Title: Complete a Basic Weld
Course: WLDT 260 Welding Automation

Complete a Basic Weld
Learning Objectives
Objective SCO 2477
Instructions
DO NOT BEGIN THIS ASSIGNMENT UNTIL YOU HAVE COMPLETED ASSIGNMENT #4

First read all of the steps shown below, then follow the steps shown in the order given.
1. Retrieve your lab notebook.
2. Follow the instructions on the following pages.
3. Take complete notes on your activities, documenting the welding procedure, the results and any other information that will help you to remember how to recreate the assignment at a later date without the help of the instructions found here.
4. Contact your instructor with any questions as they arise.

Project Grading Rubric
Review the following Project Grading Rubric and associated instructions.

Project Grading Rubric

Your grade for this project will be calculated based on your instructor’s evaluation of your level of achievement with regard to the items found in the left hand column of the grading rubric found below.

Your level of achievement for each of the items will be scored from 0 to 5.

A score of:

0 = There is not enough information to make a judgment.
1 = The student made an attempt but did not complete the task.
2 = The student makes significant errors in performing the skill and cannot be determined to have learned the skill.
3 = The student performs the basic tasks of the skill but still makes some errors.
4 = The student performs the skill accurately but not fluidly.
5 = The student performs the skill accurately, fluidly, and demonstrates full understanding of the skill

The final points for each of the items is calculated by multiplying the 0 to 5 score by the weight for that particular item. For example: a score of 5 for the column that reads "All safety procedures, guidelines, etc. were followed in the performance of this project." will result in a total of 20 points (5 times a weight of 4 equals 20)

There are a total of 100 Points possible for this project.

Description | 0 | 1 | 2 | 3 | 4 | 5 | Weight | Student Earned Points | Total Possible Points
All safety procedures, guidelines, etc. were followed in the performance of this project. |  |  |  |  |  |  | 4 |  | 20
The student followed directions and performed all required tasks in the performance of this project. |  |  |  |  |  |  | 4 |  | 20
The weld project was properly assembled as required by the provided instructions / procedure / print / etc. |  |  |  |  |  |  | 2 |  | 10
The automated welding system was properly configured to make the weld. |  |  |  |  |  |  | 4 |  | 20
The weld project was properly placed into the welding system in preparation for welding. Joint alignment with the welding torch was correct. |  |  |  |  |  |  | 3 |  | 15
The weld was made in accordance with the assigned welding procedure. |  |  |  |  |  |  | 3 |  | 15
 |  |  |  |  |  |  |  |  | 100

Safety Requirements
The following safety information is for the use of the 36E Longitudinal Seamer located at Southwestern Illinois College Sam Wolf Granite City Campus.  This information along with the safety information contained in the owner's manual for this eqipment and your instructors guidance is to be used to safely operate the seamer.  Although this information may or may not apply to other seamers, this information is not intended to replace the safety requirements of any other seamer, place of work, place of learning, etc.

Personal Protective Equipment (PPE) Requirements

The following personal protective equipment is required when operating the SWIC Longitudinal Seamer.
1. OSHA Approved Safety Glasses with Sideshields
2. Leather Work Boots
3. Weld shop appropriate full length work pants
4. Weld shop appropriate long sleeve work shirt
5. Welding helmet with a #10 shade lens or a full face shield appropriate for seamer welding with a #10 shade lens
6. Ear plugs (when sound levels are 85 decibels or above)
7. Work gloves (preferably thin gloves made for gas tungsten arc welding) Note: do not wear gloves when using pedestal grinder or around any moving parts where gloves may get caught and pull hands and fingers into pinch points

Pinch Points

The following is a list of potential pinch point areas of the SWIC seamer. Keep yourself and others safe while operating the seamer by staying clear of these areas.
1. Between the carriage and the sidebeam
2. Between both the front and rear banks of fingers and the mandrel
3. Between the slide block and the slide base
4. Between the end latch and the mandrel
5. Between the torch and the mandrel or the weld piece
6. Between the torch and either end of the upper frame

Additional Safety Requirements
1. Follow all weld lab safety rules as posted upon entry into the weld lab
2. Follow all additional safety precautions as given by your instructor
3. If you feel unsafe at any time, or have any other safety concerns, safely stop what you are doing and tell your instructor
4. Always maintain an awareness of your surroundings and activities going on around you with safety in mind
5. Notify your instructor immediately if you or someone else is injured

Welding Procedure
Review the welding procedure.

Welding Procedure #1

Welding Station: | A1 | Equipment: | Seamer
Welding Process: | GTAW | Position: | 1G
Material: | Stainless Steel | Thickness: | .062”
Joint Design: | Square Groove | Groove Angle: | 0 Degrees
Root Opening: | 0” | Land: | N/A
Backing: | Yes | Back Material: | Copper
Backup Bar Groove | None |  |
Current Type: | DCEN | Pulse: | No
Amperage: | 100 Amps | Voltage | 9 Volts
Travel Speed | 20 IPM | Number of Passes: | 1
Shielding Gas: | Argon – 100% | Flow Rage: | 25 CFH
Backup Purge Gas: | N/A | Backup Flow Rate: | N/A
Filler Material | N/A | Filler Metal Size: | N/A
Wire Speed Feed: | N/A | Filler Feed Angle: | N/A

Operational InstructionsOperational Instructions:

Now that you have reviewed the safety requirements, the grading rubric and the welding procedure follow these additional steps to complete this assignment:

1.   Obtain the base material
2.   Check the end latch
3.   Turn on the carriage control power
4.   Turn on the main air valve to the seamer
5.   Turn on and set the shielding gas flow rate
6.   Set the seamer carriage control settings as required
7.   Set the welding parameters as required
8.   Clamp the fingers
9.   Clean the backup bar
10.  Unclamp the fingers
11.  Insert the weld joint into the seamer and clamp
12.  Set the travel limit switches as required
13.  Perform a dry run
14.  HOLD POINT - Contact your instructor for setup review prior to welding
15.  Make the weld
16.  Unclamp the weld
17.  Shut down the equipment
18.  Prepare your completed weld and turn it in for grading
SAFETY REQUIREMENT!  ALWAYS ENSURE THAT NO PERSONS OR OBJECTS ARE LOCATED IN ANY PINCH POINT DANGER ZONES OF THE SEAMER!

The carriage rides on the sidebeam to carry the torch along the weld seam.

The following video shows the movement of the carriage on the sidebeam close to the end of beam.  At each end of the sidebeam there are hard stops that keep the carriage from rolling off of the beam.  There is a pinch point between the carriage and each of the hard stops.  Always ensure to keep yourself, others and objects from being located between the carriage and the hard stops.