AY Honors/Welding

Welding
Vocational
Skill Level 123
Approval authority North American Division	Year of Introduction 1978

• Overview
• Requirements
• Answer Key
• Lesson Plans

AY Honors/Welding/Overview

The most challenging requirement of this honor is probably this:

11. Using the designated processes, perform the following:

a. PAC: Make one straight cut at least three inches long in mild steel or aluminum.

b. SMAW: Complete i and ii, or complete iii.

i. Make two bead-on-plate welds at least two inches total length

ii. Make one square-groove weld in the flat position

iii. Make one corner weld in the flat position

c. GMAW: Complete i and ii, or complete iii.

i. Make two bead-on-plate welds at least two inches total length

ii. Make one square-groove weld in the flat position

iii. Make one lap weld in the flat position

1. Successfully complete a minimum of three hours of classroom instruction.*

2. Identify the following:

a. Welding hood

b. GMAW welding wire

c. SMAW power supply

d. Welding gas regulator

e. GMAW welding torch

f. 220-volt electrical outlet

g. PAC torch

3. Explain the following terms:

a. Fusion welding

b. Electrode

c. Oxidation

d. Slag

e. Alloy

4. Select and describe one fusion welding process.

a. How is heat generated?

b. Why is filler metal added?

c. Describe how the molten metal is protected from oxidation.

5. Name at least one thermal and one mechanical cutting process.

a. Describe how each one works.

b. Discuss relative advantages and limitations of each.

6. Demonstrate a knowledge of risks and hazards associated with welding and cutting, and the steps to prevent or reduce them.

a. Electric current

b. High temperatures

c. Ultraviolet radiation

d. Toxic fumes

e. Moving machinery/blades

f. High-pressure gases

7. Describe the safety gear required for various fusion welding and cutting processes.

a. Head/eye protection

b. Clothing

c. Gloves

d. Hearing

e. Filtration/ventilation

8. For either the GMAW or SMAW welding process, demonstrate an ability to use welding guidelines, such as handbook tables, to select the appropriate welding process parameter settings, including proper amperage and electrode type/size for various types and thicknesses of a selected metal.

9. Explain and demonstrate proper equipment setup and consumables selection for at least one welding process.

10. Describe all the components of the equipment to be used and their function.

11. Using the designated processes, perform the following:

a. PAC: Make one straight cut at least three inches long in mild steel or aluminum.

b. SMAW: Complete i and ii, or complete iii.

i. Make two bead-on-plate welds at least two inches total length

ii. Make one square-groove weld in the flat position

iii. Make one corner weld in the flat position

c. GMAW: Complete i and ii, or complete iii.

i. Make two bead-on-plate welds at least two inches total length

ii. Make one square-groove weld in the flat position

iii. Make one lap weld in the flat position

Note: * Must pass a knowledge exam upon completion.
^ These are minimum requirements; additional welding is encouraged

Edit Answer Key

Qualified welding instructor required.

The Welding Honor is perhaps of all the AY honors, the one with the greatest potential to cause injury. If done wrong you can also create unsafe equipment (see requirement note at end) Do not attempt to teach yourself how to weld. An experienced instructor is absolutely required for this honor.

1

Successfully complete a minimum of three hours of classroom instruction.*

2

Identify the following:

2a

Welding hood

2b

GMAW welding wire

2c

SMAW power supply

2d

Welding gas regulator

2e

GMAW welding torch

2f

220-volt electrical outlet

2g

PAC torch

3

Explain the following terms:

3a

Fusion welding

3b

Electrode

3c

Oxidation

3d

Slag

3e

Alloy

4

Select and describe one fusion welding process.

4a

How is heat generated?

4b

Why is filler metal added?

4c

Describe how the molten metal is protected from oxidation.

5

Name at least one thermal and one mechanical cutting process.

5a

Describe how each one works.

5b

Discuss relative advantages and limitations of each.

6

Demonstrate a knowledge of risks and hazards associated with welding and cutting, and the steps to prevent or reduce them.

6a

Electric current

6b

High temperatures

6c

Ultraviolet radiation

6d

Toxic fumes

6e

Moving machinery/blades

6f

High-pressure gases

7

Describe the safety gear required for various fusion welding and cutting processes.

7a

Head/eye protection

7b

Clothing

7c

Gloves

7d

Hearing

7e

Filtration/ventilation

8

For either the GMAW or SMAW welding process, demonstrate an ability to use welding guidelines, such as handbook tables, to select the appropriate welding process parameter settings, including proper amperage and electrode type/size for various types and thicknesses of a selected metal.

9

Explain and demonstrate proper equipment setup and consumables selection for at least one welding process.

10

Describe all the components of the equipment to be used and their function.

11

Using the designated processes, perform the following:

11a

PAC: Make one straight cut at least three inches long in mild steel or aluminum.

11b

SMAW: Complete i and ii, or complete iii.

11bi

Make two bead-on-plate welds at least two inches total length

11bii

Make one square-groove weld in the flat position

11biii

Make one corner weld in the flat position

11c

GMAW: Complete i and ii, or complete iii.

11ci

Make two bead-on-plate welds at least two inches total length

11cii

Make one square-groove weld in the flat position

11ciii

Make one lap weld in the flat position

Note

* Must pass a knowledge exam upon completion.
^ These are minimum requirements; additional welding is encouraged

References

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