CRR 101 - Sheet Metal Welding

Credits: 2
Lecture Hours: 0
Lab Hours: 4
Practicum Hours: 0
Work Experience: 0
Course Type: Voc/Tech

1. Determine safety and personal health hazards according to OSHA guidelines and the “Emergency Planning and Right to Know” (HP-I)
   1. Identify personal safety; eye, skin, and respiratory protection (ie. welding helmet)
   2. Show proper use of required clothing and correct hand/foot protection
   3. Explain O.S.H.A. requirements for the work place
   4. Take part in the “Emergency Planning and Right to Know” requirement
   5. Identify and take precautions with hazardous operations and materials according to federal, state, and local regulations (HP-I)
   6. Demonstrate proper storage, handling, and installation of high pressure gas cylinders
2. Examine weldable materials used in collision repair
   1. Identify types of metals used in vehicle construction
   2. Compare types and thicknesses of steel
3. Assess welding and cutting of various metals (HP-I)
   1. Identify cutting process for different materials and locations; perform cutting operation (HP-I)
   2. Demonstrate proper set-up and operation of Plasma cutter and Oxy/Acetylene cutting equipment.
   3. Determine the correct GMAW (MIG) welder, electrode, wire type, diameter, and type of gas to be used in a specific welding situation (HP-I)
   4. Demonstrate setting up and adjusting the GMAW (MIG) welder to “tune” for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the material being welded (HP-I)
   5. Determine work clamp (ground) location and attach. (HP-I)
   6. Demonstrate setting up and adjusting aluminum welding equipment. Adjust voltage, wire speed, gas flow rate for the aluminum being welded. (HP-I)
   7. Demonstrate setting up and adjusting silicon bronze welding equipment. Adjust welder voltage, wire speed and gas flow rate.
   8. Determine proper use and locations for silicon bronze welding.
4. Develop the following GMAW (MIG) welds: continuous, stitch, tack, plug, butt weld with and without backing, for aluminum and steel.
   1. Demonstrate cleaning and preparation of the metal to be welded, assure good metal fit-up, apply weld through primer if necessary, and clamp as required (HP-I)
   2. Show 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 (HP-I)
   4. Determine the type of weld (continuous, stitch, plug, etc.) for each specific joint type (HP-I)
   5. Develop a lap weld, plug weld, and butt welds with backer in the horizontal / vertical and overhead positions, using various metal thickness. Steel only.
5. Take part in visual and destructive tests on each weld type as outlined on 4.5
   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
6. Pass  I-CAR introduction Series.   (#7, #8) 
   1. Complete OPTION: I-CAR Welding qualification test, end of welding course qualification test for steel and aluminum, student pay.
   2. Complete Vehicle Construction Material Types (GEO 10 E 01)

 
Competencies Revised Date: 2019