STATE BUDGET EDUCATIONAL INSTITUTION OF INITIAL VOCATIONAL EDUCATION PROFESSIONAL LYCEUM №13
MOSCOW REGION
affirm
director of GBOU npo pl No. 13
___________ kalachanova n.b.
"_____" ______________ 20____
PROFESSIONAL module PM.02
WELDING AND CUTTING OF PARTS FROM VARIOUS STEELS, NON-FERROUS METALS AND THEIR ALLOYS, CAST IRON IN ALL SPATIAL POSITIONS
(MDK.02.02)
FOR THE PROFESSION 150709.02 Welder
(electric welding and gas welding works)
Ramenskoye
2011
The work program of the discipline was developed on the basis of the Federal State Educational Standards (hereinafter referred to as the Federal State Educational Standard) for the professions of primary vocational education (hereinafter referred to as NPO) 150709.02 welder (electric and gas welding and gas welding work)
Developer Organization: GBOU NPO PL. No. 13 "State budgetary educational institution of primary vocational education professional lyceum No. 13 of the Moscow region"
Developers: Zhitkova A.A. Lecturer, SBEI NPO "Professional Lyceum No. 13" of the Moscow Region
Conclusion of the Expert Council No. ___________ dated "____" __________ 200__
room
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CONTENT
page
PASSPORT OF THE WORKING PROGRAM OF THE EDUCATIONAL DISCIPLINE
results of mastering the professional module
STRUCTURE and content of the EDUCATIONAL DISCIPLINE
conditions for the implementation of the program of the academic discipline
Monitoring and evaluation of results Mastering the academic discipline
1. passport of the WORKING PROGRAM of the EDUCATIONAL DISCIPLINE" GAS WELDING TECHNOLOGY "
1.1. Scope of the program
The exemplary program of the academic discipline is part of the exemplary basic professional educational program in accordance with the Federal State Educational Standard for the professions of NGOs that are part of the enlarged group of professions 150000 Metallurgy, mechanical engineering and material processing, in the direction of preparation 150203 Welding production:
150709.02 Welder (electric and gas welding works);
150709.03 Laser welder;
150709.04 Welder on electron-beam installations.
An exemplary program of the discipline can be used in additional vocational education (in advanced training and retraining programs) and vocational training in the professions of workers: 18329 Welder of reinforcing mesh and frames, 18333 Welder of refractory metal products, 18350 Thermite welder, etc.
1.2. The place of discipline in the structure of the main professional educational program: discipline is included in the professional cycle.
1.3. The goals and objectives of the discipline are the requirements for the results of mastering the discipline:
As a result of mastering the discipline, the student should have practical experience:
Perform gas welding of medium complexity and complex assemblies, parts and pipelines from carbon and structural and simple parts from non-ferrous metals and alloys;
Performing manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys;
Performing automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels;
Performing oxygen, air-plasma cutting of metals of rectilinear and complex configuration;
Reading blueprints of medium complexity and complex metal structures;
Organization of the safe performance of welding work at the workplace in accordance with the sanitary and technical requirements of labor protection.
As a result of mastering the discipline, the student should be able to:
Perform technological methods of manual arc, plasma and gas welding, automatic and semi-automatic welding using a plasma torch of parts, assemblies, structures and pipelines of varying complexity from structural and carbon steels, cast iron, non-ferrous metals and alloys in all spatial positions of the seam;
Perform automatic welding of critical complex building and technological structures operating in difficult conditions;
Perform automatic welding in a shielding gas environment with a non-consumable electrode of hot-woven strips made of non-ferrous metals and alloys under the guidance of an electric welder of a higher qualification;
Perform automatic microplasma welding;
Perform manual oxygen, plasma and gas rectilinear figured cutting and cutting with petrol and kerosene cutting machines on portable, stationary and plasma cutting machines of parts of varying complexity from various steels, non-ferrous metals and alloys according to marking;
Perform oxygen-flux cutting of parts made of high-chromium and chromium-nickel steels and cast iron;
Perform oxygen cutting of ship objects afloat;
Perform manual electric arc air planing of varying complexity of parts made of various steels, cast iron, non-ferrous metals in various positions;
Perform preliminary and concomitant heating when welding parts in compliance with the specified mode;
Set welding modes according to the specified parameters;
Use materials and energy economically, handle tools, equipment and equipment with care;
Comply with labor safety and fire safety requirements;
As a result of mastering the discipline, the student should know:
Arrangement of serviced electric welding and plasma cutting machines, gas welding equipment, automatic machines, semi-automatic devices, plasma torches and power supplies;
Properties and purpose of welding consumables, rules for their selection;
Marks and types of electrodes;
Rules for setting welding modes according to specified parameters;
Features of welding and electric arc planing on alternating and direct current;
The technology of welding products in chambers with a controlled atmosphere;
Basics of electrical engineering within the scope of the work performed;
Methods for obtaining and storing the most common gases used in gas welding;
Gas cutting process of alloy steel;
Cutting mode and gas consumption during oxygen and gas-electric cutting;
Rules for reading drawings of welded spatial structures, welded assembly units and mechanisms;
Manufacturing technology of welded standard machine-building parts and structures;
Materials and regulatory documents for the manufacture and installation of welded structures;
The essence of the technology of welded parts and structures;
Requirements for the organization of the workplace and the safety of welding.
Total - 668 hours, including:
maximum student workload 86 hours, including:
obligatory classroom teaching load of the student 65 hours;
student's independent work 21 hour;
educational and industrial practice - 582 hours
2. RESULTS OF MASTERING THE PROFESSIONAL MODULE
The result of mastering the professional module is the mastering of the types of professional activities by students AccomplishmentsGAS WELDING TECHNOLOGY , including professional (PC) and general (OK) competencies.
The code
Name of learning outcomes
PC 2.1
Perform gas welding of medium complexity and complex assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys.
PC 2.2
Perform manual arc and plasma welding of medium complexity and complex machine parts and assemblies. Structures and pipelines and structural and carbon steels, cast iron, non-ferrous metals and alloys.
PC 2.3
Perform automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels.
PC 2.4
Perform oxygen, air-plasma cutting of metals of straight and complex configuration.
PC 2.6
Ensure the safe performance of welding work at the workplace in accordance with the sanitary and technical requirements of labor protection.
OK 4
Search for information necessary for the effective performance of professional tasks.
OK 5
Use information and communication technologies in professional activities.
OK 6
Work in a team, communicate effectively with colleagues, management, customers.
OK 7
Perform military duty, including with the application of acquired professional knowledge (for young men).
3. STRUCTURE and content of the professional module
3.1. Thematic plan of the professional module (option for open source software)
professional competencies
Names of sections of the professional module
Total hours
The amount of time allotted for the development of an interdisciplinary course (courses)
Practice
Mandatory classroom workload of a student
Independent work of the student
educational,
Production
(according to the specialty profile),**
Total,
including laboratory work and practical exercises,
Total,
including term paper (project),
PC 2.1- 2.6
Section 1. Performance of gas welding and plasma works.
PC 2.1- 2.6
Section 2 The essence of the process of automatic submerged arc welding and in shielding gases.
Industrial practice, (according to the profile of the specialty), hours
Total:
3.2. Thematic plan and content of the discipline " GAS WELDING TECHNOLOGY»
Name of sections of the professional module (PM), interdisciplinary courses (IDC) and topics
Watch volume
Level of development
1
2
3
4
Section 1 PM 02.
MDK 02.01. Performance of gas welding and plasma works
Introduction
General information. Classification of thermal cutting methods
Topic 1.1. Gas welding and cutting of metals
Brief information about welding and cutting metals
Materials used in gas welding and metal cutting
Equipment, fixture and tool
Gas welding technology
Oxy cutting technology
Technology of welding cast iron and non-ferrous metals
Gas welding and brazing
Quality control of welds and joints
Safety and fire prevention measures
Modern surfacing methods
warming flame
Separation flame cutting technology for steel
Methods for improving productivity and cutting quality
Separation oxyfuel cutting
Laboratory works:Acquaintance with the essence of processes, methods, equipment and technological capabilities of gas welding of metals and alloys
Workshops: Not provided.
Topic 1.2. Plasma and microplasma welding, and arc cutting
The essence and technological capabilities of the compressed arc
Compressed Arc Welding Technology
Microplasma welding
Features of the plasma welding process
Plasma torch operation
Oxy-arc and air-arc cutting
Plasma arc cutting
Laboratory works: Not provided.
Workshops: For gas welding of mild steel in the lower position, describe the technology, select the welding mode, and calculate the total consumption of combustible gas.
Independent work in the study of section 1 PM 2
Performing a computer presentation on the topic "What is the difference between a compressed arc of direct action and a compressed arc of indirect action."
Self-study: SP 105-34-96 Welding and quality control of welded joints
GOST 14782-86 Non-destructive testing. Seams are welded. GOST 12.3.003-86 System of Occupational Safety Standards work electric welding safety requirements
Making an abstract on the topic: "Disadvantages of gas-flame welding arising from the slow heating of the welded edges."
Educational practice
Types of jobs.
Reading working drawings of welded building metal structures of varying complexity.
Ensuring the safe performance of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements.
Implementation of technological methods of gas welding of butt joints of pipes.
Implementation of technological methods of gas welding of lap joints.
Implementation of technological methods of gas-flame surfacing of pipe butt joints.
Implementation of technological methods of gas-flame surfacing of overlapping sheet joints.
Section 2 The essence of the process of automatic submerged arc welding and in shielding gases
MDK 02.02. The essence of the process of automatic submerged arc welding and in shielding gases
Topic 2.1 Welding in shielding gases
The essence and varieties of arc welding in shielding gases
Welding consumables
Equipment and apparatus for gas-shielded arc welding
Technology of mechanized and automatic gas-shielded arc welding
Laboratory works: The study of the features of methods of arc welding in shielding gases, welding equipment and welding techniques.
Workshops: Not provided.
Topic 2.2. Automatic submerged arc welding
The essence and features of the submerged arc welding process
Submerged Arc Equipment
Submerged Arc Welding Materials
Submerged Arc Technology
Features of submerged arc welding of steels of various alloying systems
Laboratory works: Choice of gas welding parameters. Position
mouthpiece.
Workshops: Cast iron welding technology
Independent work in the study of section 2 PM 02.
Performing a computer presentation on the topic "Causes of the explosion of acetylene"
Independent study: SP53-101-98 Code of rules for design and construction.
Production and quality control of steel building structures. GOST 14782-86 Non-destructive testing. Seams are welded.
Approximate topics for homework
Systematic study of class notes, educational and special technical literature (on
paragraph, chapters of tutorials compiled by the teacher).
Preparation for laboratory and practical work using the teacher's methodological recommendations, registration of laboratory and practical work, reports and preparation for their defense.
Making an essay on the topic: "Chemical interaction and metallurgical processes in gas welding"
Educational practice
Types of jobs
Flame type selection and flame power adjustment, position selection
torch mouthpiece when welding metal of various thicknesses;
Melting of the base metal and formation of a weld without filler
material due to flanging;
Gas surfacing and welding of mild steel plates in the lower
seam position;
Gas cladding and welding of mild steel plates in vertical
seam position;
Gas surfacing and welding of mild steel plates in horizontal
seam position;
Welding of simple products.
Internship
Types of jobs
Fabrication by gas welding of structures from thin sheet metal and metal
box section;
Repair of agricultural machines and mechanisms, welding of machine parts and
gas welding mechanisms;
Welding of pipes "visor", welding of rotary joints of pipes;
Production of registers from pipes Ø25, 33, 50, 76 mm, gas welding of fixed
pipe joints;
Gas welding of simple parts made of carbon and structural steels;
Gas welding of complex structures and pipelines made of carbon and
structural steels, hot straightening of complex and critical
structures.
Total
To characterize the level of mastering the educational material, the following designations are used:
1. - introductory (recognition of previously studied objects, properties);
2. - reproductive (performing activities according to a model, instructions or under guidance)
3. - productive (planning and independent implementation of activities, solving problematic tasks)
4. conditions for the implementation of the discipline program
4.1. Minimum Logistics Requirements
The implementation of the discipline program requires the presence of a study room "" and a welding workshop.
Study room equipment:
Seats by the number of students;
Teacher's workplace;
A set of teaching and visual aids " Technologies of electric arc welding and metal cutting»;
3D models of welding tubular structures;
Samples of assembly and welding of structures (beam, lattice, sheet, reinforcing meshes and frames);
Samples of typical parts (separable, one-piece, keyed, slotted, etc.).
Samples of defects in welded joints (beads, undercuts, craters, burns, etc.)
Technical training aids:
Computer with licensed software and multimedia projector.
Workshop equipment:
by the number of students:
Workplace of a gas welder;
Workplace for an electric welder (welding booths with an individual transformer TDM - 31 - U2 and lighting);
Ballast rheostats for current power regulation;
Welding rectifier VD - 401 UZ;
Acetylene generator ASP - 10;
A set of cutters and burners;
Set of working tools;
Measuring and marking tool;
to workshop:
Oven for drying electrodes;
Thermal case;
Magnetic holders of the return wire;
Electrode holder;
Double-sided grinding and grinding machine;
Drilling machine;
Shield for connecting external consumers to 220V;
Shield for connecting consumers from an external current source;
Electric grinder;
Lever and chair scissors;
Exhaust and supply ventilation.
when studying the course, excursions to industrial enterprises are useful to study the experience of transport systems, automation of blank production operations, and methods for reducing welding deformations.
after studying the course in the process of passing production practices, the main provisions of the studied discipline are fixed.
4.3. General requirements for the organization of the educational process
Mastering the professional module precedes the academic disciplines and modules:
Fundamentals of engineering graphics.
Fundamentals of materials science.
Occupational Safety and Health.
Basics of production automation.
Fundamentals of electrical engineering.
Tolerances and technical measurements.
4.4. Staffing of the educational process
The requirement for the qualification of pedagogical (engineering and pedagogical) personnel providing training in an interdisciplinary course (courses): the presence of higher professional education, corresponding to the profile of the module " Defects and methods of testing welded seams ", specialty 150709.02 Welder (electric welding and gas welding).
Requirements for the qualification of teaching staff who manage the practice.
Engineering and teaching staff: graduates - teachers of interdisciplinary courses, as well as general professional disciplines.
Masters: the presence of 5-6 qualification category with a mandatory internship in professional organizations at least 1 time in 3 years.
Experience in organizations in the relevant professional field is mandatory.
4.5. Information support of training
Main sources:
M.D. Bannov; Yu.V.Kazakov; M.G. Kozulin "Welding and cutting of materials" - a textbook; M .: publishing center "Academy", 2001. – 400pp.
IN AND. Maslov "Welding" - a textbook; M .: publishing center "Academy", 2004. - 240pp.
N.I. Nikiforov, S.P. Neshumova, I.A. Antonov "Handbook of a gas welder and a gas cutter" - a training manual; M .: publishing center "Academy", 2005. - 240pp.
V.V. Ovchinnikov "Gas cutter" - a textbook; M .: publishing center "Academy", 2007. – 50pp.
V.V. Ovchinnikov "Gas welder" - a textbook; M .: publishing center "Academy", 2007. – 50pp.
V.V. Ovchinnikov "Electric welder on automatic and semi-automatic machines" - a textbook; M .: publishing center "Academy", 2007. – 50pp.
GOST 12.3.003-86* System of labor safety standards "Electric welding works"
GOST 12.1.004-91 Fire safety general requirements.
Additional sources:
1. Glizmanenko D.A. Gas welding and cutting of metals. - M.: Higher. school, 1969.-304s.
2. Khrenov K.K. Welding, cutting and soldering of metals - M.: Mashinostroenie, 1973.-408 p.
3.
Steklov O. I. Fundamentals of welding production - M .: Vyssh. school, 1986.-224 p., ill.
4.
Rybakov V.M. Welding and cutting of metals-M.: Higher. school, 1979.-214 p., ill.
5.
Kitaev A.M., Kitaev Ya.A. Arc welding-M.: Mashinostroyeniye. 1983.-272 p. ill.
6.
Shebeka L.P. Industrial training of electric and gas welders - M.: Vyssh. school, 1984.-167 p., ill.
7.
Gevorkyan V.G. Fundamentals of welding business - M .: Vyssh. school, 1985.-168 p., ill.
8.
Dumov S.I. Technology of electric fusion welding - L .: Mashinostroenie. 1987.-461s., Ill.
Electronic resources: www.kisar.ru - Equipment, materials, gases.
– Welding equipment, welding machines, welding semiautomatic devices.
5. Control and evaluation of the results of the development of the Discipline
Results (mastered professional competencies)
PC 2.1. Perform gas welding of medium complexity and complex assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys.
Determine the sequence of technological operations of welding;
Select modes and methods of pipe welding;
Select types of welding and equipment
Current control in the form:
Protection of practical classes;
Test papers on the topics of the professional module;
Comprehensive exam on the professional module
PC 2.2. Perform manual arc and plasma welding of medium complexity and complex machine parts and assemblies. Structures and pipelines and structural and carbon steels, cast iron, non-ferrous metals and alloys.
Clearly define the types and methods of permanent connection of parts and assemblies;
Classify materials for the manufacture of welded structures and determine steel grades;
Types of welded structures; materials from which welded structures are made
PC 2.3. Perform automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels.
Appointment of pipe structures; materials used in the manufacture of pipe structures; ways of welding branch pipes and flanges;
Types of butt joints of tubular structures;
The procedure for applying welds
PC 2.4. Perform oxygen, air-plasma cutting of metals of straight and complex configuration.
Profile of typical parts, purpose;
Profile and components of the assembly unit;
Application of typical parts and assembly units;
The sequence of welding units and the procedure for applying welds in the manufacture of spatial structures;
Appointment of sheet structures; types of rolled products used for manufacturing;
The sequence of assembly and welding of sheet structures; welding methods and equipment
Make a selection of materials and specifications according to drawings and diagrams;
Classify according to drawings and connection diagrams, determine their characteristics, methods and technology of execution
Ensure the safe performance of welding work at the workplace in accordance with the sanitary and technical requirements of labor protection.
Terminology, regulatory documentation, the structure of control and management of labor protection;
Personal protective equipment against harmful production factors
Forms and methods of monitoring and evaluating learning outcomes should allow students to check not only the formation of professional competencies, but also the development of general competencies and the skills that provide them.
Outcomes (learned general competencies)
Main indicators for evaluating the result
Forms and methods of control and evaluation
Search for information necessary for the effective performance of professional tasks.
Effective search for the necessary information;
Use of various sources, including electronic
Interpretation of the results of observations of the activities of the student in the process of mastering the educational program
Use information and communication technologies in professional activities.
Work on modern technological equipment
Work in a team, communicate effectively with colleagues, management, customers.
Interaction with students, teachers and masters during training
Perform military duty, including with the application of acquired professional knowledge (for young men).
Use of professional knowledge during military service
Developers:
GBOU NPO PL No. 13 Lecturer of special disciplines Zhitkova A.A.
Experts:
(place of work) (position held) (initials, surname)
____________________ ___________________ _________________________
(place of work) (position held) (initials, surname)
Section of a professional module is a part of the program of a professional module, which is characterized by logical completeness and is aimed at mastering one or more professional competencies. A section of a professional module may consist of an interdisciplinary course or part of it and the corresponding parts of educational and industrial practices. The name of a section of a professional module should begin with a verbal noun and reflect the totality of competencies, skills and knowledge being mastered.
** Industrial practice (according to the profile of the specialty) can be carried out in parallel with the theoretical studies of the interdisciplinary course (dispersed) or in a specially allocated period (concentrated).
Methodical development: lesson on the topic "Welding transformers".
Outline of the lesson "Welding transformers"
Lesson Objectives:
Educational:
To study the design features and principle of operation of welding transformers;
To consolidate knowledge about the external current-voltage characteristics of welding equipment;
To generalize and systematize knowledge about the tools of an electric welder;
Contribute to the development of skills for solving practice-oriented problems.
Developing:
To develop in students the ability to highlight the main thing in the material being studied;
Contribute to the formation of the ability to apply the acquired knowledge in practical activities
Educational:
- to promote the formation of students' respect for the chosen profession;
- contribute to the education of purposefulness;
- show the connection of the subject with industrial practice;
General competencies:
OK 1. Understand the essence and social significance of your future profession, show a steady interest in it.
OK 2. Organize their own activities, based on the goal and ways to achieve it, determined by the head.
OK 3. Analyze the working situation, carry out current and final control, evaluation and correction of their own activities, be responsible for the results of their work.
OK 4. Search for information necessary for the effective performance of professional tasks.
OK 6. Work in a team, communicate effectively with colleagues, management, clients.
OK 7. Perform military duty, including using the acquired professional knowledge.
Professional competencies:
PC 2.1. Perform gas welding of medium complexity and complex assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys.
PC 2.2. Perform manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys.
PC 2.3. Perform automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels.
PC 2.4. Perform oxygen, air-plasma cutting of metals of straight and complex configuration.
PC 2.6. Ensure the safe performance of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements.
Lesson type: primary learning lesson
Teaching methods:
- explanatory and illustrative(explanation, show)
-partial search ( solving cognitive problems and problem situations)
Means of education:
Video "Automation of welding production"
Presentation "Welding transformers";
Slides and task cards “Characteristics of the main types of welding transformers”, “Transformer device TSK-500”, “Commandments of a welder”;
Tests with tasks
During the classes:
Slide 1 "The topic of the lesson"
1. Organizational moment:
Greeting students; test readiness for the lesson.
2.Goal setting and motivation. Emotional mood.
Teacher:
Today our lesson will be held under the motto: "Modern technical progress is inextricably linked with the improvement of welding production"
Showing the video "Automation of welding production"
Slide 2: What do we know?
Teacher: We will continue to study the topic "Equipment of the welding station" and consolidate our knowledge on the topic "Requirements for power sources of the welding arc."
Slide 3 lesson plan
Slide 4 "Lesson goals"
Teacher: Please write the plan and objectives of today's lesson in your notebook.
Slide 5 What do we know?
3. Actualization of basic knowledge
(form of conducting - professional dictation)
Teacher: I will dictate the beginning of the sentence to you, and you need to add its ending to your notebook, then check your answers with the answers of your friend. Find errors, if any.
Slide 5 "External characteristics of power supplies"
Teacher: You and I know that current sources for powering the welding arc must have a special external characteristic. What is called the external characteristic of the power supply?
: The external characteristic of the power supply is the dependence of the voltage at its output terminals on the load current.
Teacher: What are the external characteristics of power supplies?
Estimated student response: steeply dipping, gently dipping, hard, increasing.
Teacher: What are the characteristics of welding transformers?
Estimated student response: Transformers have a steeply falling external characteristic.
4. Work on the topic of the lesson
Slide 6 "Characteristics of the main types of welding transformers"
Teacher: Welding transformers are divided into two groups according to the principle of operation and design: transformers with normal magnetic dissipation and transformers with increased magnetic dissipation.
Transformers STN, STE, TSD are transformers with normal magnetic dissipation - they are used for automatic and semi-automatic submerged arc welding.
The principle of operation of transformers with increased magnetic dissipation is based on the use of magnetic shunts, moving coils or stepped (turn) regulation.
Transformers with moving coils TS, TSK, TD are single-station transformers. TD transformers are currently being replaced by more advanced TDM transformers.
Now the most widely used welding transformers are TS and TSK.
Transformers with magnetic shunts OSTA, STAN, STSH are not currently produced, but are still quite often used in production.
Transformers with magnetizable shunt and step regulation are used for automatic submerged arc welding. These are TDF 1001 and TDF 2001 transformers.
So, we got acquainted with the types of transformers that our industry produces. Please write in your notebook how transformers are classified. Specifically, we will study each type of transformer in the following lessons.
Slide 7 "Transformer device TSK-500"
Explanation of the device of the TSK-500 transformer on the layout.
Teacher: The TSK-500 transformer consists of: - a core-magnetic core made of transformer steel;
Primary and secondary windings are placed on the core;
The transformer is connected to an alternating current network with a voltage of 380V;
The primary winding is fixed motionless, and the secondary moves along the core, adjusting the amount of welding current.
To move the coils, a vertical screw with a tape thread is used, equipped with a handle.
The principle of operation of the welding transformer is simple (explanation on the layout):
When the coils approach each other, the magnetic leakage and the inductive resistance of the windings caused by it decreases, and the welding current increases;
When the coils move away from each other, most of the magnetic flux is dissipated, i.e., it does not pass completely through the steel core, but partially goes through the air space surrounding them. This increases the E.D.S. self-induction directed against the main E.D.S., i.e., it increases the inductive resistance of the windings, which leads to a decrease in the current in the welding circuit;
The magnitude of the welding current is regulated by moving the coils along the magnetic circuit;
To accurately determine the magnitude of the welding current, an ammeter is used;
The capacitor serves to improve the power factor.
I ask you to name the main parts of the welding transformer and show on the layout: magnetic circuit, primary and secondary coils.
Teacher: How is the welding current adjusted?
Estimated student response: The magnitude of the welding current is regulated by moving the primary coil along the magnetic circuit.
Teacher: At what position of the coils will the current be greater?
Estimated student response: When the coils approach each other, the inductive resistance of the windings decreases, and the strength of the welding current increases.
Teacher: What is a capacitor used for?
Estimated student response: The capacitor is used to improve the power factor.
Slide 8 "Rules for the operation of welding transformers"
Teacher: When servicing welding transformers, the following rules must be observed:
Regularly check the condition of the welding and grounding circuit, tightening of the fasteners of the core and casing;
Lubricate the adjusting mechanism more often;
When moving the apparatus, use the handles or lifting rings of the transformer casing.
Please copy the table from the screen "Rules for the operation of welding transformers" into your notebook
Slide 9 "Note to the welder"
Teacher: And now, we will consider what type of service and in what terms it is necessary to carry out maintenance and overhaul of welding transformers (students are involved in the discussion)
Slide 10 "Solution of the situational problem"
5. Consolidation of the studied material
Teacher: To consolidate the material covered, you are offered the following tasks:
1. In the cards - tasks "Device of a welding transformer" mark the correct answer. You can check your answers with the correct answers on the red cards that are on your tables.
2. Safety precautions when working with welding equipment you repeat every lesson in industrial training and in the lessons of our subject. We studied the rules for providing first aid at the very beginning of the school year. The second task offers you a test in which you need to analyze the situations that may arise during the performance of welding work and give the correct answer. You need to check your answers with the answers of your comrades and find errors, if any, (a brief analysis of the answers to the tests with the involvement of students for discussion).
Slide 11 "Five commandments of a welder"
5. Summing up the work
Teacher: And, as a result of our work, the commandments of the welder when working with welding equipment.
(the help of students who read the commandments aloud and comment on them).
Slide 12 "What have you learned and why do you need this knowledge"
(a brief survey of students on the topic studied)
(students compare the objectives of the lesson and its result, evaluate their work, draw conclusions, argue the answers).
Behavior of the results (voicing the names of the students who worked most actively in the lesson).
Homework: write a summary of the last lesson
6. Final word of the teacher
Today at the lesson, studying the design features and principle of operation of welding transformers, we were convinced of the importance of theoretical knowledge for mastering a profession, for developing professional and general competencies.
I hope that the knowledge gained will help you in practice when working with welding equipment, because the modern labor market requires a specialist with high professional mobility, the ability to quickly adapt to new working conditions, and who are confident in their professional knowledge.
Conclusion
In the modern world, welding is of fundamental importance in the construction and creation of many structures without which it is difficult to imagine everyday life: cars, houses, bridges, etc.
The welding process requires serious knowledge and skills, you can’t just take a welding machine and put a seam.
A professional welder will have to master the technology of melting metals, the methods and principles of operation of the units and equipment used. He will have to understand the physical essence of all ongoing processes, to know the features of welding different types of metals.
And taking into account the fact that technologies do not stand still and are constantly evolving, the welder is required to constantly improve their skills and study modern promising trends.
The flexibility of welding production is determined primarily by the versatility of welding equipment and the high qualification of welders.
Bibliography
1. Gerasimenko electric gas welding. - Rostov / ND: Phoenix, 2006.
2. Borilov manual arc welding. - Rostov/ND: Phoenix, 2008.
3. http://www. profvibor. en/catalog/article. php
4. http://www. edu. ru/abitur/act.86/index. php
Applications.
Technical dictation
Exercise: complete the sentence
No. p / p | Beginning of a sentence | Sample response |
A specially equipped place for welding is called ... | welding post |
|
The main equipment of the welding post are… | power supplies |
|
The power source of the welding arc on alternating current is ... | welding transformer |
|
To clamp the electrode and supply welding current to it, ... | electrode holder |
|
To protect the eyes and skin of the face from arc rays, metal spatter and slag, ... | filters or protective glasses |
|
To supply current from the power source to the electrode holder and the product, ... | welding wires |
|
The dependence of the voltage at the output terminals of the power supply on the current in the electrical circuit is called ... | external characteristic |
|
Welding arc power sources must have an external characteristic ... | steeply falling sloping, hard, increasing |
|
The welding current, voltage and power at which the source does not overheat in the maximum design mode are called ... | nominal |
|
GOST establishes the maximum open-circuit voltage for AC power supplies, which should be no more than ... | ||
GOST establishes the maximum open-circuit voltage for DC power supplies, which should be no more than ... |
Test
"Safety when working with welding equipment"
During the welding work with the welder, one of the cases occurred. Your actions in this case: (choose the correct answer)
No. pp | Exercise | Sample response |
In case of inflammation of the mucous membrane of the eyes, it is necessary: 1. call a doctor; 2. take the victim to fresh air; 3. put on the eyes a compress soaked in a weak solution of baking soda or a 2% solution of boric acid; 4. transfer the victim to a dark room | Apply a compress to the eyes soaked in a weak solution of baking soda or a 2% solution of boric acid |
|
In case of gas poisoning, it is necessary: 1. take the victim to fresh air; 2. drink hot tea; 3. if necessary, make artificial respiration; 4. give oxygen to breathe from the oxygen bag. | Remove victim to fresh air |
|
In case of electric shock, the salvation of the victim depends on: 1. the strength of the current from which the defeat occurred; 2. from the speed of releasing it from the current and quick and correct actions when providing first aid. | From the speed of releasing it from the current and quick and correct actions when providing first aid |
|
Determine the sequence of actions for first aid in case of electric shock: | 1. turn off that part of the installation that the victim touches; 2. to separate the victim from current-carrying parts, you can take his clothes if it is dry (jacket, coat floors) |
Unified Tariff and Qualification Directory of Works and Professions of Workers (ETKS), 2019
Part No. 1 of issue No. 2 ETKS
The issue is approved by the Decree of the Ministry of Labor of the Russian Federation of November 15, 1999 N 45
(as amended by the Order of the Ministry of Health and Social Development of the Russian Federation of November 13, 2008 N 645)
gas welder
§ 6. Gas welder of the 2nd category
Job Description. Tacking of parts, products from structures in all spatial positions of the weld. Preparation of joints for welding and cleaning of seams after welding. Preparation of gas cylinders for work. Maintenance of portable gas generators. Gas welding of simple parts, assemblies and structures made of carbon steels in the lower and vertical position of the weld. Surfacing of simple details. Elimination of shells and cracks by surfacing in simple castings. Heating of structures and parts during straightening.
Must know: device and principle of operation of serviced gas welding machines, gas generators, oxygen and acetylene cylinders, reducing devices and welding torches; types of welds and joints; rules for the preparation of simple products for welding; types of sections and designations of welds in the drawings; handling rules and basic properties of gases and liquids used in welding; permissible residual gas pressure in cylinders; purpose and brand of fluxes used in welding; causes of defects in welding, characteristics of the gas flame; colors of cylinders; arrangement of communications for supplying gas to places of consumption and rules for connecting to them.
Work examples
1. Box bolts, column bolts and center bolts - surfacing of working places.
2. Necks of gas tanks of cars - soldering.
3. Details of side awning frames - tacking and welding.
4. Portholes and covers - welding.
5. Cones of oil pumps and filters of automobiles - surfacing of shells in castings.
6. Protective covers - welding.
7. Gutter covers for undercar lighting - welding.
8. Brackets for attaching the muffler to the car frame - surfacing of cracks.
9. Flasks - welding ears.
10. Pallets for machines - welding.
11. Receiving pipes - welding of safety nets.
12. Car fender reinforcements - welding.
13. Corner sheets of the inner and outer sheathing of the tram - welding of cuts.
14. Clamps of hydraulic mechanisms of dump trucks - welding.
§ 7. Gas welder of the 3rd category
Job Description. Gas welding of medium complexity assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys in all spatial positions of the weld, except for ceiling ones. Elimination of shells and cracks in parts and assemblies of medium complexity by surfacing. Hardfacing of simple parts. Preliminary and concomitant heating when welding parts in compliance with the specified mode.
Must know: arrangement of serviced gas welding equipment; structure of welds and methods of their testing; basic properties of welded metals; rules for preparing parts and assemblies for welding and surfacing; rules for choosing a metal heating mode depending on its grade and thickness; causes of internal stresses and deformations in welded products and measures to prevent them; basic technological methods of welding and surfacing of parts made of steel, non-ferrous metals and cast iron.
Work examples
1. Fittings made of tin bronzes and silicon brass under test pressure up to 1.6 MPa (15.5 atm.) - elimination of defects by welding.
2. Crankshafts and camshafts of automobiles - deposition of defective semi-finished forgings with special steels.
3. Mufflers - welding.
4. Internal combustion engines (fuel and air system) - welding.
5. Car parts (oil heater necks, box crankcase, crankcase covers) - elimination of defects by welding.
6. Bronze brake discs - elimination of shells.
7. Casings of elastic couplings - welding.
8. Rear axles of cars - elimination of shells in castings.
9. Facing of a car radiator - elimination of cracks.
10. Level regulator floats (fittings) - welding.
11. Frame profile windows of the driver's cabin - welding.
12. Frames of pantographs - pattern welding.
13. Reservoirs for non-flammable liquids and brake systems of rolling stock - welding.
14. Bulkhead shaft seals - fusing of the body and pressure sleeve.
15. Rear wheel hubs, rear axle and other car parts - malleable iron soldering.
16. Ventilation pipes - welding.
17. Copper exhaust pipes - welding.
18. Tied fire tubes in boilers and superheater tubes - welding.
19. Pipes of the brake line - welding.
20. Non-pressure pipelines for water (except for main ones) - welding.
21. Pipelines of external and internal networks of water supply and heating - welding in workshop conditions.
22. Brass (open) gasifier balls - welding.
§ 8. Gas welder of the 4th category
Job Description. Gas welding of complex parts, structures and pipelines from carbon and structural steels and parts of medium complexity from non-ferrous metals and alloys in all spatial positions of the weld. Surfacing with hard alloys using ceramic fluxes in a protective gas of parts and assemblies of medium complexity. Elimination of defects in large cast iron and aluminum castings for machining and test pressure welding. Elimination of shells and cracks by welding in machined parts and assemblies. Hot straightening of complex structures.
Must know: methods for establishing metal welding modes depending on the configuration and thickness of the parts to be welded; methods of welding non-ferrous alloys, cast iron; testing of welds from non-ferrous metals and alloys; basic rules for the weldability of metals; general concepts of methods for obtaining and storing the most common gases used in gas welding (acetylene, hydrogen, oxygen, propane-butane, etc.); types of defects in welds and methods for their prevention and elimination; rules for reading drawings.
Work examples
1. Shut-off valves made of non-ferrous metals and alloys under test pressure over 1.6 to 4.9 MPa (over 15.5 to 48.4 atm) - elimination of defects by welding.
2. Babbit filling of bearings - welding.
3. Cylinder blocks of car engines - elimination of shells in castings.
4. Crankshafts - fusing of necks.
5. Bronze and brass bushings - hardfacing on steel bearings.
6. Parts and assemblies made of non-ferrous metals - welding followed by pressure testing.
7. Spool frames, pendulums - welding.
8. Teeth of cast iron gears - hardfacing.
9. Thin-walled non-ferrous alloy products (air cooler covers, end shields, turbine generator fans) - body welding with brass or silumin.
10. Large cast iron products (frames, pulleys, flywheels, gears) - elimination of cavities and cracks.
11. Crankcases of large motors and housings of mechanical transmission of diesel locomotives - welding.
12. Coils of poles of electrical machines from strip copper - welding of jumpers.
13. Cases of brush holders, segments of reversers, rotors of electric motors - hardfacing.
14. Aluminum furniture - welding.
15. Heaters - welding of a holder, a hot-water pipe with a holder, a cone, rings and flanges.
16. Pistons of pneumatic hammers - elimination of shells and cracks.
17. Bearings and bushings, axle boxes, drawbars - fusing along the frame and fusing cracks.
18. Porthole frames made of aluminum alloys - welding.
19. Air trolleybus tanks - welding.
20. Single and twisted metal meshes for pulp and paper production - soldering the ends with silver solder.
21. Tubes for sensors with a radioactive isotope - elimination.
22. Pipe elements of boilers, armor plates, etc. - hot editing.
23. Pipelines of external and internal networks of water supply and heating - welding at installation.
24. Technological pipelines (category 5) - welding.
25. Pipelines of external and internal low-pressure gas supply networks - welding in workshop conditions.
26. Brass refrigerators - welding seams for hydrotesting at pressures up to 2.5 MPa (24.2 atm).
27. Balls, floats and tanks made of special aluminum alloys - welding.
§ 9. Gas welder of the 5th category
Job Description. Gas welding of complex parts, assemblies, mechanisms, structures and pipelines made of high-carbon, alloyed, special and corrosion-resistant steels, cast iron, non-ferrous metals and alloys, designed to work under dynamic and vibration loads and under pressure. Surfacing with hard alloys of complex parts, assemblies, structures and mechanisms. Welding and elimination of cracks and cavities in thin-walled products and in products with hard-to-reach places for welding. Heat treatment with a gas burner of welded joints after welding.
Must know: mechanical and technological properties of welded metals, including high-alloy steels, as well as deposited metal; rules for choosing the technological sequence of suturing and welding modes; methods of control and testing of welds; the influence of heat treatment on the properties of the welded joint.
Work examples
1. Blast furnace embrasures - welding of shells and cracks.
2. Shut-off pipeline fittings made of tin bronze and brass (silicon) - welding under test pressure over 5 MPa (48.4 atm).
3. Cylinders, caps, spheres operating in vacuum - welding.
4. Lead baths - welding.
5. Bronze and brass propellers - correction of defects by welding.
6. Details of gas welding equipment - silver soldering.
7. Copper coils - welding.
8. Caissons of open-hearth furnaces (hot repair) - internal welding.
9. Bellows-type expansion joints made of corrosion-resistant steels - soldering.
10. Manifolds of complex configuration of 20 or more parts made of corrosion-resistant steels and heat-resistant steel with macrostructure verification using X-ray - welding.
11. Cast iron bodies, covers, tees, elbows, cylinders - elimination of defects by welding.
12. Steam boilers - cracking.
13. Aluminum and bronze castings, complex and large - surfacing of shells and cracks.
14. Molds - welding in hard-to-reach places.
15. Rotors of electrical machines - welding of short-circuited rings, rods, welding.
16. Complex beds, aprons of large lathes - welding, surfacing of cracks.
17. Tubes for impulse control and automation systems - welding.
18. Pipe elements of steam boilers with pressure up to 4.0 MPa (38.7 atm.) - welding.
19. Pipelines of external and internal low-pressure gas supply networks - welding at installation.
20. Technological pipelines of the 3rd and 5th categories (groups), pipelines of steam and water of the 3rd and 5th categories - welding.
21. Lead pipes - welding.
22. Pipelines of external gas supply networks of medium and high pressure - welding at installation.
23. Brass refrigerators - welding of seams for hydrotesting at pressures above 2.5 MPa (24.2 atm.).
24. Cylinders of internal combustion engines - welding of internal and external shirts.
25. Tires, tapes, compensators for them from non-ferrous metals - welding.
§ 10. Gas welder of the 6th category
Job Description. Gas welding of complex parts, mechanism units, structures and pipelines made of high-carbon, alloyed, special and corrosion-resistant steels, cast iron, non-ferrous metals and alloys, designed to work under dynamic and vibration loads and under high pressure. Surfacing with hard alloys of complex parts, assemblies, structures and mechanisms.
Must know: variety of light and heavy alloys, their welding and mechanical properties; types of corrosion and factors causing it; metallography of welded seams; methods of special tests of welded products and the purpose of each of them.
Work examples
1. Blocks for separation of air-oxygen shops - welding of parts from non-ferrous metals.
2. Parts and assemblies made of non-ferrous metals, operating under pressure over 4.0 MPa (38.7 atm.) - welding.
3. Vacuum and cryogenic tanks, caps, spheres and pipelines - welding.
4. Blades of rotors and stators of turbines - soldering.
5. Wiring impulse turbines and boilers - welding.
6. Pipe elements of steam boilers with pressure over 4.0 MPa (38.7 atm.) - welding.
7. Pipelines of external gas supply networks of medium and high pressure - welding during installation.
8. Technological pipelines of the 1st and 2nd category (groups), as well as steam and water pipelines of the 1st and 2nd categories - welding.
Gas welding is relatively simple, does not require complex, expensive equipment and a source of electricity.
The disadvantage of gas welding is the lower heating rate of the metal compared to the arc welding and the large zone of thermal effect on the metal. In gas welding, the heat concentration is less, and the warping of the parts to be welded is greater.
Due to the relatively slow heating of the metal by the flame and the low heat concentration, the productivity of gas welding decreases with an increase in the thickness of the metal being welded. For example, with a steel thickness of 1 mm, the gas welding speed is about 10 m / h, with a thickness of 10 mm - only 2 m / h. Therefore, gas welding of steel with a thickness of more than 6 mm is less productive than arc welding.
The cost of acetylene and oxygen is higher than the cost of electricity, so gas welding is more expensive than electric welding. The disadvantages of gas welding also include explosion and fire hazards in case of violation of the rules for handling calcium carbide, combustible gases and liquids, oxygen, compressed gas cylinders and acetylene generators. Gas welding is used in the following works: the manufacture and repair of steel products with a thickness of 1-3 mm; welding of vessels and tanks of small capacity, welding of cracks, welding of patches, etc.; repair of cast products made of cast iron, bronze, silumin; welding joints of pipes of small and medium diameters; production of products from aluminum and its alloys, copper, brass and lead; production of units of structures from thin-walled pipes; surfacing of brass on parts made of steel and cast iron; joining malleable and ductile iron using brass and bronze filler rods, low-temperature welding of cast iron.
Almost all metals used in engineering can be joined by gas welding. Cast iron, copper, brass, lead are easier to gas welding than arc welding.
GAS WELDING TECHNIQUE
Gas welding can be used for bottom, horizontal, vertical and ceiling seams. Ceiling joints are the most difficult to perform, since in this case the welder must support and distribute liquid metal over the joint using the pressure of the flame gases. Butt joints are most often performed by gas welding, less often corner and end joints. Gas welding is not recommended for lap and tee joints, as they require intense heating of the metal and are accompanied by increased warping of the product.
Beaded joints of thin metal are welded without filler wire. Intermittent and continuous seams are used, as well as single-layer and multi-layer seams. Before welding, the edges are thoroughly cleaned from traces of oil, paint, rust, scale, moisture and other contaminants.
In table. 10 shows the preparation of edges in gas welding of carbon steels with butt welds.
TORCH MOVEMENT DURING WELDING
The flame of the burner is directed to the metal being welded so that the edges of the metal are in the reduction zone, at a distance of 2-6 mm from the end of the core. It is impossible to touch the molten metal with the end of the core, as this will cause carburization of the bath metal. The end of the filler wire must also be in the reduction zone or immersed in the molten metal bath. In the place where the end of the flame core is directed, the liquid metal is slightly inflated by the pressure of the gases to the sides, forming a recess in the weld pool.
The rate of metal heating during gas welding can be adjusted by changing the angle of the mouthpiece to the metal surface. The larger this angle, the more heat is transferred from the flame to the metal and the faster it will heat up. When welding thick or well-conducting heat metal (for example, red copper), the angle of inclination of the mouthpiece a is taken more than when welding thin or low thermal conductivity. On fig. 86, a shows the angles of inclination of the mouthpiece recommended for left (see § 4 of this chapter) welding of steel of various thicknesses.
On fig. 86b shows the ways to move the mouthpiece along the seam. The main thing is to move the mouthpiece along the seam. Transverse and circular movements are auxiliary and serve to regulate the rate of heating and melting of the edges, and also contribute to the formation of the desired shape of the weld.
Method 4 (see Fig. 86, b) is used when welding thin metal, methods 2 and 3 - when welding metal of medium thickness. During welding, care must be taken to ensure that the pool metal is always protected from the surrounding air by the gases of the flame reduction zone. Therefore, method 1, in which the flame is periodically diverted to the side, is not recommended, since it can oxidize the metal with atmospheric oxygen.
BASIC METHODS OF GAS WELDING
Left welding (Fig. 87, a). This method is the most common. It is used for welding thin and low-melting metals. The burner is moved from right to left, and the filler wire is led ahead of the flame, which is directed to the unwelded section of the seam. On fig. 87, and below is a diagram of the movement of the mouthpiece and wire in the left welding method. Flame power during left welding is taken from 100 to 130 dm 3 acetylene per hour per 1 mm of metal (steel) thickness.
Right welding (Fig. 87, b). The burner is driven from left to right, the filler wire is moved after the burner. The flame is directed to the end of the wire and the welded section of the seam. Transverse oscillatory movements are not produced as often as with left welding. The mouthpiece makes slight transverse vibrations; when welding metal with a thickness of less than 8 mm, the mouthpiece is moved along the axis of the weld without transverse movements. The end of the wire is kept immersed in the weld pool and the liquid metal is mixed with it, which facilitates the removal of oxides and slags. Flame heat is dissipated to a lesser extent and is better utilized than in left hand welding. Therefore, in right-hand welding, the opening angle of the seam is made not 90 °, but 60-70 °, which reduces the amount of deposited metal, wire consumption and warpage of the product from shrinkage of the weld metal.
By right welding, it is advisable to connect metal with a thickness of more than 3 mm, as well as metal of high thermal conductivity with cutting edges, such as red copper. The quality of the seam with the right welding is higher than with the left one, because the molten metal is better protected by the flame, which simultaneously anneals the weld metal and slows down its cooling. Due to the better use of heat, right-handed welding of thicker metal is more economical and productive than left-handed welding - the speed of right-handed welding is 10-20% higher, and gas savings are 10-15%.
Right-hand welding connects steel up to 6 mm thick without beveled edges, with full penetration, without welding on the reverse side. Flame power during right welding is taken from 120 to 150 dm 3 acetylene per hour per 1 mm of metal (steel) thickness. The mouthpiece must be inclined to the metal to be welded at an angle of at least 40°.
For right-hand welding, it is recommended to use a filler wire with a diameter equal to half the thickness of the metal being welded. When welding on the left, a wire with a diameter of 1 mm larger is used than when welding on the right. Wire with a diameter of more than 6-8 mm is not used for gas welding.
Welding with a through roller (Fig. 88). Sheets are installed vertically with a gap equal to half the thickness of the sheet. The flame of the burner melts the edges, forming a round hole, the lower part of which is fused with filler metal to the entire thickness of the metal being welded. Then the flame is moved higher, melting the upper edge of the hole and applying the next layer of metal to the lower side of the hole, and so on until the entire seam is welded. The seam is obtained in the form of a through roller connecting the sheets to be welded. The weld metal is dense, without pores, shells and slag inclusions.
Bath welding. In this way, butt and corner joints of metal of small thickness (less than 3 mm) are welded with a filler wire. When a pool with a diameter of 4-5 mm is formed on the seam, the welder inserts the end of the wire into it and, having melted a small amount of it, moves the end of the wire into the dark, reducing part of the flame. At the same time, he makes a circular motion with the mouthpiece, moving it to the next section of the seam. The new bath should overlap the previous one by 1/3 of the diameter. To avoid oxidation, the end of the wire must be kept in the reduction zone of the flame, and the core of the flame must not be immersed in the bath in order to avoid carburization of the weld metal. Welded in this way (lightweight seams) thin sheets and pipes made of mild and low alloy steel give excellent quality joints.
Multilayer gas welding. This method of welding has a number of advantages compared to a single-layer one: a smaller metal heating zone is provided; annealing of underlying layers is achieved during surfacing of subsequent ones; it is possible to forge each layer of the seam before applying the next one. All this improves the quality of the weld metal. However, multi-layer welding is less productive and requires more gases than single-layer welding, so it is used only in the manufacture of critical products. Welding is carried out in short sections. When applying layers, care must be taken to ensure that the joints of the seams in different layers do not coincide. Before applying a new layer, it is necessary to carefully clean the surface of the previous one from scale and slag with a wire brush.
Welding with an oxidizing flame. This method welds mild steels. Welding is carried out with an oxidizing flame having the composition
To deoxidize the iron oxides formed in this process in the weld pool, wires of the Sv-12GS, Sv-08G and Sv-08G2S grades according to GOST 2246-60 are used, containing increased amounts of manganese and silicon, which are deoxidizers. This method improves productivity by 10-15%.
Welding propane - butane-oxygen flame. Welding is carried out at an increased oxygen content in the mixture
in order to increase the temperature of the flame and increase the penetration and fluidity of the bath. To deoxidize the weld metal, wires Sv-12GS, Sv-08G, Sv-08G2S, as well as wire Sv-15GU (0.5-0.8% aluminum and 1-1.4% manganese) according to GOST are used.
The studies of A. I. Shashkov, Yu. I. Nekrasov and S. S. Vaksman established the possibility of using in this case a conventional low-carbon filler wire Sv-08 with a deoxidizing coating containing 50% ferromanganese and 50% ferrosilicon diluted on liquid glass. The weight of the coating (excluding the weight of liquid glass) is 2.8-3.5% of the weight of the wire. Coating thickness: 0.4-0.6 mm when using wire with a diameter of 3 mm and 0.5-0.8 mm with a diameter of 4 mm. Propane consumption 60-80 l / h per 1 mm of steel thickness, β = 3.5, the angle of inclination of the bar to the metal plane is 30-45 °, the angle of cutting the edges is 90 °, the distance from the core to the bar is 1.5-2 mm, to metal 6-8 mm. This method can weld steel up to 12 mm thick. The best results were obtained when welding steel with a thickness of 3-4 mm. Wire Sv-08 with the specified coating is a full-fledged substitute for more scarce grades of wire with manganese and silicon when welding with propane-butane.
Features of welding various seams. Horizontal seams are welded in the right way (Fig. 89, a). Sometimes welding is carried out from right to left, holding the end of the wire on top and the mouthpiece on the bottom of the tub. The weld pool is placed at a certain angle to the weld axis. This facilitates the formation of the seam, and the metal of the bath is kept from flowing.
Vertical and inclined seams are welded from bottom to top in the left way (Fig. 89, b). With a metal thickness of more than 5 mm, the seam is welded with a double roller.
When welding ceiling seams (Fig. 89, c), the edges are heated until melting (fogging) begins, and at this moment a filler wire is introduced into the bath, the end of which is quickly melted. The bath metal is kept from flowing down by the rod and the pressure of the flame gases, which reaches 100-120 gf/cm 2 . The rod is held at a slight angle to the metal to be welded. Welding is carried out in the right way. It is recommended to use multi-layer seams welded in several passes.
Welding of metal with a thickness of less than 3 mm with flanged edges without filler metal is carried out with spiral (Fig. 89, d) or zigzag (Fig. 89, e) movements of the mouthpiece.
Administration Overall rating of the article: Published: 2011.05.31
Diary of the practice of a student welder who had an internship at the Rostov plant of metal structures "Yuzhtekhmontazh" in 2017.
Diary of educational practice of a 2nd year student of the Professional Lyceum No. 2 of Bataysk Krivoshlykov Alexey Nikolaevich, specialty 150709.02: "Welder (electric welding and gas welding work)". The practice took place from 03/13/2017 to 04/03/2017 at the Rostov plant of metal structures "Yuzhtekhmontazh".
| period | types of jobs | marks |
| 03/13/2017 | Familiarization with the working conditions, passing briefings, studying the rules for the safe performance of welding work, signing an employment contract. | |
| 03/14/2017 | Performing standard plumbing manipulations related to the preparation of metal for welding. | |
| 03/15/2017 - | Arc welding: Alloys and non-ferrous metals; Seams located in the ceiling position; Seams of complex configuration and circular. Studying the features of pipeline welding, performing pipe welding exercises. | |
| 03/17/2017 - | Arc welding of beads at the position of the seam: Lateral; oblique; Horizontal. | |
| 03/21/2017 | Arc welding of plates located in various positions. Arc welding is multilayer, performing welding exercises with an electrode located in an inclined and lying position. | |
| 03/22/2017 | Gas surfacing and welding of non-carbon steel plates in vertical and horizontal positions. Gas welding of simple and complex units. | |
| 03/23/2017 | Automatic and semi-automatic welding of alloys, non-ferrous metals and low alloy steels. | |
| 03/24/2017 | Performing oxygen and oxygen-flux cutting of metals. | |
| 03/27/2017 | Work with copper and its alloys - gas welding. Multilayer gas welding. Cold and hot welding of cast iron, welding of cracks in cast iron products. | |
| 03/28/2017 | Self-preparation of the semi-automatic device for work, arc welding on semi-automatic devices in shielding gas, self-shielding and flux-cored wire. Studying the rules for using two-pole holders when welding from three-phase current. | |
| 03/29/2017 | Arc welding on automatic machines in argon and nitrogen environment. | |
| 03/30/2017 | Welding of copper and aluminum alloys. Study and practical application of welding techniques with twin and beam electrodes. | |
| 03/31/2017 | Study of the drawing of a welded structure. Together with the head of the practice, the manufacture of a metal structure by manual arc welding using a non-consumable and consumable electrode. Application in practice of ways to reduce deforming processes during welding, hot melting of welded structures. | |
| 04/03/2017 | The final day of practice, passing the final test to the head, writing a report and preparing a diary. |
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Abstract: Welding and work of a welder
Graduate work
Welding and welder labor
Introduction
Welding history
Modern technological progress in industry is inextricably linked with the improvement of welding production. Welding as a high-performance process for the manufacture of permanent joints is widely used in the manufacture of metallurgical, chemical and energy equipment, various pipelines, in mechanical engineering, in the production of building and other structures.
Welding is the same necessary technological process as metal processing, cutting, casting, forging. The great technological capabilities of welding have ensured its widespread use in the manufacture and repair of ships, automobiles, aircraft, turbines, boilers, reactors, bridges and other structures. The prospects for welding, both scientifically and technically, are endless. Its application contributes to the improvement of mechanical engineering and the development of rocket science, nuclear energy, and radio electronics.
On the possibility of using "electric sparks" for melting metols as early as 1753. spoke Academician of the Russian Academy of Sciences G.R. Richman in the study of atmospheric electricity. In 1802 Professor. St. Petersburg Military Surgical Academy V.V. Petrov discovered the phenomenon of an electric arc and indicated the possible areas of its practical use. However, it took many years of joint efforts of scientists and engineers aimed at creating energy sources necessary for the implementation of the process of electric welding of metals. A possible role in the creation of these sources was played by discoveries and images in the field of magnetism and electricity.
In 1882 Russian scientist engineer N.N. Benardos, working on the creation of rechargeable batteries, discovered a method for electric arc welding of metals with a non-consumable carbon electrode. He developed a method of arc welding in shielding gas and arc cutting of metals.
In 1888 Russian engineer N.G. Slavyanov proposed to carry out welding with consumable metallurgical electrodes. His name is associated with the development of the metallurgical foundations of electric arc welding, the development of fluxes to influence the composition of the weld metal, and the creation of the first electric generator.
In the mid 1920s. intensive studies of welding processes were started in Vladivostok (V.P. Vologdin, N.N. Rykalin), in Moscow (G.A. Nikolaev, K.K. Okerblom). Academician E.O. Paton, who organized in 1992. laboratory, and then the Institute of Electric Welding (IES).
In 1924-1934 Mainly used manual welding with electrodes with thin ionizing (chalky) coatings. During these years, under the leadership of Academician V.P. Vologdin, the first domestic boilers and hulls of several ships were manufactured. From 1935-1939 began to use thickly coated electrodes, in which the rods were made of alloyed steel, which ensured the widespread use of welding in industry and construction. In the 1940s submerged arc welding was developed, which made it possible to increase the productivity of the process and the quality of welded products, to mechanize the production of welded structures. In the early 1950s at the Institute of Electric Welding. E.O. Paton creates electroslag welding for the manufacture of large-sized parts from cast and forged billets, which has reduced costs in the manufacture of heavy engineering equipment.
Since 1948 methods of arc welding in shielding gases have received industrial application: manual welding with non-consumable electrodes, mechanized and automatic welding with non-consumable and consumable electrodes. In 1950-1952 at TSNIITMash with the participation of MSTU. N.E. Bauman and E.O. Paton Electric Welding Institute developed a high-performance process for welding low-carbon and low-alloy steels in a carbon dioxide environment, which ensures high quality of welded joints.
In the last decade, the creation by scientists of new energy sources - concentrated electron and laser beams - has led to the emergence of fundamentally new methods of fusion welding, called electron beam and laser welding. These welding methods are successfully used in our industry.
Welding was also required in space. In 1969 found by cosmonauts V. Kubasov and G. Shonin, and in 1984 S. Savitskaya and V. Dzhanibekov brought welding, cutting, and soldering of various metals into space.
Gas welding, in which the heat of a burning mixture of gases is used to melt the metal, is also a fusion welding method. The gas welding method was developed at the end of the nineteenth century, when the industrial production of oxygen, hydrogen and acetylene began, and is the main method for welding metals.
The most widely used gas welding using acetylene. At present, the volume of gas welding in industry has been significantly reduced, but it is successfully used in the repair of products made of sheet steel, aluminum and its alloys, in soldering and welding of copper, brass and other non-ferrous metals, gas-thermal cutting is used in modern production processes, for example, in shop conditions and on installation.
Pressure welding includes contact welding, which uses the heat generated in the contact of the parts to be welded when an electric current is passed. There are spot, butt, seam and relief contact welding.
The main methods of resistance welding were developed at the end of XlX. In 1887 N.N. Benardos got a moment on the methods of spot and seam resistance welding between carbon electrodes.
Later, when electrodes made of copper and its alloys appeared, these resistance welding methods became the main ones.
Resistance welding occupies a leading place among mechanized welding methods in a car building when connecting thin-sheet stamped structures of a car body. Butt welding connects the joints of railway rails, joints of main pipelines. Seam welding is used in the manufacture of thin-walled containers. Relief welding is the most highly productive method of reinforcement for building reinforced concrete structures. Capacitor resistance welding is widely used in the radio engineering industry in the manufacture of element base and microcircuits. One of the most developing areas in welding production is the widespread use of mechanized and automatic welding. We are talking about both mechanization and automation of the welding processes themselves (i.e., the transition from manual labor of a welder to mechanized), and complex mechanization and automation, covering all types of robots associated with the manufacture of welded structures (preparation, assembly, etc.) and the creation of flow and automatic production lines. With the development of technology, it becomes necessary to weld parts of various thicknesses from different materials, in connection with this, the set of types and methods of welding used is constantly expanding. Currently, parts are welded with a thickness from several micrometers (microelectronics) to tens of centimeters and even meters (in heavy engineering). Along with structural carbon and low-carbon steels, it is increasingly necessary to weld special steels, light alloys and alloys based on titanium, molybdenum, chromium, zirconium and other metals, as well as dissimilar materials.
In conditions of continuous complication of structures and an increase in the volume of welding work, the correct training - theoretical and practical - of qualified workers - welders, plays an important role.
1.1 Classification of types of welding
There are more than 150 types of welding processes. GOST 19521-74 classifies welding processes according to the main physical, technical and technological features.
The basis of classification by physical characteristics is the type of energy used to obtain a welded joint. According to physical features, all welding processes are classified into one of three classes: thermal, thermomechanical, and mechanical.
Thermal class - all types of fusion welding carried out using thermal energy (gas, arc, electroslag, plasma, electron beam and laser).
Thermomechanical class - all types of welding carried out using thermal energy and pressure (contact, diffusion, forging, gas and arc pressing).
Mechanical class - all types of welding, pressure, visible using mechanical energy (cold, friction, ultrasonic and explosion).
According to technical features, welding processes are classified depending on the method of protecting the metal in the welding zone, the continuity of the process and the degree of its mechanization.
1.2 High-performance types of RDS
To facilitate the work of the welder and to increase labor productivity, various high-performance types of welding are used.
Welding with an electrode beam - two or more electrodes are connected into a beam (the contact ends are welded to each other in two or three places) and welding is carried out with an electrode holder. When welding with an electrode beam, contact occurs between the workpiece to be welded and one of the electrode rods as it melts, the contact passes to the next rod. When welding with an electrode beam, you can use increased current strength.
Welding with deep penetration - a thicker layer of coating is applied to the electrode rod, thereby increasing the thermal power of the arc and increasing its penetration action, that is, increasing the depth of melting of the base metal. Welding is carried out with a short arc, the combustion of which is maintained due to the operation of the visor of the coating on the base metal; it is used when welding corner and tee joints.
Welding with inclined electrodes - the electrode is placed in the groove of the seam, to hold the electrode in the groove and to isolate and protect the arc, copper linings are used;
Welding an electrode with large diameters - 8-12mm and a current value of 350-600A but has its drawbacks:
1. Difficult to perform in tight spaces.
2. Rapid fatigue of the welder.
3. Significant magnetic blowing occurs.
Bath welding is performed with one or more electrodes at an increased current value, which ensures heating of the elements to be welded to form a large pool of liquid metal, which is held in a special shape during the welding process, the deposited metal is constantly in a liquid state at the end of the welding process to accelerate and cool the weld pool, the arcs are periodically interrupted.
Flameless welding - the electrode is not fixed in the holder, but welded to it with an end, which allows the use of the entire rod.
1.3 Types of welding
Manual arc welding.
Gas welding and cutting.
Semi-automatic welding
Automatic submerged arc and shielding gas welding.
Argon - arc welding
Electrocontact welding
2. Special part
2.1 Purpose and design description
The pipeline is used to transport cold, hot water in the room for heating, compressed gases, steam. This work consists of two separate pipe sections interconnected by manual arc welding.
2.2 Selection and description of material
For the manufacture of the structure, low-carbon steel grade 3 is used, which belongs to the group of well-welded steels. Carbon in it is up to 0.25%, manganese 0.5%, silicon 0.35%.
For welding low-carbon steels, electrodes of grades are used: OZS - 3; OZS - 4; MR - 3, the rod of these electrodes is made of wire grade sv - 08A. The composition of the coating includes: 30 - 50% titanium dioxide, feldspar, ferromanganese, liquid glass.
This electrode will give the lowest percentage of metal spatter, suitable for welding on direct and alternating current, it is not harmful to the human body, therefore it is widely used in industry.
2.3 Equipment selection and power supply specifications
I chose pipeline welding. For pipe welding, the TDM-401 transformer is most convenient, since you can easily select the current strength. The transformer itself consists of a closed core, primary and secondary windings. When the primary and secondary windings of the transformer are connected in series, part of the turns of the primary winding is included in the electrical circuit, and a range of low currents is obtained.
When the windings are connected in parallel, all branches of the primary winding are included in the electrical circuit, and a range of high currents is obtained.
The secondary winding is movable, with the help of which the current strength is regulated.
2.5 Preparation of metal for welding
In the place of welding of the pipeline, the edges are carefully cleaned with an iron brush from dirt, oil, rust, which lead to the formation of defects.
The quality of welds largely depends on the state of the surface of the welded edges.
2.6 Assembly of the structure
When assembling, it is important to ensure the required accuracy and coincidence of the edges of the elements to be welded.
For precise assembly of parts for welding, you need to use measuring tools.
And great attention should be paid to the fact that when the metal is heated, it can be deformed when welding the root of the seam, you need to be especially careful to carefully clean it from slag.
Tacks are made with an electrode with a diameter of 3 mm
2.7 Welding mode selection
The electrode diameter is chosen depending on the thickness of the metal, the leg of the seam, the position of the seam in space.
The approximate relationship between the thickness of the metal (s) and the diameter of the electrode when welding the seam in the desired position is:
Smm 1 – 2 3 – 5 4 – 10 12 – 24 30 – 60
dmm 2 – 3 3 – 5 4 – 5 5 – 6 or more
The strength of the welding current is usually set depending on the selected electrode diameter.
When welding seams in the lower position, the current strength can be determined by the state of Jd = (20+60) d Jb (40÷60) for electrodes with a diameter of less than 3 mm Jd = 30 d.
Arc voltage 18 - 20, seam width 15 - 16mm arc length 1 - 0.5mm from the base metal,
Jw ≈ 80 – 120 H
Lower position Jsv ≈ 120A
Horizontal position Jsv ≈ 100A
Vertical position Jsv ≈ 80A.
Ceiling position Jsv ≈ 60A
2.8 Consumption of welding material
The consumption of coated electrodes is determined by multiplying the mass of deposited metal by the consumption coefficient.
Gne \u003d Gn * Kr (kg, gr)
Gne are the masses of coated electrodes.
Gн - masses of directed metal
Кр – electrode consumption coefficient
Cr = 1.5 – 1.8
for coated electrodes in RDS
Gн = 7.85 * F * L
Gn \u003d 7.85 g / cm3 * 0.32 cm2 * 49.9 cm \u003d 125
Gne \u003d 125 * 1 * 7 \u003d 212 * 5≈212
G of one electrode =(4*970kg)/125pcs =39*76g
Number of electrodes 212gr/(39*76) = 5*33 ≈ 6pcs
The consumption of welding electrodes per product was 6 electrodes
2.9 Determination of the norm of time
Time limit for welding. T
t0 - main time
Kuch - the coefficient taking into account the organization of labor is taken at RDS 0.25 - 0.40.
Arc burning time T0 is determined by the formula:
t0 = 7.85*F*L/hнj
where 7.85 is the specific gravity of steel g/cm2
F - cross-sectional area of the seam - with a metal thickness of 8mm
F = 64cm2/2 = 0.32 cm2
L * Fm \u003d 1/2 * a2 seam length
L = Ø * P L = 159 * 3.14 = 499.26 ≈ 499mm
Ln – setting coefficient for MP electrodes – 3 Ln = 16 g/nh
J - welding current, A J = 30 * deK
K - coefficient of arc power reduction when welding on alternating current (0.7-0.97)
30 is amps per mm of electrode
J = 87*3 ≈ 90A
t0 \u003d (7.85 g / cm3 * 0.32 cm2 * 49.9 cm) / (16g * 7 * 90A) \u003d (125 * 34mm) / 1440 \u003d \u003d 0.08 h
T = 0.08/0.25 = 0.68 = 32 min
It took 32 min.
2.10 Welding technique and sequence
For 170 pipes, according to calculations, I made three tacks, a tack 30mm long.
Tacks are applied every 30mm.
For welding the root of the seam, I chose an electrode with a diameter of 3mm.
For welding the second seam, I chose 4mm.
To pass the second seam, it is necessary to make oscillatory movements from side to side to capture (weld) both edges.
3. Technical control
3.1 Organization of quality control
Defects in welded joints can be caused by poor quality of welded materials, inaccurate assembly and preparation of joints for welding, violation of welding technology, low qualification of the welder and other reasons. The task of quality control of joints is to identify possible causes of defects and prevent them.
Work on quality control of welding works is carried out in three stages:
Preliminary control carried out before the start of work:
Control in the process of assembly and welding (upon operational).
Quality control of finished welded joints.
Preliminary control includes: checking the qualifications of welders, defect inspectors and engineers who supervise assembly, welding and control work.
In the manufacturing process (step-by-step control), the quality of edge preparation and assembly, welding modes, the order of making seams, the appearance of the seam, its geometric dimensions, and the serviceability of the welding equipment are checked.
The last control operation is to check the quality of welding in the finished product: external inspection and measurements of welded joints, density tests, ultrasound control, magnetic control methods.
Welder qualification check: Welders' qualifications are checked when the category is established. The category is assigned in accordance with the requirements stipulated by the tariff-qualification reference books, the tests of welders before admission to responsible work are carried out according to the rules for the certification of welders and welding production specialists.
Base metal quality control. The quality of the base metal must comply with the requirements of the certificate sent by the factories - suppliers, along with a batch of metal, must conduct an external inspection to establish the mechanical properties and chemical composition of the metal.
During an external examination, the absence of scale, rust, cracks and other defects on the metal is checked.
A preliminary check of the metal in order to detect surface defects is a necessary and mandatory operation, thanks to which it is possible to prevent the use of low-quality metal when welding a product.
The mechanical properties of the base metal are determined by testing standard samples on tensile machines, pesses and copra in accordance with GOST 1497 - 73 metal tensile testing methods.
Quality control of the welding wire: the brand and diameter of the welding wire, the chemical composition of the acceptance rule and test methods, the requirements for packaging, marking, transportation and storage are set on the steel surfacing wire.
Each coil of welding wire must have a metal tag on which the name and trademark of the manufacturer are indicated. Welding wire, on which there is no documentation, is subjected to careful control.
Electrode quality control. When welding structures, in the drawings of which the type of electrode is indicated, it is impossible to use an electrode that does not have a certificate. The electrode without a certificate is checked for the strength of the coating and the welding properties are also determined by the mechanical properties of the weld metal and the welding joint of the electrode made from the tested batch.
Flux quality control. The flux is checked for uniformity in appearance, its mechanical composition, grain size, volume, mass and moisture content are determined.
Workpiece control. Before the workpieces enter the assembly, the cleanliness of the metal surface and the dimensions of the quality of the edge preparation are checked.
Assembly control: assembled control: the gap between the edges, blunting and opening angle for butt joints: the width of the lap and the gap between places for lap joints.
Quality control of welding equipment and devices. They check the serviceability of control and measuring instruments, the reliability of contacts and insulation, the correct connection of the welding arc, the serviceability of closed devices, the electrode holder, welding torches, gearboxes, wires.
Control of the welding process: before proceeding to welding, the welder gets acquainted with the technological maps, which indicate the sequence of operations, the diameter and brand of the electrodes used, the welding modes and the required dimensions of the welds. Not following the order of suturing can cause significant deformation.
4. Organization of the workplace
4.1 Requirements for the organization of the workplace
When performing production operations, a worker or a team of workers is assigned a workplace in the form of a certain section of the production area, equipped according to the requirements of the technological process, with appropriate equipment and necessary accessories. The workplace of a welder is called a welding post.
To protect workers from arc radiation in permanent welding places, a separate cabin 2x2.5 or 2x2 in size is installed for each welder.
Cabin walls can be made of thin iron or other non-combustible material 1.8-2.0 m high, for better ventilation not reaching the floor by 0.2-0.3 m. The floor must be made of fire-resistant material: brick, concrete, cement. The walls are painted in light gray with paints that absorb ultraviolet rays well. The cabin is equipped with local ventilation with air exchange of 40 m3/hour per worker.
The ventilation suction is positioned so that the gases released during welding pass by the welder.
Welding of the part is carried out on a working table with a height of 0.5-0.7 m. The table cover is made of cast iron 20-25 mm thick; in some cases, various devices are installed on the table for assembling and welding products.
A steel bolt is welded to the bottom of the cover or table leg, which serves to fasten the conductive wire from the welding current source and for the table ground wire. On the side of the table there are sockets for storing electrodes. The drawer of the table stores tools and technological documentation. For the convenience of working in the cab, a metal chair with a lifting screw seat made of a non-conductive material is installed. Under the feet of the welder should be a rubber mat.
The welding post is equipped with a generator or a welding transformer.
5. Safety
5.1 Welding safety
Persons at least 18 years old are allowed to work on welding after passing the technical minimum according to safety regulations.
The organization of each workplace must ensure the safe execution of the robot.
The workplace must be equipped with various kinds of fences, protective and safety devices and adapted.
To create a safe environment for robot welders, it is necessary to take into account, in addition to the general provisions of industrial safety, the specifics of performing various welding jobs. Such features are possible electric shocks, poisoning with harmful gases and vapors, burns from the radiation of a welding arc and molten metal, injuries from explosions of cylinders with compressed and liquefied gases.
An electric welding arc emits bright visible light rays and invisible ultraviolet and infrared rays. Light rays have a blinding effect. Ultraviolet rays cause eye diseases, and with prolonged exposure lead to skin burns.
Shields, masks or helmets are used to protect the eyes and skin of the face; light filters are inserted into the viewing holes that block and absorb rays. To protect the hands of welders from burns and splashes of molten metal, it is necessary to use protective gloves, and put on a tarpaulin special on the body. clothes.
During welding, a significant amount of aerosol is released, which leads to poisoning of the body. The highest concentration of dust and harmful gases in the cloud of smoke rising from the welding zone, so the welder must ensure that the flow does not fall behind the shield. To remove harmful dust gases from the welding zone, it is necessary to install local ventilation, exhaust and general volume supply - exhaust. In winter, supply ventilation should supply heated air into the room. In case of poisoning, the victim must be taken out to fresh air, freed from tight clothing and given rest until the doctor arrives, and if necessary, artificial respiration should be applied.
5.2 Electrical safety
Electric shock occurs when a person comes into contact with live parts of the equipment. The resistance of the human body, depending on its condition (fatigue, skin moisture, health status) varies in wide aisles from 1000 to 20000 ohms. The open-circuit voltage of the arc power sources reaches 90V, and the compressed arc - 200V in accordance with Ohm's law, in an unfavorable condition of the welder, a current close to the limit can pass through it:
To prevent possible electric shock when performing electric welding, you must follow the basic rules:
Cases of equipment and apparatus to which electric current is connected must be grounded;
All electrical wires coming from switchboards and to workplaces must be reliably insulated and protected from mechanical damage;
It is forbidden to use the ground loop, metal structures of buildings, as well as pipes of water and heating systems as a return wire of the welding circuit;
When performing welding work inside closed vessels (boilers, tanks, reservoirs, etc.), wooden shields, rubber mats, gloves, galoshes should be used: Welding must be carried out with an assistant outside the vessel. It should be remembered that for lighting purposes inside the vessels, as well as in damp rooms, an electric current with a voltage of no higher than 12V is used, and in dry rooms - no higher than 36V, in vessels without ventilation, the welder should work no more than 30 minutes with breaks for outdoor recreation .
Installation, repair of electrical equipment and supervision of it must be carried out by electricians. Welders are strictly prohibited from correcting power electrical circuits. In case of electric shock, it is necessary to turn off the current of the primary circuit, free the victim from its effects, provide him with access to fresh air, call a doctor, and, if necessary, give artificial respiration before the doctor arrives.
5.3 Fire safety
The causes of fire during welding can be sparks or drops of molten metal and slag, careless handling of the burner flame in the presence of combustible materials in the vicinity of the welder's workplace. The risk of fire should be especially taken into account at construction and installation sites and during repair work in rooms not suitable for welding.
To prevent fires, the following fire prevention measures must be observed:
Do not store flammable or flammable materials near the welding site, as well as carry out welding work in rooms contaminated with rags, paper, wood waste, etc.;
It is forbidden to use clothes and gloves with traces of oils, fats, gasoline, kerosene and other flammable liquids;
Carry out welding and cutting with freshly painted oil paints of structures until they are completely dry
It is forbidden to perform welding of devices under electrical voltage and vessels under pressure;
It is impossible to carry out welding and cutting of containers from liquid fuel without special preparation;
When performing temporary welding work in the premises, wooden floors, floorings and platforms must be protected from ignition by sheets of asbestos or iron;
It is necessary to constantly have and monitor the good condition of fire fighting equipment - fire extinguishers, sandboxes, shovels, buckets, fire hoses, etc., as well as keep the fire alarm in good condition;
After completion of welding work, it is necessary to turn off the welding machine, and also make sure that there are no burning objects. Fire extinguishing agents are water, foam, gases, steam, powder compositions, etc.
To supply water to fire extinguishing installations, special water pipes are used. The foam is a concentrated emulsion of carbon dioxide in an aqueous solution of mineral salts containing foaming agents.
When extinguishing a fire with gases and steam, carbon dioxide, nitrogen, flue gases, etc. are used.
When extinguishing kerosene, gasoline, oil, burning electrical wires, it is forbidden to use water and foam fire extinguishers. In these cases, carbon dioxide or dry fire extinguishers should be used.
6. Environmental protection
In accordance with the constitution, in the interests of the living and future generations, measures are being taken to protect and rationally use the land and its subsoil, water resources and flora and fauna, to maintain clean air and water, ensure the reproduction of natural resources and improve the human environment. These activities in the annual plans of enterprises are grouped into sections: protection and use of water resources, protection of the air basin, protection and rational use of land, protection and use of mineral resources.
The protection and use of water resources include measures for the construction of facilities for water intake and reservoirs, wastewater treatment, water recycling systems in order to reduce irretrievable water losses, etc.
In welding production, many enterprises use a reverse water supply system; water used to cool welding equipment is reused after its natural cooling.
The protection of the air basin provides for measures to neutralize substances harmful to humans and the environment emitted with exhaust gases: the construction of treatment plants in the form of wet dry dust traps, for chemical and electrical gas purification, as well as for the capture of valuable substances, waste disposal, etc. For example , from the exhaust products of combustion produce liquefied carbon dioxide for welding and other purposes.
The protection and rational use of land provides for measures aimed at reducing the exit of land from agricultural circulation, protecting it from eposis and other destructive processes, land reclamation, etc.
The protection and rational use of mineral resources provide for measures to improve systems and methods for the development of mineral deposits and ore dressing schemes, the use of waste from metallurgical production and engineering, the increase of purchased valuable components from ores, etc. The activity of the enterprise should not violate the normal conditions of the work of other enterprises and organizations worsen the living conditions of the population. To this end, the gas plans also provide for measures to combat industrial noise, vibration, and the effects of electric and magnetic fields. Noise generated by welding equipment should be kept to a minimum.
Welding arc power sources, as well as a number of electrical devices used in automatic and semi-automatic welding machines, interfere with radio and television reception. In order to eliminate this phenomenon, anti-interference devices are installed in all types of welding equipment that create such interference.
Weld defects
| Defect name | Detection method | Remedy |
| 1. Lack of penetration of subsurfaces | External inspection. | Cutting out the defective area and subsequent welding. |
| 2. Undercut | External inspection and measurement with a probe. | Cleaning, cutting areas and welding. |
| 3. Waviness of the seam with sharply defined boundaries. | External inspection. | Cutting out the defective area. |
| 4. Uneven wrinkling. | External inspection. | Cutting out the defective area. |
| 5. Various sizes of fillet welds. | Template measurement. | 1) at K and K, seam processing. 2) at K and K X welding. |
| 6. Incorrect seam height. | Template measurement. Note local deviations in the height of the overlap exceeding the tolerances should not be more than 10% of the total length of the weld local deviation up to 15 mm | a) seam processing to the main size. b) welding with preliminary stripping. |
| 7. Uneven overlap width. | Template measurement. | Seam hem. |
Literature
1. Vinogradov V.S. Equipment and technology for automatic and mechanized arc welding, M: 1997;
2. Rybakov V.M. Arc and gas welding, M: VSH, 1986.
3. Stepanova V.V. Welder's Handbook, M: 1982.
4. Fominykh V.P. Electric welding, M: V.Sh..., 1978.
5. Chernyshev G.G. Welding, M: 2003.
www.ronl.ru
The program of educational practice in the profession "Welder"
Ministry of Education of the Penza Region
State Autonomous Professional
educational institution of the Penza region
"Penza multidisciplinary college"
APPROVE
Head of construction department
GAPOU PO PMPK
WORKING PROGRAMM
TRAINING PRACTICE
profession 15.01.05 "Welder"
(electric welding and gas welding works)
study period 2.5 years
profession according to the general classifier (OK 016-94)
1. Electric and gas welder
Agreed:
_____________________
Penza, 2015
EXPLANATORY NOTE
This internship program is designed to train qualified workers in the profession "Welder (electric welding and gas welding)" under the program of secondary vocational education.
The program includes: an explanatory note, professional and general competencies, a summary thematic plan for industrial training, a curriculum.
The organization of training is carried out on the basis of the list of professions of primary vocational education and the federal state educational standard of primary vocational education (FGOS SVE)
The program provides for a specific range of professions that reflect the labor market of the region, determines the content of professional competencies, taking into account the specifics of the region.
A professional characteristic reflects the content parameters of professional competence: its main types, as well as their theoretical foundations.
The requirements for the learning outcomes are the main parameters in assessing the quality of training of trainees in the profession "Welder" (electric welding and gas welding).
The fulfillment of these requirements serves as the basis for the issuance of state-recognized documents to graduates on the level of qualification in the profession "Welder" (electric welding and gas welding).
The working program of vocational training was developed on the basis of the Federal State Educational Standard for the Profession, the Regulations on Training Practice (Industrial Training) and Industrial Practice for Students Mastering Basic Professional Educational Programs
Organization-developer:
State Autonomous Vocational Educational Institution of the Penza Region "Penza Multidisciplinary College" Department of Construction (hereinafter - GAPOU PO PMPK)
1. PASSPORT OF THE WORKING PROGRAM
TRAINING PRACTICE
Scope of the program:
The work program of the training practice is part of the main professional educational program in accordance with the Federal State Educational Standards of secondary vocational education in the profession Welder (electric welding and gas welding) in terms of mastering the qualifications:
gas welder,
Electric and gas welder,
Electric welder on automatic and semi-automatic machines,
hand welding electric welder,
gas cutter
and main types of professional activity (VPD):
1. Preparatory and welding work.
3. Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure.
The work program of educational practice can be used in additional education and training in the professions of workers:
19756 Electric and gas welder;
19906 Manual electric welder;
11620 Gas welder.
1.2. Goals and objectives of the production practice:
Formation of students' initial practical professional skills within the framework of the OPOP SVE modules on the main types of professional activities for mastering a working profession, training in labor techniques, operations and methods of performing work processes that are characteristic of the corresponding profession and necessary for their subsequent development of general and professional competencies in their chosen profession .
Requirements for the results of mastering industrial practice
As a result of passing the educational practice by types of professional activity, the student should be able to:
| Skill Requirements |
|
| 1. Preparatory and welding work | PC 1.1. Perform typical locksmith operations used in preparing metal for welding. PC 1.2. Prepare gas cylinders, control and communication equipment for welding and cutting. PC 1.3. Perform assembly of products for welding. PC 1.4. Check assembly accuracy. |
| 2. Welding and cutting of parts from various steels, non-ferrous metals and their alloys, cast irons in all spatial positions. | PC 2.1. Perform gas welding of medium and complex PC 2.2. Perform manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. PC 2.3. Perform automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels. PC 2.4. Perform oxygen, air-plasma cutting of metals of straight and complex configuration. PC 2.6. Ensure the safe performance of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements. |
| 3. Surfacing of defects in parts and components of machines, structural mechanisms and castings for machining and test pressure. | PC 3.1. Surfacing parts and assemblies of simple and medium complexity structures with hard alloys. PC 3.2. Surfacing complex parts and assemblies of complex tools. PC 3.3. Surfacing worn simple tools, parts made of carbon and structural steels. PC 3.4. Fuse heated cylinders and pipes, defects in machine parts, mechanisms and structures. PC 3.5. Perform surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. PC 3.6. Perform surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity. |
| 4. Detection of welds and quality control of welded joints. | PC 4.1. Clean seams after welding. PC 4.2. Determine the causes of defects in welds and joints. PC 4.3. Prevent and eliminate various types of defects in welds. PC 4.4. Perform hot straightening of complex structures. |
1.3. Number of hours for mastering the work program of educational practice (industrial training):
Total - 540 hours, including:
As part of the development of PM 01. - 72 hours
As part of the development of PM 02. - 270 hours
As part of the development of PM 03. - 162 hours
As part of the development of PM 04. -36 hours
1.4. Number of hours for mastering the work program of industrial practice:
PP - 52 weeks - 312 hours
As part of the development of BCP 01. - 36 hours
As part of the development of PP 02. - 138 hours
As part of the development of BCP 03. - 102 hours
As part of the development of BCP 04.-36 hours
2. RESULTS OF MASTERING THE WORKING PROGRAM OF TRAINING PRACTICE
The result of mastering the work program of industrial practice is the formation of students' initial practical professional skills within the framework of the OPOP SVE modules for the main types of professional activity (VPA),
| Name of the result of mastering the practice |
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| Perform typical locksmith operations used in preparing metal for welding. |
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| Prepare gas cylinders, control and communication equipment for welding and cutting. |
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| Perform assembly of products for welding. |
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| Check assembly accuracy. |
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| Perform gas welding of medium complexity and complex assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys. |
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| Perform manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. |
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| Perform automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels. |
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| Perform oxygen, air-plasma cutting of metals of straight and complex configuration. |
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| Ensure the safe performance of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements. |
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| Surfacing parts and assemblies of simple and medium complexity structures with hard alloys. |
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| Surfacing complex parts and assemblies of complex tools. |
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| Surfacing worn simple tools, parts made of carbon and structural steels. |
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| Fuse heated cylinders and pipes, defects in machine parts, mechanisms and structures. |
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| Perform surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. |
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| Perform surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity. |
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| Clean seams after welding. |
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| Determine the causes of defects in welds and joints. |
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| Prevent and eliminate various types of defects in welds. |
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| Perform hot straightening of complex structures. |
3. THEMATIC PLAN AND CONTENT OF INTERNSHIP
3.1. Thematic plan of production practice
| Code and names of professional modules | Number of hours by PM | Types of jobs | Names of topics of industrial practice | Number of hours by topic |
|
| Preparatory and welding work | Perform straightening and bending, marking, cutting, mechanical cutting, metal filing; prepare gas cylinders for work; assemble products for welding in assembly and welding fixtures with tacks; check assembly accuracy; be able to work on the simulator MTDS - 05. | Topic 1.1. Locksmith operations performed in the preparation of metal for welding | |||
| Intermediate certification |
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| Welding and cutting of parts from various steels, non-ferrous metals and their alloys, cast irons in all spatial positions | Perform technological methods of manual arc, plasma and gas welding, automatic and semi-automatic welding using a plasma torch of parts, assemblies, structures and pipelines of varying complexity from structural and carbon steels, cast iron, non-ferrous metals and alloys in all spatial positions of the seam; perform automatic welding of critical complex building and technological structures operating in difficult conditions; perform automatic welding in a shielding gas environment with a non-consumable electrode of hot-woven strips made of non-ferrous metals and alloys under the guidance of an electric welder of a higher qualification; perform automatic microplasma welding; perform manual oxygen, plasma and gas straight and figured cutting and cutting with petrol and kerosene cutting machines on portable, stationary and plasma cutting machines of parts of varying complexity from various steels, non-ferrous metals and alloys according to marking; perform oxygen-flux cutting of parts made of high-chromium and chromium-nickel steels and cast iron; carry out oxygen cutting of ship objects afloat; perform manual electric arc air planing of varying complexity of parts from various steels, cast iron, non-ferrous metals and alloys in various positions; perform preliminary and concomitant heating when welding parts in compliance with the specified mode; set welding modes according to the specified parameters; use materials and energy economically, handle tools, equipment and equipment with care; comply with labor safety and fire safety requirements; read working drawings of welded metal structures of varying complexity. | Familiarization with equipment for manual arc welding. | |||
| Cutting, assembly and arc welding of steel plates in inclined, vertical, horizontal seam positions. |
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| Assembly and arc welding of simple parts and assemblies from low carbon steel |
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| Gas welding of beads and welding of mild steel plates in the lower, vertical position of the seam. |
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| intermediate Certification in the form of a differential test |
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| low carbon |
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| Oxygen metal cutting |
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| Alloy welding |
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| Welding and soldering |
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| Intermediate certification in the form of a differential test |
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| Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure | Carry out hardfacing of simple parts; carry out surfacing with hard alloys using ceramic fluxes in a protective gas of parts and assemblies of medium complexity; eliminate defects in large cast iron and aluminum castings for machining and test pressure by surfacing; to remove by surfacing defects in nodes, mechanisms and castings of varying complexity; carry out fusion of heated cylinders and pipes; to weld shells and cracks in parts, assemblies and castings of varying complexity. | Arc surfacing of plates in the lower, inclined vertical and horizontal positions. | |||
| Topic 3.2. Oxy-gas surfacing in all spatial positions. |
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| Hardfacing |
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| Detection of welds and quality control of welded joints | Clean seams after welding; check the quality of welded joints in appearance and fracture; identify defects in welds and eliminate them; apply methods to reduce and prevent deformation during welding; perform hot straightening of welded structures. | Classification of defects and their causes. Influence of defects on the strength of welds | |||
| Non-destructive quality control of welds |
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| Destructive view of quality control of welds |
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| Intermediate certification in the form of a differentiated test |
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| Total hours |
| Code and name professional modules and themes industrial practice | development |
||
| PM 01. Preparatory and welding work | |||
| Types of jobs: 1. Performing standard plumbing operations used in preparing metal for welding. 2. Performing the assembly of welded structures in various ways. 3. Tacking the assembled parts. 4. Performing operations to control the assembly of welded structures. 5. Preparation of gas cylinders, control and communication equipment for gas welding and metal cutting. |
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| Locksmith operations performed in the preparation of metal for welding | 1. Cleaning and straightening of metal. 2. Marking and cutting parts. 3. Preparation of the edges of parts for welding. | ||
| Familiarization and work on a low-ampere arc simulator for a welder MDTS - 05. Safety precautions. | 1. Manual arc welding (RDE). Practicing the technique of excitation and maintenance of the arc. 2. Manual arc welding (RDE). Development of techniques for maintaining the arc length and a given welding speed. 3. Manual arc welding (RDE). Development of techniques for maintaining the arc length, a given welding speed and electrode inclination angles. 4. Manual argon arc welding (TIG). Development of techniques for maintaining the arc length, a given welding speed and electrode inclination angles. 5 Mechanized gas-shielded consumable electrode welding (MAG). Development of techniques for maintaining the arc length, a given welding speed and electrode inclination angles. 6. Manual arc welding of pipeline joints. Development of techniques for maintaining the arc length, the specified welding speed and the angle of inclination of the electrode when welding fixed joints of pipelines. | ||
| Product assembly and control | 1. Assembly of beams and frames 2. Assembly of lattice structures | ||
| Intermediate certification in the form of a differentiated test | |||
| PM 02. Welding and cutting of parts from various steels, non-ferrous metals and their alloys, cast irons in all spatial positions | |||
| Types of jobs: 1. Briefing on the operation of assembly and welding devices. 2. Organization of the workplace and labor safety. 3. Assembly and welding of butt joints. 4. Assembly for welding of butt joints (without bevel edges, with one-sided and two-sided bevel edges), setting the required gap during assembly. 5. Installation of tacks. 6. Assembly and welding of corner and tee joints. The order of assembly, setting of tacks, equipment and technology of surfacing, welding. 7. Checking the quality of welded joints in appearance and fracture. Correction of defects in welds. Cutting out the defective area and re-welding. 8. Arc cutting with a carbon and metal electrode: marking and cutting out flanges, rings, various round and figured holes; cutting corners and channels, punching holes in plates, cutting pipes. 9. Separating air-arc cutting of profile metal, burning holes, cutting pipes and channels. 10. Surface air-arc cutting of grooves made on carbon and alloy steel plates, selection of defective welds. 11. Plasma-arc cutting of simple parts made of alloyed and non-ferrous metals. 12. Performing manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. 13. Performing automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels. 14. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configuration. 15. Reading drawings of medium complexity and complex welded metal structures. 16. Gas welding of units of medium complexity and complex units, parts and pipelines made of carbon, structural steel, non-ferrous metals and alloys. 17. Performing automatic and mechanized welding of units, parts, structures, pipelines from various structural materials 18. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configuration. 19. Performing welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements. 20. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configuration. 21. Reading drawings of medium complexity and complex welded metal structures. 22. Reading instructional and technological maps, diagrams. 23. Butt welding of pipes in a rotary and non-rotary position. 24. Execution of circumferential seams of containers for storage of various types of bulk materials. 25. Welding of various stiffeners. 26. Welding of transition platforms, frames, fences, gratings. 27. Welding of various kinds of scarves, slats to beams, trusses. 28. Welding of various building structures (beams, building frames, trusses, sheet structures, hull transport structures). 29. Welding of pipelines. 30. Checking the quality of welds, eliminating defects in welds. |
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| Familiarization with equipment for manual arc welding | Acquaintance with welding equipment and apparatus, rules for their maintenance. Briefing on the organization of the workplace and labor safety. Turning the DC arc power supply on and off. Current regulation, wire connection. Clamping the electrode in the electrode holder. Training in arc excitation and maintenance of its burning until the electrode is completely melted. | ||
| Cutting, assembly and arc welding of steel plates in the bottom position of the seam. | 1. Acquaintance with the rules and methods of surfacing and welding. Briefing on the organization of the workplace and labor safety. Surfacing of the bead on the plate in the lower position of the seam. 2. Single-layer welding of sheet metal, welding of plates in an overlap, in a corner, in a butt joint with cutting edges, in tees. 3. Surfacing of beads on an inclined plate. Surfacing of adjacent parallel beads in different directions. 4. Cutting plates with coated electrodes in a straight line, along a curve and along a marking. Cutting metal of various profiles. Hole cutting. 5. Grooving, removal of defective welds. Cutting the root of the seam on the reverse side for welding | ||
| Cutting, assembly and arc welding of steel plates in inclined, vertical and horizontal seam positions | 1.Cutting wafers into wafers in oblique, vertical and horizontal seam positions. Cutting metal of various profiles. 2. Surfacing of beads on the ascent and descent on a plate installed at different angles. 3. Assembly of parts for welding, setting the required gap, determining the places of tacks in various spatial positions. 4. Setting tacks and cleaning them. 5. Butt welding of inclined plates, in an inclined position. | ||
| Assembly and arc welding of simple low-carbon steel parts and assemblies. | 1. Assembly of parts for welding, setting the required gap, determining the places of tacks. 2. Tacking the assembled parts in various spatial positions. 3. Welding of plates, scarves, stiffeners to simple products in the lower position of the seam. 4. Welding of plates, scarves, stiffeners to simple products in the vertical position of the seam. 5. Welding of plates, scarves, stiffeners to simple products in the horizontal position of the seam | ||
| Gas welding of beads and welding of mild steel plates in the lower, vertical position of the seam | 1. Choice of welding mode. Surfacing of filler material. 2. Surfacing of beads on steel plates in the lower position of the seam. 3. Surfacing of beads on steel plates in the vertical position of the seam. 4. Butt welding of plates in all spatial positions | ||
| Intermediate certification in the form of a differentiated test | |||
| Assembly and gas welding of simple products and assemblies from low carbon | 1. Assembly of parts for welding, setting the required gap, determining the locations of tacks and the sequence of their application. 2. welding of simple products in inclined, vertical and horizontal positions of seams. 3. Welding of shells and cracks in simple details 4. Checking the quality of simple connections. Identification of defects and their elimination. | ||
| Oxyfuel cutting of metals | 1. Oxygen cutting of plates. 2. Oxygen cutting of corners, channels | ||
| Welding of alloyed steels. | 1. Acquaintance with the rules and methods of welding alloyed steels. 2. Surfacing of beads with coated electrodes on alloy steel plates. 3. Welding of butt joints without cutting edges in various spatial positions 4. Briefing on the organization of the workplace and labor safety in argon arc welding. Acquaintance with the methods of welding alloyed steels by argon arc welding. 5. Development of skills in the surfacing of beads by argon arc welding 6. Argon-arc welding of corner, tee joints in all spatial positions | ||
| Cast iron welding and brazing | 1. Briefing on the organization of the workplace and labor safety. Familiarization with the methods and techniques of welding cast iron. 2. Cold welding of cast iron with steel electrodes on steel studs. 3. Surfacing of a layer of brass on a cast iron plate. 4. Cutting out defects and preparing the edges of products for welding. | ||
| Welding of non-ferrous metals and their alloys. | 1. Gas welding of beads on aluminum plates 2. Butt welding of aluminum plates 3. Gas welding of beads on plates made of copper and their alloys 4. Gas butt welding of copper plates. 5. Argon-arc surfacing of beads on aluminum plates 6. Argon-arc surfacing of beads on plates made of copper and their alloys end-to-end. | ||
| Intermediate certification in the form of a differentiated test | |||
| PM 03. Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure | |||
| Types of jobs: 1. Surfacing of parts and assemblies of simple and medium complexity structures with hard alloys; surfacing of complex parts and assemblies of complex tools. 2. Surfacing of worn simple tools, parts made of carbon and structural steels. 3. Surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. 4. Surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity; implementation of hardfacing with the use of ceramic fluxes in a protective gas of parts and assemblies of medium complexity. 5. Removal by surfacing of defects in units, mechanisms and castings of varying complexity; fusing heated cylinders and pipes. surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. 6. Surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity. |
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| Surfacing technique to eliminate defects in large cast iron and aluminum castings for machining and test pressure | 1 Surfacing of parts and assemblies of simple and medium complexity structures with hard alloys 2. Surfacing of complex parts and assemblies of complex tools 3. Surfacing of worn simple tools, parts made of carbon and structural steels 4. Surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. 5. Surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity. 6. Implementation of surfacing with hard alloys. 7. Removal by surfacing of defects in units, mechanisms and castings of varying complexity. 8. Fuse heated cylinders and pipes 9. Welding of complex parts and assemblies, complex tools | ||
| Oxy-gas surfacing in all spatial positions | 1. Operation of automatic welding machines for mechanized arc surfacing. 2. Regulation of welding modes for mechanized arc surfacing. 3. Gas surfacing of surfaces of parts made of various metals. 4. Development of techniques for eliminating defects in machined parts and assemblies by surfacing with a gas burner. 5. Surfacing of parts and assemblies of simple and medium complexity structures with hard alloys. 6. Surfacing of structures with hard alloy | ||
| Arc automatic and semi-automatic surfacing | 1. Surfacing of complex parts and assemblies of complex tools. 2. Surfacing of worn simple tools, parts made of carbon steels. 3. Application of technological methods of automatic and mechanized deposition of defects in machine parts, mechanisms and structures. 4 Surfacing of worn simple tools, parts made of alloy steels 5 Surfacing of worn simple tools, structural steel parts. 6. Hardfacing | ||
| Surfacing with hard alloys. | 1. Acquaintance with the techniques of hardfacing. 2. Surfacing of simple parts and assemblies with hard alloys. 3. Surfacing of complex parts and assemblies with hard alloys. 4. Surfacing with powder alloys | ||
| Intermediate certification in the form of a differentiated test | |||
| PM 04. Detection of welds and quality control of welded joints | |||
| Types of jobs: 1. Perform cleaning of seams after welding. 2. Determining the causes of defects in welds and joints. 3. Prevention and elimination of various types of defects in welds. 4. Performing hot straightening of complex structures. |
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| Classification of defects and the reason for their occurrence. | 1. Cleaning of seams after welding. 2. Defects in welded joints. Welding deformations. Reasons for the defect | ||
| Non-destructive testing of welds | 1. Visual quality control of the welded joint. 2. Ultrasonic testing of welds | ||
| Destructive testing of welds | 1.Hydraulic control of welds 2 Hot straightening of welded structures. | ||
| Intermediate certification in the form of a differentiated test |
To characterize the level of mastering the educational material, the following designations are used:
2 - reproductive (performance of activities according to a model, instructions or under guidance);
3 - productive (planning and independent performance of activities, solving problematic tasks)
4. CONDITIONS FOR THE IMPLEMENTATION OF THE INTERNSHIP WORK PROGRAM
4.1. Minimum Logistics Requirements
The implementation of the work program of the training practice assumes the presence of enterprises and organizations of the Penza region that carry out electric welding and gas welding on the basis of direct contracts with GBOU SPO PO "PMPC".
Equipping enterprises or organizations:
1. Equipment:
1. Post manual arc welding.
2. Gas welding post.
3. Post for semi-automatic welding in shielding gas.
4. Welding stations for direct current manual arc welding.
5. Welding stations for manual arc welding of alternating current.
6. Equipment and fixtures for assembly and welding.
7. Electrodes for welding.
2. Tools and fixtures:
1. A set of locksmith and measuring tools.
2. Tool for manual and mechanized metal processing.
3. Sets of control and measuring tools for checking cutting edges.
4. Sets of control and measuring tools for checking the accuracy of the assembly.
5. Instruments for determining the hardness of metals.
6. Assembly and welding fixtures.
7. Universal and special devices.
8. Test tool and template.
9. Metalworker's tool for an electric welder.
10. Devices for editing and straightening.
3. Learning tools:
1. Technical documentation for various types of metal processing.
2. Journal of briefing on safe working conditions.
3. Technological documentation.
4. Means of individual and collective protection.
4.2. General requirements for the organization of the educational process
Industrial training is carried out by industrial training masters and mentors at a professional cycle enterprise. Industrial training is carried out in a concentrated manner.
4.3. Staffing of the educational process
Masters of industrial training, who manage the work experience of students, must have a qualification category of 3-4 in the profession, higher or secondary vocational education in the profession, undergo a mandatory internship in specialized organizations at least 1 time in 3 years.
5. MONITORING AND EVALUATION OF PROGRAM DEVELOPMENT RESULTS
TRAINING PRACTICE
Control and evaluation of the results of mastering the educational practice is carried out by the head of the practice in the process of conducting training sessions, independently completing assignments by students, and performing practical test work. As a result of mastering educational practice within the framework of professional modules, students undergo intermediate certification in the form of a differentiated test.
| Learning Outcomes (learned skills within the framework of the VPA) | Forms and methods of monitoring and evaluating learning outcomes |
| PC 1.1. Performing typical plumbing operations used in preparing metal for welding. | |
| PC 1.2. Preparation of gas cylinders, control and communication equipment for welding and cutting. | |
| PC 1.3. Assembly of products for welding. | Expert evaluation of the student's activities |
| PC 1.4. Assembly accuracy check. | Expert evaluation of the student's activities |
| PC 2.1. Perform gas welding of medium and complex assemblies, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys. | Expert evaluation of the work performed |
| PC 2.2. Performing manual arc and plasma welding of medium complexity and complex parts of apparatuses, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. | Expert evaluation of the work performed |
| PC 2.3. Performing automatic and mechanized welding using a plasma torch of medium complexity and complex devices, assemblies, parts, structures and pipelines made of carbon and structural steels. | Expert evaluation of the work performed |
| PC 2.4. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configuration. | Expert evaluation of the work performed |
| PC 2.5. Reading blueprints of medium complexity and complex welded metal structures. | Expert evaluation of the student's activities |
| PC 2.6. Ensuring the safety of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements. | Expert evaluation of the student's activities |
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Work program of industrial practice
STATE BUDGET PROFESSIONAL EDUCATIONAL INSTITUTION
MOSCOW REGION
"INDUSTRIAL AND ECONOMIC TECHNICIUM"
Working programm
industrial practice
150709.02 Welder (electric welding and gas welding).
The internship program was developed on the basis of the Federal State Educational Standard for the Profession of Primary Vocational Education (hereinafter - NPO)
150709.02 Welder (electric welding and gas welding).
INTERNSHIP PROGRAM PASSPORT
STRUCTURE AND CONTENT OF THE PROGRAM
PROGRAM CONDITIONS
CONTROL AND EVALUATION OF DEVELOPMENT RESULTS
INTERNSHIP
1. INTERNSHIP PROGRAM PASSPORT
1.1.Scope of the program
The internship program is part of the main professional educational program in accordance with the Federal State Educational Standard by profession NPO 150709.02 Welder (electric and gas welding).
The internship program can be used in additional vocational education (in advanced training and retraining programs) and vocational training of workers by profession work.
1.3. Goals and objectives of the production practice:
As a result of mastering the program of industrial practice, the student should be able to:
Perform straightening and bending, marking, cutting, mechanical cutting, metal filing;
Prepare gas cylinders for work;
Perform assembly of products for welding in assembly and welding fixtures and tacks;
Check assembly accuracy.
As a result of mastering the program, the student should have practical experience:
Assembly accuracy checks.
Performing typical plumbing operations used in welding;
Preparation of cylinders, control and communication equipment for welding and cutting;
Assembly of products for welding;
Assembly accuracy checks.
1.4. The number of hours for the development of the program of industrial practice -216.
Explanatory note
This program has been drawn up in order to provide practical assistance to the master of industrial training in conducting pre-graduation practical training for students of a vocational school to train electric and gas welders of 3-4 categories. The program recommends internships in the shops of enterprises, in construction and in private enterprises engaged in the performance of electric and gas welding.
After acquiring the skills necessary to master and complete the program, students are given specific tasks that will help them in completing trial qualification works. In connection with the improvement of production conditions, changes and additions may be made to the practice program.
The direction of students to practice is drawn up by an agreement with the enterprise, which reflects the timing, conditions for ensuring the safety of the work.
At the end of the practice, the students are issued with characteristics certified by the seal, which indicate: the fulfillment of production standards, the ability to handle technological tools, equipment and fixtures, knowledge of the technological process, the recommended category.
Students draw up a diary of work practice, in which they indicate the types of work performed, the category, the quality of the work. At the end, the date of completion of the work is put, the signature of the responsible person and certified by a seal.
General provisions
Students undergo work experience at the workplaces of enterprises, where, if possible, they will work after graduating from the technical school.
Fund time for field trip 216 hours over 6 weeks. According to the agreements, students of the educational group are distributed among the enterprises of the district, taking into account the specifics of the profession.
The mode of work of students: work under the guidance of a mentor or as part of teams in one or two shifts in accordance with the regime operating in the shops or at the sites of enterprises.
The duration of the working day of students is determined by the Constitution of the Russian Federation and the legislation on the labor of adolescents. For students over 18 years of age - 41 hours per week, under 18 years of age - 36 hours per week.
Graduates who have mastered the profession are assigned the third category of an electric and gas welder. The best students, by decision of the State Examination Commission, may be assigned the fourth category.
The practice is managed by a master of industrial training with the help of highly qualified workers. Control over the course of practice is carried out by the senior master and the deputy director of the school for educational and production work according to the control schedule.
Targets and goals
The purpose of pre-graduation work practice, as the final stage of the educational process, is to complete industrial training and prepare the future worker for independent high-performance work at the enterprise.
The main tasks of pre-graduation work practice: Adaptation of students in specific work conditions.
Education of conscious discipline, comradely mutual assistance, respect for the traditions of the enterprise and the desire to increase them.
Consolidation and improvement of professional knowledge, skills and abilities in the chosen profession.
Accumulation of experience in independent performance of work of an electric and gas welder of 3-4 categories.
Study of technical documentation, new production technologies.
Acquisition of skills to work on modern equipment.
Formation of such professionally valuable qualities as speed of reaction, accuracy, coordination of actions, observation.
Types of jobs
Students must perform the work of an electric and gas welder of 3-4 categories.
Instruction on labor safety, study of instructions on the organization of the workplace and safe working methods. Inspection of the workplace, checking the availability and serviceability of tools and devices, signaling and protective devices, fire fighting equipment. Accurate and accurate journaling.
Performing work in the workplace. Compliance with operating parameters, requirements, technological process. Periodic quality control of products, equipment operation.
Compliance with the procedures for equipment malfunctions.
The study and application of advanced high-performance techniques and methods of work, tools, fixtures, equipment used in welding.
Implementation of measures for the most efficient use of working time, prevention of marriage, economical use of materials.
Preparation of the workplace for delivery. Fulfillment of obligations for the exemplary content of the workplace. Shift delivery. Maintaining diary entries.
Thematic plan
Name of topics
Hours
1. Introductory lesson. Learning objectives. Briefing on the organization of the workplace, the study of the technological process, documentation. Safe practices in the workplace.
2. Independent performance of work with a complexity of 3-4 digits of manual arc welding.
3. Independent performance of work with a complexity of 3-4 gas welding categories.
4. Control of welding work.
5. The study and application of progressive technology and advanced techniques and methods of work.
6. Trial qualifying work and final qualifying examinations.
With each movement during the internship, it is necessary to conduct a three-hour safety briefing to develop and consolidate automatic skills for the perfect implementation of labor safety requirements (due to the time for each topic).
1. Briefing on safe working conditions and familiarization with the workplace (6 hours)2. Independent performance of manual arc welding works (150 h) 1) Welding of beams and frames - Procurement operations - Assembly of parts for welding - Welding of I-section beams - Welding of box section beams - Welding of frames 2) Welding of lattice structures - Procurement operations - Assembly of parts for welding - Welding of lattice structures3) Welding of pipe structures- Blanking operations- Assembly of parts for welding- Welding of pipelines4) Welding of shell structures- Blanking operations- Assembly of parts for welding- Welding of tanks5) Surfacing and cutting of parts- Surfacing of parts for machining- Manual arc cutting- Cutting and adjustment of parts from profile metal-cutting of workpieces from alloyed steel4. Control of welding works (36 h)3. Independent performance of gas welding works (30 h) - Welding of silencers - Elimination of defects in car parts by welding - Elimination of shells in castings - Welding of a tank for non-flammable liquids - Welding of ventilation pipes - Welding of free-flow pipes for water - Elimination of defects in fittings made of bronze and brass - Surfacing of steels for defective forgings - Soldering of malleable iron parts - Oxyfuel cutting4. Control of welding works (6 hours)5. Learning and applying progressive technology and advanced labor methods and techniques (30 hours) - Learning how to increase productivity - Three-phase arc welding - Recumbent electrode welding - Deep penetration welding6. Qualifying exams (6 hours)
performance of standard locksmith operations used in the preparation of metal for welding;
Preparation of cylinders, control and communication equipment for welding and cutting;
Assembly of products for welding;
Assembly accuracy checks.
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