Teaching Outline Mtk 303

KOLEJ VOKASIONAL LIKAS KOTA KINABALU

TEACHING OUTLINE

PROGRAMME

:

WELDING TECHNOLOGY

COURSE NAME

:

GMAW (GAS METAL ARC WELDING) PROCESS 1

CODE NAME

:

MTK 303

LEVEL

:

2 SEMESTER 3

CREDIT UNIT

:

2.0

CONTACT HOUR

:

FACE TO FACE

: 4.0 HOURS / WEEK

NON FACE TO FACE : COURSE TYPE

:

VOCATIONAL

PRE-REQUISITE

:

MTK 103 : SMAW (SHIELDED METAL ARC WELDING) PROCESS 1 MTK 302 : SMAW (SHIELDED METAL ARC WELDING

CORE REQUISTE

:

-

NO. OF CONTENT STANDARD

:

4

COURSE OUTCOMES At the end of the course, the students should be able to:1. Select filler wire & shielding gas 2. Set up GMAW equipment and accessories 3. Weld carbon steel plate of thickness range 3-9 mm in 2F position 4. Weld carbon steel plate of thickness range 3-9 mm in 1G position COURSE DESCRIPTION This unit identifies the competence required to select filler wire and shielding gas, set up GMAW equipment and accessories, weld carbon steel plate of thickness range 3mm to 9mm in 1G and 2F position by preparing the plate, setting up the equipment and welding using GMAW process so that the plate is welded according to a given procedure and the weldment is free from defect and meet the specific welding standard.

CONTENT STANDARD 1

:

SELECT FILLER WIRE & SHIELDING GAS

LEARNING STANDARD 1.1 Check parent metal 1.2 Describe type of shielding gas 1.3 Identify and choose filler wire

PERFORMANCE CRITERIA 1.1.1

Identify type of metals and its specification according to BS/AWS codes and standards. 1.1.2 Identify different type of common base metals visually according to BS/AWS codes and standards 1.2.1 Describe type of shielding gases use in GMAW welding process such as carbon dioxide, argon, helium and other mixed mixture gases according to BS/AWS codes and standards 1.2.2 Practise safety precaution according to OSHA. 1.3.1 1.3.2

Identify type of filler wires used in GMAW process according to BS/AWS codes and standards. Install wire to wire feeder securely set and safe to operate according to manufacturer recommendation.

TEACHING STRATEGIES A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI B. MENYATAKAN OBJEKTIF PEMBELAJARAN: - Identify the information to be delivered. - Prepare notes for briefing. - Deliver briefing to welders. C. AKTIVITI PENGAJARAN: 1.1 Check parent metal 1.1.1 Identify type of metals and its specification according to BS/AWS codes and standards. 1.1.2 Identify different type of common base metals visually according to BS/AWS codes and standards 1.2 Describe type of shielding gas

1.2.1 1.2.2

Describe type of shielding gases use in GMAW welding process such as carbon dioxide, argon, helium and other mixed mixture gases according to BS/AWS codes and standards Practise safety precaution according to OSHA.

1.3 Identify and choose filler wire 1.3.1 Identify type of filler wires used in GMAW process according to BS/AWS codes and standards. 1.3.2 Install wire to wire feeder securely set and safe to operate according to manufacturer recommendation. D. REFLEKSI

CONTENT STANDARD 2

:

SET UP GMAW EQUIPMENT AND ACCESSORIES

LEARNING STANDARD 2.1 Identify and select welding machine. 2.2 Install regulators, flow meters, nozzle/tips 2.3 Fix welding hoses 2.4 Identify and select safety accessories

PERFORMANCE CRITERIA

2.1.1 2.1.2 2.1.3 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3.1 2.3.2 2.3.3

Apply safety precaution related to handling and operating of GMAW equipment according to standard operational procedures. Define principle of GMAW process according to BS/AWS welding standards. Identify GMAW equipment according to manufacturer recommendation. Apply procedure of installing regulators and flow meter according to manufacturer recommendation. Determine gas regulators for the required welding process. Identify size of tip/nozzle according to manufacturer specifications. Identify regulator and flow meter at welding machine according to manufacturer recommendation. Install regulators to flow meters and welding set according to manufacturer recommendation. Practise safety precaution in accordance to Occupational Safety & Health Act (OSHA) to minimise accidents and injuries at work site. Apply Safety precaution related to handling of welding hoses. Identify type of welding hoses for the required welding process. Assemble and connect welding hoses to equipment for the required welding process.

2.4.1 2.4.2

Identify potential hazards in welding operation for the required welding process. Identify and select safety equipment/accessories for the required welding process.

TEACHING STRATEGIES A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI B. MENYATAKAN OBJEKTIF PEMBELAJARAN: - Identify the information to be delivered. - Prepare notes for briefing. - Deliver briefing to welders. C. AKTIVITI PENGAJARAN: 2.1 Identify and select welding machine. 2.1.1 Apply safety precaution related to handling and operating of GMAW equipment according to standard operational procedures. 2.1.2 Define principle of GMAW process according to BS/AWS welding standards. 2.1.3 Identify GMAW equipment according to manufacturer recommendation. 2.2 Install regulators, flow meters, nozzle/tips 2.2.1 Apply procedure of installing regulators and flow meter according to manufacturer recommendation. 2.2.2 Determine gas regulators for the required welding process. 2.2.3 Identify size of tip/nozzle according to manufacturer specifications. 2.2.4 Identify regulator and flow meter at welding machine according to manufacturer recommendation. 2.2.5 Install regulators to flow meters and welding set according to manufacturer recommendation. 2.2.6 Practise safety precaution in accordance to Occupational Safety & Health Act (OSHA) to minimise accidents and injuries at work site. 2.3 2.3.4 2.3.5 2.3.6

Fix welding hoses Apply Safety precaution related to handling of welding hoses. Identify type of welding hoses for the required welding process. Assemble and connect welding hoses to equipment for the required welding process.

2.4 2.4.1 2.4.2

Identify and select safety accessories Identify potential hazards in welding operation for the required welding process. Identify and select safety equipment/accessories for the required welding process.

D. REFLEKSI

CONTENT STANDARD 3

LEARNING STANDARD

:

WELD CARBON STEEL PLATE OF THICKNESS RANGE 3-9 MM IN 2F POSITION

3.1 Prepare carbon steel plate 3.2 Set up welding machine 3.3 Set up filler wire to wire feeder 3.4 Set up tip nozzle and gas flow rate 3.5 Set up current and speed 3.6 Set up work piece 3.7 Carry out welding 3.8 Inspect welded joint

PERFORMANCE CRITERIA

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.2.1 3.2.2 3.2.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4.1 3.4.2 3.4.3 3.5.1

Identify material classification according to manufacturer recommendation. Identify type, basic properties and weldability of carbon steel according to BS/AWS codes and standard. Identify type of joint design and its preparation according to BS/AWS codes and standard. Measure and mark plate for intended welding process. Prepare cutting tools and equipment and cut carbon steel for welding work according to SOP. Apply safety precaution related to handling and operating welding machines according to manufacturer specification. Identify type of welding machine and its applications according to manufacturer specification. Install securely all accessories and hoses at welding machine according to manufacturer recommendation. Identify various types of filler wires, classification, composition and application according to manufacturer specification. Set filler wire to wire feeder Describe function of anti spatter for GMAW welding machine according to manufacturer specification. Identify type of filler wire and install it according to manufacturer recommendation. Determine and setting contact tip, nozzle and gas flow rate according to manufacturer recommendation. Install contact tip and nozzle according to manufacturer recommendations. Practise safety precaution in compliance with OSHA requirement

3.5.5

Apply safety precaution related to handling and operating electrical equipment according to OSHA. List basic electricity related to welding work according to work requirement. List units of current – ampere, volt and watt according to work requirement. Set welding current/amperage and travel speed for welding work according to work requirement. Prepare work piece to welding circuit according to SOP.

3.6.1 3.6.2 3.6.3

Fix welding material to positions required for intended welding work. Describe importance of welding alignment. Align work piece for welding.

3.5.2 3.5.3 3.5.4

3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.8.1 3.8.2

Define GMAW principle and process in accordance to BS/AWS codes and standards. Describe technique of welding using GMAW process according to BS/AWS welding standards. Set up GMAW equipment according to manufacturer recommendation Perform technique of welding carbon steel plate, in 2F horizontal position using GMAW in accordance to BS/AWS standards. Practise safety precaution related to GMAW according to OSHA. Identify welding defects related to GMAW process in accordance to BS/AWS codes and standards. Inspect welding defect visually according to BS/AWS codes.

TEACHING STRATEGIES A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI B. MENYATAKAN OBJEKTIF PEMBELAJARAN: - Identify the information to be delivered. - Prepare notes for briefing. - Deliver briefing to welders. C. AKTIVITI PENGAJARAN: 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

Prepare carbon steel plate Identify material classification according to manufacturer recommendation. Identify type, basic properties and weldability of carbon steel according to BS/AWS codes and standard. Identify type of joint design and its preparation according to BS/AWS codes and standard. Measure and mark plate for intended welding process. Prepare cutting tools and equipment and cut carbon steel for welding work according to SOP.

3.2 Set up welding machine 3.2.1 Apply safety precaution related to handling and operating welding machines according to manufacturer specification. 3.2.2 Identify type of welding machine and its applications according to manufacturer specification. 3.2.3 Install securely all accessories and hoses at welding machine according to manufacturer recommendation.

3.3 Set up filler wire to wire feeder 3.3.1 Identify various types of filler wires, classification, composition and application according to manufacturer specification. 3.3.2 Set filler wire to wire feeder 3.3.3 Describe function of anti spatter for GMAW welding machine according to manufacturer specification. 3.3.4 Identify type of filler wire and install it according to manufacturer recommendation.

3.4 3.4.1 3.4.2 3.4.3

Set up tip nozzle and gas flow rate Determine and setting contact tip, nozzle and gas flow rate according to manufacturer recommendation. Install contact tip and nozzle according to manufacturer recommendations. Practise safety precaution in compliance with OSHA requirement

3.5 Set up current and speed 3.5.1 Apply safety precaution related to handling and operating electrical equipment according to OSHA. 3.5.2 List basic electricity related to welding work according to work requirement. 3.5.3 List units of current – ampere, volt and watt according to work requirement. 3.5.4 Set welding current/amperage and travel speed for welding work according to work requirement. 3.5.5 Prepare work piece to welding circuit according to SOP. 3.6 Set up work piece 3.6.1 Fix welding material to positions required for intended welding work. 3.6.2 Describe importance of welding alignment. 3.6.3 Align work piece for welding. 3.7 Carry out welding 3.7.1 Define GMAW principle and process in accordance to BS/AWS codes and standards. 3.7.2 Describe technique of welding using GMAW process according to BS/AWS welding standards. 3.7.3 Set up GMAW equipment according to manufacturer recommendation 3.7.4 Perform technique of welding carbon steel plate, in 2F horizontal position using GMAW in accordance to BS/AWS standards. 3.7.5 Practise safety precaution related to GMAW according to OSHA. 3.8 Inspect welded joint 3.8.3 Identify welding defects related to GMAW process in accordance to BS/AWS codes and standards. 3.8.4 Inspect welding defect visually according to BS/AWS codes. D. REFLEKSI

CONTENT STANDARD 4

LEARNING STANDARD

4.1 Prepare carbon steel plate 4.2 Set up welding machine

:

WELD STAINLESS STEEL PLATE OF THICKNESS RANGE 6 TO 9mm IN 2G POSITION.

4.3 Set up filler wire to wire feeder 4.4 Set up contact tip, nozzle and gas flow rate 4.5 Set up current and speed 4.6 Set up work piece 4.7 Carry out welding 4.8 Inspect welded joint PERFORMANCE CRITERIA

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

Identify material classification according to manufacturer recommendation Identify type, basic properties and weldability of carbon steel. Identify type of joint design and its preparation. Measure and mark plate for intended welding process. Prepare cutting tools and equipment and cut carbon steel for welding work.

4.2.1

Apply safety precaution related to handling and operating welding machines according to manufacturer specification. Identify type of welding machine and its applications. Install securely all accessories and hoses at welding machine.

4.2.2 4.2.3 4.3.1 4.3.2 4.3.3 4.3.4

4.4.1 4.4.2 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.6.1 4.6.2 4.6.3 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5

Identify various types of filler wires, classification, composition and application according to BS/AWS codes and standard. Set filler wire to wire feeder according to manufacturer recommendation. Describe function of anti spatter for GMAW welding machine feeder according to manufacturer recommendation. Identify type of filler wire and install it according to manufacturer recommendation.

Determine and setting contact tip, nozzle and gas flow rate according to manufacturer recommendation. Install contact tip and nozzle according to manufacturer recommendations. Apply safety precaution related to handling and operating electrical equipment. List basic electricity related to welding work. List units of current – ampere, volt and watt related to welding work Set welding current/amperage and travel speed for welding work according to work requirement. Prepare work piece to welding circuit according to SOP. Fix welding material to positions required for intended welding work. Describe importance of welding alignment according to BS/AWS codes and standard. Align work piece for welding according to SOP. Define GMAW principle and process in accordance to BS/AWS codes and standards. Describe technique of welding using GMAW process according to BS/AWS welding standards. Set up GMAW equipment according to manufacturer recommendation Perform technique of welding carbon steel plate, in 1G flat position using GMAW in accordance to BS/AWS codes and standards. Practise safety precaution related to GMAW process according to manufacturer recommendation

4.8.1 4.8.2

Identify welding defects related to GMAW process in accordance to BS/AWS codes and standards. Inspect welding defect visually according to BS/AWS codes.

TEACHING STRATEGIES A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI B. MENYATAKAN OBJEKTIF PEMBELAJARAN: - Identify the information to be delivered. - Prepare notes for briefing. - Deliver briefing to welders. C. AKTIVITI PENGAJARAN: 4.9 Prepare carbon steel plate 4.1.6 Identify material classification according to manufacturer recommendation 4.1.1 Identify type, basic properties and weldability of carbon steel. 4.1.2 Identify type of joint design and its preparation. 4.1.3 Measure and mark plate for intended welding process. 4.1.4 Prepare cutting tools and equipment and cut carbon steel for welding work. 4.2 Set up welding machine 4.2.1 Apply safety precaution related to handling and operating welding machines according to manufacturer specification. 4.2.2 Identify type of welding machine and its applications. 4.2.3 Install securely all accessories and hoses at welding machine. 4.3 Set up filler wire to wire feeder 4.3.1 Identify various types of filler wires, classification, composition and application according to BS/AWS codes and standard. 4.3.2 Set filler wire to wire feeder according to manufacturer recommendation. 4.3.3 Describe function of anti spatter for GMAW welding machine feeder according to manufacturer recommendation. 4.3.4 Identify type of filler wire and install it according to manufacturer recommendation.

4.4 Set up contact tip, nozzle and gas flow rate 4.4.1 Determine and setting contact tip, nozzle and gas flow rate according to manufacturer recommendation. 4.4.2 Install contact tip and nozzle according to manufacturer recommendations. 4.5 Set up current and speed 4.5.1 Apply safety precaution related to handling and operating electrical equipment. 4.5.2 List basic electricity related to welding work. 4.5.3 List units of current – ampere, volt and watt related to welding work 4.5.4 Set welding current/amperage and travel speed for welding work according to work requirement.

4.5.5

Prepare work piece to welding circuit according to SOP.

4.6 Set up work piece 4.6.1 Fix welding material to positions required for intended welding work. 4.6.2 Describe importance of welding alignment according to BS/AWS codes and standard. 4.6.3 Align work piece for welding according to SOP. 4.7 Carry out welding 4.7.1 Define GMAW principle and process in accordance to BS/AWS codes and standards. 4.7.2 Describe technique of welding using GMAW process according to BS/AWS welding standards. 4.7.3 Set up GMAW equipment according to manufacturer recommendation 4.7.4 Perform technique of welding carbon steel plate, in 1G flat position using GMAW in accordance to BS/AWS codes and standards. 4.7.5 Practise safety precaution related to GMAW process according to manufacturer recommendation 4.8 Inspect welded joint 4.8.1 Identify welding defects related to GMAW process in accordance to BS/AWS codes and standards. 4.8.2 Inspect welding defect visually according to BS/AWS codes.

D. REFLEKSI

SUGGESTED LEARNING ACTIVITIES

1. Student reports by individuals 2. Class discussion conducted by teacher. 3. Presentations by student panels from the class. 4. Lecture by teacher. 5. Practical

SUGGESTED ITEM EVALUATION To Develop Item Construction Assessment Guidelines Based On Assessment Instruments That Are To Be Determined By The Examination Board: Quiz / Observation / Theory short test / Oral test / Assignment / Practical

REFERENCES Journals / Text Books / Website / Specification and manuals (Kaedah APA) 1. A Guide to the Occupational Health and Safety Act (OHSA). (2012) dari laman Web http://www.labour.gov.on.ca/english/hs/pubs/ohsa/ 2. C. Ray Asfahl. (1995). Industrial safety and health management. Prentice Hall, Inc. , New Jersey. 3. Jabatan Pendidikan Teknik dan Vokasional, Fakulti Pendidikan. (2003). Keselamatan bengkel. SPE 1032 / SPK 2032, UTM. 4. Jawatankuasa Keselamatan Bengkel Sekolah, Kementrian Pelajaran Malaysia. (1977). Panduan keselamatan bengkel sekolah. DBP, Kuala Lumpur. 5. Phil Hughes, Ed Ferrett. (2008). Health and Safety in Construction. Elsevier Ltd. All rights reserved.Uk 6. Mohd. Nasir Ahmad. (1987). Teori asas kimpalan arka. Kuala Lumpur: Dewan Bahasa dan Pustaka. 7. Nicholas, C.W & Gorman, C.V .(1977). The heart of instruction: classroom and laboratory management. Ohio Deparment of Education-Division of Vocational. 8. Keselamatan di Makmal & Bengkel - OSH in School dari laman web: http://www.oshinschool.net.my/index.php 9. Panduan keselamatan bengkel sekolah dari laman web: http://elib.uum.edu.my/kip/Record/upm000118 10. Shielded metal arc welding. Horbart school of welding technology (1982) : Projek link