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December Edition

2012

MINISTRY OF EDUCATION, MALAYSIA VOCATIONAL COLLEGE STANDARD CURRICULUM MODULE INFORMATION

MODULE CODE LEVEL CREDIT UNIT CONTACT HOUR

: : : : :

JOINTS AND MATERIAL FOR WELDING MWT 202 1 SEMESTER 2 2.0 FACE TO FACE : 4.0 HOURS / WEEK NON FACE TO FACE :

MODULE TYPE PRE RE!UISITE CORE RE!UISITE

: : :

VOCATIONAL MTK 10": MATERIAL AND CONSUMA#LE

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MODULE OUTCOMES: At the end of the course, the students should be able to:1. 2. . !. #. '. ). -. Set up oxy-acetylene cutting equipment and accessories Lay out material for cutting process Set up oxy-acetylene cutting equipment and accessories "ut material using air plasma cutting process $abricate %oints for a gi&en %ob (erform fitting for %oint *ac+ ,eld ,or+ piece .rind ,or+ piece

MODULE DESCRIPTION: *his unit identifies the competence required to set up gas cutting equipment and accessories, lay out material for cutting processes, set up gas cutting flame and cut material using gas and plasma cutting process so that the material is cut to the required si/e, shape and dimensional accuracy as per dra,ing specification. 0t also identifies the competence required to fabricate %oints for a gi&en %ob, perform fitting for %oint, tac+ ,eld, grinding ,or+ piece so that the ,or+ piece is tac+ed, aligned and free from dimensional defect as per specification and ready for ,elding.

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

: : :

WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202

CONTENT STANDARD 1. SET UP O$Y ACETYLENE CUTTING E!UIPMENT AND ACCESSORIES

LEARNING STANDARD 1.1 0dentify and select oxy-acetylene cutting equipment and accessories

PERFORMANCE CRITERIA 1.1.1 0dentify safety precaution related to handling and operating of oxy acetylene cutting equipment according to 1S2A requirement 3 0dentify type of gas required and its application for cutting process. 1.1.2 0dentify principle of oxy-acetylene cutting in accordance ,ith application tas+s, chec+ed for ser&iceability and any faults reported to the super&isor. 1.1. 0dentify and choose oxy-acetylene cutting equipment and accessories for the required cutting process. 1.1.! (ractise cleanliness and tidiness throughout cleaning process in accordance to standard safety procedures. 1.2.1 1.2.2 1.2. 0dentify and perform correct procedure of installing oxy-acetylene cutting equipment and accessories in accordance to standard operational procedures. 4etect and set ,or+ing oxy-acetylene gas pressure in accordance ,ith material to be cut, standards operational procedures and 1S2A regulations. (ractice safety precaution in compliance ,ith ,or+ safety requirement according to 1S2A

1.2 0nstall oxy-acetylene cutting equipment and accessories including no//le

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1. 0nspect lea+age on installed equipment

1. .1 1. .2 1. .

0dentify method of chec+ing lea+ages according to standards operational procedures. "arry out lea+ test on defecti&e parts according to standards operational procedures. (ractise safety precaution in compliance ,ith ,or+ safety requirement in accordance to 1S2A regulations.

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

: : :

WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202

CONTENT STANDARD 2. LAY OUT MATERIAL FOR CUTTING PROCESS

LEARNING STANDARD 2.1 0dentify and select measuring tools and instrument, mar+ing tools and material 2.1.1 2.1.2 2.1. 2.2 "onstruct cutting layout 2.2.1 2.2.2 2.2. 2.2.! 2.2.# 2.2.' 2.2.) 2.2.-

PERFORMANCE CRITERIA 0dentify safety precaution related to handling of measuring tools, instrument and mar+ing tools. 0dentify type of measuring tools and instrument5 mar+ing tools and materials according to ,or+ requirement. 4emonstrate technique of using measuring tools, instrument and mar+ing tools according to 1S2A 0dentify basic geometrical construction for material preparation 0dentify technique for mar+ing medium3material by referring to engineering dra,ing. 6se engineering dra,ing for material preparation to meet required cutting process. Apply related mathematical calculation in metal construction process. 0nterpret dra,ing requirement for mar+ing according to ,or+ specifications. "onstruct basic geometrical de&elopment according to specific ,or+ instructional. 6se measuring and mar+ing tools and instrument according to manufacturer7s specifications and recommendations. 0dentify cutting allo,ances for +erf and ,idth for the required cutting process.
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CONTENT AND LEARNING STANDARDS COURSE MODULE CODE : : : WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202 LEARNING STANDARD .1 0dentify and select type of flame required PERFORMANCE CRITERIA .1.1 Apply safety precaution related to application of oxy-acetylene flame according to manufacturer7s recommendations. .1.2 4efine principle of flame combustions and effect. .1. 0dentify type of flames used according to flame chart characteristic gi&en. .1.! Set cutting flame according to cutting ,or+ requirement. .2.1 Apply safety precaution related to handling and ad%usting of oxyacetylene gas cutting equipment. .2.2 0dentify correct procedures of ad%usting gas. .2. 0dentify causes of bac+ fire and flash bac+ in oxy acetylene cutting process .2.! 4emonstrate procedure to arrest bac+ fire and flash bac+ according to standard operational procedures. .2.# (ractise consciousness, cautious and proper ,or+ing etiquette accordance to 8S3A9S ,elding procedure and standard safety procedures. . .1 Apply safety precaution related to cleaning of materials. . .2 0dentify and select tools for cleaning surface. . . Apply correct methods of cleaning surfaces using tools for cleaning. . .! :emo&e un,anted material from surface and application according to correct technique of cleaning surface.
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CONTENT STANDARD ". SET UP O$Y ACETYLENE CUTTING FLAME AND CUT MATERIAL USING O$Y ACETYLENE CUTTING PROCESS

.2

Ad%ust gas pressure

"lean surface of material

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.!

Select cutting technique

.!.1 0dentify and demonstrate &arious cutting technique according to standard operational procedures. .!.2 0dentify appropriate cutting speeds in cutting process. .!. ;easure tip distance3gap and cutting angle for cutting ,or+. .!.! 0dentify effect of drag and slag in cutting process. .!.# (ractise consciousness, cautious and proper ,or+ing etiquette accordance to standard safety procedures .#.1 Apply safety precaution related to handling of hot material and cutting material according to 1S2A. .#.2 0dentify and use &arious cutting guides in cutting ,or+ according to standard operational procedures. .#. 4etermine cutting allo,ances for the cutting process to meet specific ,or+ dimension. .#.! 1perate gas cutting equipment according to standard operational procedures. .#.# 4emonstrate correct and safe cutting technique according to standard operational procedures. .#.' 2andle hot metal safely in compliance ,ith ,or+ safety requirement .'.1 Apply post cutting process according to standard operational procedures. .'.2 6se measuring tools and instrument to chec+ ,or+ piece after cutting. .).1 Apply correct method to shutting do,n gas pressure according to standard operational procedures. .).2 :elease gas in the hose and manifold according to standard operational procedures .). :elease gas in hoses and regulators according to standard operational procedures. .).! (ractise consciousness, cautious and proper ,or+ing etiquette accordance to standard safety procedures.

.#

"ut material

.'

0nspect ,or+ piece after cutting

.)

Shut do,n equipment

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

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WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202

CONTENT STANDARD 4. CUT MATERIAL USING AIR PLASMA CUTTING PROCESS !.1

LEARNING STANDARD 0dentify air plasma cutting equipment. !.1.1 !.1.2 !.1. !.2 Set compressed air pressure !.2.1 !.2.2 !.2. !.2.! !.2.# !.2.'

PERFORMANCE CRITERIA Apply safety precaution related to handling and operating air plasma cutting equipment according to standard operating procedure. 0dentify capacity and performance of machine according to manufacturer specification. 4efine principle of air plasma cutting process and application in accordance to manufacturer7s specifications. Apply safety precaution related to handling and operating of compressed air according to 1S2A 0dentify compressor operating procedure according to manufacturer specifications. Set pressure and flo, rate of air according to manufacturer specifications. "hoose type of torch-transfer arc and non-transfer arc for require cutting process. Set gauge regulators according to manufacturer7s specifications and recommendations (repare cutting and cooling pressures according to manufacturer7s specifications and recommendations

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!.

0dentify and select cutting !. .1 torch and consumable <tungsten electrode, air no//le, s+irt and collet= !. .2 "ut ,or+ piece !.!.1 !.!.2 !.!. !.!.!

0dentify cutting torch accessories <air no//le, electrode, s+irt, collect etc.= for require cutting process according to manufacturer7s specifications and recommendations. Select no//le and tungsten electrode for require cutting process according to manufacturer7s specifications and recommendations. Apply safety precaution related to cutting process according to Standard operational procedures. Set air pressure, flo, rate and cutting speed for cutting follo,ing standard instruction of cutting process according to manufacturer7s specifications and recommendations 1perate plasma cutting machine according to standard operating procedures. 4emonstrate correct cutting technique to produce metal as required by instructional gi&en Apply correct technique of cleaning ,or+ piece after cutting 4etect and chec+ for contamination due to cutting process according to specific instructional gi&en. (ractise cleanliness and tidiness throughout cleaning process accordance to standard operational procedures. 6se measuring tools and instrument correctly to chec+ ,or+ piece after cutting according to standard operating procedures. (ractise consciousness, cautious and proper ,or+ing etiquette accordance standard safety procedures.

!.!

!.#

"lean ,or+ piece after cutting.

!.#.1 !.#.2 !.#.

!.'

0nspect ,or+ piece.

!.'.1 !.'.2

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

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WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202

CONTENT STANDARD %. FA#RICATE JOINTS FOR A GIVEN TASK #.1

LEARNING STANDARD 0dentify and choose material for preparation of tas+ 0dentify and choose %oint required

PERFORMANCE CRITERIA #.1.1 0dentify and describe types of ferrous and non-ferrous metal and its properties #.1.2 4istinguish type of ferrous and non ferrous metal &isually #.2.1 0dentify basic %oints in ,elding in compliance to 8S and A9S codes and standards. #.2.2 4escribe modification of butt and fillet %oints in compliance to 8S and A9S codes and standards. #.2. 4escribe nomenclature of %oint in compliance to 8S and A9S codes and standards. #.2.! 0nterpret related dra,ing and blue print related to ,elding %oint #. .1 "hoose type of measuring and mar+ing tools in compliance to manufacturer recommendation. #. .2 6se measuring and mar+ing tools and instrument according to manufacturer recommendation.

#.2

#.

;ar+ material

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#.!

(repare edges of material

#.!.1 Apply safety precaution related to handling and operating of oxy acetylene cutting, plasma and mechanical cutting equipment according to standard operational procedures. #.!.2 .i&e definition for arc gouging process in compliance to 8S and A9S code and standards. #.!. 6se oxy acetylene cutting, plasma cutting or mechanical cutting equipment to prepare edges of material according to standards operational procedure. #.#.1 6se measuring and mar+ing tools according to standards operational procedures. #.#.2 >erify dimension of prepared material against specifications. #.#. (ractise safety consciousness, cautious and proper ,or+ing etiquette according to 1ccupational Safety and 2ealth Act.

#.#

0nspect prepared material

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

: : :

WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202

CONTENT STANDARD &. PERFORM FITTING FOR JOINT

LEARNING STANDARD '.1 0nterpret related dra,ing '.1.1 '.1.2 '.1. '.2 Arrange parts '.2.1 '.2.2 '. '. '. '. .1 .2 . .!

PERFORMANCE CRITERIA 0nterpret dra,ing and ,elding procedure specifications according to related dra,ing gi&en. 0dentify types of %oint in compliance to 8S and A9S code and standards. 4ra, radial, parallel, triangulation and intersection de&elopment methods according to 8S3A9S standard . 0dentify and select parts to be fitted for ,elding. 4etermine order of arrangement for material according to ,elding ,or+ requirement. Apply safety precaution related to erecting and fitting of %oint. 0dentify %oints configuration according to 8S3A9S specification. Apply fitting techniques according to 8S3A9S specification. 0dentify and use %igs and fixtures required for specific ,elding process. ?rect %oint for ,elding according to ,elding requirement. Align parts and %oints for ,elding ,or+ according to 8S3A9S specification. 4escribe and distinguish the difference bet,een ,or+ against dra,ing 3 specification according to standard.
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'.

Assemble parts

'. .# '. .' '.! 0nspect fitted parts


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'.!.1

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CONTENT AND LEARNING STANDARDS

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CONTENT AND LEARNING STANDARDS

COURSE MODULE CODE

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WELDING TECHNOLOGY JOINTS AND MATERIAL FOR WELDING MWT 202 LEARNING STANDARD -.1 0dentify and select grinder PERFORMANCE CRITERIA -.1.1 Apply safety precaution related to handling and grinding operation in accordance to standard operation procedure. -.1.2 0dentify types of grinders and grade, classification and si/e grinding ,heels. -.1. 0dentify and choose grinder required for grinding ,or+. -.2.1 Apply safety precaution storage of grinding ,heels according to manufacturer7s recommendation. -.2.2 "arry out maintenance of grinding ,heels according to standard operation procedure. -. .1 (erform technique of grinding ,or+ piece in accordance to standard operation procedure. -. .2 1perate grinder according to standard operation procedure. -. . (ractise safety consciousness, cautious and proper ,or+ing etiquette in compliance ,ith ,or+ safety requirements according to 1ccupational Safety and 2ealth Act. -.!.1 -.!.2 ;easure ground ,or+piece against specification (ractise safety consciousness, cautious and proper ,or+ing etiquette in compliance ,ith ,or+ safety requirements.

CONTENT STANDARD '. GRIND WORK PIECE

-.2 0nspect grinding ,heel

-.

(erform grinding

-.! 0nspect ,or+ piece after grinding

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