Fabrication Processes 1

Course Number: MFG 151
Transcript Title: Fabrication Processes 1
Created: March 25, 2021
Updated: March 25, 2021
Total Credits: 3
Lecture Hours: 0
Lecture / Lab Hours: 60
Lab Hours: 0
Satisfies Cultural Literacy requirement: No
Satisfies General Education requirement: No
Grading options: A-F (default), P-NP, audit
Repeats available for credit: 0

Prerequisites

Course Description

Builds on fabrication principles started in MFG 150 and adds Pos 4 welding on mild steel in groove and fillet fitments. Focuses on scientific principles that effect weld outcomes and how those principles can be used by welders to ensure quality weld and fabrication outcomes. Teaches use of Oxy-Fuel cutting equipment. Prerequisites: MFG 150. Audit available.

Intended Outcomes

Upon successful completion of this course, students will be able to:

  1. Create Position 4 Fillet weldments using SMAW and GMAW processes for destructive testing as per AWS D1.1 code.
  2. Create Position 4 Groove weldments using SMAW and GMAW processes for destructive testing as per AWS D1.1 code.
  3. Accurately account for welding warp in mild steel processes.
  4. Demonstrate knowledge of heat affected zone chemistry and its practical considerations in welding.
  5. Use Oxygen-Fuel cutting techniques to process and handle materials in a fabrication environment.
  6. Apply the technicalskills and math needed to carry out correct joint preparation and fit-up.

Outcome Assessment Strategies

Outcomes are assessed through a mixture of hands on and written assessments.  Priority is given to hands-on proficiency based assessment in an environment that rewards demonstration of skill needed for success in industry.

  • Lecture and in booth coaching and direct instruction.
  • Direct instruction in full class demonstration of skills.
  • Written exams.
  • Student proficiency through demonstration of learned strategies and skills in industry standard environment.
  • Mock AWS Testing procedure (destructive testing) or mock local industry supported on-site testing procedures.
  • Job readiness based on performance.
  • In class lab experiments and testing using the scientific process with written result reporting.

Texts and Materials

Resources are available openly on the web, but largely the curriculum adaptation needs to be done based on the instructors existing skill set.  Since there are many ways to teach the content, the “teach what you know, and teach well what you do” is very appropriate for courses like this.

The following books are recommended:
  • Welding Skills, 5th Edition, B.J. Moniz
  • Welding Skills Workbook, 5th Edition, Jonathan F. Gosse
  • Print Reading for Welders, 5th Edition, Thomas E. Proctor, Jonathan F. Goss
Some Suggested resources:
  • AWS Structural Code Book 2020
  • Aeorspacewelding.com
  • Thefabricator.com
  • Aws.org
  • Millerwelds.com
  • Lincolnelectric.com

Course Activities and Design

The determination of teaching strategies used in the delivery of outcomes is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: lecture, small group/forum discussion, flipped classroom, dyads, oral presentation, role play, simulation scenarios, group projects, service learning projects, hands-on lab, peer review/workshops, cooperative learning (jigsaw, fishbowl), inquiry based instruction, differentiated instruction (learning centers), graphic organizers, etc.

Course Content (Themes, Concepts, Issues and Skills)

Outcome #1: Create Position 4 Fillet weldments using SMAW and GMAW processes for destructive testing as per AWS D1.1 code.
  • Understand American Welding Society (AWS) D1.1 structural code for SMAW 7018 fillet weld process in position 4.
  • Prepare plate for welding according to structural standard.
  • Weld plate to code specification.
  • Prepare plate for destructive testing per AWS Code.
  • Interpret destructive testing results.
Outcome #2: Create Position 4 Groove weldments using SMAW and GMAW processes for destructive testing as per AWS D1.1 code.
  • Understand American Welding Society (AWS) D1.1 structural code for SMAW 7018 groove weld process in position 4.
  • Prepare plate for welding according to structural.
  • Weld plate to code specification.
  • Prepare plate for destructive testing per AWS Code.
  • Interpret destructive testing results.
Outcome #3: Accurately account for welding warp in mild steel processes.
  • Define and predict using a formula the amount of warp an assembly will experience based on the expected heat input.
  • Create basic tacked together assemblies with warp tolerances pre-accounted for.
  • Manufacture and finish assemblies and use quality control best practices to ensure tolerances are met post welding.
Outcome #4: Demonstrate knowledge of heat affected zone chemistry and its practical considerations in welding and fabrication.
  • Understand the chemical changes that occur within the heat effected zone and the resulting change in material structure.
  • Define the different zones within the heat affected zone and how they are chemically and physically different from the welded zone and base material.
  • Understand mitigation strategies for reducing heat affected zone size and fatigue in mild steel.
  • Prepare and implement heat affected zone mitigation strategies.
Outcome #5: Use Oxygen-Fuel cutting techniques to process and handle materials in a fabrication environment.
  • Understand Oxygen-Fuel cylinder safety and handling procedures.
  • Demonstrate proper Oxy-Fuel cutting torch setup and shut down.
  • Produce industry standard cuts in material up to 1” thick using appropriate cutting torch size and setup.
  • Determine gas flow necessary for appropriate cutting torch operation.
  • Understand practical and procedural differences in different types of fuel gasses commonly used in torch cutting.
  • Demonstrate basic torch maintenance and upkeep procedures.
Outcome #6: Apply the technical skills and math needed to carry out correct joint preparation and fitup.
  • Use circumference math and tube sizing formula to calculate the amount of tube needed to make bent product.
  • Calculate angles of triangles and length of triangles in assemblies to accurately determine length of materials needed for projects.
  • Accurately calculate material amount needed for large scale project from blueprints and cost material using online resources.

Department Notes

Safety glasses are required at all times in the welding lab and are provided for students. Students may also purchase their own safety glasses from a local supplier. Long pants and closed toed shoes are required in the welding lab at all times. Appropriate clothing must be worn to work in the lab (no synthetic materials, ect.). Safety requirements are covered prior to work in the lab.