Difference between revisions of "AY Honors/Welding/Answer Key"

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< AY Honors‎ | WeldingAY Honors/Welding/Answer Key
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{{honor_header|3|1978|Vocational|General Conference}}
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{{HonorSubpage}}
  
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==(Instructor Required) ==
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<!--{{Honor Master|honor={{#titleparts:{{PAGENAME}}|1|3}}|master=Technician}}-->
−
The Welding Honor is perhaps of all the AY honors, the one with the greatest potential to cause injury.  '''''Do not attempt to teach yourself how to weld.'''''  An experienced instructor is absolutely required for this honor.
+
<section begin="Body" />
  
−
==1. Identify all parts of the following: ==
+
<noinclude><translate></noinclude>
−
===a. Welding and cutting torches ===
+
==Qualified welding instructor required.== <!--T:190-->
 +
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.
 +
<noinclude></translate></noinclude>
  
−
A welding torch has a nozzle with one hole, the torch body mixes oxy and acet, and you get your flame.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=1}}
 +
<noinclude><translate><!--T:160-->
 +
</noinclude>
 +
<!-- 1. Successfully complete a minimum of three hours of classroom instruction.* -->
  
−
A cutting torch has a bunch of nozzles in a circle, with an oxy/acet mix (like the welding torch), and a bigger hole in the middle where oxygen comes out.
+
<!--T:161-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 1 -->
  
−
The outer holes heat the steel, the inner hole cuts.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2}}
 +
<noinclude><translate><!--T:170-->
 +
</noinclude>
 +
<!-- 2. Identify the following: -->
  
−
===b. Oxygen and acetylene gauges and their differences ===
+
<!--T:171-->
 +
<noinclude></translate></noinclude>
  
−
The pressure regulators enable the user to reduce the high pressure contained in the cylinder to a usable working pressure. There are several handling and set up procedures that are important to the overall operation of the pressure regulator. The pressure regulator on each tank shows two things:
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2a}}
 +
<noinclude><translate><!--T:191-->
 +
</noinclude>
 +
<!-- a. Welding hood -->
  
−
• Cylinder pressure (How much gas is in the cylinder)
+
<!--T:192-->
−
• Working or line pressure
+
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2a -->
  
−
Installing the regulators
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2b}}
 +
<noinclude><translate><!--T:193-->
 +
</noinclude>
 +
<!-- b. GMAW welding wire -->
  
−
• Before installing the regulator Crack the cylinder valve to clean out any dirt or dust
+
<!--T:194-->
−
• Mount the regulator onto the cylinder
+
<noinclude></translate></noinclude>
−
o Ensure that the oxygen pressure regulator is on the oxygen tank
+
{{CloseReq}} <!-- 2b -->
−
• Do Not over tighten regulator nut
 
−
• Before opening the cylinder valve ensure that the pressure regulator screws are released (turned out)
 
−
• Never use oil or grease on the regulators
 
−
o Frictional heat as a result of high pressures can cause oil to ignite and possibly cause an explosion
 
  
−
===c. Oxygen and acetylene hoses and their differences ===
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2c}}
−
Oxygen hoses are green. Acetylene hoses are red.
+
<noinclude><translate><!--T:195-->
 +
</noinclude>
 +
<!-- c. SMAW power supply -->
  
−
HOSES:
+
<!--T:196-->
−
The oxy acetylene welding hoses are made out of a durable rubber that is designed to withstand different pressures. There are several things to remember about the hoses:
+
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2c -->
  
−
• Red = Fuel
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{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2d}}
−
• Green = Oxygen
+
<noinclude><translate><!--T:197-->
−
• Do not kink hoses
+
</noinclude>
−
• Keep hoses away from work area
+
<!-- d. Welding gas regulator -->
−
• Wrap hoses when not in use
 
−
• Keep hoses away from sparks and hot metal
 
  
−
Hose fittings
+
<!--T:198-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2d -->
  
−
• Acetylene fitting are notched
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2e}}
−
• Acetylene fittings are left hand thread
+
<noinclude><translate><!--T:199-->
−
• Oxygen fittings are smooth
+
</noinclude>
−
• Oxygen fittings are right hand thread
+
<!-- e. GMAW welding torch -->
−
• Both tanks should always be fitted with anti flash back arrestors
 
  
−
===d. Oxygen and acetylene tanks and their differences ===
+
<!--T:200-->
−
The oxygen and acetylene cylinders are designed to hold high-pressure gases. There are some important things to remember when using these cylinders:
+
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2e -->
  
−
• Cylinders must always be stood upright and be secured by a chain
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2f}}
−
• When not in use (regulator mounted) they must always have a valve protection cap in place
+
<noinclude><translate><!--T:201-->
−
• Cylinders should be stored in a cool dry place away from direct sunlight or extreme cold
+
</noinclude>
 +
<!-- f. 220-volt electrical outlet -->
  
−
Oxygen Cylinders
+
<!--T:202-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2f -->
  
−
• Usually red in colour, smaller in diameter and taller than Acetylene
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=2g}}
−
• 2200 PSI when full
+
<noinclude><translate><!--T:203-->
−
• The cylinder valve must be opened fully (double seated valve) or it could leak!
+
</noinclude>
−
• You should not run an oxygen tank below 50 PSI.
+
<!-- g. PAC torch -->
  
−
Acetylene Cylinders
+
<!--T:204-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 2g -->
 +
{{CloseReq}} <!-- 2 -->
  
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• Usually black, large in diameter and short
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3}}
−
• 250 PSI when full
+
<noinclude><translate><!--T:172-->
−
• The cylinder valve should only be opened ¼ of a turn.
+
</noinclude>
−
• The acetylene cylinder should never be laid down as this will result in the gas becoming unstable.
+
<!-- 3. Explain the following terms: -->
−
• You should not run an acetylene tank below 50 PSI.
 
  
−
==2. Explain the safe working pressures of oxygen and acetylene, as per your instruc­tor's directions, for various procedures. ==
+
<!--T:173-->
−
When welding and brazing with an oxy-acetylene torch, acetylene should be set at 5psi. Oxygen should be set at 5 or 6psi, but no more.
+
<noinclude></translate></noinclude>
  
−
When cutting with an oxy-acetylene torch, acetylene should again be set at about 5psi. Oxygen, however is set much higher, about 25psi, when cutting.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3a}}
 +
<noinclude><translate><!--T:205-->
 +
</noinclude>
 +
<!-- a. Fusion welding -->
  
−
1. Always use goggles when welding or cutting
+
<!--T:206-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 3a -->
  
−
2. Use aprons and gloves.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3b}}
 +
<noinclude><translate><!--T:207-->
 +
</noinclude>
 +
<!-- b. Electrode -->
  
−
3. Do not point the flame towards the regulators and   
+
<!--T:208-->
−
another person.
+
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 3b -->
  
−
4. When finished welding shut off the main valves , bleed
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3c}}
−
the lines and loosen the regulator adjusting screws.
+
<noinclude><translate><!--T:209-->
 +
</noinclude>
 +
<!-- c. Oxidation -->
  
−
5. Wind up the hoses when finished shutting everything 
+
<!--T:210-->
−
off.
+
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 3c -->
  
−
6. Do not turn acetylene valve more than 1 ½ turns.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3d}}
 +
<noinclude><translate><!--T:211-->
 +
</noinclude>
 +
<!-- d. Slag -->
  
−
7. Never use oil near oxygen equipment
+
<!--T:212-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 3d -->
  
−
8. Threads used for acetylene are LEFT-HANDED.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=3e}}
 +
<noinclude><translate><!--T:213-->
 +
</noinclude>
 +
<!-- e. Alloy -->
  
−
9. Threads used for oxygen are RIGHT HANDED.
+
<!--T:214-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 3e -->
 +
{{CloseReq}} <!-- 3 -->
  
−
10. There will be no horseplay.
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=4}}
 +
<noinclude><translate><!--T:174-->
 +
</noinclude>
 +
<!-- 4. Select and describe one fusion welding process. -->
  
−
==3. While blindfolded, demonstrate ability to hook up an entire oxyacetylene kit, including tanks, gauges, hoses, and torches, and light the same.** ==
+
<!--T:175-->
−
==4. As per your instructor's directions, weld two mild steel test plates (1/8 inch x 1 inch x 8 inches) (0.3 cm x 2.5 cm x 20.3 cm) in horizontal, and vertical positions.==
+
<noinclude></translate></noinclude>
−
==5. Use a cutting torch and demonstrate your skill by making one 12 inches (30.5 cm) straight-line cut, one circle cut of at least 3 inches (7.6 cm) in diameter and one 3 inch (7.6 cm) star cut. The cuts are to be made on mild steel plate at least 1/4 inch (0.6 cm) thick. ==
 
−
==6. Demonstrate your ability to braze a cast-iron object with at least 1/4 inch (0.6 cm) double bevel butt weld 2 inches (5 cm) long.==
 
  
−
==7. Explain the safety precautions and safety equipment normally used in electric welding in relation to eyes, hands, and exposed skin areas. Why should the tank valves never be oiled? ==
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=4a}}
−
==8. Explain the difference between oxyacetylene and electric arc welding. ==
+
<noinclude><translate><!--T:215-->
−
Oxy-acetylene welding uses two gases in the process of producing a weld. Acetylene, which is the fuel and is the main source of heat, and oxygen, which is a propellant.
+
</noinclude>
 +
<!-- a. How is heat generated? -->
  
−
Electric arc welding does not use gas to produce a weld like oxy-acetylene welding does. Electric arc welding uses an electric current to produce its welds. A clamp, with the one side of the current flowing through it, is attached to a base plate. Then the another clamp/nozzle, with the other side of the current flowing through it, is held in a hand. A filler rod is then used to complete the circuit and create the heat needed to heat the pieces of metal being joined and melt the filler rod (used to bind the pieces of metal together).
+
<!--T:216-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 4a -->
  
−
==9. Demonstrate ability to select from an electrode guide the proper amperage and electrode for various types and thicknesses of metal. ==
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=4b}}
−
==10. Demonstrate ability to weld flat, vertical, horizontal, and overhead on (1/8 inch x 1 inch x 8 inches) (0.3 cm x 2.5 cm x 20.3 cm) mild steel test plates. ==
+
<noinclude><translate><!--T:217-->
 +
</noinclude>
 +
<!-- b. Why is filler metal added? -->
  
−
==Note: An instructor is a must. Welding is a very critical and serious skill to learn and is not a home-type course. Welding essentially takes the place of bolts and rivets, and if not properly done, is most dangerous. Example: A trailer hitch not properly bond­ed, or machinery exposed to the strain of pull or weight, is an invitation to disaster.==
+
<!--T:218-->
−
+
<noinclude></translate></noinclude>
−
==Note: ** This requirement demonstrates one's skill in working in darkness, such as in an emergency. All acetylene connection threads are left-handed, while all oxygen connection threads are right-handed. ==
+
{{CloseReq}} <!-- 4b -->
  
−
==References==
+
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=4c}}
−
* [http://www.tpub.com/content/construction/14250/ Steelworker, Volume 1], A U.S. Navy Training Manual.  As an original document produced by the U.S. government, this publication is in the public domain and has a lot of information that should be incorporated into this text.
+
<noinclude><translate><!--T:219-->
 +
</noinclude>
 +
<!-- c. Describe how the molten metal is protected from oxidation. -->
  
−
[[Category:Adventist Youth Honors Answer Book|{{SUBPAGENAME}}]]
+
<!--T:220-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 4c -->
 +
{{CloseReq}} <!-- 4 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=5}}
 +
<noinclude><translate><!--T:176-->
 +
</noinclude>
 +
<!-- 5. Name at least one thermal and one mechanical cutting process. -->
 +
 
 +
<!--T:177-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=5a}}
 +
<noinclude><translate><!--T:221-->
 +
</noinclude>
 +
<!-- a. Describe how each one works. -->
 +
 
 +
<!--T:222-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 5a -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=5b}}
 +
<noinclude><translate><!--T:223-->
 +
</noinclude>
 +
<!-- b. Discuss relative advantages and limitations of each. -->
 +
 
 +
<!--T:224-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 5b -->
 +
{{CloseReq}} <!-- 5 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6}}
 +
<noinclude><translate><!--T:178-->
 +
</noinclude>
 +
<!-- 6. Demonstrate a knowledge of risks and hazards associated with welding and cutting, and the steps to prevent or reduce them. -->
 +
 
 +
<!--T:179-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6a}}
 +
<noinclude><translate><!--T:225-->
 +
</noinclude>
 +
<!-- a. Electric current -->
 +
 
 +
<!--T:226-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6a -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6b}}
 +
<noinclude><translate><!--T:227-->
 +
</noinclude>
 +
<!-- b. High temperatures -->
 +
 
 +
<!--T:228-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6b -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6c}}
 +
<noinclude><translate><!--T:229-->
 +
</noinclude>
 +
<!-- c. Ultraviolet radiation -->
 +
 
 +
<!--T:230-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6c -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6d}}
 +
<noinclude><translate><!--T:231-->
 +
</noinclude>
 +
<!-- d. Toxic fumes -->
 +
 
 +
<!--T:232-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6d -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6e}}
 +
<noinclude><translate><!--T:233-->
 +
</noinclude>
 +
<!-- e. Moving machinery/blades -->
 +
 
 +
<!--T:234-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6e -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=6f}}
 +
<noinclude><translate><!--T:235-->
 +
</noinclude>
 +
<!-- f. High-pressure gases -->
 +
 
 +
<!--T:236-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 6f -->
 +
{{CloseReq}} <!-- 6 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7}}
 +
<noinclude><translate><!--T:180-->
 +
</noinclude>
 +
<!-- 7. Describe the safety gear required for various fusion welding and cutting processes. -->
 +
 
 +
<!--T:181-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7a}}
 +
<noinclude><translate><!--T:237-->
 +
</noinclude>
 +
<!-- a. Head/eye protection -->
 +
 
 +
<!--T:238-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 7a -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7b}}
 +
<noinclude><translate><!--T:239-->
 +
</noinclude>
 +
<!-- b. Clothing -->
 +
 
 +
<!--T:240-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 7b -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7c}}
 +
<noinclude><translate><!--T:241-->
 +
</noinclude>
 +
<!-- c. Gloves -->
 +
 
 +
<!--T:242-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 7c -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7d}}
 +
<noinclude><translate><!--T:243-->
 +
</noinclude>
 +
<!-- d. Hearing -->
 +
 
 +
<!--T:244-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 7d -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=7e}}
 +
<noinclude><translate><!--T:245-->
 +
</noinclude>
 +
<!-- e. Filtration/ventilation -->
 +
 
 +
<!--T:246-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 7e -->
 +
{{CloseReq}} <!-- 7 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=8}}
 +
<noinclude><translate><!--T:182-->
 +
</noinclude>
 +
<!-- 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. -->
 +
 
 +
<!--T:183-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 8 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=9}}
 +
<noinclude><translate><!--T:184-->
 +
</noinclude>
 +
<!-- 9. Explain and demonstrate proper equipment setup and consumables selection for at least one welding process. -->
 +
 
 +
<!--T:185-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 9 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=10}}
 +
<noinclude><translate><!--T:186-->
 +
</noinclude>
 +
<!-- 10. Describe all the components of the equipment to be used and their function. -->
 +
 
 +
<!--T:187-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 10 -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11}}
 +
<noinclude><translate><!--T:247-->
 +
</noinclude>
 +
<!-- 11. Using the designated processes, perform the following: -->
 +
 
 +
<!--T:248-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11a}}
 +
<noinclude><translate><!--T:249-->
 +
</noinclude>
 +
<!-- a. PAC: Make one straight cut at least three inches long in mild steel or aluminum. -->
 +
 
 +
<!--T:250-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11a -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11b}}
 +
<noinclude><translate><!--T:251-->
 +
</noinclude>
 +
<!-- b. SMAW: Complete i and ii, or complete iii. -->
 +
 
 +
<!--T:252-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11bi}}
 +
<noinclude><translate><!--T:253-->
 +
</noinclude>
 +
<!-- i. Make two bead-on-plate welds at least two inches total length -->
 +
 
 +
<!--T:254-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11bi -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11bii}}
 +
<noinclude><translate><!--T:255-->
 +
</noinclude>
 +
<!-- ii. Make one square-groove weld in the flat position -->
 +
 
 +
<!--T:256-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11bii -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11biii}}
 +
<noinclude><translate><!--T:257-->
 +
</noinclude>
 +
<!-- iii. Make one corner weld in the flat position -->
 +
 
 +
<!--T:258-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11biii -->
 +
{{CloseReq}} <!-- 11b -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11c}}
 +
<noinclude><translate><!--T:259-->
 +
</noinclude>
 +
<!-- c. GMAW: Complete i and ii, or complete iii. -->
 +
 
 +
<!--T:260-->
 +
<noinclude></translate></noinclude>
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11ci}}
 +
<noinclude><translate><!--T:261-->
 +
</noinclude>
 +
<!-- i. Make two bead-on-plate welds at least two inches total length -->
 +
 
 +
<!--T:262-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11ci -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11cii}}
 +
<noinclude><translate><!--T:263-->
 +
</noinclude>
 +
<!-- ii. Make one square-groove weld in the flat position -->
 +
 
 +
<!--T:264-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11cii -->
 +
 
 +
{{ansreq|page={{#titleparts:{{PAGENAME}}|2|1}}|num=11ciii}}
 +
<noinclude><translate><!--T:265-->
 +
</noinclude>
 +
<!-- iii. Make one lap weld in the flat position -->
 +
 
 +
<!--T:266-->
 +
<noinclude></translate></noinclude>
 +
{{CloseReq}} <!-- 11ciii -->
 +
{{CloseReq}} <!-- 11c -->
 +
{{CloseReq}} <!-- 11 -->
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Latest revision as of 14:36, 21 March 2023

Other languages:
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Welding

Skill Level

3

Year

1978

Version

16.04.2024

Approval authority

North American Division

Welding (NAD) AY Honor.png
Welding
Vocational
Skill Level
123
Approval authority
North American Division
Year of Introduction
1978
See also
Technician Master Award



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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