Welding Fabrication for 2009

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W ELDING F ABRICATION P URPOSE To evaluate each contestant 9s preparation for employment and to recognize outstanding students for excellence and professionalism in the field of welding fabrication. First, refer to General Regulations, Page 9. C LOTHING R EQUIREMENT Official SkillsUSA khaki work shirt and pants, black or brown leather work shoes, and safety glasses with side shields or goggles.

(Prescription glasses can be used only if they are equipped with side shields. If not, they must be covered with g oggles.) To purchase official work clothes, contact Midwest Trophy Manufacturing Co. Inc.

by calling 1 - 800 - 324 - 5996 or order online at www.mtmrecognition.com/skillsusa/ . Note: Contestants must wear their official contest clothing to the contest orientation meeting. E LIGIBILITY Open to active SkillsUSA members enrolled in programs with welding as the occupational objective.

This is a team event. Each Team will be comprised of three student member s from the same school and training program. E QUIPMENT AND M ATERIALS : 1.

Supplied by the technical committee: a. All necessary welding equipment and materials b. All instructions and procedure sheets with drawings c.

Power tools needed for the competitio n. d. Some tools will be provided.

Please see updated list on ... more. less.

the SkillsUSA website prior to the competition. 2. Supplied by the contestant Team: a. Hearing and/or ear protection b. Welding helmet with appropriate filter plate/lens and protective cover pl ate/lens in a flip or slide front. Auto darkening shields are permissible c. Spare spatter and filter lenses/plates for arc welding helmet and oxyacetylene goggles d. Pocket calculator e. Lead pencil and/or ballpoint pen f. Soap stone with holder g. Scrib e with magnet h. Combination square set i. Fillet weld gauge j. Center punch k. Chipping hammer with or without wire brush l. Stainless steel wire brush m. One - page, typewritten résumé n. a 3 - 5 minute presentation answering the following: i. What we lding process would you use to manufacture this project and why. *Project drawings will be posted ahead of time for students on the SkillsUSA website. ii. What would you change to this project to make it easier to build or more functional and why. S C OPE OF THE C ONTEST The scope of the contest is defined by industry standards as identified by the following companies: American Welding Society Inc., Harris Products Group, Hobart Brothers Co., Lincoln Electric Co., Linweld Inc., and Miller Electric Manufa cturing Co. All drawings, welding symbols and welding terms conform to the latest edition of the American Welding Society (AWS) standards. Knowledge Performance The contest will include a written knowledge exam that assesses the practical knowledge of we lding, including safety, measurement and blue print reading. Other common fabrication operations will also be assessed such as saw operation, drilling, grinding, and material handling. Skill Performance The skill performance assessment includes the compl etion of a metal project and a demonstration of the ability to weld carbon steel, aluminum or stainless steel project in various positions using a variety of filler metals. Contestants will be involved in the completion of a metal project that involves var ious manufacturing methods. Contest Guidelines 1. Contestants must correctly use the welding equipment during the contest. The contest chairman and contest coordinator may stop a contestant at any section of the contest if they deem a contestant 9s manner to be hazardous to either themselves or others. Such stoppage shall disqualify the participant for that section of the contest. If the contestant is warned a second time, he or she will be disqualified as a contest participant. 2. While the contest is in progress, there shall be no communication between the contestants or between other teams or anyone else, except as directed by a judge, contest coordinator or contest chair. It is expected that team members will communicate to each other. 3. Time limits will be established on the contest procedure sheets for all segments of the test. 4. Evaluation of the completed project will be judged visually. Nondestructive and/or destructive tests may be used to complete the project evaluation. 5. Welding and cutti ng operation instructions will be specified in drawings and procedure sheets provided to the contestants. 6. Welding equipment used in the contest may be obtained from a variety of manufacturers and may include transformers, rectifiers and/or inverters. 7 . Filler metals will be compatible with the metals being welded and will be detailed on the contest procedure sheet. Instructions to the contestants will define more specifically the filler metals that may be used. 8. Welds will be evaluated visually util izing a rating system as established by the SkillsUSA technical committee. Nondestructive and/or destructive tests may be used to complete the project evaluation. 9. Final judging of the welded projects will be evaluated according to the difficulty of the assigned task and by utilizing the following visual inspection criteria: dimensional accuracy, including distortion; conformity to drawing requirements, including determination of whether all welds have been completed and whether the finished welds confor m to the required size and contour; and visual examination of the welds for cracks, undercut, overlap, crater fill, spatter, arc strikes, porosity, convexity and reinforcement. Standards and Competencies WF 1.0 4 Identify safety standards on a test in ac cordance to ANSI Z49 1.1 Demonstrate proper use and inspection of equipment used for protection of personnel 1.2 Model proper work area operation 1.3 Demonstrate proper use and inspection of equipment used for ventilation 1.4 Demonstrate proper Hot Zon e operation 1.5 Demonstrate proper working in confined spaces 1.6 Understand precautionary labeling 1.7 Model proper use and inspection of equipment used for each required welding or thermal cutting process WF 2.0 4 Demonstrate an understanding of pra ctical measurement 2.1 Identify basic metal - working tools used in measuring 2.2 Use visual measuring tools to accuracy of 1 D 64 of an inch 2.3 Employ the components of a combination square set 2.4 Use layout and marking tools as required 2.5 Determine wire feed speed as indicated on drawing WF 3.0 4 Read and interpret blueprints 3.1 Apply information found in the information block of the drawing 3.2 Read and understand three - dimensional drawings 3.3 Identify the basic views used in blueprints inclu ding assembly, detail and fit - up drawings 3.4 Identify common types of lines, abbreviations and symbols in accordance with national drawing standards (ANSI) 3.5 Identify basic welding symbols and components of a symbol (such as arrow, reference line, tai l, size or length) in accordance with the current national welding symbol standard AWS A 2.4 current edition WF 4.0 4 Produce welds using a Shielded Metal Arc Welding (SMAW) process to AWS QC10 standards 4.1 Demonstrate safety procedures for SMAW 4.2 De monstrate ability to correctly set up SMAW power sources, related welding equipment and do basic process and equipment troubleshooting 4.3 Correctly identify base metal prior to welding 4.4 Set up and shut down equipment for welding of carbon steel and/o r stainless steel 4.5 Select correct type of filler metal size of electrode based on carbon steel and/or stainless steel plate (1 D 4 - inch to 1 D 2 - inch thickness) 4.6 Prepare carbon steel and/or stainless steel for welding 4.7 Start, stop and restart strin ger beads on carbon steel and/or stainless steel in the flat, horizontal, vertical up and down and overhead positions 4.8 Weld a pad with a multiple - pass weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and down and over head positions 4.9 Weld a lap joint with a single - pass, fillet weld on carbon steel and stainless steel sheet/plate in flat, horizontal, vertical up and down and overhead positions 4.10 Weld a lap joint with a multiple - pass, fillet weld on carbon steel a nd stainless steel plate in the flat, horizontal, vertical up and down and overhead positions 4.11 Weld a T - joint with a single - pass, fillet weld on carbon steel and stainless steel sheet/plate in the flat, horizontal, vertical up and down and overhead po sitions 4.12 Weld a T - joint with a multiple - pass, fillet weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and down and overhead position 4.13 Weld a butt joint with a single - pass, square groove weld on carbon steel and stainless steel sheet/plate in the flat, horizontal, vertical up and down and overhead positions 4.14 Weld a butt joint with a partial joint penetration, single pass, double V - groove weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and down and overhead positions 4.15 Weld a butt joint with a multiple - pass, V - groove weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and down and overhead positions 4.16 Weld a butt joint with complete joi nt penetration, multiple pass, double groove weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and down and overhead positions 4.17 Weld 2 - to 8 - inch diameter, schedules 40 to 80 carbon steel and stainless steel pipe, sin gle/multiple - pass V - groove weld in the 2G, 5G and 6G positions 4.18 Layout, weld, cut and prepare coupons for evaluation 4.19 Test the prepared coupon WF 5.0 4 Produce welds using a Gas Metal Arc Welding (GMAW) process to AWS QC10 standards 5.1 Demonst rate correct safety procedures for GMAW 5.2 Demonstrate ability to correctly set up GMAW power sources, related welding equipment and do basic process and equipment troubleshooting 5.3 Correctly identify base metal prior to welding 5.4 Set up and shut d own equipment for short circuiting, globular, spray and pulsed transfer welding of carbon steel, stainless steel and/or aluminum 5.5 Select correct type of filler metal size of electrode, type of shielding gas, wire feed speed and voltage based on carbon steel, stainless steel and/or aluminum sheet and/or plate (1/16 - inch to 3/8 - inch thickness) 5.6 Prepare the carbon steel, stainless steel and/or aluminum for welding 5.7 Start, stop and restart stringer beads on carbon steel, stainless steel and aluminum steel sheet/plate in the flat, horizontal, vertical up and down, and overhead positions 5.8 Weld a pad with a multiple - pass weld on carbon steel, stainless steel and aluminum sheet/plate in the flat, horizontal, vertical up and down and overhead position s 5.9 Weld a lap joint with a single - pass, fillet weld on carbon steel, stainless steel and aluminum sheet/plate in flat, horizontal, vertical up and down and overhead positions 5.10 Weld a lap joint with a multiple - pass, fillet weld on carbon steel, sta inless steel and aluminum plate in the flat, horizontal, vertical up and down and overhead positions 5.11 Interrupt root pass at mid point and restart arc 5.12 Weld a T - joint with a single - pass, fillet weld on carbon steel, stainless steel and aluminum s heet/plate in the flat, horizontal, vertical up and down and overhead positions 5.13 Weld a T - joint with a multiple - pass, fillet weld on carbon steel, stainless steel and aluminum plate in the flat, horizontal, vertical up and down and overhead positions 5.14 Weld a butt joint with a single - pass, square groove weld on carbon steel, stainless steel and aluminum sheet/plate in the flat, horizontal, vertical up and down and overhead positions 5.15 Weld a butt joint with a partial joint penetration; single - p ass, and double V - groove weld on carbon steel, stainless steel and aluminum plate in the flat, horizontal, vertical up and down and overhead positions 5.16 Weld a butt joint with a multiple - pass, V - groove weld on carbon steel, stainless steel and aluminum plate in the flat, horizontal, vertical up and down and overhead positions 5.17 Weld a butt joint with complete joint penetration; multiple - pass, and double V - groove weld on carbon steel, stainless steel and aluminum plate in the flat, horizontal, vertic al up and down and overhead positions 5.18 Weld 2 - to 8 - inch diameter, schedule 40 to 80 carbon steel, stainless steel and aluminum pipe, single/multiple pass V - groove weld in the 2G, 5G and 6G positions 5.19 Layout, weld, cut and prepare coupons for eva luation 5.20 Test prepared coupons WF 6.0 4 Produce welds using a Fluxed Cored Arc Welding (FCAW) process to AWS QC10 standards 6.1 Demonstrate correct safety procedures for FCAW 6.2 Demonstrate ability to correctly set up FCAW power sources, related w elding equipment and do basic process and equipment troubleshooting 6.3 Correctly identify base metal prior to welding 6.4 Set up and shut down equipment for welding of carbon steel and/or stainless steel 6.5 Select correct type of filler metal, size of electrode, type of shielding gas (if needed), wire feed speed and voltage based upon carbon steel and/or stainless steel sheet and/or plate (1/16 - inch to 3/8 - inch thickness) 6.6 Prepare carbon steel and/or stainless steel for welding 6.7 Start and stop and restart stringer beads on carbon steel and stainless steel sheet/plate in the flat, horizontal, vertical up and overhead positions 6.8 Weld a pad with a multiple - pass weld on carbon steel and stainless steel sheet/plate in the flat, horizontal, vertic al up and overhead positions 6.9 Weld a lap joint with a single - pass, fillet weld on carbon steel and stainless steel sheet/plate in flat, horizontal, vertical up and overhead positions 6.10 Weld a lap joint with a multiple - pass, fillet weld on carbon st eel and stainless steel plate in the flat, horizontal, vertical up and overhead positions. Stop and restart in the middle of the joint 6.11 Weld a T - joint with a single - pass, fillet weld on carbon steel and stainless steel sheet/plate in the flat, horizon tal, vertical up and overhead positions 6.12 Weld a T - joint with a multiple - pass, fillet weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and overhead positions 6.13 Weld a butt joint with a single - pass, square groove w eld on carbon steel and stainless steel sheet/plate in the flat, horizontal, vertical up and overhead positions 6.14 Weld a butt joint with a partial joint penetration, single pass, double V - groove weld on carbon steel and stainless steel plate in the fla t, horizontal, vertical up and overhead positions 6.15 Weld a butt joint with a multiple - pass, V - groove weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and overhead positions 6.16 Weld a butt joint with complete joint penetration, multiple - pass, double V - groove weld on carbon steel and stainless steel plate in the flat, horizontal, vertical up and overhead positions 6.17 Weld 2 - to 8 - inch diameter, schedules 40 to 80 carbon steel and stainless steel pipe, single/multip le pass V - groove weld in the 2G, 5G and 6G positions 6.18 Layout, cut and prepare coupons for evaluation 6.19 Test prepared coupons WF 7.0 4 Produce welds using a Gas Tungsten Arc Welding (GTAW) process to AWS QC10 standards 7.1 Demonstrate safety proc edures for GTAW 7.2 Demonstrate ability to correctly set up GTAW power sources, related welding equipment and do basic process and equipment troubleshooting 7.3 Correctly identify base metal prior to welding 7.4 Set up and shut down equipment for regula r and pulsed welding of aluminum, stainless steel and/or carbon steel 7.5 Select the correct size and type of tungsten and/or filler metal based on aluminum, stainless steel or carbon steel sheet and/or plate (1/16 - inch to 1/4 - inch thickness) 7.6 Prepare aluminum, stainless steel and/or carbon steel for welding 7.7 Start, stop and restart stringer beads on aluminum, stainless steel and carbon steel sheet/plate in the flat, horizontal, vertical up and down and overhead positions 7.8 Weld a pad with multi ple - pass weld on aluminum, stainless steel and carbon steel sheet/plate in the flat, horizontal, vertical up and down and overhead positions 7.9 Weld a lap joint with a single - pass, fillet weld on aluminum, steel, stainless steel and carbon steel sheet/pl ate in flat, horizontal, vertical up and down and overhead positions. 7.10 Weld a lap joint with a multiple - pass, fillet weld on aluminum, stainless steel and carbon steel plate in the flat, horizontal vertical up and down and overhead positions 7.11 We ld a T - joint with a single - pass fillet weld on aluminum, stainless steel and carbon steel sheet/ plate in the flat, horizontal, vertical up and down and overhead positions 7.12 Weld a T - joint with a multiple - pass, fillet weld on aluminum, stainless steel and carbon steel plate in the flat, horizontal, vertical up and down and overhead positions 7.13 Weld a butt joint with a single - pass, square groove weld on aluminum, stainless steel and carbon steel sheet/plate in the flat, horizontal, vertical up and do wn and overhead positions 7.14 Weld a butt joint with a partial joint penetration, single - pass, double V - groove weld on aluminum, stainless steel and carbon steel plate in the flat, horizontal vertical up and down and overhead positions 7.15 Weld a butt joint with a multiple - pass, V - groove weld on aluminum, stainless steel and carbon steel plate in the flat, horizontal, vertical up and down and overhead positions 7.16 Weld a butt joint with complete joint penetration, multiple - pass, and double V - groove w eld on aluminum, stainless steel and carbon steel plate in the flat, horizontal, vertical up and down and overhead positions 7.17 Weld 2 - to 8 - inches diameter, schedules 40 to 80 aluminum, stainless steel, carbon steel pipe, single/multiple pass V - groove weld in the 2G, 5G and 6G positions 7.18 Layout, weld, cut and prepare coupons for evaluation 7.19 Test prepared coupons WF 8.0 4 Produce cut materials using an Oxygen Fuel Cutting (OFC) process to AWS QC10 standards 8.1 Demonstrate safety procedures f or OFC 8.2 Demonstrate ability to correctly set up the OAC equipment for cutting and do basic process troubleshooting 8.3 Correctly identify base metal prior to cutting 8.4 Set up and shut down equipment for cutting carbon steel plate 8.5 Select correc t tip size and gas pressure for serving carbon steel plate (1/4 - inch to 1/2 - inch thickness) 8.6 Prepare carbon steel for cutting 8.7 Cutting operations will be specified in drawings and procedure sheets provided to the contestants 8.8 Properly light, ad just the flame, and shut down the oxygen fuel equipment 8.9 Use a straight edge and soapstone laying out the prescribed pattern 8.10 Make a square cut on carbon steel in flat, horizontal, vertical and overhead positions 8.11 Make a bevel cut (45 - degree angle) on carbon steel plate in the flat, horizontal, vertical and overhead positions 8.12 Pierce a hole on carbon steel in the flat, horizontal, vertical and overhead position 8.13 Make a pipe and tubing cut on carbon steel pipe in flat, horizontal, ver tical and overhead positions 8.14 Make a gouge and groove cut on carbon steel in flat, horizontal, vertical and overhead positions. 8.15 Layout, weld, cut and prepare coupons for evaluation 8.16 Test prepared coupon WF 9.0 4 Produce cut materials using a Plasma Arc Cutting (PAC) process to AWS QC10 standards 9.1 Demonstrate safety procedures for PAC 9.2 Demonstrate ability to correctly set up the PAC power sources, related cutting equipment and do basic process and equipment troubleshooting 9.3 Corre ctly identify base metal prior to cutting 9.4 Set up and shut down equipment for cutting carbon steel, stainless steel and/or aluminum 9.5 Select correct cutting head and gas pressure for severing carbon steel, stainless steel or aluminum plate and/or sh eet (1/16 - inch to 1/4 - inch thickness) 9.6 Prepare carbon steel, stainless steel and/or aluminum for cutting 9.7 Cutting operations will be specified in drawings and procedure sheets provided to the contestants 9.8 Properly adjust and use the plasma arc equipment 9.9 Use a straight edge and soapstone laying out the prescribed pattern 9.10 Make a square cut on carbon steel, stainless steel and aluminum sheet/plate in flat, horizontal, vertical and overhead positions 9.11 Make a bevel cut (45 - degree angl e) on carbon steel, stainless steel and aluminum sheet/plate in the flat, horizontal, vertical and overhead positions 9.12 Pierce a hole on carbon steel, stainless steel and aluminum sheet/plate in the flat, horizontal, vertical and overhead position 9.13 Make a pipe and tubing cut on carbon steel, stainless steel and aluminum pipe in the horizontal position 9.14 Make a gouge and groove cut on carbon steel, stainless steel and aluminum sheet/plate in the flat position 9.15 Layout, cut and prepare coupon s for evaluation 9.16 Test prepared coupon WF 10.0 4 Demonstrate knowledge of visual inspection 10.1 Examine and measure undercut 10.2 Examine and measure porosity 10.3 Measure fillet size 10.4 Examine and measure weld reinforcement 10.5 Determine a cceptability of welded samples in accordance with provided acceptance criteria Committee Identified Academic Skills The technical committee has identified that the following academic skills are embedded in this contest. Math Skills " Use fractions to solv e practical problems " Measure angles " Construct three - dimensional models Science Skills " Describe and recognize solids, liquids and gases " Use knowledge of principles of electricity and magnetism Language Arts Skills " Provide information in oral presentations Connections to National Standards State - level academic curriculum specialists identified the following connections to national academic standards. Math Standards " Geometry " Measurement " Problem Solving " Communication " Connections " Representation Source: NCTM Principles and Standards for School Mathematics. To view high school standards, visit: standards.nctm.org/document/chapter7/index.htm . Select cStandards d from menu. Science Standards " Un derstands the structure and properties of matter " Understands the sources and properties of energy " Understands forces and motion " Understands the nature of scientific inquiry Source: McREL compendium of national science standards. To view and search the com pendium, visit: www.mcrel.org/standards - benchmarks/ . Language Arts Standards " Students apply a wide range of strategies to comprehend, interpret, evaluate and appreciate texts. They draw on their p rior experience, their interactions with other readers and writers, their knowledge of word meaning and of other texts, their word identification strategies, and their understanding of textual features (e.g., sound - letter correspondence, sentence structure , context, graphics) Source: IRA/NCTE Standards for the English Language Arts. To view the standards, visit: www.readwritethink.org/standards/index.html . Welding Fabrication Contest Score card Contest Number Items Evaluated Possible Points 1 2 3 4 5 6 7 8 SMAW 40 GTAW 85 FCAW 152.5 OXYFUEL 107.5 WRITTEN TEST 90 FABRICATION 275 TEAMWORK 100 SAFETY 100 TEAM ORAL PRESEN TATION 50 Total Possible Score 1000 Résumé Penalty 0 or - 50 only Clothing Penalty Up to - 50 Total Score

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