Aluminum GTAW/TIG Fabrication Processes 2

Course Number: MFG 282
Transcript Title: Aluminum GTAW/TIG Fab Proc 2
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 MFG 281 by continuing structural code practice, adding in pipe and tube welding techniques in aluminum, and creating pressure vessels in out of position weldments. Provides understanding of warp and how to account for warp in building multi-part assemblies, as well as sanitary/clean practices for welding aluminum. Prerequisite: MFG 281. Audit available.

Intended Outcomes

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

  1. Create Position 3 Fillet weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.
  2. Create Position 3 Groove weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.
  3. Manufacture and weld product built from aluminum tube and pipe.
  4. Create aluminum pressure vessels tested to 35psi in out of position weldments.
  5. Identify and account for warp in aluminum weldments and assemblies.
  6. Demonstrate knowledge of sanitary welding practices in GTAW AC aluminum processes.

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
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 3 Fillet weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.
  • Understand American Welding Society (AWS) D1.2 structural code for aluminum GTAW fillet weld process in position 3.
  • 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 3 Groove weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code
  • Understand American Welding Society (AWS) D1.2 structural code for aluminum GTAW Groove weld process in position 3.
  • 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 #3: Manufacture and weld product built from aluminum tube and pipe.
  • Build aluminum weldment and products using multiple facets of fabrication and design including aluminum tube and pipe.
  • Correctly identify amperage and frequency for appropriate joint fusion depending on location and fitment. 
  • Account for aluminum’s unique characteristics when fabricating tube and pipe, especially with bends.
Outcome #4: Create aluminum pressure vessels tested to 35psi in out of position weldments.
  • Demonstrate knowledge of amperage and frequency needed for correct penetration on aluminum joints.
  • Use correct fitup and prep work to ensure the strongest joints possible.
  • Show knowledge of manufacturing changes and machine adjustments needed when welding pressure-critical out of position joints.
  • Prepare different tungsten end grinds to suit the joint being welded.
  • Test welded out of position square pressure vessel to 35psi.
  • Test welded out of position round pressure vessel to 35psi. 
Outcome #5: Identify and account for warp in aluminum weldments and assemblies
  • Define and predict 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 #6: Demonstrate knowledge of sanitary welding practices in GTAW AC aluminum processes.
  • Define and explain the uses of sanitary or clean manufacturing principles using aluminum.
  • Prepare weldments using correct procedures for sanitary or clean manufacturing principles.
  • Weld materials using appropriate filler and welding processes to ensure sanitary or clean weld outcomes with appropriate joint strength.
  • Post treat weldments or assemblies using correct sanitary or clean welding procedures.

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.