CRR 101 - Sheet Metal Welding

1. Identify and take precautions with hazardous operations and materials according to federal, state, and local regulations
   1. Personal safety, selecting the proper eye protection and welding helmet
   2. Use the proper clothing required
   3. Show proper use of correct hand and foot protection
   4. Store, handle, and install high-pressure gass cylinders
2. Identify safety and personal health hazards according to OSHA guidelines and the “Right-to-Know Law”
   1. Identify personal safety; eye, skin and respiratory protection
   2. Understand OSHA requirements for the work place
   3. Complete the “Right-to-Know Law” requirement
   4. Identify the safety procedures shown on the safety video tape
3. Identify weldable and non-weldable materials used in collision repair
   1. Identify types of materials used in vehicle construction
   2. Differentiate types and thicknesses of steel
   3. Differentiate types and thicknesses of aluminum
   4. Reproduce the three types of flames to the instructor with Oxy-Acetylene equipment
4. Weld and cut high-strength steel and other metals
   1. Identify cutting process for different materials and locations; perform cutting operation
   2. Demonstrate proper set-up and operation of Oxy/Acetylene welding/cutting equipment and perform basic welds
   3. Determine the correct GMAW (MIG) welder type, electrode, wire type, diameter, and gas to be used in a specific welding situation
   4. Set up and adjust the GMAW (MIG) welder to “tune” for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for t6he material begin welded
   5. Determine work clamp (ground) location and attach
   6. Set up, adjust, and weld using Oxy/Acetylene welding equipment
   7. Weld and cut aluminum
5. Perform the following welds: continuous, stitch, tack, plug, butt weld with and without backing, and fillet weld
   1. Clean and prepare the metal to be weleded, assure good metal fit-up, apply weld through primer if necessary, and clamp as required
   2. Use the proper angle of the gun to the joint and direction of gun travel for the type of weld being made in the flat, horizontal, vertical, and overhead positions
   3. Determine the joint type (butt joint with backing, lap, etc.) for weld being made.
   4. Determine the type of weld (continuous, stitch, plug, etc.) for each specific joint type
6. Perform visual and destructive tests on each weld type
   1. Identify the causes of various welding defects; make necessary adjustments
   2. Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments
7. Demonstrate knowledge in the proper set up and shut down of GMAW equipment
   1. Complete video #2, #3, #4 and workbook assignments
   2. Demonstrate proper set up and shut down
   3. Determine proper shielding gas and flow rate
8. Practice running beads on sheet metal with pushing and pulling technique
9. Practice making welds on laps, tees and butt joints in the flat position
10. Practice making welds on laps, tees, and butt joints in the horizontal position
11. Practice welding tee joints in the vertical down position
12. Practice making spot welds, plug welds, and stitch welds in the flat position
13. Practice running beads in the flat position with aluminum, .030 diameter electrode and Argon shielding gas
14. Perform manual flame cutting on various thicknesses of metals
    1. Select videos #8 and #9 and complete workbook assignments
    2. Set up cutting torch with proper tip and fuel mixture
    3. Manually flame cut, 1/4”, 1/2” plate, pierce holes and cut bevels
15. Lab test over Oxy-Acetylene and Gas Metal Arc Welding for final grade