Welding: Answer Key
Qualified welding instructor required.
The Welding Honor is perhaps of all the AY honors, the one with the greatest potential to cause injury. If done wrong you can also create unsafe equipment (see requirement note at end) Do not attempt to teach yourself how to weld. An experienced instructor is absolutely required for this honor.
1. Successfully complete a minimum of three hours of classroom instruction.*
2. Identify the following:
2a. Welding hood
2b. GMAW welding wire
2c. SMAW power supply
2d. Welding gas regulator
2e. GMAW welding torch
2f. 220-volt electrical outlet
2g. PAC torch
3. Explain the following terms:
3a. Fusion welding
3b. Electrode
3c. Oxidation
3d. Slag
3e. Alloy
4. Select and describe one fusion welding process.
4a. How is heat generated?
4b. Why is filler metal added?
4c. Describe how the molten metal is protected from oxidation.
5. Name at least one thermal and one mechanical cutting process.
5a. Describe how each one works.
5b. Discuss relative advantages and limitations of each.
6. Demonstrate a knowledge of risks and hazards associated with welding and cutting, and the steps to prevent or reduce them.
6a. Electric current
6b. High temperatures
6c. Ultraviolet radiation
6d. Toxic fumes
6e. Moving machinery/blades
6f. High-pressure gases
7. Describe the safety gear required for various fusion welding and cutting processes.
7a. Head/eye protection
7b. Clothing
7c. Gloves
7d. Hearing
7e. Filtration/ventilation
8. For either the GMAW or SMAW welding process, demonstrate an ability to use welding guidelines, such as handbook tables, to select the appropriate welding process parameter settings, including proper amperage and electrode type/size for various types and thicknesses of a selected metal.
9. Explain and demonstrate proper equipment setup and consumables selection for at least one welding process.
10. Describe all the components of the equipment to be used and their function.
11. Using the designated processes, perform the following:
11a. PAC: Make one straight cut at least three inches long in mild steel or aluminum.
11b. SMAW: Complete i and ii, or complete iii.
11bi
Make two bead-on-plate welds at least two inches total length
11bii
Make one square-groove weld in the flat position
11biii
Make one corner weld in the flat position
11c. GMAW: Complete i and ii, or complete iii.
11ci
Make two bead-on-plate welds at least two inches total length
11cii
Make one square-groove weld in the flat position
11ciii
Make one lap weld in the flat position
Note
* Must pass a knowledge exam upon completion.
^ These are minimum requirements; additional welding is encouraged
References
Adapted from AY Honors/Welding/Answer Key on the Pathfinder Wiki, licensed under CC BY-SA 3.0. See the original page's history for its authors.
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