Content Outline and Competencies:

I. Safety 

A. Identify Personal Protective Equipment (PPE). 

B. List several JCCC/MFAB safety rules. 

C. Identify several hazards associated with welding. 

D. List compressed gasses used in industry. 

E. Identify the parts of a fire triangle.

F. Demonstrate the assembly of oxy-fuel equipment.  

II. Oxy-Fuel Welding and Cutting Apparatus 

A. Identify the five types of joints. 

B. Identify safety devices on oxygen and acetylene cylinders. 

C. Describe how acetylene gas is made and stored. 

D. Describe the fundamentals of combustion. 

E. Demonstrate safe handling of gas cylinders. 

F. Explain why high-pressure cylinders utilize double seating valves. 

G. Identify safe and proper procedure to set up and shut down an oxy-fuel cutting torch. 

H. Demonstrate lighting and adjusting for three types of flame. 

I. Demonstrate proper handling and manipulation of an oxy-fuel cutting torch.  

III. Powered Cutting and Hand Tools Equipment  

A. Select the proper power equipment for the operation being performed.

B. Select the proper hand tool for the operation being performed. 

C. Select proper grinding wheel for the operation being performed. 

IV. Welding Processes

A. Identify welding processes used for mild steel.

B. Identify welding processes used for stainless steel.

C. Identify welding processes used for aluminum.

D. Identify welding processes used for specialized applications. 

V. AWS Electrode Identification 

A. Select the amperage control for the electrode size, type, and position being used. 

B. Describe factors that change current values for electrodes. 

C. Identify the AWS number system for mild steel and stainless steel electrodes. 

D. List the four classification groups of the AWS mild steel electrodes. 

E. Explain the functions of the electrode's flux coating.  

VI. GTAW Techniques

A. List the advantages of GTAW. 

B. List the disadvantages of GTAW.

C. Describe the set-up and shut down of GTAW equipment.

D. Describe the different types of tungsten used with GTAW.

E. Describe the different types of gases used with GTAW. 

VII. SMAW Techniques 

A. List the advantages of SMAW. 

B. List the disadvantages of SMAW.

C. Explain the forehand welding technique. 

D. Explain the backhand welding technique. 

E. Describe the four main welding positions. 

F. Explain the importance of travel angles and travel speed.

G. Demonstrate SMAW welds. 

VIII. PAC Techniques

A. List the advantages of PAC. 

B. List the disadvantages of PAC.

C. List the best position to use when plasma arc cutting. 

D. Describe the importance of travel angles and speed when using the PAC.

E. Explain the term kerf.

F. Demonstrate PAC. 

IX. Oxy-Fuel Welds and Cuts 

A. List the advantages of oxy-fuel welding and cutting. 

B. List the disadvantages of oxy-fuel welding and cutting. 

C. List several welding positions. 

D. Describe the importance of travel angles and speed.   

E. Explain why welding tip selection and metal thicknesses matters when welding.

F. Demonstrate oxy-fuel welds. 

G. Demonstrate oxy-fuel cuts.  

H. Demonstrate oxy-fuel braze welds.  

X. GMAW Techniques 

A. List the advantages of GMAW. 

B. List the disadvantages of GMAW.

C. Explain the forehand welding technique. 

D. Explain the backhand welding technique. 

E. Describe the four main welding positions. 

F. Explain the importance of travel angles and travel speed.

G. Demonstrate GMAW welds.

Content Outline and Competencies:

I. Shop Safety

A. Explain why it is important to develop safe work habits.

B. Apply safe work practices when operating in a machine shop.

C. List the personal protective equipment (PPE) required for different machining operations and when using chemicals and fluids.

D. List shop safety hazards and how to correct them.

II. Drawings and Layout Work

A. Explain the information found on a typical mechanical drawing.

B. Explain the basics of geometric dimensioning and tolerance.

C. Explain why layouts are needed.

D. Identify common layout tools.

E. Perform a basic layout.

F. Explain a machining sequence plan.

III. Measurement

A. Measure to 1/64 of an inch with a steel rule.

B. Measure to .003 of an inch using a Dial Caliper.

C. Read a Vernier measuring tool.

D. Measure to .003 of an inch using a micrometer depth gauge.

E. Measure to .001 of an inch using an outside micrometer.

F. Measure angles to .5 of a degree using a shop protractor.

G. Identify various types of gauges found in a machine shop.

H. Describe the various transfer gauges found in a machine shop.

I. Describe basic care and utilization of different dial indicators.

J. Describe the care and used of gauge blocks.

IV. Hand Tools, Fasteners and Cutting Fluids

A. Identify the most commonly used machine shop hand tools.

B. Use hand tools correctly and safely.

C. Identify several types of fasteners.

D. Select the proper fastening technique for a specific job.

E. Explain why cutting fluids are necessary.

F. List how cutting fluids should be applied.

V. General Purpose Machines

A. Explain the parts of a twist drill.

B. Explain the safety rules that pertain to drilling operations.

C. List various drilling machines.

D. Demonstrate the technique to sharpen a twist drill.

E. Dress and true a grinding wheel on a pedestal grinder.

F. Prepare a pedestal grinder for safe operation.

G. Perform a grinding operation.

H. Explain the three tooth rule when selecting a saw blade.

I. Describe the proper use of a hacksaw.

J. Explain the advantages of vertical band saw.

K. List the proper blade for a given job.

L. Prepare a saw blade by cutting it to the right length, welding it and mounting it.

M. Prepare a band saw for operation.

N. Describe the broaching operation.

VI. Lathe and Milling Machine Operations

A. Identify the various parts of a lathe.

B. Calculate cutting speeds and feeds for various sizes and types of materials.

C. Describe how a taper is turned on a lathe.

D. Calculate tailstock set over for turning a taper.

E. Demonstrate the ability to safely set up and operate a lathe for taper turning.

F. Describe the characteristics of an American Unified National thread and the use of Acme threads.

G. Demonstrate the ability to safely set up the lathe for a thread cutting operation, using the correct thread formulas to determent the information needed to cut threads.

H. Perform drilling, boring and knurling operations on a lathe.

I. Demonstrate the ability to indicate in a square part, using a four jaws chuck, to within .002 of an inch Total Run Out, (TRO).

J. Identify the various parts of a mill.

K. Tram in a milling vise and head for correct alignments.

L. Select the proper cutter for the job.

M. Explain the various work-holding devices used on a milling machine.

N. Demonstrate the ability to set up and perform various cutting, drilling and boring operations on a milling machine.

VII. Precision Grinding

A. Identify the various types of precision grinding machine.

B. Explain the grinding wheel marking system.

C. List safety rules related to precision grinding.

D. Select, dress and true grinding wheels.

E. Demonstrate the ability to safely set up and operate a surface grinder.

VIII. Metal Characteristics

A. Explain how metals are classified.

B. Describe the characteristics of metals.

C. Recognize the hazards that are posed when certain metals are machined.

D. List the codes system use to identify steel.

IX. Heat Treatment of Metals and Metal Finishing

A. Explain why some steels are heat-treatable and others are not.

B. Explain the difference types of heat treatment processes and how they are performed.

C. Describe case hardening of low carbon steels.

D. List the difference hardness testing techniques and when they are used.

E. Describe how the quality of a machined surface is determined.

F. Describe some metal finishing techniques.

X.  CNC and Electro Machining Processes

A. Describe the difference between the incremental and absolute positioning methods.

B. Explain how manual and computer-aided programming is done.

C. Write a basic manual CNC program.

D. Describe electro machining discharge machining (EDM), its advantages and disadvantages.

E. Explain electrical discharge wire cutting.

Content Outline and Competencies:

I. Shielded Metal Arc Process

A. Differentiate between types and uses of current.

B. Identify the advantages and disadvantages of SMAW.

C. Identify types of SMAW welding power sources.

D. Identify different components of a SMAW workstation

E. Describe basic electrical safety.

II. SMAW Workstation

A. Demonstrate proper inspection of equipment.

B. Demonstrate proper use of personal protective equipment (PPE).

C. Demonstrate proper placement of workpiece connection.

D. Check for proper setup of equipment.

E. Inspect area for potential hazards/safety issues.

III. Electrode Selection

A. Identify SMAW electrode classification.

B. Explain the American Welding Society (AWS) electrode nomenclature.

C. Determine the proper elctrode for given joint based on material and position of weld.

D. Determine proper type of electrodes to be used in a variety of industry applications.

E. Identify proper electrode storage and handling.

IV. Flat Position Surfacing Pads

A. Use the proper safety procedures and PPE.

B. Use the proper setup procedures.

C. Create a pad of beads using SMAW electrode.

D. Weld exhibits proper uniformity and profile.

V. Horizontal Position Surfacing Pads

A. Use the proper safety procedures and PPE.

B. Use the proper setup procedures.

C. Create a pad of beads using SMAW electrode.

D. Weld exhibits proper uniformity and profile.

VI. SMAW on Selected Weld Joints 

A. Use the proper safety procedures and PPE.

B. Use the proper setup procedures.

C. Perform a fillet weld in horizontal position (2F).

D. Perform a fillet weld in flat position (1F).

E. Perform a groove weld in a flat position (1G).

F. Perform a groove weld in a horizontal position (2G).

G. Use tools appropriate for the task.

VII. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Determine cause of discontinuities and defects of welds.

C. Inspect welds for pass/fail ratings according to industry standards.

D. Use appropriate inspection tools.

Content Outline and Competencies:

I. GMAW Process 
  A. Describe different modes of transfer used during he operation of the GMAW process. 
  B. Differentiate between types and uses of current used when operating the GMAW process. 
  C. Identify the advantages and disadvantages of the GMAW process.
  D. Identify types of welding power sources. 
  E. Identify several different components of the GMAW station.
  F. Describe basic electrical safety.  

II. GMAW Workstation Set-up and Safety 
  A. Demonstrate the proper inspection of GMAW equipment. 
  B. Demonstrate proper use of personal protective equipment (PPE). 
  C. Demonstrate proper placement of workpiece connection. 
  D. Check the GMAW equipment for proper setup.
  E. Inspect the physical welding area for potential hazards and/or safety issues before welding.
  F. Troubleshoot the GMAW equipment and perform minor maintenance. 

III. GMAW Electrode Classification and Base Metal Joint Criteria 
  A. Identify SMAW electrode classification.
  B. Explain the American Welding Society (AWS) electrode nomenclature. 
  C. Determine the proper electrode for given joint based on material and position of weld. 
  D. Determine proper type of electrodes to be used in a variety of industry applications.
  E. Identify proper electrode storage and handling.
  F. Identify consumables used during the GMAW process.  

IV. Electrode Selection and Use Based on Metal Types and Thickness 
  A. Identify consumables used during the GMAW process for various electrode sizes. 
  B. Select the proper GMAW electrode type and electrode size relative to the base metal size, type and thickness.
  C. Select the proper GMAW electrode type and size based on material specifications.  

V. Flat Position Surfacing Pads
  A. Use the proper safety procedures and PPE.
  B. Use the proper setup procedures.
  C. Use the proper metal transfer.
  D. Create a pad of beads using GMAW.
  E. Weld exhibits proper uniformity and profile. 

VI. Horizontal Position Surfacing Pads
  A. Use the proper safety procedures and PPE.
  B. Use the proper setup procedures.
  C. Use the proper metal transfer.
  D. Create a pad of beads using GMAW.
  E. Weld exhibits proper uniformity and profile. 

VII. GMAW on Selected Weld Joints 
  A. Use the proper safety procedures and PPE.
  B. Use the proper setup procedures.
  C. Perform a fillet weld in horizontal position (2F).
  D. Perform a fillet weld in flat position (1F).
  E. Perform a groove weld in a flat position (1G).
  F. Perform a groove weld in a horizontal position (2G).
  G. Use tools appropriate for the task. 

VIII. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Determine cause of discontinuities and defects of welds.
  C. Inspect welds for pass/fail ratings according to industry standards.
  D. Use appropriate inspection tools.

Content Outline and Competencies:

I. GTAW Process
  A. Differentiate between types and uses of current. 
  B. Identify the advantages and disadvantages of GTAW. 
  C. Identifies types of welding power sources. 
  D. Identify different components of a GTAW workstation. 
  E. Describe basic electrical safety.  

II. GTAW Workstation Set-Up and Safety
  A. Demonstrate the proper inspection of GTAW equipment. 
  B. Demonstrate proper use of personal protective equipment (PPE). 
  C. Demonstrate proper placement of work piece connection. 
  D. Check the GTAW equipment for proper setup.
  E. Inspect the physical welding area for potential hazards and/or safety issues before welding.
  F. Troubleshoot the GTAW equipment and perform minor maintenance. 

III. GTAW Electrode and Filler Metal Classification and Base Metal Joint Criteria
  A. Identify GTAW electrode classification.
  B. Explain the American Welding Society (AWS) electrode and filler metal nomenclature. 
  C. Determine the proper electrode and filler metal for given joint based on material and position of weld. 
  D. Determine the proper type of electrodes to be used in a variety of industry applications.

IV. Electrode and Filler Metal Selection and Use Based on Metal Types and Thickness 
  A. Use safety hazard precautions and PPE.
  B. Prepare the tungsten electrode profile relative to base material. 
  C. Demonstrate weld performance by using the GTAW process appropriate to electrode size and filler metal size. 
  D. Select the proper electrode and filler metal type and size relative to metal size, type and thickness. 
  E. Select the proper electrode and filler metal type and size based on material specification.
  F. Use the appropriate tools for the GTAW task.  

V. Flat Position Surfacing Pads 
  A. Use the proper safety procedures and PPE.
  B. Use the proper setup procedures.
  C. Create a pad of beads using GTAW.
  D. Exhibit proper uniformity and profile on welds. 

VI. Horizontal Position Surfacing Pads 
  A. Use the proper safety procedures and PPE.
  B. Use the proper setup procedures.
  C. Create a pad of beads using GTAW.
  D. Weld exhibits proper uniformity and profile.

VII. GTAW on Selected Weld Joints
  A. Conduct proper base metal preparation. 
  B. Use safety hazard precautions and PPE.
  C. Demonstrate proper GTAW equipment setup and troubleshooting. 
  D. Perform a fillet weld in horizontal position (2F). 
  E. Perform a fillet weld in flat position (1F).
  F. Perform a groove weld in a flat position (1G).
  G. Perform a groove weld in a horizontal position (2G).
  H. Use tools appropriate for the task. 

VIII. Visual Inspection of Welds 
  A. Identify common visual discontinuities and defects on welds.
  B. Determine cause of discontinuities and defects of welds.
  C. Inspect welds for pass/fail ratings according to industry standards.
  D. Use appropriate inspection tools.

Content Outline and Competencies:

I. Safety
   A. Identify safety rules.
   B. Answer questions about common safety rules used in the welding repair industry.
   C. Identify, select and use proper personal protective clothing and equipment for the OFC, PAC, SMAW, GMAW, grinding and sawing processes.
   D. List the components of the fire triangle.
   E. Complete statements concerning basic rules for the use and care of fuel gas and shielding gas cylinders.
   F. Complete statements concerning eye protection.
   G. List hazards concerning electrical safety for arc welding and plasma arc cutting.
   H. Select correct shade filter lens for the OFC, PAC, SMAW and GMAW processes.
   I. List statements that are true concerning environmental safety. 

II. Demonstrate Steps to Safely and Correctly Set Up and Shut Down the Following Equipment and Processes
   A. Oxy-acetylene equipment for cutting (OFC). 
   B. Plasma arc cutting power sources (PAC).
   C. SMAW power source.
   D. GMAW power source. 

III. Welding Joints, Symbols and Positions
   A. List the five basic weld joints.
   B. Identify selected basic weld symbols.
   C. Compare and contrast 1G, 2G, 3G, 4G groove weld positions with the 1F, 2F, 3F, 4F fillet weld positions. 

IV. Blueprints, Sketches, Shop Drawings
   A. Identify basic lines used when reading blueprints, sketches and shop
drawings.
   B. Select correct weld symbols for weld joint configuration.
   C. Interpret selected blueprints, sketches and freehand shop drawings.
   D. Identify arrow side and other side in reference to weld symbols.
   E. List and identify several essential lines used when interpreting blueprints. 

V. Basic Theory of Welding and Cutting Processes
   A. Explain the basic theory of the SMAW process.
   B. Explain the basic theory of the GMAW process.
   C. Explain the basic theory of the OFC cutting process.
   D. Explain the basic theory of the PAC cutting process.
   E. List factors to consider when setting up a welding or cutting process. 

VI. Measurement, Measuring Tools and Minor Equipment Repair
   A. Complete statements concerning the use of a tape measure.
   B. Demonstrate the ability to correctly identify increments found on a tape measure.
   C. Use a tape measure to accurately lay out dimensions for cutting and welding activities.
   D. Demonstrate the ability to use a combination square.
   E. Demonstrate the ability to use a framing square.
   F. Demonstrate the ability to use an adjustable square.
   G. Demonstrate the ability to use a 24-inch level.
   H. Demonstrate the ability to use a straight edge.
   I. Demonstrate the ability to use a protractor by identifying selected angles.
   J. Demonstrate the ability to change out a GMAW gun liner.
   K. Demonstrate the ability to remove and replace a SMAW electrode holder.
   L. Demonstrate the ability to remove and replace a work piece connection.
   M. Demonstrate the ability to remove and replace the components of a GMAW gun.
   N. Demonstrate the ability to adjust a GMAW/SMAW power supply to a predetermined voltage or amperage.
   O. Demonstrate the ability to adjust the GMAW wire feed speed.
   P. Identify, select and/or list common hand and power tools.
   Q. List components of the SMAW, OFC, GMAW and PAC equipment.
   R. List safe operating rules for the use and care of hand and power tools.
   S. List safe operating rules for SMAW, OFC, GMAW and PAC equipment. 

VII. Electrode Selection and Identification
   A. Demonstrate the ability to use the AWS numbering system to identify a selected electrode's characteristics when using the SMAW process.
   B. Demonstrate the ability to use the AWS numbering system to identify a selected electrode's characteristics when using the GMAW process.
   C. Compare and contrast SMAW electrodes to GMAW electrodes.
   D. Identify several methods to identify electrodes.
   E. List several common AWS electrode classifications a maintenance welder must know. 

VIII. SMAW and GMAW
   A. Use proper safety techniques while performing SMAW and GMAW.
   B. Demonstrate the ability to successfully perform selected welds using E-6010-1/8 electrodes.
   C. Demonstrate the ability to successfully perform selected welds using E-7024-1/8 electrodes.
   D. Demonstrate the ability to successfully perform selected welds using E-7018-1/8  and 3/32 electrodes.
   E. Demonstrate the ability to successfully perform selected welds using S-70-X .035 electrodes.
   F. List electrode selection considerations. 

IX. Oxy-fuel and Plasma Arc Cutting Processes
   A. Use proper safety techniques while performing OFC.
   B. Successfully produce selected cutting assignments using the OFC process.
   C. Use proper safety techniques while performing PAC.
   D. Successfully produce selected cutting assignments using the PAC process. 

X. Metallurgy
   A. Match terms related to ferrous metal.
   B. Identify alloy characteristics used to enhance metal.
   C. Identify reasons for proper metal identification.
   D. Conduct spark tests to identify common metals.
   E. List ways a maintenance welder may use to determine a type of metal.

Content Outline and Competencies:

I. Related blue print and welding symbol information for welders.
   A. Explain the history of prints.
   B. List several names used to identify prints from the past to the present.
   C. List several tools a draft person must use to make a print.
   D. Identify several types of media that prints are developed on.
   E. Match and /or complete statements to include:
      1. Paper
      2. Line description
      3. Angles
      4. Title blocks
      5. Drawing tools

II. Representation of objects, lines and views.
   A. Identify line representations views of weld joints.
   B. Explain groove welds and fillet welds.
   C. Define the terms, weld symbol, sketch, axonometric drawing, isometric drawing, and oblique drawing.
   D. List several types of weld examination methods and their letter designation.
   E. List several types of lines and views found on sketches and prints.
   F. Sketch, match and/or complete statements specific to weld symbols, lines, and views found on sketches or prints.

III. Weld joint design and properties.
   A. Identify several mechanical properties of selected types of metals and their behavior under applied loads.
   B. Define physical properties, and chemical properties as related to weld joint design.
   C. List weld joint selections to include:
      1. Joint types
      2. Joint weld positions
      3. Weld joint access
      4. Weld joint locations
   D. Match and/or complete statements specific to weld joint design and properties of metals.

IV. Types of weld processes, contours and finishes, fasteners and structural shapes.
   A. Define the terms Fasteners, Structural shapes, and Weld Processes used in the metal working trade to include:
      1. Oxy-Fuel Cutting (OFC)
      2. Shielded Metal Arc Welding (SMAW)
      3. Gas Metal Arc Welding (GMAW)
      4. Flux-Core Arc Welding (FCAW)
      5. Resistance Welding (RW)
      6. Gas Tungsten Arc Welding (GTAW)
   B. Identify and discuss several fasteners used in the welding trade.
   C. Identify and discuss several structural steel shapes used in the welding trade.
   D. List types and finish requirements that may be found on a print.
   E. Explain a concave symbol and, convex symbol, and combined weld symbols as they relate to weld completions.
   F. Match and/or complete statements specific to fasteners, structural shapes, weld symbols, and welding processes.

V. Weld bead backing, spacers, inserts consumable, and melt through welds.
   A. Define the terms back weld, backing weld, inserts, spacers, and melt through welds.
   B. Identify and discuss symbols used to identify back or backing welds.
   C. Identify and discuss symbols used to describe a melt through weld.
   D. Identify and discuss symbols used to describe a consumable insert.
   E. Match and/or complete statements specific to bead backing, spacers, inserts consumable, and melt through welds.

VI. Applications of plug and slot welding.
   A. Define the terms plug weld and Slot weld.
   B. Identify and discuss symbols used to identify plug welding and slot welding.
   C. Match and/or complete statements specific to plug and slot welding.

VII. Applications of surfacing welds.
   A. Define the term surfacing welds.
   B. Identify and discuss symbols used to identify surfacing welding.
   C. Match and/or complete statements specific to surfacing welds.

VIII. Applications of spot, seam, and stud welds.
   A. Define the terms spot, seam, and stud welds
   B. Identify and discuss symbols used to identify spot, seam, and stud welding.
   C. Match and/or complete statements specific to spot, seam, and stud welding.

IX. Pipe welding and pipe fitting terms.
   A. Define the terms fitting, single line drawing, double line drawing, and pipe connections.
   B. List types of weld joints found when pipe welding to include:
      1. Flange joints
      2. Screwed joints
   C. Describe pipe edge preparation, weld fit up, root pass, hot pass, filler pass, cover pass.
   D. Identify AWS pipe welding positions
   E. List organizations that set pipe welding standards.
   F. Match and/or complete statements specific to pipe welding.

X. Metallurgical terms used by welders and draftspersons.
   A. Define the terms metal, pure metal, alloy.
   B. List types of metal lattices.
   C. Identify several types of metals welders use in the welding trade.
   D. Describe the effects of heat on welded structures.
   E. Define the “heat -affected zone”.
   F. Explain the terms pre-heat, and post-heat.
   G. Define weld quality, weld defects, weld testing, and welder certification.
   H. Match and/or complete statements specific to welding metallurgy.

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 SMAW.

II. SMAW on Selected Joint Configuration

A. Identify base materials.

B. Perform material and joint preparation

C. Define welding procedures for low carbon steel alloys

D. Demonstrate SMAW on selected joint configuration.

III. Test Coupon Preparation

A. Prepare mild steel for welding and testing.

B. Use the oxy-fuel cutting torch to prepare test coupons.

C. Demonstrate accuracy when setting up fillet and groove weld test specimens in the F3 and F4 positions for welding.

D. Prepare weld test coupons.

IV. 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.

V. 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.

VI. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Determine cause of discontinuities and defects of welds.

C. Inspect welds for pass/fail ratings according to industry standards.

D. Use appropriate inspection tools.

VII. Destructive Inspection of Welds

A. Describe tensile test techniques.

B. Describe fillet weld break test.

C. Perform bend test.

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 GMAW.  

II. Shielding Gases and Regulation Equipment 

A. Identify shielding gas types. 

B. List several mixed gas selections. 

C. List several types of gas regulation devices. 

D. Demonstrate correct cylinder selection, safe handling, and storage of cylinders.  

III. GMAW Electrode Size and Material

A. Demonstrate base metal selection. 

B. Demonstrate base metal preparation. 

C. Demonstrate filler metal selection. 

D. Perform pre-heating, inter-pass, and post heating as needed.  

IV. Low Carbon Alloys Welding with GMAW on Selected Joint Configuration

A. Identify base materials. 

B. Explain the GMAW terms spray arc, and pulse arc. 

C. Perform material and joint preparation 

D. Define welding procedures for low carbon steel alloys 

E. Demonstrate GMAW on selected joint configuration.  

V. Stainless Steel and Aluminum Welding with GMAW on Selected Joint Configuration

A. Identify base materials.

B. Perform material and joint preparation 

C. Define welding procedures for material thicknesses selected. 

D. Demonstrate GMAW on selected joint configeration.

E. Demonstrate using push-pull equipment.

F. Demonstrate using spool gun equipment. 

VI. GMAW 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. 

VII. GMAW 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. 

VIII. Visual Inspection of Welds 

A. Identify common visual discontinuities and defects on welds.

B. Determine cause of discontinuities and defects of welds.

C. Inspect welds for pass/fail ratings according to industry standards.

D. Use appropriate inspection tools.

E. Perform dye-penetrant inspection of welds.

Content Outline and Competencies:

I. General Safety

A. Follow safety rules and procedures at all times according to JCCC and industry guidelines.

B. Demonstrate the appropriate use of personal protective equipment (PPE) when operating welding equipment, hand tools, and related shop equipment.

C. Describe safety hazards associated with heavy industrial construction and maintenance.

D. Describe inspection and testing methods used to ensure public safety with respect to steel structures, piping systems, storage tanks and vessels.

II. General Layout

A. Use applied mathematics.

B. Use the English system for linear measurement.

C. Demonstrate the ability to convert fractions to decimals and vice versa.

D. Demonstrate the ability to convert angular dimensions from degrees to in./ft. of pitch and vice-versa.

E. Use applied geometry to perform common layout practices on steel by using layout tools.

III. Structural Steel and General Fabrication

A. Identify the use of standard drawings for the fabrication of structural steel and several miscellaneous welded construction items

B. Identify views on structural steel drawings

IV. Structural Steel Components

A. Steel structures and fabrication materials.

B. Explain the American Welding Society (AWS) D1.1 Structural Steel Welding Code.

C. Identify general code requirements.

D. Identify testing and inspection methods.

E. Identify visual inspection methods.

F. Demonstrate the fabrication and welding of mock up structural components.

V. Structural Steel Components Sizing and Dimensioning Methods

A. Develop a cut list.

B. Fabricating components by using punches and drilling holes, coping, notching, shearing, and burning techniques.

C. Use fit up techniques.

VI. Welding Processes

A. Fabricate an industry recognized standard mock up structure.

B. Use accepted inspection practices.

C. Use standard shop drawings.

D. Fit and weld the structure.

E. Perform quality welds by means of the SMAW, FCAW, and GMAW processes.

VII. Assembly and Erection

A. Use standard drawings for assembly and erection.

B. Use hand tools and equipment common to the trade.

C. Use rigging and lifting equipment and techniques.

D. Perform, assembly and erection of an in-service mock up.

E. Use visual testing, hydro testing and inspecting methods.

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 FCAW. 

II. FCAW Process
  A. Define FCAW. 
  B. Describe the FCAW Process. 
  C. Identify modes of operation. 
  D. Explain the FCAW systems. 
  E. Explain several applications of the FCAW process.  

III. FCAW Electrodes 
  A. Identify manufacturing of FCAW filler materials. 
  B. Explain specification of filler material. 
  C. Explain identification labels of self shielding and dual shielding electrodes.
  D. Describe electrode packaging.
  D. Select correct FCAW electrode type and size.

IV. Shielding Gases and Regulation Equipment 
  A. Identify shielding gas types. 
  B. List several mixed gas selections. 
  C. List several types of gas regulation devices. 
  D. Demonstrate correct cylinder selection, handling, and storage.  

V. 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. 

VI. 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. Successfully complete selected quality groove welds. 

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

Content Outline and Competencies:

I. Safety
   A List recommended safety precautions when performing laboratory experiments, tasks and/or demonstrations.
   B. List general safety rules related to metallurgy.
   C. Follow safety rules and procedures at all times according to the JCCC safety sheet.
   D. Use PPE during demonstrations as required.

II. Identify and Locate Various Controls on Equipment Related to the Study of Metallurgy
   A. Perform safe and correct set up and shut down of equipment used for
experiments, demonstrations, tasks or laboratory experiments.
   B.  Perform experiments using a variety of equipment and processes.
   C. Demonstrate knowledge and safety when performing selected metallurgical tasks.

III. Define and Interpret the Study of Metallurgical Characteristics
   A.  Describe various methods and tests used in the study of metallurgy.
   B.  Interpret charts, tables and graphs used in the study of metallurgy.
   C. Define selected metallurgical terms.
   D.  List common terms associated with metallurgy.

IV. Select a Variety of Metallurgical Tests
   A. Demonstrate knowledge of metallurgical factors by selecting the correct charts, tables and processes for selected assignments.
   B. Discuss processes of identification of metals using metallurgical methods.
   C. List metal properties and abilities.
   D. Define terms related to properties of metals.
   E. List various selected metals unique abilities.

V. Analyze and Identify Various Metals and Their Uses
   A. Discuss how to determine the composition of selected metals.
   B.  Discuss techniques  used in laboratory and field testing. devices.
   C. List procedures to correctly and safely identify selected metals.

VI. Explain the Metal Working Processes
   A.  Describe factors related to safety and the environment when producing metal.
   B. List and define several processes used in the metal working industry.
   C. Explain terms used in the metal working industry.
   D. Explain the effects of heat on metals.
   E. List several common metal working processes.

VII. Explain a Variety of Tests Used on Metals
   A. List the steps used for dye penetrant testing (PT).
   B. Explain the results of the PT.
   C. Explain how the magnetic particle test works.
   D. Explain the spark test method.
   E. Identify the results from the spark test on several metal samples.
   F. List factors that determine if a metal is ferrous or non ferrous.

VIII. Explain the Characteristics of Heat Treatment Processes
   A. Explain the term, tempering.
   B. Explain the term, annealing.
   C. Explain the term, case hardening.
   D. Explain the term, quenching.
   E. Explain the term, surfacing.
   F. List examples of the five metallurgical characteristics and give examples where each may be used.

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 GTAW. 

II. Measuring Devices and Tools

A. Demonstrate the layout of a pipe saddle, cut, and weld of a 90 degree round 2” diameter tube or pipe. 

B. Demonstrate the layout a pipe saddle, cut, and weld of a 90-degree, square 2” tube with 3/16” wall thickness.

C. Demonstrate the fit-up fabricating technique to notch a pipe saddle in a 2” diameter pipe or tube to mate with another 2” diameter pipe or tube to form a 90-degree angle.  

III. Material Thickness

A. Demonstrate quality fillet tee joint welds on selected thin square tubing. 

B. Demonstrate quality fillet tee joint welds on selected thick round tubing. 

C. Demonstrate quality fillet tee joint welds on thick to thin material in selected positions. 

IV. GTAW 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. 

V. GTAW 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. 

VI. GTAW Groove Welds on Round Tubing 

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. 

VII. Visual Inspection of Welds 

A. Identify common visual discontinuities and defects on welds.

B. Determine cause of discontinuities and defects of welds.

C. Inspect welds for pass/fail ratings according to industry standards.

D. Use appropriate inspection tools.

E. Perform dye-penetrant inspection of welds.

Content Outline and Competencies:

I. General Safety

A. Follow safety rules and procedures at all times according to JCCC and industry guidelines.

B. Demonstrate the appropriate use of personal protective equipment (PPE) when operating welding equipment, hand tools, and related shop equipment.

C. Describe safety hazards associated with heavy industrial construction and maintenance.

D. Describe inspection and testing methods used to ensure public safety with respect to steel structures, piping systems, storage tanks and vessels.

II. Pipe Systems Layout

A. Use standard drawings and concepts for pipe configurations.

B. Use drawings and layouts pipe configurations

C. Identify nomenclatures and dimensional recognition.

D. Read and interpret pipe symbols.

E. Identify the American Society of Mechanical Engineers (ASME) B-31.3, Process Piping Code.

F. Explain ASME B-31.3 Code structure and intent.

G. Use general ASME B-31.3 Code requirements.

H. Apply testing and inspection methods.

III. Pipe Systems Fabrication

A. Develop skill in basic pipe welding using the following processes, Shielded Metal Arc Welding (SMAW)

B. Perform welds in the 2G position.

C. Perform welds in the 5G position.

D. Perform welds in the 6G position.

E. Develop skill in basic pipe welding using the following processes, Gas Tungsten Arc Welding (GTAW)

F. Perform welds in the 2G position.

G. Perform welds in the 5G position.

H. Perform welds in the 6G position.

IV. Tanks and Vessel Fabrication

A. Use standard drawings and concepts for storage tanks and vessels.

B. Use drawings and layouts tanks and vessels.

C. Identify nomenclatures sizing and dimensioning.

D. Identification of tanks and vessel components, and use dimensioning.

E. Identify and weld spherical heads.

F. Identify and weld nozzles.

G. Use ASME, code Section 8, and Pressure Vessel Construction and American Petroleum Institute (API) API-650 standards.

H. Use general code requirements.

I. Fabricate and weld mock up piping components.

J. Develop a cut list.

K. Perform fabrication by cutting and grinding.

L. Use fit up techniques.

M. Perform welding processes.

N. Use the GTAW process.

O. Use the SMAW process.

P. Use the Gas Metal Arc Weld (GMAW) process.

Q. Use the Flux Core Arc Weld (FCAW) process.

R. Perform required ASME/API inspection techniques.

V. Standard Components Layout

A. Use standard drawings and concepts for component assembly and erection.

B. Perform nomenclature, sizing and dimensioning.

C. Use print/drawing orientation skills.

VI. Standard Components Fabrication

A. Demonstrate welding and fabricating skills for components.

B. Use spud wrenches.

C. Use impact wrenches.

D. Use drift pins.

E. Use advanced welding techniques.

F. Fabricate components for a mock up piping loop, storage tank/vessel, and miscellaneous parts from sets of shop drawings.

VII. Assembly and Erection

A. Use proper rigging and lifting techniques for equipment.

B. Identify rigging safety.

C. Locate rigging equipment.

D. Perform assembly and erection of an in-service mock up.

E. Use testing and inspecting methods

F. Use visual testing.

G. Identify hydro-testing.

H. Assemble and erect a mock piping loop, storage tank/vessel, and miscellaneous parts to industry recognized standards.

Content Outline and Competencies:

I. Safety

A. Recognize safe and unsafe work practices in a metal cutting shop.

B. Identify and correct hazards in the shop area.

C. Select personal protective equipment (PPE) required for machining and other shop operations.

D. Demonstrate and apply all machine shop safety rules.

II. Job Planning

A. Identify the meaning of various lines used on engineering drawing.

B. Recognize the various symbols on a drawing used to convey information.

C. Read and explain engineering drawing or prints.

D. Identify the different machine operations, bench work and tools needed to produce a completed product to print requirement.

III. Measurement

A. Demonstrate the care and maintenance of all measurement equipment.

B. Identify types of steel rules and measure a part to 1/64-inch accuracy.

C. Identify the most common types of outside micrometers and their use.

D. Measure the size of a variety of objects to within 0.001 of an inch accuracy.

E. Demonstrate the ability to measure a work piece to within accuracy of .002 of an inch using a dial caliper.

F. Measure a hole diameter in a part to within .002 of an inch of accuracy using a telescope gauges and micrometer.

G. Measure the depths of a hole to an accuracy of 0.004 of an inch using a dial caliper.

H. Measure depths of a slot to an accuracy of .002 of an inch using a micrometer depth gauge.

I. Explain the setup and use of a dial bore gauge to measure a hole to within .0001 of an inch accuracy.

J. Demonstrate the uses of a Vernier height gauge with test dial indicator and transfer the reading to a height gauge to measure the height of a work piece within .0002 of an inch accuracy.

K. Explain the care, use and application of gauge blocks.

L. Calculate the gauge block buildups for a give dimension.

M. Create angular measurements to an accuracy of 20' (minutes) of a degree using a universal bevel protractor, or combination square with protractor head.

N. Create angular measurements to less than 5’ of a degree using a sine bar, gauge blocks and a dial indicator on a height stand.

O. Explain the principles of comparison measurement.

P. Identify three type of comparators measurement and describe their use.

Q. Demonstrate the use of a back plunger indicator.

R. Interpret the surface finish symbols that appear on a drawing.

S. Select a surface roughness gauge to measure the surface finish on a part.

IV. Metal-Cutting Machines and Bench Grinder

A. Demonstrate the ability to safely set up and operate a bench grinder.

B. Explain the care and use of cutoff saw, horizontal and contour band saws.

C. Explain the terminology of a saw blade, e.g., pitch, set, width and gauge.

D. Explain the twist drills characteristics and drill size systems.

V. Engine Lathe

A. Explain the necessary safety precautions required to run a lathe.

B. Demonstrate the care and maintain of the engine lathe.

C. Set the lathe to run a required speed in revolutions per minute (RPM).

D. Set the proper feed rate for a finishing cut.

E. List all the lathe accessories and their uses.

F. Determine the depth of cut you can make in a lathe for a given part.

G. Demonstrate by safely setting up and operating a lathe for the following operations:

1. Machining between centers.

2. Knurling, grooving operations.

3. Taper turning operations both internal and external tapers.

4. Calculate all the information needed to perform threading operations.

5. Chasing thread operations, both external and internal thread.

6. Turning an eccentric on the lathe.

7. Demonstrate the ability to use a steady rest or follower rest when machining a long shaft.

VI. Milling Machines

A. Describe how angular surfaces can be machined.

B. Demonstrate the care and maintenance of the milling machine.

C. Demonstrate by safely setting up and operating a milling machine for the following operations:

1. Machine a part square and parallel.

2. Machine an angular surface, both a simple and a compound angle.

3. Machine a radius using rotary table.

4. Milling a key-way on a shaft.

VII. Grinding

A. List the safety rules associated with grinding.

B. Demonstrate the care and maintainance of grinding machine.

C. Demonstrate the ability to select the proper grinding wheel for a given applications.

D. Demonstrate the ability to true and dress a given grinding wheel.

E. Demonstrate the ability to safely set up and perform the following grinding operations:

1. Grinding a part to hold dimensions within +/-.0002 inches accuracy.

2. Grinding to produce a surface finish to a given RMS (Roughness Measurement System) finish requirement.

3. Grinding a part flat within .0005 inches accuracy.

4. Grinding a workpiece square within .0005 of an inch in 4 inches accuracy.

5. Grinding a angular surface within +/- .025 degree accuracy.

6. Demonstrate the ability to cut off a part with a cutoff wheel.

7. Use the surface grinder as a cylindrical grinder.

VIII. Shop Math and Trigonometry

A. Calculate the length of a saw band for a two-pulley machine.

B. Calculate the RPM for different sizes of twist drills of a given material.

C. Select the feed rate to be used for various operations, such as drilling, reaming, counter sinking, counter boring and taping.

D. Calculate the indexing necessary for a given number of divides, using an indexing head.

E. Calculate the information needed to machine a rack-and-pinion gear set.

F. Machine a rack-and-pinion gear set.

IX. Metallurgical Information

A. Identify six properties of metals.

B. Describe the effect of alloying elements on steel.

C. Demonstrate the ability to select the proper grade of tool steel for a workpiece.

D. List recommendations for tool steel selection to improve machinability and wear resistance.

E. Calculate the information to properly heat-treat a workpiece to give hardness.

X. Tool Steel Classification and Identification

A. List the two types of classifications of tool steel.

B. Identify the type of steel defined by the AISI (American Iron and Steel Institute) numbers.

C. Determine the types of steel by its SAE (Society of Automotive Engineers) numbers.

D. Explain the differences between ferrous and nonferrous metals and alloys.

XI. Heat-Treating Equipment

A. Demonstrate the care and maintainance of heat-treating equipments.

B. Demonstrate by safely setting up and operating the heat-treating equipment.

C. Demonstrate the ability to anneal a hardened steel part.

D. Demonstrate by safely setting up and operating a Rockwell hardness tester.

E. Describe cryogenic treatment and tempering.

XII. CNC and Advanced Machine Technology

A. Explain the advantages and disadvantages of Computer Numerical Control (CNC).

B. Identify the types of systems and controls use in CNC.

C. List the steps required to produce a part by CNC.

D. Explain the advantages of Computer Aid Design (CAD) in producing CNC program.

E. Demonstrate the ability to write a CNC program for a Simple part using M and G codes.

F. Describe the Direct Metal Deposition (DMD) process and its advantages.

G. Describe other CNC machining equipment and how it works with regard to Electrical Discharge Machining (EDM), wire and sinker, water jet, and plasma cutting.

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 SMAW. 

II. Heat Control Techniques

   A. Describe the effects of the heat-affected zone (HAZ).

   B. Demonstrate pre-heating techniques, maintaining the inter-pass temperature, and post heating techniques.

   C. Define the terms associated with heat treatments when welding on mild steel.

   D. Demonstrate safe and correct methods for monitoring temperatures when welding on thick material.

III. Identify, Select and Prepare Welding Coupons for Testing According to Industrial Standards.

   A. Prepare mild steel for welding and testing.

   B. Prepare weld test coupons.

   C. Demonstrate accuracy when setting up weld test specimens.

IV. 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.

   F. Demonstrate correct heat control techniques.

V.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.

VI. Visual Inspection of Welds

   A. Identify common visual discontinuities and defects on welds.

   B. Determine cause of discontinuities and defects of welds.

   C. Inspect welds for pass/fail ratings according to industry standards.

   D. Use appropriate inspection tools.

VII. Destructive Inspection of Welds

   A. Describe tensile test techniques.

   B. Describe fillet weld break test.

   C. Perform bend test.

Content Outline and Competencies:

I. Introduction to Internship
   A. Interpret program requirements.
   B. Complete the required forms from the handbook.
   C. Discuss the procedures set forth by the Career Program Facilitator.

II. The Job Search Process
   A. Find three sources of job information.
   B. Identify three job postings in your career program field.
   C. Write a resume

III. Obtaining Employment
   A. Write a letter of inquiry.
   B. Complete a job application.
   C. Describe a job interview.

IV. Employer/Employee Relationships
   A. Define labor relations.
   B. Explain human relations.
   C. Write examples of conflict and resolution.

V. Employee Growth and Development
   A. Define employment advancement.
   B. Examine personal assessment of your job performance.
   C. Depict management opportunities in your career area.

VI. Leadership in the Work Place
   A. Describe qualities of leadership.
   B. Define fellowship.

VII. Dealing with Termination
   A. Define termination with cause.
   B. Define termination without cause.
   C. Describe how to deal with employment termination.

VIII. The Structure of Business and Industry
   A. Explain organizational theory.
   B. Describe work flow patterns.

IX. Conclusion
   A. Summarize your employer evaluation.
   B. Write a self evaluation.