets operating parameters for SMAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-13.03.01P |
determine parameters |
parameters are determined according to WPS/WPDS and application |
| D-13.03.02P |
set/adjust amperage |
amperage is set/adjusted according to base metal thickness and electrode type and size |
| D-13.03.03P |
set and adjust additional machine options |
additional machine options are set and adjusted according to application |
| D-13.03.04P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode and position |
Range of Variables
- machine options include: arc force (dig), hot start
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-13.03.01L |
demonstrate knowledge of SMAW processes, equipment, components and their characteristics, applications and operation |
describe fundamentals of SMAW process |
| identify SMAW equipment and components and describe their characteristics and applications |
| identify power sources, and describe their characteristics and applications |
| identify welding components, and describe their characteristics and applications |
| describe operating principles of SMAW equipment |
| interpret and apply welding symbols and information pertaining to SMAW equipment found on drawings and specifications |
| describe metric and imperial electrode designations |
| D-13.03.02L |
demonstrate knowledge of procedures to set operating parameters for SMAW equipment |
identify hazards, and describe safe work practices pertaining to setting operating parameters for SMAW equipment |
| describe procedures to set operating parameters for SMAW equipment |
| describe procedures to set/adjust additional machine options for SMAW equipment |
Range of Variables
- components include: work lead clamps, electrode holders, cables, remote controls
- power source (CC capable) includes: inverters, rectifiers, generators, transformers
- hazards include: fumes, electrical shocks, ultraviolet (UV) and infrared light, visible light rays, burns, flying debris
- machine options include: arc force (dig), hot start
D-13.04 - Performs weld using SMAW equipment
D-13.04 - Performs weld using SMAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-13.04.01P |
start up equipment |
equipment is started up according to safe operating procedures and manufacturers’ recommendations |
| D-13.04.02P |
strike arc and manipulate electrode |
arc is struck and electrode is manipulated while maintaining arc length, electrode angle and travel speed |
| D-13.04.03P |
perform electrode manipulation techniques |
electrode manipulation techniques are performed |
| D-13.04.04P |
perform tacking, backstepping and sequencing techniques |
tacking, backstepping and sequencing techniques are performed according to application, and controlling heat distortion |
| D-13.04.05P |
adjust travel speed and angle |
travel speed and angle are adjusted taking into consideration factors to maintain a consistent weld profile |
| D-13.04.06P |
stop arc |
arc is stopped ensuring proper tie-ins and avoiding weld discontinuities |
| D-13.04.07P |
remove slag using tools |
slag is removed using tools |
| D-13.04.08P |
identify weld discontinuities |
weld discontinuities are identified by performing visual inspection |
| D-13.04.09P |
determine cause of weld discontinuities and defects |
cause of weld discontinuities and defects are determined by troubleshooting SMAW equipment, process and electrode manipulation techniques |
| D-13.04.10P |
repair weld discontinuities |
weld discontinuities are repaired by grinding/gouging and re-welding |
| D-13.04.11P |
re-start arc |
arc is re-started ensuring proper tie-ins and avoiding weld discontinuities and defects |
| D-13.04.12P |
finish weld |
weld is finished showing proper tie-ins in all positions and containing no unacceptable weld discontinuities and defects |
| D-13.04.13P |
shut down equipment |
equipment is shut down according to safe operating procedures and manufacturers’ recommendations |
Range of Variables
- electrode manipulation techniques include: whip, using backhand and forehand techniques to achieve desired bead width and shape (weave and stringer) to direct heat; and control penetration and build-up
- factors include: base metal, joint configuration, position, heat input, WPS/WPDS
- tools include: wire wheels, chipping hammers, wire brushes
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-13.04.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using SMAW process |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-13.04.02L |
demonstrate knowledge of procedures to weld using SMAW equipment |
identify hazards, and describe safe work practices pertaining to welding using SMAW equipment |
| identify SMAW equipment used to weld, and describe their procedures for use |
| identify types of welds, and describe their characteristics and applications |
| describe procedures to start up and shut down equipment |
| describe electrode manipulation techniques |
| identify SMAW electrodes, and describe their classifications, characteristics, flux coating composition, and applications |
| identify weld position |
| identify joint configurations |
| identify electrical characteristics |
| describe procedures to maintain travel speed, electrode angle and heat inputs |
| describe pre-heating, post-heating and interpass temperature requirements for base metals |
| describe techniques to repair weld discontinuities and defects |
| describe procedures to control waste and recycle SMAW equipment, components and consumables |
| D-13.04.03L |
demonstrate knowledge of training and qualification requirements to weld using SMAW equipment |
identify training and qualification requirements to weld using SMAW equipment |
| D-13.04.04L |
demonstrate knowledge of regulatory requirements pertaining to welding using SMAW process |
identify codes, standards and regulations pertaining to welding using SMAW process |
Range of Variables
- hazards include: burns, flying debris, fumes, falling objects, fire hazards, falling hazards, UV and infrared light, visible light rays
- types of welds include: fillet, groove, plug, slot, surfacing
- electrode manipulation techniques include: whip, using backhand and forehand techniques to achieve desired bead width and shape (weave and stringer) to direct heat; and control penetration and build-up
- classifications include: AWS, CSA, ASME, (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition, fast freezing, fast fill, freeze fill
- flux coating composition includes: rutile (titania), cellulose, low-hydrogen (basic), iron-powder
- weld position includes: flat, horizontal, vertical, overhead, 1G, 2G, 5G, 6G
- joint configurations include: butt, tee, edge, corner, lap
- electrical characteristics include: current type, duty cycle, amperage
Task D-14 Welds using flux cored arc welding (FCAW), metal cored arc welding (MCAW) and gas metal arc welding (GMAW) processes
Task Descriptor
The FCAW is a semi-automatic process that uses tubular wire with a granular flux core, which can be gas shielded or self shielded. It is widely used in production shops because, compared to SMAW and GTAW processes, it has high productivity, low operating cost and high efficiency.
The MCAW process uses a tubular wire with a powdered metal core. Some of the advantages of this process include no slag produced, very little spatter and interpass cleaning required, and a very high deposition rate. It is used in similar applications as the FCAW process.
The GMAW process uses solid wire for welding metals and their alloys. It is used for applications such as sheet metal, structural steel and piping. It has a low distortion rate, a high deposition rate and requires minimal cleaning.
These processes typically use a constant voltage (CV) power source and a wire feeder that supplies continuously fed wire.
D-14.01 - Selects FCAW, MCAW and GMAW gas, equipment and consumables
D-14.01 - Selects FCAW, MCAW and GMAW gas, equipment and consumables
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-14.01.01P |
select power source |
power source is selected according to application and primary power supply availability |
| D-14.01.02P |
select wire type and diameter |
wire type and diameter are selected according to base metal thickness and composition, joint type and position and WPS/WPDS to ensure fusion and avoid weld discontinuities |
| D-14.01.03P |
select FCAW, MCAW and GMAW equipment and components |
FCAW, MCAW and GMAW equipment and components are selected according to application |
| D-14.01.04P |
select shielding gas |
shielding gas is selected according to factors |
Range of Variables
- power sources include: CV capable machines (inverters, rectifiers, generator); constant current (CC) machine with voltage sensing wire feeder
- wire type includes: solid and tubular wire, self-shielded
- equipment and components include: guns (air-cooled, water-cooled), nozzles, contact tips, wire feeders, drive rolls, gas diffusers, liners, work lead clamps, regulators/flow meters, gas lines
- shielding gas includes: CO2, argon, helium, mixed gases
- factors include: base metal composition, process, WPS/WPDS, mode of transfer, position, density-to-air ratio
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-14.01.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using FCAW, MCAW and GMAW processes |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-14.01.02L |
demonstrate knowledge of FCAW, MCAW and GMAW processes, gas, equipment, components and consumables, and their, characteristics, applications and operation |
describe fundamentals of FCAW, MCAW and GMAW processes |
| identify FCAW, MCAW and GMAW equipment and components, and describe their characteristics and applications |
| identify FCAW, MCAW and GMAW wires and describe their characteristics and applications |
| identify shielding gases, and describe their characteristics and applications |
| identify power sources, and describe their characteristics and applications |
| describe operating principles of FCAW, MCAW and GMAW equipment |
| describe digital technology used in FCAW, MCAW and GMAW processes |
Range of Variables
- equipment and components include: guns (air-cooled, water-cooled), nozzles, contact tips, wire feeders, drive rolls, gas diffusers, liners, work lead clamps, regulators/flow meters, gas lines
- wire type includes: solid and tubular wire, self-shielded
- shielding gas includes: CO2, argon, helium, mixed gases
- power sources include: CV capable machines (inverters, rectifiers, generator); constant current (CC) machine with voltage sensing wire feeder
- digital technology includes: waveform programming, real-time monitoring, pre-sets
D-14.02 - Sets up FCAW, MCAW and GMAW equipment
D-14.02 - Sets up FCAW, MCAW and GMAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-14.02.01P |
identify damage and defects in FCAW, MCAW and GMAW equipment |
damage and defects in FCAW, MCAW and GMAW equipment are identified |
| D-14.02.02P |
set machine settings |
machine settings are set according to FCAW, MCAW and GMAW process |
| D-14.02.03P |
set required current type |
required current type is set by adjusting selector switch or connecting cables (leads) to appropriate terminals |
| D-14.02.04P |
assemble gun components and connect gun to wire feeder |
gun components are assembled and gun is connected to wire feeder |
| D-14.02.05P |
connect regulator to gas supply and gas hose to wire feeder |
regulator is connected to gas supply and gas hose to wire feeder according to electrode selection |
| D-14.02.06P |
install wire roll in wire feeder |
wire roll is installed in wire feeder |
| D-14.02.07P |
feed wire through drive rolls, liner and gun, and clip end of wire for appropriate stick-out |
wire is fed through drive rolls, liner and gun, and end of wire is clipped for appropriate stick-out according to manufacturers’ specifications |
| D-14.02.08P |
adjust wire drive roll tension |
wire drive roll tension is adjusted according to manufacturers’ specifications to achieve a consistent rate of wire feed |
| D-14.02.09P |
attach work lead clamp to base metal |
work lead clamp is attached to base metal to complete circuit |
| D-14.02.10P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode and position |
Range of Variables
- gun components include: gas diffusers, contact tips, nozzles
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-14.02.01L |
demonstrate knowledge of FCAW, MCAW and GMAW processes, gas, equipment, components and consumables, and their, characteristics, applications and operation |
describe fundamentals of FCAW, MCAW and GMAW processes |
| identify power source |
| identify FCAW, MCAW and GMAW equipment and components, and describe their characteristics and applications |
| identify types of wire for FCAW, MCAW and GMAW processes and describe their characteristics and applications |
| identify shielding gases, and describe their characteristics and applications |
| identify power sources, and describe their characteristics and applications |
| describe operating principles of FCAW, MCAW and GMAW equipment |
| D-14.02.02L |
demonstrate knowledge of procedures to set up FCAW, MCAW and GMAW equipment and components |
identify hazards, and describe safe work practices pertaining to FCAW, MCAW and GMAW equipment and components |
| describe procedures to set up FCAW, MCAW and GMAW equipment and components |
| describe procedures to control waste and recycle FCAW, MCAW and GMAW equipment and components |
| describe digital technology used in FCAW, MCAW and GMAW processes |
| D-14.02.03L |
demonstrate knowledge of training and qualification requirements pertaining to FCAW, MCAW and GMAW equipment and components |
identify training and qualification requirements pertaining to FCAW, MCAW and GMAW equipment and components |
| identify training and certification requirements and limitations pertaining to setting up primary wiring for FCAW, MCAW and GMAW equipment |
| D-14.02.04L |
demonstrate knowledge of regulatory requirements pertaining to FCAW, MCAW and GMAW equipment and components |
identify codes, standards and regulations pertaining to FCAW, MCAW and GMAW equipment and components |
Range of Variables
- equipment and components include: guns (air-cooled, water-cooled), nozzles, contact tips, wire feeders, drive rolls, gas diffusers, liners, work lead clamps, regulators/flow meters, gas lines
- power sources include: CV capable machines (inverters, rectifiers, generator); CC machine with voltage sensing wire feeder
- types of wire include: solid and tubular wire, self-shielded
- shielding gases include: CO2, argon, helium, mixed gases
- hazards include: pinch points, burns, electrical burns, electrical shocks, falling objects, moving parts, asphyxiation, ozone and phosgene gases, UV and infrared light, visible light rays
- digital technology includes: waveform programming, real-time monitoring, pre-sets
D-14.03 - Sets operating parameters for FCAW, MCAW and GMAW
D-14.03 - Sets operating parameters for FCAW, MCAW and GMAW
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-14.03.01P |
determine parameters |
parameters are determined according to WPS/WPDS and application |
| D-14.03.02P |
set wire feed speed and voltage |
wire feed speed and voltage are set according to WPS/WPDS and application |
| D-14.03.03P |
set gas flow rate |
gas flow rate is set according to WPS/WPDS and application |
| D-14.03.04P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode and position |
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-14.03.01L |
demonstrate knowledge of FCAW, MCAW and GMAW processes, equipment, components, and their characteristics, applications and operation |
describe fundamentals of FCAW, MCAW and GMAW processes |
| identify FCAW, MCAW and GMAW equipment and components, and describe their characteristics and applications |
| describe operating principles of FCAW, MCAW and GMAW equipment |
| interpret and apply welding symbols and information pertaining to FCAW, MCAW and GMAW equipment found on drawings and specifications |
| describe metric and imperial electrode designations |
| D-14.03.02L |
demonstrate knowledge of procedures to set operating parameters for FCAW, MCAW and GMAW equipment |
identify hazards, and describe safe work practices pertaining to setting operating parameters for FCAW, MCAW and GMAW equipment |
| describe procedures to set operating parameters for FCAW, MCAW and GMAW equipment |
| identify modes of transfer |
| identify operational working pressures |
| describe digital technology used in FCAW, MCAW and GMAW processes |
Range of Variables
- equipment and components include: guns (air-cooled, water-cooled), nozzles, contact tips, wire feeders, drive rolls, gas diffusers, liners, work lead clamps, regulators/flow meters, gas lines
- hazards include: burns, electrical burns, electrical shocks, moving parts, asphyxiation, fumes, ozone and phosgene gases, UV and infrared light, visible light rays
- modes of transfer include: short circuit, globular, spray, pulse spray
- digital technology includes: waveform programming, real-time monitoring, pre-sets
D-14.04 - Performs weld using FCAW, MCAW and GMAW equipment
D-14.04 - Performs weld using FCAW, MCAW and GMAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-14.04.01P |
start up equipment |
equipment is started up according to safe operating procedures and manufacturers’ recommendations |
| D-14.04.02P |
start arc and manipulate electrode |
arc is started and electrode is manipulated while maintaining electrode angle and travel speed |
| D-14.04.03P |
perform wire manipulation techniques |
wire manipulation techniques are performed |
| D-14.04.04P |
perform tacking, backstepping and sequencing techniques |
tacking, backstepping and sequencing techniques are performed according to application and code, and controlling heat distortion |
| D-14.04.05P |
adjust travel speed and angle |
travel speed and angle are adjusted taking into consideration factors to maintain a consistent weld profile |
| D-14.04.06P |
stop arc |
arc is stopped ensuring proper tie-ins and avoiding weld discontinuities |
| D-14.04.07P |
remove slag using tools |
slag is removed using tools |
| D-14.04.08P |
identify weld discontinuities and defects |
weld discontinuities and defects are identified by performing visual inspection |
| D-14.04.09P |
determine cause of weld discontinuities and defects |
cause of weld discontinuities and defects are determined by troubleshooting FCAW, MCAW and GMAW equipment, process and wire manipulation techniques |
| D-14.04.10P |
repair weld discontinuities and defects |
weld discontinuities and defects are repaired by grinding/gouging and re-welding |
| D-14.04.11P |
re-start arc |
arc is re-started ensuring proper tie-ins and avoiding weld discontinuities |
| D-14.04.12P |
finish weld |
weld is finished showing proper tie-ins in all positions and containing no unacceptable welding discontinuities |
| D-14.04.13P |
shut down equipment |
equipment is shut down according to safe operating procedures and manufacturers’ recommendations |
Range of Variables
- wire manipulation techniques include: using backhand and forehand techniques to achieve desired bead width and shape (weave and stringer) to direct heat, and control penetration and build-up
- tacking includes: penetrating, bridge
- factors include: base metal, joint configuration, position, heat input, WPS/WPDS
- tools include: wire wheels, chipping hammers, wire brushes, grinding discs, air chippers, needle guns
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-14.04.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using GMAW, MCAW and FCAW processes |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-14.04.02L |
demonstrate knowledge of procedures to weld using GMAW, MCAW and FCAW equipment |
identify hazards, and describe safe work practices pertaining to welding using GMAW, MCAW and FCAW equipment |
| identify GMAW, MCAW and FCAW equipment used to weld, and describe their procedures for use |
| identify types of welds, and describe their characteristics and applications |
| describe procedures to start up and shut down equipment |
| describe wire manipulation techniques |
| identify GMAW, MCAW and FCAW electrodes, and describe their classifications, characteristics, flux composition and applications |
| identify weld position |
| identify joint configurations |
| identify electrical characteristics |
| identify modes of transfer |
| describe procedures to maintain travel speed, electrode angle and heat inputs |
| describe pre-heating, post-heating and interpass temperature requirements for base metals |
| describe techniques to repair weld discontinuities |
| describe procedures to control waste and recycle GMAW, MCAW and FCAW equipment, components and consumables |
| D-14.04.03L |
demonstrate knowledge of training and qualification requirements to weld using GMAW, MCAW and FCAW equipment |
identify training and qualification requirements to weld using GMAW, MCAW and FCAW equipment |
| D-14.04.04L |
demonstrate knowledge of regulatory requirements pertaining to welding using GMAW, MCAW and FCAW processes |
identify codes, standards and regulations pertaining to welding using GMAW, MCAW and FCAW processes |
Range of Variables
- hazards include: burns, flying debris, fumes, falling objects, fire hazards, falling hazards, UV and infrared light, visible light rays
- types of welds include: fillet, groove, plug, slot, surfacing
- wire manipulation techniques include: using backhand and forehand techniques to achieve desired bead width and shape (weave and stringer) to direct heat, and control penetration and build-up
- classifications include: AWS, CSA, ASME, (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition
- flux composition (MCAW, FCAW) includes: rutile, low-hydrogen (basic)
- weld position includes: flat, horizontal, vertical, overhead
- joint configurations include: butt, tee, edge, corner, lap
- electrical characteristics include: current type, wire feed speed (amperage), voltage
- modes of transfer include: short circuit, globular, spray, pulse spray
Task D-15 Welds using gas tungsten arc welding (GTAW) process
Task Descriptor
The GTAW process uses a non-consumable tungsten electrode and may include the use of a hand-fed filler rod. It provides high quality welds and requires minimal clean-up. It welds most ferrous and non-ferrous metals. It requires the most dexterity of all welding processes.
D-15.01 - Selects GTAW gas, equipment and consumables
D-15.01 - Selects GTAW gas, equipment and consumables
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-15.01.01P |
select power source |
power source is selected according to application and primary power supply availability |
| D-15.01.02P |
select GTAW gas, equipment, components and consumables |
GTAW gas, equipment, components and consumables are selected according to factors and application |
| D-15.01.03P |
select shielding gas |
shielding gas is selected taking into consideration factors |
| D-15.01.04P |
select purging equipment |
purging equipment is selected according to application and base metal |
| D-15.01.05P |
select tungsten electrode and filler rod compositions and diameters |
tungsten electrode and filler rod compositions and diameters are selected taking into consideration base metal thickness and composition, joint type, position and WPS/WPDS to ensure fusion and avoid weld discontinuities |
Range of Variables
- power source (CC capable) includes: inverters, rectifiers, generators, transformers, high-frequency option, AC option
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- factors (for selecting equipment and components) include: joint type, shielding gas, base metal, welding position, WPS/WPDS
- shielding gas includes: argon, helium, mixed gases
- factors (for selecting shielding gas) include: base metal composition, WPS/WPDS, welding position
- tungsten electrodes include: pure, thoriated, zirconiated, lanthanated, ceriated, rare earth
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-15.01.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that have specialized applications for using GTAW equipment |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-15.01.02L |
demonstrate knowledge of GTAW processes, gas, equipment, components and consumables, and their characteristics, applications and operation |
describe fundamentals of GTAW process |
| identify GTAW equipment and components, and describe their characteristics and applications |
| identify types of tungsten electrodes and filler rod, and describe their characteristics and applications |
| identify shielding gases, and describe their characteristics and applications |
| identify power sources, and describe their characteristics and applications |
| identify purging equipment, and describe their characteristics and applications |
| describe operating principles of GTAW equipment |
| describe digital technology used in GTAW processes |
Range of Variables
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- tungsten electrodes include: pure, thoriated, zirconiated, lanthanated, ceriated, rare earth
- shielding gas includes: argon, helium, mixed gases
- power source (CC capable) includes: inverters, rectifiers, generators, transformers, high-frequency option, AC option
- digital technology includes: waveform programming, real-time monitoring, pre-sets
D-15.02 - Sets up GTAW equipment
D-15.02 - Sets up GTAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-15.02.01P |
identify damage and defects in GTAW equipment and components |
damage and defects in GTAW equipment and components are identified |
| D-15.02.02P |
set machine settings |
machine settings are set according to GTAW process and high frequency settings used according to application and WPS |
| D-15.02.03P |
connect work lead clamp and torch to power source |
work lead clamp and torch are connected to power source |
| D-15.02.04P |
connect regulator/flow meter to gas supply and hoses |
regulator/flow meter is connected to gas supply and hoses |
| D-15.02.05P |
assemble equipment and components and connect assembly to power source |
equipment and components are assembled and assembly is connected to power source |
| D-15.02.06P |
shape end of tungsten electrode and adjust stick-out |
end of tungsten electrode is shaped and stick-out is adjusted according to joint configuration and base metal |
| D-15.02.07P |
attach work lead clamp to base metal |
work lead clamp is attached to base metal to complete circuit |
| D-15.02.08P |
dam and purge weld area |
weld area is dammed and purged taking into consideration factors |
| D-15.02.09P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode filler metal and position |
Range of Variables
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- machine settings include: AC, DC, scratch start, lift start, high frequency start, pre-purge, post purge pulse, AC balance, AC frequency, AC for sine wave, amperage, current type
- tungsten electrodes include: pure, thoriated, zirconiated, lanthanated, ceriated, rare earth blends
- factors (for damming and purging work area) include: base metal composition, joint configuration, position, WPS/WPDS
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-15.02.01L |
demonstrate knowledge of GTAW processes, gas, equipment, components and consumables, and their characteristics, applications and operation |
describe fundamentals of GTAW processes |
| identify power source |
| identify GTAW equipment and components, and describe their characteristics and applications |
| identify types of torches, and describe their components, characteristics and applications |
| identify types of regulators/flow meters, cylinders and hoses, and describe their characteristics and applications |
| identify types of filler metals, and describe their classifications, characteristics and applications |
| identify types of tungsten electrodes, and describe their colour codes, characteristics and applications |
| describe operating principles of GTAW equipment and components |
| D-15.02.02L |
demonstrate knowledge of procedures to set up GTAW equipment and components |
identify hazards, and describe safe work practices pertaining to GTAW equipment and components |
| describe procedures to set up GTAW equipment and components |
| describe procedures to control waste and recycle GTAW equipment and components |
| describe damming and purging methods and applications |
| describe procedures to refuel and perform general maintenance checks of engine-driven power sources |
| describe digital technology used in GTAW processes |
| D-15.02.03L |
demonstrate knowledge of training and qualification requirements pertaining to GTAW equipment and components |
identify training and qualification requirements pertaining to GTAW equipment and components |
| D-15.02.04L |
demonstrate knowledge of regulatory requirements pertaining to GTAW equipment and components |
identify codes, standards and regulations pertaining to GTAW equipment and components |
Range of Variables
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- power source (CC capable) includes: inverters, rectifiers, generators, transformers, high-frequency option, AC option
- types of torches include: air-cooled and liquid-cooled
- types of filler metals include: rods, wire, consumable inserts
- tungsten electrodes include: pure, thoriated, zirconiated, lanthanated, ceriated, rare earth blends
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, electromagnetic field (EMF), UV and infrared light, visible light rays, radiation
- digital technology includes: waveform programming, real-time monitoring, pre-sets
D-15.03 - Sets operating parameters for GTAW
D-15.03 - Sets operating parameters for GTAW
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-15.03.01P |
determine parameters |
parameters are determined according to WPS/WPDS and application |
| D-15.03.02P |
set amperage, current type and frequency to match parameters |
amperage, current type and frequency are set to match parameters according to base metal type and thickness, size and composition of filler metal, and position of weld |
| D-15.03.03P |
set shielding gas flow rate including pre- and post-flow time |
shielding gas flow rate, including pre- and post-flow time, is set according to WPS/WPDS and application |
| D-15.03.04P |
set up damming and purging |
damming and purging is set up according to WPS/WPDS, application and base metal |
| D-15.03.05P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode filler metal and position |
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-15.03.01L |
demonstrate knowledge of GTAW processes, gas, equipment, components and consumables, and their characteristics, applications and operation |
describe fundamentals of GTAW processes |
| identify GTAW equipment and components, and describe their characteristics and applications |
| describe operating principles of GTAW equipment |
| interpret and apply welding symbols and information pertaining to GTAW equipment found on drawings and specifications |
| describe metric and imperial designations |
| D-15.03.02L |
demonstrate knowledge of procedures to set operating parameters for GTAW equipment |
identify hazards, and describe safe work practices pertaining to setting operating parameters for GTAW equipment |
| describe procedures to set operating parameters for GTAW equipment |
| identify amperage controls, and describe their characteristics and applications |
| identify start options |
| identify AC balance |
| identify current type |
| identify operational working pressures and flow rates |
| describe digital technology used in GTAW processes |
Range of Variables
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, electromagnetic field (EMF), UV and infrared light, visible light rays
- amperage controls include: foot pedal, thumb control, remote, power source controls
- start options include: scratch start, lift arc, high frequency
- digital technology includes: waveform programming, real-time monitoring, pre-sets, frequency, pulse
D-15.04 - Performs weld using GTAW equipment
D-15.04 - Performs weld using GTAW equipment
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yes |
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yes |
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yes |
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-15.04.01P |
start up equipment |
equipment is started up according to safe operating procedures and manufacturers’ recommendations |
| D-15.04.02P |
clean base metal and filler metal |
base metal and filler metal are cleaned according to manufacturers’ specifications and recommendations, material and safe work practices |
| D-15.04.03P |
start arc, and manipulate tungsten electrode (torch) and filler metal |
arc is started, and tungsten electrode (torch) and filler metal are manipulated while maintaining arc length, angles, and travel speed |
| D-15.04.04P |
adjust amperage |
amperage is adjusted with amperage controls |
| D-15.04.05P |
perform torch manipulation techniques and filler metal manipulation techniques |
torch manipulation techniques and filler metal manipulation techniques are performed |
| D-15.04.06P |
perform tacking, backstepping and sequencing techniques |
tacking, backstepping and sequencing techniques are performed according to application and code, and controlling heat distortion |
| D-15.04.07P |
adjust travel speed and angle |
travel speed and angle are adjusted taking into consideration factors to maintain a consistent weld profile |
| D-15.04.08P |
stop arc |
arc is stopped ensuring proper tie-ins and avoiding weld discontinuities |
| D-15.04.09P |
clean welded areas using tools |
welding areas are cleaned using tools according to application |
| D-15.04.10P |
identify weld discontinuities and defects |
weld discontinuities and defects are identified by performing visual inspection |
| D-15.04.11P |
determine cause of weld discontinuities and defects |
cause of weld discontinuities and defects are determined by troubleshooting GTAW equipment, process, torch manipulation techniques and filler metal manipulation techniques |
| D-15.04.12P |
repair weld discontinuities and defects |
weld discontinuities and defects are repaired by grinding/gouging and re-welding |
| D-15.04.13P |
re-start arc |
arc is re-started ensuring proper tie-ins and avoiding weld discontinuities |
| D-15.04.14P |
finish weld |
weld is finished showing proper tie-ins in all positions and containing no unacceptable weld discontinuities |
| D-15.04.15P |
shut down equipment |
equipment is shut down according to safe operating procedures and manufacturers’ recommendations |
Range of Variables
- amperage controls include: foot pedal, thumb control, remote, power source controls
- torch manipulation techniques include: walking the cup; forehand and backhand to achieve desired bead width and shape (weave and stringer)
- tacking includes: penetrating, bridge
- factors include: base metal, joint configuration, position, heat input, filler metal, WPS/WPDS
- tools include: wire wheels, wire brushes, chemical cleaners
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-15.04.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that have specialized applications for using GTAW process |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-15.04.02L |
demonstrate knowledge of procedures to weld using GTAW equipment and components |
identify hazards, and describe safe work practices pertaining to welding using GTAW equipment |
| identify GTAW equipment and components used to weld, and describe their procedures for use |
| identify specialized GTAW equipment |
| identify types of welds, and describe their characteristics and applications |
| describe procedures to start up and shut down equipment |
| describe autogenous (no filler) welding technique |
| describe torch manipulation techniques |
| describe pre- and post-flow shielding |
| describe storage requirements for filler rods |
| identify GTAW filler metals, and describe their classifications, characteristics, and applications |
| identify weld position |
| identify joint configurations |
| identify electrical characteristics |
| describe procedures to maintain travel speed, electrode angle and heat inputs |
| describe amperage requirements |
| describe pre-heating, post-heating and interpass temperature requirements for base metals |
| describe techniques to repair weld discontinuities |
| describe procedures to control waste and recycle GTAW equipment, components and consumables |
| D-15.04.03L |
demonstrate knowledge of training and qualification requirements to weld using GTAW equipment |
identify training and qualification requirements to weld using GTAW equipment |
| D-15.04.04L |
demonstrate knowledge of regulatory requirements pertaining to welding using GTAW process |
identify codes, standards and regulations pertaining to welding using GTAW process |
Range of Variables
- equipment and components include: tungsten electrodes, gas lenses, collets, collet bodies, work lead clamps, torches and cables (leads), regulators/flow meters, shielding gases, hoses, water coolers, remote controls, cups
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, EMF, UV and infrared light, visible light rays, radioactivity (thoriated tungsten)
- specialized GTAW equipment includes: robotic welders, orbital welders, automatic machines, semi-automatic machines, hot wire
- types of welds include: fillet, groove, plug, slot, surfacing
- torch manipulation techniques include: walking the cup; forehand and backhand to achieve desired bead width and shape (weave and stringer)
- classifications include: AWS, CSA, ASME, (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition
- weld position includes: flat, horizontal, vertical, overhead, 1G, 2G, 3G, 4G, 5G, 6G
- joint configurations include: butt, tee, edge, corner, lap
- electrical characteristics include: current type, duty cycle, amperage
Task D-16 Welds using submerged arc welding (SAW) process
Task Descriptor
The SAW process provides the highest production rate. The most difficult part of this process is setting up the equipment. It is the only wire feed process that may use AC and DC currents concurrently.
This process is mostly used on large scale productions, including pressure vessels, tanks, bridges and ship construction.
D-16.01 - Selects SAW equipment and consumables
D-16.01 - Selects SAW equipment and consumables
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-16.01.01P |
select power source |
power source is selected according to application and primary power supply availability |
| D-16.01.02P |
select electrode type and diameter |
electrode type and diameter is selected according to base metal thickness and composition, joint type and position and WPS/WPDS to ensure fusion and avoid weld discontinuities |
| D-16.01.03P |
select flux |
flux is selected according to base metal thickness and composition, electrode selection, joint type and position and WPS/WPDS to ensure fusion and avoid weld discontinuities |
| D-16.01.04P |
select SAW equipment and components |
SAW equipment and components are selected according to application |
Range of Variables
- power source includes: inverters, rectifiers, transformers
- flux includes: fused, bonded, active, reactive, neutral
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, tracks, flux recycling equipment
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-16.01.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using SAW process |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-16.01.02L |
demonstrate knowledge of SAW processes, equipment, components, consumables, and their characteristics, applications and operation |
describe fundamentals of SAW process |
| identify SAW equipment, components and consumables, and describe their characteristics and applications |
| identify power sources, and describe their characteristics and applications |
| identify SAW electrodes, and describe their classifications, characteristics and applications |
| identify flux and describe their characteristics and applications |
| describe storage requirements for SAW electrodes and flux |
| describe operating principles of SAW equipment |
| interpret and apply welding symbols and information pertaining to SAW equipment, components and consumables found on drawings and specifications |
Range of Variables
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, tracks, flux recycling equipment
- power source includes: inverters, rectifiers, transformers
- classifications include: AWS, CSA, ASME, (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition
- flux includes: fused, bonded, active, reactive, neutral
D-16.02 - Sets up SAW equipment
D-16.02 - Sets up SAW equipment
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-16.02.01P |
identify damage and defects in SAW equipment |
damage and defects in SAW equipment are identified |
| D-16.02.02P |
select machine settings on power source(s) |
machine settings on power source(s) are selected according to SAW process |
| D-16.02.03P |
connect cables (leads) to power source(s) and wire feeder |
cables (leads) are connected to power source(s) and wire feeder |
| D-16.02.04P |
assemble equipment and components |
equipment and components are assembled |
| D-16.02.05P |
adjust wire drive roll tension |
wire drive roll tension is adjusted according to manufacturers’ specifications to achieve a consistent rate of wire feed |
| D-16.02.06P |
feed wire through liner, drive rolls, barrel and contact tip, and clip end of wire for appropriate stick-out |
wire is fed through liner, drive rolls, barrel and contact tip, and end of wire is clipped for appropriate stick-out |
| D-16.02.07P |
set required current type |
required current type is set by adjusting selector switch or connecting cables (leads) to appropriate terminals |
| D-16.02.08P |
attach work lead clamp to base metal |
work lead clamp is attached to base metal to complete circuit |
| D-16.02.09P |
fill flux hopper |
flux hopper is full |
| D-16.02.10P |
verify setup |
setup is verified by ensuring tracking consistency and required travel speed |
Range of Variables
- power source(s) includes: inverters, rectifiers, transformers
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, tracks, flux recycling equipment, demagnetizer, runoff tabs
- flux includes: fused, bonded, active, reactive, neutral
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-16.02.01L |
demonstrate knowledge of SAW processes, equipment, components, and their characteristics, applications and operation |
identify SAW equipment and components, and describe their characteristics and applications |
| identify power source(s) |
| identify types of filler wire and flux combinations, and describe their classifications, characteristics and applications |
| describe operating principles of SAW equipment and components |
| D-16.02.02L |
demonstrate knowledge of procedures to set up SAW equipment and components |
identify hazards, and describe safe work practices pertaining to SAW equipment and components |
| describe procedures to set up SAW equipment and components |
| identify multiple wire setups and polarities |
| describe procedures to control waste and recycle SAW equipment and components |
| describe digital technology used in SAW processes |
| D-16.02.03L |
demonstrate knowledge of training and qualification requirements pertaining to SAW equipment and components |
identify training and qualification requirements pertaining to SAW equipment and components |
| identify training and certification requirements and limitations pertaining to setting up primary wiring for SAW equipment |
| D-16.02.04L |
demonstrate knowledge of regulatory requirements pertaining to SAW equipment and components |
identify codes, standards and regulations pertaining to SAW equipment and components |
Range of Variables
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, tracks, flux recycling equipment, demagnetizer, runoff tabs
- power source(s) includes: inverters, rectifiers, transformers
- classifications (filler wire and flux) include: AWS, CSA, ASME, (tensile strength, composition)
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, slip hazards
- digital technology includes: waveform programming, realtime monitoring, pre-sets, frequency
D-16.03 - Sets operating parameters for SAW
D-16.03 - Sets operating parameters for SAW
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PE |
NB |
QC |
ON |
MB |
SK |
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BC |
NT |
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NU |
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yes |
yes |
yes |
NV |
yes |
yes |
yes |
yes |
yes |
NV |
NV |
NV |
Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-16.03.01P |
determine parameters |
parameters are determined according to WPS/WPDS and application |
| D-16.03.02P |
set/adjust amperage |
amperage is set/adjusted according to WPS/WPDS, base metal and electrode selected |
| D-16.03.03P |
set wire feed speed and voltage |
wire feed speed and voltage are set according to WPS/WPDS, base metal type and thickness, size and composition of wire, position of weld and selection of gas |
| D-16.03.04P |
set electrode stick-out |
electrode stick-out is set according to WPS/WPDS and application |
| D-16.03.05P |
set flux rate |
flux rate is set according to WPS/WPDS and application |
| D-16.03.06P |
set travel speed |
travel speed is set according to WPS/WPDS and application |
| D-16.03.07P |
verify setup |
setup is verified by welding a test specimen of same base metal, electrode and position |
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-16.03.01L |
demonstrate knowledge of SAW processes, equipment, components, consumables, and their characteristics, applications and operation |
describe fundamentals of SAW processes |
| identify SAW equipment, and describe their characteristics and applications |
| describe operating principles of SAW equipment |
| interpret and apply welding symbols and information pertaining to SAW equipment found on drawings and specifications |
| describe metric and imperial electrode and flux designations |
| D-16.03.02L |
demonstrate knowledge of procedures to set operating parameters for SAW equipment |
identify hazards, and describe safe work practices pertaining to setting operating parameters for SAW equipment |
| describe procedures to set operating parameters for SAW equipment |
| describe digital technology used in SAW processes |
Range of Variables
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, tracks, flux recycling equipment, demagnetizer, runoff tabs
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, slip hazards
- digital technology includes: waveform programming, real-time monitoring, pre-sets, frequency
D-16.04 - Performs weld using SAW equipment
D-16.04 - Performs weld using SAW equipment
| NL |
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PE |
NB |
QC |
ON |
MB |
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AB |
BC |
NT |
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NU |
| yes |
yes |
yes |
yes |
NV |
yes |
yes |
yes |
yes |
yes |
NV |
NV |
NV |
Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| D-16.04.01P |
start up equipment |
equipment is started up according to safe operating procedures and manufacturers’ recommendations |
| D-16.04.02P |
adjust head height |
head height is adjusted to maintain appropriate stick-out and to control flux coverage |
| D-16.04.03P |
verify setup |
setup is verified by performing a dry run to ensure tracking consistency |
| D-16.04.04P |
initiate arc |
arc is initiated by engaging wire feed, travel and current according to manufacturers’ recommendations |
| D-16.04.05P |
perform sequencing techniques |
sequencing techniques are performed according to application, code, and controlling heat distortion |
| D-16.04.06P |
monitor and adjust travel speed and angle |
travel speed and angle are monitored and adjusted to maintain consistent tracking |
| D-16.04.07P |
recover, filter and demagnetize flux |
flux is recovered, filtered and demagnetized according to client requirements and manufacturers’ specifications |
| D-16.04.08P |
stop arc |
arc is stopped ensuring proper tie-ins and avoiding weld discontinuities |
| D-16.04.09P |
remove slag using tools |
slag is removed using tools |
| D-16.04.10P |
identify weld discontinuities and defects |
weld discontinuities and defects are identified by performing visual inspection |
| D-16.04.11P |
determine cause of weld discontinuities and defects |
cause of weld discontinuities and defects are determined by troubleshooting SAW equipment and process |
| D-16.04.12P |
repair weld discontinuities and defects |
weld discontinuities and defects are repaired by grinding/gouging and re-welding |
| D-16.04.13P |
finish weld |
weld is finished showing proper tie-ins in all positions and containing no unacceptable weld discontinuities and defects |
| D-16.04.14P |
shut down equipment |
equipment is shut down according to safe operating procedures and manufacturers’ recommendations |
Range of Variables
- tools include: wire wheels, chipping hammers, wire brushes, grinding discs, air chippers, needle guns
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| D-16.04.01L |
demonstrate knowledge of base metals, their characteristics and applications |
identify base metals, and describe their characteristics and applications |
| describe base metal chemical composition and metallurgy |
| identify base metals that can and cannot be welded using SAW process |
| identify ferrous and non-ferrous metals, and describe their characteristics and applications |
| D-16.04.02L |
demonstrate knowledge of procedures to weld using SAW equipment and components |
identify hazards, and describe safe work practices pertaining to welding using SAW equipment and components |
| identify SAW equipment and components used to weld, and describe their procedures for use |
| identify types of welds, and describe their characteristics and applications |
| describe procedures to start up and shut down equipment |
| describe storage requirements for filler wire and flux |
| identify SAW electrodes, and describe their classifications, characteristics, and applications |
| identify flux and describe its classifications, characteristics and applications |
| identify weld position |
| identify joint configurations |
| identify electrical characteristics |
| identify multiple arc configurations |
| describe procedures to maintain travel speed, stick-outs, angle and heat inputs |
| describe pre-heating, post-heating and interpass temperature requirements for base metals |
| describe techniques to repair weld discontinuities |
| describe procedures to control waste and recycle SAW equipment, components and consumables |
| D-16.04.03L |
demonstrate knowledge of training and qualification requirements to weld using SAW equipment and components |
identify training and qualification requirements to weld using SAW equipment and components |
| D-16.04.04L |
demonstrate knowledge of regulatory requirements pertaining to welding using SAW process |
identify codes, standards and regulations pertaining to welding using SAW process |
Range of Variables
- equipment and components include: drive rolls, contact tips, hoppers, work lead clamps, welding head and control system, cables, wire straightener, booms, sub-arc tractors, tracks, flux recovery system, demagnetizer, runoff tabs
- hazards include: burns, fumes, hazardous gases, falling objects, fire hazards, falling hazards, slip hazards, flux dust, moving equipment
- types of welds include: fillet, groove, surfacing
- flux includes: fused, bonded, active, reactive, neutral
- classifications include: AWS, CSA, ASME, (tensile strength, position, composition, F-numbers)
- characteristics include: tensile strength, position, composition
- weld position includes: flat, horizontal
- joint configurations include: butt, tee, surface build up
- electrical characteristics include: current type, duty cycle, amperage