FAB2048 Flux Cored Arc Welding 1

Intermediate · 1 credit · TMT - Trades, Manufacturing and Transportation

Description: Students develop an understanding of the advantages and disadvantages of Flux Cored Arc Welding (FCAW) processes, and they gain experience using FCAW processes by performing flat, horizontal and vertical fillet welds and flat groove welds.
Prerequisite: FAB1048: Semi-automated/Automated Welding
Parameters: Access to a fabrication work centre, complete with FCAW equipment and supplies, and to instruction from an individual with formal, specialized training in arc welding practices.

Outcomes The student will:

1 outline the advantages and disadvantages of FCAW processes versus other forms of arc welding processes
- 1.1 identify the advantages and disadvantages of FCAW processes as compared with other arc welding processes
- 1.2 identify the variables that can directly affect weld quality; e.g., the welding current and voltage, modes of metal transfer such as short arc, globular and spray arc, diameter and type of filler metal, type and condition of equipment, welding technique such as forehand or pushing, backhand or pulling
- 1.3 identify possible causes of welding defects; e.g., surface porosity, subsurface porosity, lack of fusion, burn-through, lack of penetration, cold lapping
- 1.4 identify problems common to out-of-position welding
2 describe the characteristics of a desirable flux cored arc weld
- 2.1 complete a visual inspection, i.e., non-destructive test, by observing and assessing:
  - 2.1.1 overall size, shape and appearance of the beads
  - 2.1.2 plate penetration
  - 2.1.3 fusion
  - 2.1.4 degree of undercutting and overlapping
3 identify safe set-up and maintenance procedures with FCAW equipment
- 3.1 describe and demonstrate the maintenance required for wire drive systems and gun assemblies
4 demonstrate safe FCAW practices and perform: • fillet welds on mild steel plate in the flat, horizontal and vertical positions • groove welds on mild steel plate in the flat position
- 4.1 describe safety issues related to:
  - 4.1.1 using personal protective equipment
  - 4.1.2 handling and storing consumables
  - 4.1.3 keeping the welding area free of hazards
  - 4.1.4 ensuring adequate ventilation
- 4.2 describe a safety plan in case of an accident
- 4.3 apply safe work practices and procedures to:
  - 4.3.1 select and use appropriate personal protective equipment
  - 4.3.2 maintain a clean and tidy workstation
  - 4.3.3 demonstrate safe tool/material handling and storage techniques
- 4.4 for a given type of weld and/or weldment, select the appropriate:
  - 4.4.1 wire type, size and feed rate
  - 4.4.2 current
  - 4.4.3 shielding gas type and flow rate
- 4.5 prepare and clean all surfaces to be welded
- 4.6 properly position metal for welding
- 4.7 demonstrate safe FCAW techniques and perform fillet welds in the flat, horizontal and vertical positions on mild steel plate
- 4.8 demonstrate safe FCAW techniques and perform groove welds in the flat position on mild steel plate
- 4.9 perform a destructive test, where appropriate
5 demonstrate basic competencies
- 5.1 demonstrate fundamental skills to:
  - 5.1.1 communicate
  - 5.1.2 manage information
  - 5.1.3 use numbers
  - 5.1.4 think and solve problems
- 5.2 demonstrate personal management skills to:
  - 5.2.1 demonstrate positive attitudes and behaviours
  - 5.2.2 be responsible
  - 5.2.3 be adaptable
  - 5.2.4 learn continuously
  - 5.2.5 work safely
- 5.3 demonstrate teamwork skills to:
  - 5.3.1 work with others
  - 5.3.2 participate in projects and tasks
6 identify possible life roles related to the skills and content of this cluster
- 6.1 recognize and then analyze the opportunities and barriers in the immediate environment
- 6.2 identify potential resources to minimize barriers and maximize opportunities