Welding Lab Pre-Quiz

TECH 1711

Purpose

This presentation is intended to familiarize you with the welding lab.

Read and Understand the Safety Handout

Safety Precautions

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PART 1: Metal Fabrication

Before you weld, you will use the 55 ton hydraulic ironworker to shear and punch your workpieces.

DANGER: This machine will easily crush and/or amputate fingers and hands. Also eye protection is required.

Ironworker Steps

1. Shear four short pieces
2. Turn off machine
3. Remove the pieces
4. Shear two more short pieces
5. Turn off machine
6. Remove the two pieces
7. Remove the short stop
8. Shear one long piece
9. Punch two holes

When you are done you will have SIX (6) short pieces, and ONE (1) long piece with holes in it. Two of the short pieces are for practice welding.

The stop shown below sets the length for your short pieces. Simply remove it for the long piece.

NOTE:

Each person must complete all steps before the next person begins.

DO NOT assist other people using the ironworker.

YOU MUST make ONE complete kit at a time. Do not try to speed things along by shearing many short pieces.

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IMMEDIATELY after you have made a kit move to the next station.

Bending

Bending will be done manually on a box brake.

ONLY bend FOUR of your short pieces. The remaining two are for welding practice and must be unbent.

Bending

You will bend FOUR of the short pieces TWO AT A TIME.Use the block to set the first bend locations as shown here. After the first bend is done, use the block to establish the spacing between bends.

Getting the Proper Bend Angle

A dowel pin stop will be installed to help you get the proper angle. Only apply light pressure to the pin. When done you will have 2 straight pieces and 4 bent.

4x

2x

MIG Welding

Pay attention to how your pieces go into the fixture.

You will be instructed on technique in lab.

Your parts should be installed in the fixture like this:

Rough Side UP

You are looking at the BACK of the rack.

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Align the corners

Hooks Down

Keep in mind you are welding the BACK of the rack.

Where to MIG Weld

Next

You can either TIG or STICK weld after you have MIG welded. You will be instructed on technique.

TIG Welding

Weld all six edge joints.

Be sure to brush the joints clean first.

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TIG both ends like this:

TIG Setup

Stick Welding

Stick weld the remaining two lap joints on the back of the rack.

You may set up on your practice piece as shown below. You can strike the arc on the practice piece and then drag the arc to the lap joint.

Put Away Your PPE

Note: TEN (10) POINTS WILL BE DEDUCTED if this process is not followed:

Tighten Headset

Face up

Glove on sides, thumbs up

Fold like this:

Return to designated shelf