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Syllabus

Gas Metal Arc Welding
WE110

YEAR:

2023-2024

CREDIT HOURS:

3.00

PREREQUISITES:

None

COREQUISITES:

None

COURSE NOTES:

None

CATALOG COURSE DESCRIPTION:

Through classroom and lab/shop activities; safe and correct set up of the GMAW workstation; correlation of GMAW and other similar wire based electrode classifications with base metals and joint criteria; proper electrode selection and use based on metal thickness; weld with .035 and .045 diameter electrodes using short circuit and spray transfer methods on various weld joints in the flat (1F & 1G), and horizontal (2F & 2G) positions to meet requirements of the late st version of the American Welding Society D1.1/D1.1M:20XX Structural Welding Code-Steel.

HutchCC INSTITUTION-WIDE OUTCOMES:

  1. Demonstrate the ability to think critically and make reasonable judgments by acquiring, analyzing, combining, and evaluating information.
  2. Demonstrate the skills necessary to access and manipulate information through various technological and traditional methods.
  3. Demonstrate effective communication through reading, writing, listening, and speaking.
  4. Demonstrate effective interpersonal and collaborative skills.
  5. Demonstrate effective quantitative-reasoning and computational skills.

AREA OR PROGRAM OUTCOMES

  1. Demonstrate the safe, effective and efficient set up of welding and cutting process to meet industry standards.
  2. Demonstrate work ethics including collaboration and communication skills.
  3. Produce and evaluate quality welds/cuts to meet or exceed industry standards.
  4. Read and accurately interpret blueprints/welding symbols.
  5. Demonstrate the accurate application of layout tools, mathematics, and measuring devices to complete assignments.
  6. Choose and apply appropriate manufacturing processes in the completion of projects.
  7. Relate theory-based welding principles to industry-based welding.

COURSE OUTCOMES AND COMPETENCIES:

  1. Explain the Gas Metal Arc Welding process (GMAW).
    1. Identify the advantages and disadvantages of the GMAW process.
    2. Describe the direction of electron flow in an electrical welding circuit.
    3. Differentiate between Direct Current Electrode Negative (DCEN), Direct Current Electrode Positive (DCEN), and Alternating Current (AC) and how they affect weld penetration, finished weld bead shape, and overall performance of a completed weld.
    4. Explain the differences between constant current and constant voltage type welding power sources and identify the common welding processes associated with the use of each type.
    5. Describe and differentiate the modes of transfer used in the gas metal arc welding process.
    6. Identify and/or list the required components needed to perform the GMAW process, including personal protective equipment, machine components, and peripheral equipment requirements.
    7. List electrical safety requirements needed for safe operation of the GMAW process in the weld shop or field.
  2. Relate Gas Metal Arc Welding electrode classifications with base metals and joint criteria.
    1. Explain the AWS electrode nomenclature for GMAW electrodes and how the transfer method applies to a given joint position, joint design, or material specification.
    2. Determine the proper electrode/s that could be used for a given joint based on the material provided and position of weld.
    3. Evaluate provided welding scenarios to justify a recommendation for or against the use of the GMAW process, and the type of electrode that would best be suited.
    4. Explain recommendations and code requirements associated with proper GMAW electrode storage and handling.
  3. Demonstrate proper electrode selection and use based on metal types and thicknesses.
    1. Identify the correct consumables associated with various electrode sizes.
    2. Select the correct electrode type and size relative to the metal size, type, and thickness.
    3. Select the correct electrode type and size based on available material specifications.
  4. Demonstrate safe and correct setup of GMAW workstation.
    1. Demonstrate electrical safety requirements needed for safe operation of the GMAW process in the weld shop or field.
    2. Demonstrate proper pre-use inspection of equipment and work area for potential hazards/safety issues, including personal protective equipment, machine components, and peripheral equipment requirements.
    3. Troubleshoot and demonstrate basic maintenance required for the GMAW process including replacing end of gun consumables, replacing GMAW gun liner, and changing electrode.
    4. Demonstrate the proper use of personal protective equipment as needed for the welding environment and the task being performed.
    5. Demonstrate proper high-pressure cylinder handling for changing or handling cylinders, start up and shut down procedures used with high-pressure shielding gas cylinders and gas manifolds.
    6. Demonstrate safe set up of work area including, proper placement of work piece connection, placement of peripheral equipment, and GMAW gun to prevent accidental feeding of electrode.
  5. Conduct visual inspection of GMAW welds.
    1. Identify common visual discontinuities and defects on welds.
    2. Determine causes of discontinuities and defects of welds and take proper action to correct discontinuities.
    3. Inspect welds for pass/fail ratings according to industry standards.
    4. Use appropriate tools for inspection.
  6. Demonstrate surfacing welds in the flat position creating a pad of beads using ER70S-X electrode in the spray transfer on carbon steel material sized no less than 6” x 6”.
    1. Setup and begin welding process from scratch.
    2. Use the proper safety procedures and PPE.
    3. Maintain straightness of welds and correct weld bead overlap to demonstrate understanding of GMAW process.
  7. Demonstrate surfacing welds in the horizontal position creating a pad of beads using ER70S-X electrode on carbon steel material sized no less than 6” x 6”.
    1. Setup and begin welding process from scratch.
    2. Use the proper safety procedures and PPE.
    3. Maintain straightness of welds and correct weld bead overlap to demonstrate understanding of GMAW process.
  8. Demonstrate a single pass fillet weld at least 8” long in the 1F test position on an outside corner joint using ER70S-X electrode on carbon steel material.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  9. Demonstrate a single pass ¼” (+1/16”) fillet weld (measured with a fillet weld gauge) at least 12” long in the 1F test position T-joint using .045 ER70S-X electrode in the axial spray transfer.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  10. Demonstrate a single pass fillet weld at least 8” long in the 2F test position on a lap joint using ER70S-X electrode in the spray transfer on carbon steel material.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  11. Demonstrate a single pass fillet weld at least 8” long in the 2F test position on a lap joint using ER70S-X electrode in the pulse spray transfer on carbon steel material.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  12. Demonstrate a lap joint single pass fillet weld at least 8” long in the 2F test position on carbon steel sheet metal using ER70S-X.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  13. Demonstrate on a T joint a single pass fillet weld at least 8” long in the 2F test position on carbon steel sheet metal using ER70S-X.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  14. Demonstrate a three pass 3/8” (+1/16”) fillet weld (measured with a fillet weld gauge) at least 12” long in the 2F test position on a T-joint using .045 ER70S-X electrode in the axial spray transfer.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  15. Demonstrate a three pass 3/8” (+1/16”) fillet weld (measured with a fillet weld gauge) at least 12” long in the 2F test position on a T-joint using ER70S-X electrode in the pulse spray transfer.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  16. Demonstrate a single pass pipe to plate fillet weld in the 2F position fixed using .045 ER70S-X electrode in the axial spray transfer and carbon steel pipe material no less than 3” in diameter (or equivalent tubing).
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  17. Demonstrate a single pass pipe to plate fillet weld in the 2F position fixed using ER70S-X electrode in the pulse spray transfer and carbon steel pipe material no less than 3” in diameter (or equivalent tubing).
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  18. Correctly prepare groove weld joint geometry as indicated in the Welding Procedure Specification or applicable welding code.
    1. Set up bevel cutting workstation regardless of using oxy-fuel, plasma, or mechanical cutting methods properly.
    2. Grind, clean, and tack weld, qualification plates in preparation for pre-welding inspection correctly.
    3. Re-cut practice plates appropriately as needed to prevent material waste and allow reuse.
  19. Complete a multi-pass V-groove butt joint B-U2a-GF on 3/8” A36 carbon steel with a 45 degree? included groove angle, ¼” root opening, and backing strip in the 1G test position, using .045 ER70S-X electrode in the axial spray transfer with appropriate mixed shielding gas; in accordance with the most recent version of the American Welding Society D1.1/D1.1M:20XX Structural Welding Code – Steel: Clause 3. Prequalification of WPS, visual acceptance criteria and Acceptance Criteria for Bend Tests as stated.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  20. Complete a multi-pass V-groove butt joint B-U4a-GF on 3/8” A36 carbon steel with a 45 degree ? included groove angle, ¼” root opening, and backing strip in the 2G test position, using .045 ER70S-X electrode in the pulse spray transfer with appropriate mixed shielding gas; in accordance with the most recent version of the American Welding Society D1.1/D1.1M:20XX Structural Welding Code – Steel: Clause 3. Prequalification of WPS, visual acceptance criteria and Acceptance Criteri a for Bend Tests as stated.
    1. Use GMAW equipment appropriately.
    2. Use the proper safety procedures and PPE.
    3. Use the proper setup procedures.
  21. Demonstrate the correct preparation and layout needed on a completed weld qualification test plate to prepare for destructive testing methods as specified in the applicable welding codes for the designated welding test being performed.
    1. Model the correct PPE and safe operation of the chosen thermal, chemical or mechanical cutting method needed to cut bend specimens from the welding qualification test plate.
    2. Model the correct PPE and safe operation of angle/bench grinders, disc sanders, belt grinders/sanders or other abrasive equipment needed to prepare bend specimens for destructive testing.
    3. Employ tolerance and cut quality requirements needed to produce properly sized and prepared bend strap coupons ready for bend evaluation.

COURSE ASSESSMENT AND EVALUATION:

Lab based welding assignments account for the minimum amount of the final grade as follows: 25% = Welding assignments not associated with multi-pass groove welds. These welds may be graded on a points, percentage, A-F, or PASS/FAIL based system as designated in the instructor sheet. 25% = Welder Qualification Testing - Multi-pass groove welds are graded according to applicable welding codes PASS/FAIL criteria. The remaining 50% of the grade will be designated by the instructor for classroom work, participation, quizzes, tests or additional percentage of welding assignments or qualification testing.

ACCOMMODATIONS STATEMENT:

Any student who has a documented disability and wishes to access academic accommodations (per the 1973 Rehabilitation Act and Americans with Disability Act) must contact the HCC Coordinator of Disability Services, at 620-665-3554, or the Student Success Center, Parker Student Union. The student must have appropriate documentation on file before accommodations can be provided.

ACADEMIC HONESTY:

Education requires integrity and respect for HutchCC's institutional values. HutchCC students are required to maintain honesty through a "responsible acquisition, discovery, and application of knowledge" in all academic pursuits. Preserving and upholding academic honesty is the responsibility of Hut chCC students, faculty, administrators and staff.

I. Student Responsibilities

All HutchCC students are required to:

  • Submit all work in all courses without cheating, fabrication, plagiarism, dissimulation, forgery, sabotage, or academic dishonesty as defined below.
  • Provide all academic records such as transcripts and test scores that are free of forgery.
  • Refrain from participating in the academic dishonesty of any person.
  • Use only authorized notes and student aids.
  • Use technology appropriately, including refraining from submitting AI (Artificial Intelligence)-generated work without express written consent from your instructor.
  • Protect the security of passwords/login/privacy/electronic files, and maintain sole individual access for any online course information.

II. Definition of Academic Dishonesty

  • Academic dishonesty is any intentional act, or attempted act, of cheating, fabrication, plagiarism, dissimulation, forgery, or sabotage in academic work.
  • Cheating includes using unauthorized materials of any kind, whether hard copies, online, or electronic, such as unapproved study aids in any academic work, copying another student's work, using an unauthorized "cheat sheet" or device, or purchasing or acquiring an essay online or from another student.
  • Fabrica tion is the invention or falsification of any information or citation in any academic work, such as making up a source, providing an incorrect citation, or misquoting a source.
  • Plagiarism is the representation of words, ideas and other works that are not the student's own as being original to the student. A no n-inclusive list of examples includes work completed by someone else, work generated by an external entity (such as AI), omitting a citation for work used from another source, or borrowing the sequence of ideas, arrangement of material, and/or pattern of thought of work not produced by the student, even though it may be expressed in the student's own words.
  • Dissimulation is the obscuring of a student's own actions with the intention of deceiving others in any academic work, such as fabricating excuses for absences or missed assignments, or feigning attendance.
  • Forgery of academic documents is the unauthorized altering, falsification, misrepresentation, or construction of any academic document, such as changing transcripts, changing grades on papers or on exams which have been returned, forging signatures, manipulating a digital file of academic work, or plagiarizing a translation.
  • Sabotage is any obstruction or attempted obstruction of the academic work of another student, such as impersonating another student, stealing or ruining another student's academic work.
  • Aiding and abetting academic dishonesty is considered as knowingly facilitating any act defined above.
  • Academic honesty violations can also include the omission or falsification of any information on an application for any HutchCC academic program.

III. Sanctions for Academic Dishonesty

Students who violate the Academic Honesty Policy may be subject to academic or administrative consequences.

Instructor Sanctions for Violation:

Students suspected of violating the Academic Honesty Policy may be charged in writing by their instructor and any of the following may apply:

  • Assign Avoiding Plagiarism Bridge Module
  • Receiving written warning that could lead to more severe sanction if a second offense occurs
  • Revising the assignment/work in question for partial credit
  • Voiding work in question without opportunity for make-up
  • Reducing the grade for work in question
  • Lowering the final course grade
  • Failing the work in question

Institutional Sanctions for Violation:

Students charged with academic dishonesty, particularly in instances of repeated violations, may further be subjected to an investigation and any of the following may apply:

  • Instructor recommendation to the Vice President of Academic Affairs (VPAA) to dismiss the student from the course in which the dishonesty occurs
  • Instructor recommendation to the VPAA to dismiss student from the course in which the dishonesty occurs with a grade of 'F." Student will not be allowed to take a 'W' for the course
  • Instructor recommendation to the VPAA that the student be suspended and/or dismissed from the program
  • Student barred from course/program for a set period of time or permanently
  • May be recommended by the instructor (after documented repeated offenses) to the VP AA that the student be placed on probation, suspended and/or dismissed from the institution.

IV. Procedure

  • Instructor will communicate in writing via the student's HutchCC email account and/or LearningZone email account to the student suspected of violating the Academic Honesty Policy.  That communication may include sanction(s). Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation Form.
  • For each violation, the instructor will submit a completed Academic Honesty Violation Form to the Department Chair. Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation form.
  • Should the instructor choose to pursue institutional sanctions, the instruct or shall notify the student in writing via the student's HutchCC email account.  Instructor shall also submit a completed Academic Honesty Violation Form and all prior completed forms regarding said student to the Department Chair and the office of the VPAA with recommendation to proceed with specific Institutional Sanctions. Department Chair will notify the student's academic advisor upon receipt of the Academic Honesty Violation Form.
  • The decision of the VPAA on Institutional Sanction is final. The VPAA will notify the student's academic advisor of any institutional sanctions.

V. Due Process Rights

Students charged with violations of academic honesty have the right of appeal and are assured of due process through the Academic Honesty Appeal process.

Academic Honesty Appeal Process

I. Due Process Rights: Students charged with violations of academic honesty have the right of appeal and are assured of due process through the Academic Honesty Appeal process.

  • If an instructor has recommended course or program dismissal, the student may continue in coursework (provi ding there are no threatening or security behavioral issues) until appeal processes are concluded. However, if an issue has been documented at a partnership location (e.g., clinical sites, secondary institutions, correctional or military facilities), then the student is no longer eligible to continue participation in internships, apprenticeships, and/or clinical-based practice. For clinical sites, this sanction is immediate.

II. Process

If the student disagrees with the charge of a violation of academic honesty, the student has the right to due process as described in the Academic Honesty Appeal process below:

  • If the matter is not resolved upon communicating with the instructor about the violation, the student shall, within five business days of the issuance of the written notice of violation, submit a completed Academic Honesty Appeal Form and supporting documentation to the appropriate department chairperson to initiate an Academic Honesty Appeal.
  • Within two business days of receiving the student's completed Academic Honesty Appeal Form, the Department Chair and VPAA will review and the VPAA will render a decision.
  • Within two business days, a response will be sent to the student's HutchCC email address. The VPAA's decision is final.

INCOMPLETE GRADE:

Instructors may give a student a grade of Incomplete (I) under the following conditions:

  1. The student must initiate the request prior to the time final course grades are submitted to Records.
  2. The request must be made because of an emergency, illness or otherwise unavoidable life-event.
  3. The instructor must agree to the request before a grade of Incomplete can be submitted.
  4. A written contract between the instructor and student, signed by both, will document the work required and date needed to complete course work.
  5. If a student does not complete the course requirements within the time frame established by the instructor, a grade of "F" will be recorded on the student's transcript at the end of the next semester.

HLC ACCREDITATION:

Hutchinson Community College is accredited by the Higher Learning Commission (HLC). The Higher Learning Commission is one of six regional institutional accreditors recognized by the US Department of Education and the Council on Higher Education Accreditation (CHEA).

Last Revised: 03/30/2023