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LEARNER GUIDE
PERFORM ADVANCED WELDING USING OXYACETYLENE
WELDING PROCESS (OAW)
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TABLE OF CONTENTS
PAGE
Introduction................................................................................................................................... 1
Welcome ............................................................................................................................. 1
This Competency Unit ........................................................................................................ 1
Before You Start ................................................................................................................. 2
Planning Your Learning Programme .................................................................................. 2
Self-Assessment Checklist.................................................................................................. 3
How To Use This Learner Guide........................................................................................ 5
Using The Computer And Other Resources ....................................................................... 6
Method Of Assessment ....................................................................................................... 6
Quality Assurance............................................................................................................... 7
LG-MEMFAB0072A:
PERFORM ADVANCED WELDING
USING OXYACETYLENE WELDING
PROCESS (OAW)
INTRODUCTION
Welcome
Welcome to the Learner Guide for Unit of Competency “Perform Advanced Welding Using
Oxyacetylene Welding Process (OAW)”. This is just one of a number of Learner Guides
produced for the maintenance stream of the Metal, Engineering and Maintenance Industry, and it
is designed to guide you, the learner, through a series of learning processes and activities that
will enable you to achieve the specified learning outcomes for the competency unit.
The content of this guide was developed from the Competency Standard LG-MEMFAB0072A,
which is one of the basic building blocks for the National Vocational Qualification of Jamaica
(NVQ-J) certification within the industry. Please refer to your Learner’s Handbook for a
thorough explanation of standards and competencies, and how these relate to the NVQ-J
certification.
You are also advised to consult the Competency Standard and assessment instrument for a better
understanding of what is required to master the competency.
Element 7: Clean up
As you go through each element, you will find critical information relating to each one. You are
advised to study them carefully so that you will be able to develop the necessary knowledge,
skills and attitudes for performing advanced welding using oxyacetylene welding process.
a. Obtain a Learner’s Logbook. You will use it to record evidence of your new
skills/competence. As you demonstrate your new skills, record your activities and have your
learning facilitator sign off on them. This will allow you to provide evidence of your
competence when you are being assessed against the competency standard.
b. Ensure that you have access to the facilities and equipment necessary for learning.
d. Ensure that you are wearing suitable clothing, that tools and equipment are safe, and that the
correct safety equipment is used.
The self-assessment checklist on the following pages will assist you in planning your training
programme and it will help you to think about the knowledge and skills needed to demonstrate
competency in this unit. As you go through each one you will be able to find out which aspects
of the elements you have already mastered and which ones you already have and which you will
need to pay more attention to as you go through the learning process.
To complete the self-assessment checklist, simply read the statements and tick the ‘Yes’ or ‘No’
box. You should do this exercise now.
Self-Assessment Checklist
Perform Advanced Welding Using Oxyacetylene Welding
Process (OAW)
If you ticked all or most of the ‘Yes’ boxes, then you might not need to go through the entire
guide. Ask your learning facilitator to assist you in determining the most appropriate action you
should take.
If you ticked a few of the ‘Yes’ boxes or none at all then you should work through all of the
guide, even though some of the material may be familiar to you.
Plan your learning based on your answers. Be sure to involve your learning facilitator in the
planning process.
This Learner Guide is designed to assist you to work and learn at your own pace.
• Check your progress at each checkpoint to ensure that you have understood the material
• Observe the icons and special graphics used throughout this guide to remind you of what you
have to do and to enhance your learning. The icons and their meanings are as follows:
Definition Box
Words/phrases are defined or explained in this box. The
words/phrases being explained are in bold print.
Checkpoint
This denotes a brain teaser and is used to check your
understanding of the materials presented. No answers are
provided for the questions asked.
Activity
This denotes something for you to do either alone or with
the assistance of your trainer/supervisor.
Reference
Points you to the reference materials and other support
documents or resources used in compiling the unit content.
• Ask your learning facilitator for help if you have any problems with the interpretation of the
contents, the procedures, or the availability of resources.
• Complete each activity as you come to it. If the activity requires you perform an actual task,
be sure to tell your learning facilitator when you get to that activity so that he/she can make
any arrangements, if necessary.
• Get your learning facilitator to sign and date the Learner Logbook when you have completed
an activity.
When you have worked through all elements of the guide, and when you can tick every ‘Yes’
box, you are ready for assessment and should ask your learning facilitator to assist you in making
the arrangements to have your performance assessed.
Where your activities refer you to the library, computer and Internet resources, ask your learning
facilitator to assist you with locating these resources. If you are getting your training in an
institution, there may be a library and a computer laboratory. If this is not the case, visit the local
library and find out what resources are available.
If you are new to the computer and the Internet, someone in the computer room should be able to
show you how to use these resources.
Please note that in many of your activities you have been referred to information on the Internet.
This is because the Internet has a vast amount of information that can help you in acquiring the
particular competencies. We would like to advise you, however, that we cannot guarantee that
all the sites will be available when you need them. If this happens, ask your learning facilitator
to assist you with locating other sites that have the information you require.
Method of Assessment
Competency will be assessed while you are actually performing the tasks related to this
competency. This may be in a real workplace or a simulated situation that accurately relates to
the work situation. You are advised to consult the associated competency standard for further
details relating to the assessment strategies.
Quality Assurance
A feedback form is included at the back of each learner guide, so all users are afforded the
opportunity to document their concerns pertinent to the various aspects of the guide. Such
concerns will assist in the review process of the learner guides. Users are encouraged to cut out
the form, complete and submit same to the address provided.
You may now start your learning. Have fun while you work!
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills and attitudes required to
select welding equipment and consumables. Your learning facilitator is there to assist you with
the various activities, so that on completion you should be able to:
1. Select correct welding equipment and consumables from weld procedure specifications.
Any job that is done in an established industry such as welding must conform to established
practices to ensure uniformity of quality. National and international codes and regulations must
be adhered to in order to ensure that welding practices are of the highest quality and standard.
Whenever you engage in any type of project, there are some key factors which should be noted:
Acetylene is a fuel gas and should be referred to by its proper name and not by the word gas.
Always use a regulator with the cylinder. Use cylinder upright and store in dry places. Always
test for leaks.
Oxygen should be referred to by its proper name, “oxygen”, and not by the word “air”. Care
should be taken when using an oxygen cylinder. Oxygen by itself cannot burn; it supports
burning. Never use oxygen as a substitute for air. The care for valves required on the oxygen
cylinder is almost the same as for acetylene cylinders.
It is very important to have the correct hose for the required gas. The colours are red for the
acetylene and other fuel-gases, green for oxygen, and black for inert gas and air. Hoses must be
in good condition to prevent fires and explosions. Keep all hoses away from hot objects, and
avoid oil and grease, which will cause the rubber to deteriorate and increase the risk of fire. Do
not repair hose with tape. Hose connections should conform to regulations and standards of the
International Acetylene Association.
Pressure reducing regulators must be used for the gas and pressure intended for.
When toxic gases, fumes, and dust are generated, proper protection are required. Welding fumes
can originate from fluxes, the coating or the flux and material being welded. The space in which
the welder operates is very important, such as height of the ceiling. When welding in a confined
space such as a tank, boiler or small compartment, good ventilation is necessary. When welding
on high-rise building, special precautions are required such as railings, safety belts, lifelines or
other safeguards.
Faulty storage can be dangerous especially when storing materials such as steel pipes, sheet steel,
and plates. Proper slacking is of great importance. Faulty or electrical wiring can cause fire and
electric shock. Trained electricians should be used to service electrical equipment. Good
housekeeping is important on welding job. Tools or other objects should be safely stocked away
to prevent hazards.
Handling cylinders
The mixture of flammable gases and air, which is highly explosive, is used in the application of
oxyacetylene welding and cutting. The following precautions are required when using cylinders:
• When lifting cylinders with a crane use a cradle on platform. Never use a sling to lift
cylinder. Never drop cylinders or allow them to strike each other violently
• To move cylinders tilt and roll them on their bottom edges. Never drag or slide them. If
transferred in a carrier, they should be fastened securely
• Cylinders should be fastened securely while in use
• Never move unattached cylinders with the regulators on. Cylinder valves must be closed
and capped before being moved. Close valve of empty cylinders, and replace the valve
protection caps, and mark MT (empty) on them
• Close cylinder valves when work is completed
• Keep cylinders away from welding and cutting operations so that hot slag, sparks, and
flame cannot reach them
• Never tamper with the number stamped on the cylinders; this is illegal. Never tamper
with the valves on safety devices or valves on cylinders
• Never attempt to refill a cylinder
You should observe and familiarize yourself with the types of tools and equipment used in the
welding trade. It is important to thoroughly check all tools for any faults and report to your
immediate supervisor. Defective tools should not be used because this will cause injury to
yourself and others. Various types of tools and equipment are used in welding process. Proper
care must be taken in maintaining and using these tools and equipment. Tools and equipment
used in the welding industry include:
Power Tools
It is very important to select the right tools for the particular job. Using the wrong tools for the
job can cause injury to yourself and others. When using tools make sure the tools and your hands
are free of oil and grease; this will help to prevent the hand from slipping and causing any injury
to yourself.
CHECKPOINT
ACTIVITY
Now that you have completed this element, see if you have fully grasped all the components by
doing the following Self-Assessment:
Checklist 1 Yes No
Checklist 2 Yes No
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills, and attitude required to
assemble welding equipment. Your learning facilitator is there to assist you with the various
activities, so that on completion you should be able to:
1. Assemble and set up welding equipment, including cylinders, regulators, hoses, torches
and tips safely in accordance with standard operating procedures
Assembling and setting up your oxy-acetylene equipment is important for a successful operation.
The oxy-acetylene welding equipment should include:
• Acetylene cylinder
• Oxygen cylinder
• A means of securing the cylinders in an upright position.
• Acetylene and oxygen regulators and gauges
• Acetylene and oxygen hoses
• Welding torch
• Spark lighter
• Safety equipment
ACTIVITY
Any job that is done in an established industry such as welding must conform to established
practices to ensure uniformity of quality. National and international codes and regulations must
be adhered to in order to ensure that welding and practices are of the highest quality and
standards.
Whenever you engage in any type of project, there are some key factors, which should be noted:
In order for you to maintain a high level of quality you should practise the following:
CHECKPOINT
ACTIVITY
CHECKPOINT
ACTIVITY
Now that you have completed this element, see if you have fully grasped all the components by
doing the following Self-Assessment:
Checklist 1 Yes No
Checklist 2 Yes No
As you go through this element, you will acquire the knowledge, skills, and attitudes to weld
joint to standards or equivalent. Your learning facilitator is there to assist you with the various
activities, so that on completion you should be able to:
You should be familiar with the symbols used in welding as these will guide you to the type of
welding required for a specific job. The interpretation from the drawing/blueprint of these
symbols is important to the reduction of defects.
When there are symbols on a drawing you should note the location of the arrow with regard to
the joint. When the weld is to be made on the arrow side of the joint the weld symbol is placed
on the reference line.
When the weld is on the other side of the joint this is specified by placing the weld symbol on the
reference line away from the joint as shown on the illustration below:
Fig. 1
Look at the figures below on the left and the right to help you read the eight elements of a weld:
Fig. 2
Each element is numbered and illustrated separately and explained in the following:
• (1) This shows the reference line, or base, for the other symbols
• (2) This shows the arrow. The arrow points to the location of the weld
• (3) This shows the basic weld symbols. In this case it should be a fillet weld located on
the arrow side of the object to be welded
• (4) This shows the dimensions and other data. The 1/2 means the weld should be 1.27 cm
(1/2 inch) thick
• (5) The 2-4 means the weld should be 5.08cm (2 inches) long (L) with a center spacing or
pitch (P) of 4 inches
• (6) This shows the supplementary symbols. This supplementary symbol means the weld
should be convex
• (7) This shows the finish symbol, G, which means the weld should be finished by
grinding. Note that the finish markings that show the degree of finish are different.
This also shows the tail. It is used to set off symbols that order the machinist to use a
certain process or to follow certain specifications or other references; in this case,
specification A-1. The tail will be omitted if it is not needed for this purpose
• (8) This shows the specifications, process, or other reference explained in item 7. In this
example, the tail of the symbol indicates the abbreviation of a process-oxyacetylene
welding (OAW)
Once you have a full understanding of the different symbols your interpretation of the different
welds, such as bead, groove, fillet and plug should be easier.
Use the diagram above to guide you with the different bead welds.
Fig.3
Fig. 4
CHECKPOINT
ACTIVITY
You should follow the sequence below to make any of the above welds:
• Make sure that all personal protective equipment (PPE) is being used
• Remove all flammable materials and solvents from the welding area
• Position the metal, using clamps if needed
Joint Weld
Fig. 5
You should interpret the type of joint from the symbols on the drawing.
You should follow the following procedures to achieve the specific joint weld.
This procedure should be used for all joints with emphasis on the location of the joint.
Fig. 6
Tee joint- single pass fillet weld, Lap Joints and Butt joints in heavy sections
Weld positions
You should weld in a flat or down hand position as much as possible. This position is standard
and the simplest way to do a weld.
• Vertical
• Horizontal
• Overhead
Vertical position is welding in an You should use this technique on thin metal because
upward or downward position on a penetration is shallow and reduces the possibility of
surface burn through.
The molten metal has a tendency to run downward and pile up when welding is done on a
vertical surface. A joint with excessive reinforcement at the lower end will result and some
undercutting on the surface of the plates if a weld that is not carefully made.
The manipulation of the torch and the filler rod keeps the metal from sagging or falling and
ensures good penetration and fusion at the joint. The flew of metal can be controlled by pointing
the flame upward at a 45 degree angle to the plate, and holding the rod between the flame and the
molten puddle . Both the torch and the welding rod should be moved back and forth to deposit a
uniform bead. The welding rod should be held slightly above the center line of the joint, and the
welding flame should sweep the molten metal across.
Horizontal position is
welding metal in straight-
line direction.
Welding at times must be done in the position in which the part will be used hence welding
cannot always be done in the most desirable position.. Often that may be on the ceiling, in the
corner, or on the floor. Proper description and definition is necessary since welding procedures
must indicate the welding position to be performed, and welding process selection is necessary
since some have all-position capabilities whereas others may be used in only one or two
positions.
Fig. 7
Horizontal welding
You should be aware of the torch and welding rod position for welding overhead butt joints. The
flame should be directed so as to melt both edges of the joint. To maintain an adequate puddle
with enough reinforcement, sufficient filler metal should be added. To avoid burning the
welding flame should support the molten metal and small welding. Only a small puddle is
required, so a rod should be used. Care should be taken to control the heat through the plates.
This is particularly important when welding is side only
Fig. 9
CHECKPOINT
ACTIVITY
You may be required to work on different types of metal using your arc welding skills. The
different metals require different approaches. You can use the following procedures:
You should have some knowledge of the kind of work the metal will perform as this will assist in
your selection of electrodes. Once you have selected your electrodes using the procedures
explained in element 1, you then need to prepare the surface for welding:
• Remove all rust with a wire brush, grease and other foreign matter by grinding
• Deposit string beads parallel (with flow of abrasive material that is used on heavy rocks
and perpendicular on material that are used on sand and soil).
Aluminium
You should remember that aluminum is a nonferrous metal that has no iron and as such has high
heat conducting properties. Aluminum alloys have an approximate melting range from 482 to
660°C (900 to 1220°F).
Galvanised
You should note the thickness of the galvanized metal as the incorrect temperature may result in
burn through. If you select the incorrect rod fusion will be incomplete.
• Heat the end of a 3.2 mm (1/8 in.) low carbon welding rod until approximately 12.7 mm
(1/2 in.) of the rod is molten.
• Hold the rod so that the molten end is above the joint to be welded
Pipe
You will require using all the techniques that were outlined above as pipes are made from high
carbon, aluminum, and galvanised steel.
The most common welding that you will require to do is to weld the circumference.
CHECKPOINT
ACTIVITY
Now that you have completed this element check if you have fully grasped all the components by
doing the following self-assessment.
Checklist 1 Yes No
Checklist 2 Yes No
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills and attitude required to
inspect welds. Your Learning Facilitator is there to assist you with the various activities, so that
on completion you should be able to:
Weld inspection can be classified as destructive or nondestructive. The former method is very
costly so therefore you should do a nondestructive inspection.
You should use the drawings to assist you on your inspection, as the symbols will guide you to
identify the correct specifications. You should also look for faulty welding. Here are some of the
things to look for in your inspection:
Poor fusion
• Faulty preparation
• Improper welding techniques
• Wrong speed
• Improper choice of rod size
• Wrong temperature
Poor Fusion
Fig. 11
Crack weld
Fig. 12
Distortion
• Excessive spatter- weld deposit placed all over the joint and away from the joint
• Poor fusion- the connection between the two surfaces is weak and in some cases burn
• through.
• Cracked weld- the bead is not smooth, there are lines running through the weld deposit.
• Distortion- one side of the metal is out of shape or bent (angular or longitudinal)
You should inspect the entire joint for any of these defects with the use of a wire brush or
chipping hammer. These tools will help you to remove any material that may prevent you from
seeing the weld properly.
Once you have seen the weld, you can use Weld Fillet Gauge to check and measure the undercut,
mismatch and groove weld height. This you can do by placing the gauge on the weld. When the
pointer is placed on the edge of the weld leg the height of the arrow will indicate weld leg size.
Refer to: The Five Essential Variables of Smaw (Stick) Welding available at
:http://deltaschooloftrades.com/stick%20essentials.htm Accessed
15/06/06
CHECKPOINT
• What are some of the signs of excessive spatter and poor fusion?
• Why do they occur and how can they be prevented?
ACTIVITY
• Examine all the welds that you have done and four other welds in
the workshop and do a visual inspection for defects.
• Develop a checklist to determine all the areas to consider when
carrying out an inspection and submit to your learning facilitator.
• List the defects and share them with colleagues and your learning
facilitator.
Now that you have completed this element check if you have fully grasped all the components by
doing the following self-assessment.
Checklist 1 Yes No
Checklist 2 Yes No
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills and attitude required to
correct defects. Your learning facilitator is there to assist you through the various activities, so
that on completion you should be able to:
1. Remove and correct defect with minimal loss of sound metal, applying correct and
appropriate techniques.
You may reduce the defects of your weld by ensuring that you follow the proper techniques and
procedures. You should however remember that not all defects are based on the skill of the
welder but also the machine that you work with. The machine controls the amperage.
• Excessive spatter is corrected by using the wire brush to rub off the excessive weld. To
remove the heavier deposit you should use a small chisel and hammer and gently chip the
deposit off the surface. To prevent this from happening again, change your angle of the
arc when welding
• Poor fusion is corrected by chiseling off the weld at the joint and doing over the weld.
Change your angle and reduce your pass over speed
• Cracks are corrected by using a wiring with a lower tensile strength or a different
chemistry. Increase the joint by preheating to slow weld cooling rate, allowing the joint to
expand and contract during heat or increase the size of the weld
• Distortion is your most difficult defect to correct with minimal loss of sound metal. You
will reheat the metal and use a hammer to reshape the metal so that its shape will change
when the metal cools
You should be able to prevent some of these defects when welding joints again. You can
prevent:
Distortion by:
Remember: You should be able to inspect, identify and correct defects and reduce the loss of
metal by doing the correct procedures.
Refer to: Minnick, William H. (1996), Gas Metal Arc Welding Handbook,
The Goodheart- Willcox Co., Inc.
CHECKPOINT
What are five different ways that you can prevent defects caused
by excessive spatter?
ACTIVITY
Using the joint that you have been working with in the previous
elements, classify the defects. Use the technique learnt to correct
the defects under the supervision of your learning facilitator. You
should take into consideration occupational health and safety
issues.
Now that you have completed this element check if you have fully grasped all the components by
doing the following self-assessment.
Checklist 1 Yes No
Checklist 2 Yes No
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills and attitude required to
maintain weld records. Your learning facilitator is there to assist you with the various activities,
so that on completion you should be able to:
You should record the entire details specific to your welding job. This is required so that anyone
checking your work will be able to determine the following:
• Machine
• Amps
• Position
• Shop/site
• Joint location
• Metal electrodes
• Date
You should complete the standard form available and should also include tests done to meet
quality assurance. Your test should be either non-destructive or destructive. On the following
page there is a standard form used by welders.
CHECKPOINT
ACTIVITY
Check all the welds that you have done from the start of the
learner guide and record all the information on the form above
and discuss with your learning facilitator.
Do a comparison with your peers regarding how well you
followed the process of completing the form and allow your
facilitator to evaluate and correct if necessary.
Now that you have completed this element, see if you have fully grasped all the components by
doing the following Self-Assessment:
Checklist 1 Yes No
Checklist 2 Yes No
ELEMENT 7: CLEAN UP
LEARNING OUTCOMES
As you go through this element, you will acquire the knowledge, skills, and attitude required to
clean up after completion of work. Your learning facilitator is there to assist you with the
various activities, so that on completion you should be able to:
Cleaning up the worksite is very important. You should pay attention to this part of the job. As
you complete the task of cleaning up, there are a few things to bear in mind.
If you do not practise cleanliness you could end up doing the job again or causing additional
expense. By removing debris and other waste you can decrease the potential for danger on a site.
In the event that you will be leaving the work area for a short time, take nothing for granted, try
to leave it as safe as possible especially if an authorized personnel will not be present.
Weld residue should be placed in a wheelbarrow and removed from work area. Chisel off the dry
weld deposit and used electrodes.
You should remove the electrodes and metal from the work area. The excess material should be
placed in an area away from the work so that it can be disposed of properly.
All other material should be placed in an area that is easily accessible to the workmen. The area
for the unwanted material should be dry and properly ventilated.
CLEAN EQUIPMENT
Since your equipment plays a very important role in your efficiency, it is definitely a good idea
to properly secure the equipment to prevent theft or injury to persons who are ignorant as to
their operating procedures. Some of these pieces of equipment include:
• Wrench
• Chipping hammer
• Wire brush
Wash the area with a power machine to remove grease and dust.
The Occupational Health & Safety requirements should also be adhered to upon completion of
the job. You should protect your equipment, clear and replace parking area and lock properly
when they are not needed.
There are steps to take before you clean the tools and equipment you have been using. Make
sure of the following:
NB: Follow the manufacturer’s instructions with regard to the respective equipment, or seek
advice on how to make this equipment safe. Secure the best liquid for cleaning them.
When storing, edges should be covered to ensure protection of cutting edge and your safety. If
any defects whatsoever are detected, the equipment must be immediately repaired, removed from
the site for repairs or if irreparable, disposed of. Equipment that is not in use should be stacked
and stored neatly out of the weather or working environment.
CHECKPOINT
ACTIVITY
Make sure that you and your colleagues agree on safety issues, on the job conduct (no alcohol,
for example), storage, cleanup of construction materials, and disposal of hazardous substances.
Know the rules and abide by them for your own safety.
A Clean Finish
A safe working condition can quickly deteriorate when you, your colleagues or a contractor does
not clean up post-welding mess. Spattering in work areas should be picked up daily and cleaned
when the project is finished. You may want to include a provision for professional janitorial
services.
ACTIVITY
You and your colleagues have been given a welding job. You notice
that your colleagues have not been giving special attention to the
cleaning up process. There are consequences for not cleaning your
worksite after completion of a job. What advice would you give your
colleagues about cleaning up?
Now that you have completed this element check if you have fully grasped all the components by
doing the following self-assessment.
Checklist 1 Yes No
Checklist 2 Yes No
Your feedback on the Learner Guides is important to us. Please complete the
form below to indicate areas for review as you see necessary. For each
component tick [√ ] the appropriate column.
Other Issues:
Telephone #: E-mail:
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