Content Outline and Competencies:

I. Shop Safety Rules

A. Identify BNSF and JCCC safety rules.

B. Answer questions about commonly used safety rules in industry.

C. Identify and select proper personal protective clothing and equipment for OFC, SMAW and grinding.

D. List the parts of the fire triangle.

E. Complete statements concerning basic safety rules for oxyfuel cylinders and gases.

F. Complete statements concerning eye protection.

G. Complete a list of safety rules for the oxyfuel work area.

H. List hazards concerning electrical safety for arc welding.

I. Select true statements concerning hazards associated with arc rays.

J. Determine steps in selecting a safe lens shade.

K. Select true statements concerning environmental safety requirements.

II. Welding Joints and Welding Positions

A. List the five basic welding joints.

B. Compare and contrast the 1G, 2G, 3G, 4G, 5G, and 6G welding positions with the 1F, 2F, 3F, and 4F welding positions.

III. OFC Safety and Setup Procedures

A. Identify parts of an oxyfuel cutting torch.

B. Complete statements about cutting-tip design, cleaning, selection and uses.

C. Complete statements concerning control of kerf and drag.

D. List reasons for poor cuts and elements of a good cut.

E. Identify proper working surfaces for oxyfuel cutting.

F. Identify special safety requirements for oxyfuel cutting.

G. Complete statements concerning technique for cutting straight lines.

H. Demonstrate proper start-up and shutdown procedures.

IV. Cutting (OFC) Process

A. List components of the oxyfuel cutting torch.

B. Explain the correct use of the welding and cutting tip selector guide.

C. Use the tip selection guide to obtain the correct tip size according to material thickness.

D. List factors to consider when selecting pressures and tip size.

E. List several factors that determine a quality OFC cut.

F. Use the oxyfuel cutting torch to cut and bevel mild steel.

V. SMAW Welding Theory and Setup

A. Match terms and definitions related to SMAW equipment, applications and techniques.

B. Define volts and amps, and explain how each is controlled in the SMAW process.

C. Describe polarity.

D. Compare and contrast constant current (C.C.) and constant voltage (C.V.) power sources and know other common names for each.

E. Explain when C.C. and C.V. should be used.

F. Complete statements concerning basic SMAW accessories and purposes.

G. Identify parts of an arc welder.

H. Demonstrate the proper setup of a SMAW power source.

I. Explain basic SMAW techniques.

J. Match characteristics of good and bad welds with causes.

K. List the five essentials of proper arc welding.

L. Describe various weld bead techniques.

M. Explain two methods of initiating the arc in SMAW.

N. Describe the proper technique for filling a weld crater.

O. Demonstrate the ability to accurately set up and shut down the SMAW equipment.

P. Demonstrate the operation of SMAW equipment by welding selected weld joints in selected positions.

VI. SMAW Electrodes and AWS System

A. Electrode use and identification.

B. List the two main functions of the core wire.

C. Describe functions of the flux coating on a SMAW electrodes.

D. Demonstrate the ability to use the AWS numbering system to identify SMAW electrode characteristics.

VII. Metallurgy

A. Match terms related to basic metals and metallurgy with definitions.

B. Identify reasons for proper metal identification.

C. Identify alloy characteristics.

D. Demonstrate the ability to conduct magnet tests, spark and chisel tests.

E. Distinguish between types of mechanical strengths in metals.

F. Match physical properties with characteristics of metals.

G. Describe aspects of annealing, hardening and tempering processes.

H. Select appropriate ways of testing metal properties.

I. Match principal alloying agents of steel with characteristics.

J. Match metals with ways to identify them by appearance.

K. Identify alloy steels by classification, characteristics and uses.

L. Identify irons by classification, characteristics and uses.

M. Identify equipment requirements for spark testing.

N. Conduct spark tests to identify common welding metals.

VIII. Set Up, Weld and Test V-groove Welds

A. Use a welding fixture to gauge root gap for tack welding before weld completion.

B. Select correct current requirements and position for selected welds.

C. Demonstrate by welding selected test weld joints.

D. Use appropriate methods to cut, clean and label weld test coupons.

E. Demonstrate the use of the guided U-bend testing equipment.

IX. Certified and a Qualified Welder

A. Define welder qualification.

B. Define welder certification.

C. List required steps a welder must take to be qualified.

D. List required steps a welder must take to be certified

X. Pass a Code Quality V-groove Guided U-bend Test

A. Define the welding terms 1F and 1G.

B. Demonstrate correct setup of welding fixture and tack welds into positions for a V-groove test plate in the 1G weld position.

C. Demonstrate by welding a V-groove test plate in the 1G weld position according to industry standards.

D. Demonstrate correct coupons selection for a face and root bend.

E. Successfully pass the V-groove butt joint with backing test in a selected 1G position.

Content Outline and Competencies:

I. An Overview of the Basic Thermite Process
   A. Explain the chemical reaction of Thermite steel.
   B. Check the temperature at various points in time and location.
   C. Describe the effect of moisture on slag and Thermite steel.
   D. Describe the recommended disposal of unused Thermite.
II. Safety
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective equipment for
Thermite welding and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning eye protection.
   F. Complete statements concerning basic safety rules for oxy-fuel
cylinders and associated gases.
   G. Complete a list of safety rules for the thermite work area.
   H. Select true statements concerning environmental safety
requirements.
   I. Liquid oxygen safety
      1. Describe the construction of the GP-22 or GP-45.
      2. Explain the operation and purpose of safety valves.
      3. Explain the gas use valve.
      4. Explain the liquid valve.
      5. Explain the pressure building valve.
      6. Demonstrate the safe set-up and operation of liquid oxygen used
with a fuel gas.
   J. Propane safety
      1. Describe the construction of the propane cylinder.
      2. Describe the safety valve.
      3. Describe the use valve.
   K. Regulator and torch safety
      1. Describe single stage regulators.
      2. Describe flow check valves vs. flashback arrestors.
      3. Explain types and uses of hoses.
      4. Select and use the proper torch handle.
      5. Select and use the proper cutting attachment.
      6. Select and use the proper torch tip.
   L. Grinder and saw safety
      1. Check rpm of equipment.
      2. Check condition of blades and stones.
      3. Wear proper protective equipment.
      4. Operate grinders and saws safely.
   M. Personal safety
      1. Wear approved hard hat.
      2. Wear approved safety glasses.
      3. Wear approved shaded eye protection.
      4. Wear approved boots.
      5. Wear approved gloves.
      6. Wear approved goggles.
      7. Wear approved face shield.
   N. Demonstrate the proper use of measuring tools, specialized Thermite
tools, hand tools, shearing tools, jacks and other tools and supplies
associated with welding rail with the Thermite welding process in a safe
manner.
III. Quality
   A. Complete a production welding report.
   B. Complete a quality welding report.
   C. Document adding or subtracting rail.
IV. Alignment Procedures
   A. Preparation – general restrictions/limitations
      1. Remove spikes or clips
      2. Saw joint or plug to fit the crib
      3. Square ends
      4. Document addition or subtraction of rail
      5. Clean rail ends
      6. Torch clean rails
      7. Document rail height
      8. Review temperature and weather conditions
      9. Examine rail requirements
     10. Observe rail movement/traffic restrictions
     11. Review track work preparation
     12. Review track concrete and wood tie requirements
     13. Review rail end preparation
     14. Explain alignment of 115#, 132#, 136# and 141#
   B. Rough crown
      1. Use a 36" steel straight edge
      2. Use a magnetic straight edge
      3. Eyeball the track
      4. Set correct dimensions
      5. Check elevation of mismatch
      6. Use the taper gage
      7. Offset vertical mismatch in the base only
   C. Base
      1. Use a 36", 1 meter or 18" straight edge
      2. Align gage side base whenever possible
   D. Ball
      1. Use a 36" or 1 meter straight edge
      2. Align gage side ball whenever possible
   E. Final alignment
      1. Check web
      2. On mismatched rail check field side alignments, as a reference
      3. Set final crown
      4. Recheck all
V. Rail Cutting
   A. Use rail saws in a safe manner
   B. Use oxyfuel cutting torch to cut rail as required to remove
expansion
   C. Clean rail ends as needed
VI. Complete Welds
   A. Perform a Rail Tech weld from start to finish
   B. Perform an Orgo Therm weld from start to finish
   C. Perform a third weld from start to finish
   D. The welder’s responsibility
      1. Insure rail end preparation is done correctly
      2. Insure proper alignment is done correctly
      3. Check mold installation
      4. Check mold packing
      5. Keep track of all times and temperatures
      6. Insure grinding is done properly
      7. Insure quality documentation is recorded
      8. Insure sawing and grinding are done properly
E. The grinder’s or helper’s responsibilities
      1. Perform or assist welder with sawing and grinding operations
      2. Assist the welder in the performance of his/her duties
VII. Mold Application
   A. Arrange for the preparation to apply the molds
   B. Complete and check the packing of molds
   C. Do filing as required
   D. Complete and check the installation of the molds and hardware
VIII. Current Brand of Torch
   A. Explain the operation of the Victor brand
   B. Explain the operation and use the Hesa/SkV brand as needed.
IX. Metallurgy
   A. Describe head hardened rail
   B. Describe standard carbon rail
   C. Describe time at temperature
   D. Describe preheat
   E. Describe postheat
   F. Describe a rail end that is too cold and too hot during preheating
X. Mold Tear Down or Removal
   A. Remove hardware
   B. Crop the top of the mold
   C. Use shear or hot-cut only when needed
   D. Cover the weld according to conditions
XI. Grinding
   A. Rough grind the weld
   B. Finish grind the weld
   C. Use a 36" or 1 meter straight edge during finish grinding
XII. Process Rules and Procedures
   A. Review Rail Tech procedures
   B. Review Orgo Therm procedures

Content Outline and Competencies:

I. Safety

A. Follow the correct and approved safety rules and procedures according to JCCC and BNSF safety sheets.

B. Use PPE when welding, cutting, sawing, grinding and testing procedures on rail steel and switch points.

C. Demonstrate correct and safe methods to set up, use and shut down the hydraulic power units, and the tools associated with the equipment.

D. Demonstrate the correct and safe method to set up and shut down the oxy-propane torch.

E. Demonstrate safety procedures when operating hydraulic rail saws and grinding equipment.

F. Demonstrate proper procedures when operating welding equipment.

G. Demonstrate the correct and safe method to set up and shut down the SMAW and FCAW equipment.

H. List safety rules for welding, cutting, hydraulic rail saws and grinding equipment.

II. Identify and locate various controls on equipment related to repairing rail steel and switch points

A. Select correct amperage and voltage required for the operation of welding power supplies.

B. Use a multi-meter to accurately measure welding voltages and welding amperage at the welding arc.

C. Demonstrate the appropriate, correct and safe method of installing the (ground clamp) work piece connection.

D. Perform accurate cuts using a hydraulic rail saw.

E. Perform accurate grinding on rail steel and switch points using appropriate grinding stones to contour rail steel and mating surfaces of switch points to meet industry standards.

III. Prepare rail steel and switch points for welding

A. Use current welding repair manual to select correct repair procedures.

B. Demonstrate correct methods to repair rail steel and switch points by welding and grinding.

C. Select the correct process, SMAW or FCAW, for the repair of rail steel and/or switch points according to the current welding repair manual.

D. List current industry standards for the repair of rail steel and switch points.

IV. Identify metallurgical effects of welds made when repairing rail steel and switch points.

A. Explain the purpose for preheat, interpass temperature and post heat.

B. Explain selected metallurgical terms.

C. Explain the approved electrode composition for the SMAW and FCAW processes.

D. Demonstrate the proper use of temperature sensing devices.

E. List and define metallurgical effects of welds made when repair welding rail steel and switch points.

V. Select correct current when operating welding power supplies

A. Identify the correct welding electrode type for SMAW of rail steel and switch points.

B. Identify the correct welding electrode type for FCAW of rail steel and switch points.

C. Select the correct parameters (amps) for the SMAW process when welding on rail steel and switch points.

D. Select the correct parameters (volts) for the SMAW process when welding on rail steel and switch points.

E. List factors that determine the type, size and parameters when selecting electrodes.

VI. Select the approved electrode for the repair of (Pandrol Plates) mild steel

A. Identify the correct electrode type for the FCAW process.

B. Select the correct parameters (volts) for FCAW electrodes.

C. List factors that determine the type, size and parameters when using FCAW.

VII. Perform maintenance and repairs on rail steel and switch points, and Pandrol weld on shoulders according to industry standards

A. Perform minor maintenance on welding equipment, e.g., power supplies, hydraulic units, work piece connections, hydraulic rail saws and grinders, cables, electrode holders, wire feed units and wire feed guns, oxy-propane equipment.

B. Demonstrate by welding to industry standards, Pandrol (weld-on-shoulder) with the FCAW process.

C. List steps and/or methods used when making minor repairs to equipment used to maintain rail steel and switch points.

VIII. Demonstrate the correct technique to successfully contour radius and straight edge rail steel and switch point mating surfaces.

A. Select correct hydraulic grinding equipment.

B. Perform grinding techniques and procedures according to current welding manual.

C. List tools required to check contour, straight edge, radius and mating surface for rail steel and switch points.

D. Use correct technique and approved gauges to verify and conform radius and running surface of repaired rail and mating surfaces for switch points.

IX. Switch point styles and sizes.

A. Follow approved practices and the current welding repair manual to identify switch point types and sizes.

B. Explain reasons for preventive grinding of switch points.

C. Identify general requirements for the repair of switch points

D. Define common sizes of selected switch points to include:

1. Knife Point switch point

2. Samson switch point

E. Demonstrate switch point preparation for grinding.

F. Demonstrate switch point welding repair.

G. Demonstrate switch point finish grinding.

H. Demonstrate switch point mating surface check

I. List essentials needed when determining if repairs are required.

X. Perform dye penetration procedures to successfully check welded rail and switch point for surface defects

A. Select approved dye penetrant solution.

B. Apply dye penetrant in a safe and correct manner.

C. Inspect rail and switch point surface for flaws or defects.

D. List steps to successfully perform the dye penetrant test on rail steel and/or switch points.

Content Outline and Competencies:

I. Shop Safety Rules

A. Identify BNSF and JCCC safety rules and describe specific differences.

B. Answer questions about commonly used safety rules in the welding industry.

C. Identify and select proper personal protective clothing and equipment for OFC and SMAW.

D. Identify the parts of a fire triangle.

E. Demonstrate appropriate safety measures in most common arc and gas welding situations.

II. Welding Joints and Welding Positions

A. Properly prepare welding joints lap, tee and butt.

B. Identify the five types of joints and variations.

III. Codes and Standard Used in the Welding Industry

A. Explain the AWS D1.1 code standards.

B. Identify the characteristics of the V-butt code test in the 3G and 4G positions.

C. Identify the proper sequence of beads in the V-butt joint.

D. Evaluate weld quality (defects, discontinues).

E. Demonstrate proper technique for preparing bend test.

IV. Oxy-Fuel Cutting (OFC) Process

A. Identify safety devices on oxygen and acetylene cylinders.

B. Demonstrate safe handling of gas cylinders.

C. Explain why high pressure cylinders utilize double seating valves.

D. List basic safety rules when using oxygen and acetylene.

V. Proper Handling and Manipulation of an OFC Torch

A. Safely and properly follow the procedure to set up, light and shut down an oxy-acetylene cutting torch.

B. Make OFC straight and beveled cuts with/without straight edges.

VI. Demonstrate an Understanding of the Shielded Metal Arc Welding (SMAW) Process

A. Explain the SMAW process.

B. Explain duty cycle.

C. Explain the relationship between arc length and arc voltage.

D. Describe the numbering systems for gas and arc welding lens.

E. Describe the difference between a weave bead and a stringer bead.

F. Explain the fundamental theory of arc welding.

G. Explain the difference between constant current and constant voltage.

H. Describe arc blow.

I. Demonstrate the use of current controls.

J. Redefine selected terms in glossary that refer to SMAW.

K. Explain the difference in heat release with DCEN, DCEP and AC.

L. Distinguish between fusion and penetration.

M. Identify the typical electric circuit for shielded metal-arc welding.

N. Distinguish between open circuit voltage and operating voltage.

O. Identify different types of power sources.

P. Describe polarity and parameters.

Q. Explain why electrode holder, workpiece connections, cable lugs and cables should match amperage ratings.

VII. Produce a 3G V-butt weld with backing that meets code quality.

VIII. Produce a 4G V-butt weld with backing that meets code quality.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective equipment (PPE) and
clothing for oxy-fuel cutting and FCAW welding in the vertical and
overhead positions.
   D. Identify and select correct PPE for grinding.
   E. Complete statements concerning basic safety rules for oxy-acetylene
cylinders and gasses.
   F. Complete statements concerning eye protection.
   G. Complete a list of safety rules for the oxy-acetylene work area.
   H. List hazards concerning electrical safety for arc welding.
   I. Select true statements concerning hazards associated with arc rays.
   J. Determine steps in selecting a safe lens shade.
   K. Select true statements concerning environmental safety
requirements.

II. Welding Joints and Positions
   A. List the five basic welding joints.
   B. Compare and contrast the 1G, 2G, 3G, 4G, 5G, and 6G welding
positions with the 1F, 2F, 3F, and 4F welding positions.
   C. Identify weld nomenclature.

III. FCAW Welding Theory
   A. Identify specific components of the FCAW welding equipment.
   B. Compare and contrast the use of constant voltage (C.V.) and constant
current (C.C.) in the FCAW process.
   C. Explain the effects of stickout when using C.V. and C.C. when using
the FCAW process.
   D. List the five essentials of arc welding.
   E. Demonstrate the proper setup of a FCAW power source.
   F. Explain basic FCAW techniques.
   G. Match characteristics of good and bad welds with causes.
   H. Describe various bead running techniques.
   I. Describe the proper techniques for filling the crater at the
conclusion of your weld.
   J. Compare and contrast different bead sequencing techniques.

IV. Metallurgy and Filler Metal Selection
   A. Describe carbon equivalency and why it is important.
   B. Explain why preheat is important and when and how it should be
used.
   C. Identify factors that will determine filler metal selection.
   D. Explain E71T-8 using the AWS electrode identification system.
   E. Compare and contrast E71T-8 with #70T-10 electrode.

V. Qualification Requirements AWS D1.1.96
   A. Describe the metal thickness requirements to be qualified for
unlimited thickness.
   B. Explain the joint fit-up required for unlimited thickness.
   C. Identify where test strips will be cut from in weld sample.
   D. List the acceptability standards for the test specimens to pass.
   E. Explain how long certification is good for.
   F. Describe what positions and joints you are qualified to weld if you
pass the 3G and 4G test.
   G. Describe the preheat procedure for one inch A36 steel.
   H. Explain visual acceptance criteria for qualification test.

VI. Perform the Following Lab Competencies (All welds use E71T-8
electrode)
   A. Set-up and properly maintain a FCAW welding station.
   B. Perform a multi-pass fillet weld in the 3F up and 4F positions.
   C. Demonstrate the ability to weld simulated V-butts with backing in
the 3G up and 4G position.
   D. Inspect selected simulated V-butts with backing for slag using a
cutting torch.
   E. Assemble and align, and tack a V-butt joint with backing.
   F. Deposit a root pass on a grooved joint in the 3G up position and 4G
position.
   G. Deposit filler passes on a grooved joint in the right sequence 3G
and 4G position.
   H. Demonstrate proper cleaning procedure between weld passes.
   I. Demonstrate proper weld technique in bead sequencing of the cover
pass 3G up and 4G.
   J. Inspect finished weld to determine its quality (defects) (visual
inspection to be done by the instructor prior to destructive testing).
   K. Demonstrate proper techniques in preparing test coupons.
   L. Pass the required destructive bend tests (FCAW).

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules.
Select true statements concerning safe clothing requirements.
   B. Identify statements concerning basic safety rules for oxyacetylene
cylinder and gases.
   C. Complete statements concerning eye protection.
   D. Demonstrate the safe way of setting up oxyacetylene equipment.
   E. Define SMAW an FCAW safety terms.
   F. Complete statements concerning important rules for safe handling of
welding cables.
   G. Compare and contrast different types of welding hoods.
   H. Determine steps in selecting a safe lens shade.
   I. Select true statements concerning environmental safety
requirements.

II. Testing and Inspection
   A. Describe the difference between mechanical and non-destruction (NDT)
testing.
   B. List the twelve cost common discontinuities and the methods used to
locate them.
   C. Explain why welds are tested.
   D. List the four most common root defects and the causes of each
defect.
   E. Discuss qualification standards for welding according to the AWS
D1.1.96 code.
   F. Evaluate a weld according to AWS D1.1.96 code parameters.

III. Welding Processes and Procedures
   A. Describe the advantages of using different electrodes.
   B. Compare and contrast the advantages and disadvantages of SMAW and
FCAW for pile welding.
   C. Describe the advantages and disadvantages of stringer and weave
beads.
   D. Discuss reasons for pre and post heat

IV. Joint Preparation and Fit Up
   A. Properly interpret blueprints to obtain proper joint fabrication and
tolerances.
   B. List the basic piling joints.
   C. Compare and contrast an open joint to using a chill ring.
   D. Discuss fish plating.
   E. List causes and cures of fit up problems.
   F. Explain lands and root openings.
   G. Prepare pipe joints and H-beam joints for welding using a torch and
grinder.
   H. Align, fit up, and tack straight joints for welding in the 2G
position.
   I. Demonstrate the ability to prepare and tack weld fish plates on
piling.
   J. Prepare and fit up gussets on cap plates.

V. Pile Welding
   A. Demonstrate ability to run root passes in the 2G.
   B. Display the ability to run hot passes in the 2G.
   C. Exhibit expertise in running filler and cover passes in the 2G
position.
   D. Demonstrate the ability to weld fish plate on H-beam piling.
   E. Weld gussets onto cap plates and piling.

Content Outline and Competencies:

I. Safety

A. Follow the correct and approved safety rules and procedures according to JCCC and BNSF safety sheets.

B. Use PPE when welding, cutting, grinding and testing procedures on rail steel.

C. Demonstrate correct and safe methods to set up and shut down the CAC-A cutting process.

D. Perform accurate cuts using the CAC-A process.

E. Demonstrate safety procedures when operating welding equipment.

F. Demonstrate proper procedures when operating grinding equipment.

G. List safety rules for welding and cutting austenitic manganese steel.

II. Identify and Locate Various Controls on Equipment Related to Repairing Austenitic Manganese Steel Castings

A. Select correct amperage and voltage required for the operation of welding power supplies.

B. Use a multi-meter to accurately measure welding voltages and welding amperage at the welding arc.

C. Demonstrate the correct method to set up and shut down grinding equipment.

D. Perform accurate grinding on austenitic manganese steel castings using appropriate grinding stones to contour rail steel to meet industry standards.

III. Identify and Appropriately Select and Prepare Austenitic Manganese Steel for Welding According to Industry Standards

A. Use current welding repair manual to select correct repair procedures for austenitic manganese steel.

B. Select SMAW or FCAW process for the correct industry standard for the repair of manganese steel castings.

C. Demonstrate correct methods for the welding repair of austenitic manganese steel.

D. List current industry standards for the repair of austenitic manganese steel.

IV. Identify Metallurgical Effects of Welds Made When Repairing Austenitic Manganese Steel Frog Castings

A. Explain the term interpass temperature.

B. Interpret hardness levels of austenitic manganese steel.

C. List and define metallurgical terms associated with austenitic manganese steel welding.

V. Select Correct Current when Operating SMAW, FCAW Power Supplies

A. Explain the term SMAW as related to austenitic manganese steel.

B. Explain the term FCAW as related to austenitic manganese steel.

C. Demonstrate correct and safe methods to set up and shut down CC and CV power supplies.

D. Use a CC power supply to successfully weld austenitic manganese steel frog castings using the correct SMAW techniques.

E. Use a CV power supply to successfully weld austenitic manganese steel frog castings using the correct FCAW techniques.

F. List correct welding procedures for SMAW.

G. List correct welding procedures for FCAW.

VI. Select the Approved Electrode for the Repair of Rail Steel

A. Identify the correct electrode types for the SMAW process.

B. Identify the correct electrode type for the FCAW process.

C. Select the correct parameters (amps) for SMAW electrodes.

D. Select the correct parameters (volts) for FCAW electrodes.

E. List factors that determine the type, size and parameters when selecting electrodes.

VII. Perform Maintenance and Repairs on Austenitic Manganese Steel According to Industry Standards

A. Use the current welding repair manual to locate correct procedures.

B. Perform minor maintenance on welding equipment, e.g., power supplies, cables, electrode holders, wire feed units and wire feed guns, CAC-A equipment.

C. List steps and/or methods used to make minor repairs to equipment used to maintain austenitic manganese steel.

VIII. Demonstrate the Correct Technique to Contour Radius and Straight Edging on Austenitic Manganese Steel Frog Castings

A. Select appropriate grinding equipment when working on an austenitic manganese steel railroad frog casting.

B. Perform grinding procedures according to current welding manual.

C. List correct gauging tools required to check contour and straight edging of austenitic manganese steel frogs.

D. Use correct technique and approved gauges to verify and confirm radius and running surface of repaired austenitic manganese steel railroad frog casting.

IX. Perform Dye Penetration Procedures to Successfully Check Welded Railroad Frogs for Surface Defects

A. Select approved dye penetrant solution.

B. Apply dye penetrant in a safe and correct manner.

C. Inspect austenitic manganese steel frog surface for flaws or defects.

D. List steps to successfully perform the dye penetrant test on austenitic manganese steel frogs.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. Oxyfuel Cutting
  A. Demonstrate the set up and breakdown of oxyfuel cutting equipment.
  B. Demonstrate straight cuts on steel plate.

III. Plasma Arc Cutting and Gouging
  A. Demonstrate the setup and breakdown of plasma arc cutting and gouging equipment.
  B. Demonstrate straight cuts on steel plate.
  C. Gouge the backing strips off the 1 1/2" test coupons.

IV. Air Carbon Arc Cutting
  A. Demonstrate the set up and breakdown of air carbon arc cutting equipment.
  B. Remove 1/4" backing plate from the single-v-groove test plate.
V. SMAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

VI. SMAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld test.

VII. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

VIII. Destructive Inspection of Welds
  A. Perform face and root bends in accordance with AWS D15.1.
  B. Inspect face and root bends in accordance with AWS D15.1.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. SMAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Complete selected quality fillet welds.

III. SMAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform side bends in accordance with AWS D15.1.
  B. Inspect side bends in accordance with AWS D15.1.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. FCAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper equipment set up for the FCAW process.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

III. FCAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper equipment set up for the FCAW process.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform side bends in accordance with AWS D15.1.
  B. Inspect side bends in accordance with AWS D15.1.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. SMAW and FCAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

III. SMAW and FCAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 pipe tests.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform face and root bends in accordance with AWS D15.1.
  B. Inspect face and root bends in accordance with AWS D15.1.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. GMAW and GTAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode and filler metal selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.
  F. Pass an AWS D15.1 sheet metal fillet weld tests.

III. GMAW and GTAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct sheet metal preparation.
  C. Demonstrate proper electrode and filler metal selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove and flare-bevel welds.
  F. Pass an AWS D15.1 sheet metal groove and flare-bevel tests.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform sheet metal tests in accordance with AWS D15.1.
  B. Inspect sheet metal tests in accordance with AWS D15.1.