Welding 140: Shielded Metal Arc Welding

(SMAW)
Syllabus Fall 2016

WLD 140 Credit(s): 3 Weekly Hrs: Lecture 1/Lab 4

COURSE INTRODUCTION:
Focus on Shielded Metal Arc Welding (SMAW) process: electrode selection and application,
equipment inspection, set-up and operation, welding current and polarity selection, weld joint
types, and all-position lab modules geared towards qualification testing.

Prerequisites/Co-requisites: WLD 100 Introduction to Welding & Industrial Safety, OSHA-

10 Certification

Lab Fees: $300

INSTRUCTOR: Gary Gouin

Office: T23B
Office Hours: Any time by appointment.
Office Phone: 1-800-682-5910 ext. 365
Cell Phone: (906) 281-0853
Email Address: garyg@gogebic.edu

Required Texts and Supplies

REQUIRED: Title: Welding Skills [Hardcover], Author: B.J. Moniz, R.T. Miller, Publisher:
American Technical Publishers (ATP), ISBN-10: | ISBN-13: 978-0-8269-3084-2|
Edition: 5th, (Current Edition)

REQUIRED: Welder’s Kit (or personal welding equipment per instructor approval)
RECOMMENDED: Ipad, Android or Windows Tablet
COURSE OVERVIEW

Major Divisions: (Topics Covered, Including Class/Laboratory Hours)

A) SMAW theory Class: 2 Lab: 8
B) SMAW applications, advantages and disadvantages Class: 2 Lab: 8
C) Equipment inspection and set-up, electrical aspects Class: 2 Lab: 8
D) Electrode principles and classification Class: 2 Lab: 8
E) Welding joint details and preparation Class: 2 Lab: 8
F) Starting and maintaining, breaking and re-starting the Arc Class: 2 Lab: 8
G) Electrode orientation: travel angle and work angle Class: 2 Lab: 8
H) SMAW weld bead characteristics, multi-pass fillet welds,
all position welding modules Class: 2 Lab: 8

TOTAL____Class: 16 Lab: 64

Performance Objectives:
a. Define SMAW.
b. Distinguish SMAW from other welding processes.
c. Contrast common metals welded with SMAW.
d. Explain characteristics of common SMAW electrical components.
e. Identify common SMAW electrode materials.
f. Distinguish between the types of SMAW electrodes.
g. Explain how electrodes are classified.
h. Distinguish between using AC and DC for SMAW.
i. Describe the factors that affect amperage selection for SMAW.
j. Describe the factors that affect voltage for SMAW.
k. Describe common methods for preparing a joint for SMAW.
l. Explain techniques for starting the arc with SMAW.
m. Explain common techniques for breaking and re-starting the arc with SMAW.
n. Distinguish between the methods of electrode orientation.
o. Explain the effects of travel speed on the SMAW process.
p. Demonstrate proper SMAW welding technique in all positions.

Learning Outcomes:
a. Apply introductory SMAW knowledge towards advanced concepts.
b. Classify SMAW electrodes using AWS classification system.
c. Demonstrate proficiency in operating SMAW equipment on carbon steel in all positions.
d. Test completion to SMAW welder performance qualification (2G and 3G, uphill, limited
thickness test plates) on carbon steel.

INSTRUCTOR RESPONSIBILITIES
Fairness and Equality: Each student will be treated fairly and equally. The Instructor makes
every effort to ensure all rules, policies, and assignments are appropriate for the course and apply
equally and fairly to each student. The Instructor reserves the ability to reconsider any element
of the course on a case-by-case basis or with the entire class, and will consider the fairness to all
students when exceptions or changes are granted.

Returning Graded Assignments: The Instructor will attempt to return all grades promptly. I
will aim to post grades within 3 weeks after the assignment deadline unless other circumstances
come about. If no urgent situation hindered grading, then starting 3 weeks after the deadline,
each student will earn 3 additional bonus points on the essay for each calendar day until scores
are made available.

Organization and Flexibility: I will work hard to keep the course on schedule and avoid
making changes during the semester. However, changes are occasionally necessary to adapt to
lab availability or other circumstances. As a result, please be patient when there are changes to
the course during the semester. I will make every effort to highlight any changes with you.

PROCEDURES AND POLICIES

Attendance: Demanding careers in the welding profession require you to be on location before
the start of your work day. It is highly recommended that you practice time management by
arriving fifteen minutes prior to the start of each class.

Gogebic Community College’s attendance policy can be viewed at the following link:
http://www.gogebic.edu/publications/policies.shtm. The instructor will keep an accurate
attendance record of all students for both the class and lab portions of the course. Arriving five or
more minutes late constitutes an unexcused absence. Additionally, voluntarily leaving (being
unaccounted for) before the scheduled end of a class/lab will be considered an unexcused
absence for the entire period. Excessive absences will be reported to the Dean of Students.
Excessive absences incurred by veterans receiving educational benefits will be reported to the
Veterans' Administration as will those of students attending college under other programs
requiring attendance reporting to the sponsoring agency.

Absences exceeding 1/16th of total class hours will be considered excessive. Out of a 16 week
semester, “1/16 total hours” equals one class or lab session. Each unexcused absence will result
in a “zero grade” entry for that class. Additionally, a grade level reduction penalty will be placed
towards the final grade for each unexcused absence. The instructor will not “work with” or
“get caught up” any student who has unexcused absences.

All absences will be unexcused unless prior arrangements are agreed upon by the student and
instructor in advance of a class or lab. “Telling the instructor” you are going to be gone does not
constitute an excuse for being absent. Requests for excused absences for time already missed
will not be granted with the exception of circumstances such as a documented illness, or
emergency(s). Requests for excused absence(s) will be done in person during scheduled office
hours. The instructor reserves the right to refuse claims of illness unless a letter is provided by
the student’s medical professional.

Class Work: A two hour period of study/research is required for each class session. It is
essential for you to plan adequate study time into your weekly schedule. Late homework will
only be accepted for full grade during the first two weeks of classes. No exceptions. Please plan
ahead. It is your responsibility to turn in any due assignments on time or ahead of time.
Students will deliver any late work to the instructor during scheduled office hours (NOT
DURING CLASS). The reduced credit for late work will be a 1 percent reduction from your
grade for each hour late. That penalty time begins immediately upon completion of the
respective class in which the work was due. The maximum consequence per day is a 15 percent
reduction.

Lab Work: Prerequisite lab modules must be completed in their designated order before
progressing on to additional work. It is the responsibility of the student to have all lab modules
completed within two weeks of the end of the semester.

Communication Policy: You are responsible for checking your e-mail twice a week or when
directed to do so by the instructor. If you do not have personal access to your email, computer
labs at GCC are available for your use. You are always welcome to email me with questions
about the course, but I ask that you attempt to find the answers on your own. I will make every
effort to reply within a reasonable time frame. I encourage you to e-mail or contact your
classmates if you require a more immediate response.
Email Guidelines:
1. Make every attempt to find your answer.
2. Contact at least one classmate first.
3. Use professionalism: be respectful, concise, and formal (avoid casual IM language).
4. You may not submit homework via email without instructor permission.

Feel free to contact my office phone or cell phone on matters that require more urgent attention.
I also accept text messages but on a limited, casual basis. DO NOT text me if you are going to
be late or are missing a class.

Academic Support and Advising: The ACES Center on campus provides students with
learning support services to promote their success at GCC. ACES provides advising, tutoring,
and testing services for students. Please visit the ACES Center for tutoring schedules or to make
an appointment for any approved testing service.
TRIO - Student Support Services (SSS) is a 100% federally funded TRiO program authorized by
the U.S. Department of Education. Each year, the SSS program at Gogebic Community College
is awarded funding to provide access and support to students. In order to be eligible for the SSS
program, students must meet one or more of the following criteria:

 First Generation Status: A student, neither of whose parents have completed a four-
year college degree (baccalaureate degree). In the event that one parent supports the
student, eligibility will be determined based on the supporting parent's degree status.
 Income: A student who meets current TAXABLE income guidelines as defined by the
U.S. Department of Education. Please contact an SSS staff member concerning income
guidelines for eligibility.
 Documented Disability: A student with a documented disability that limits her/his
ability to participate in college. Students are also encouraged to access disability related
accommodations.
ADA Accommodations for Students with Disabilities: If you believe that you need academic
accommodations for a disability that qualifies under the Americans with Disabilities Act and
Section 504 of the Rehabilitation Act, please contact the Office of Disability Services, located in
office T105C of the ACES Center, call (906) 932.4231 x 237, or e-mail jessicaln@gogebic.edu
to discuss your needs and the process for requesting accommodations. This office is responsible
for coordinating disability-related academic accommodations and will issue students with
verification letters as appropriate. Since accommodations may require early planning and
generally are not provided retroactively, please contact the office as soon as possible.
NOTE: As your instructor, I’m happy to provide you every opportunity to succeed and
provide whatever resources you may need regardless of your status with our ADA office.

GCC Policy on Dishonesty and Cheating: The GCC student handbook explains, “Dishonesty
of any kind, including plagiarism, cheating on examinations or any assigned work, may be dealt
with in any manner deemed suitable by the instructor, including the recording of a failing grade
for the course. Cheating on examinations may also result in the student appearing before the
Conduct Committee and possible suspension from school if circumstances warrant.” Academic
dishonesty includes any attempt by a student to submit someone else’s work as his/her own.
Examples include a student: Performing lab work such as welds or cutting for another student,
submitting an assignment as original work that was created by another person, using someone
else’s work without proper permission and citation. Regardless of whether the academic
dishonesty was intentional or not, the same penalty will be applied.

Team Work: The purpose of team work is to combine the individual strengths of you and your
peers into an employable pool of skilled workers. Some assignments may be assigned as group
work.

Conference Requirement: Conferences will be required. The purpose of having conversations

with the instructors is to provide students with a direct opportunity to ask questions and discuss
individual and group strengths and challenges.

Limits of Confidentiality: Most communication between students and the instructor will be
treated as confidential. However, if you communicate something that violates procedures or
policies or that seriously threatens the safety of you or others; I am legally and ethically required
to report it to the college administration and/or the proper authorities. If you feel you still need
to share that information with me, please understand I will report it.
Examples include:
 Violations of drug, tobacco or alcohol policies
 That someone is seriously hurting or abusing you
 That you plan to seriously hurt or abuse yourself or someone else
 Something that presents a serious threat to your safety or the safety of your classmates
COURSE ASSIGNMENTS

Class Assignments (10 pts): A weekly class assignment will be given to prepare and reinforce
your development in the welding lab. Each assignment will be graded and converted to 10
points which are entered into your score chart.

Skill Builders (10 pts): Each week will include a lab module in which you will perform the
required skill to a set of predefined standards. Your work will be graded and converted to 10
points which are entered into your score chart.

Extra Credit (5 to 30 points): There are options for extra credit, and if necessary, you can
complete all options to reach 30 extra credit points. No student may earn more than 30 points
of extra credit.
Grading:

Class/Lecture Lab
Point Skill Point
Assignment Value Builder Value

Week 1:-Ch. 8 SMAW SMAW Theory 10 Lab 140.1 10

SMAW advantages
Week 1 -Ch. 8 SMAW and disadvantages 10 Lab 140.2 10
Week 2 – Ch. 10 Essential Electrode
Striking an Arc Variables (1) 10 Lab 140.3 10
Week 2 – Ch. 11 Essential Electrode
Depositing Beads Variables(2) 10 Lab 140.4 10
Week 3 – Ch. 24
Surfacing SMAW applications(1) 10 Lab 140.5 10
Week 3 – Ch. 26
Repair Welding SMAW applications(2) 10 Lab 140.6 10
Week 4 – Ch. 9 AWS
Electrodes & Review A5.1/A5.4“Electrodes 10 Lab - Midterm

Week 4 MID TERM 25 MID TERM 25

Week 5 - Ch. 40 Tool Exotic Alloy SMAW
Steels & Cast Electrodes 10 Lab 140.7 10
Week 5 – Ch. 41 SMAW Stainless
Stainless Steels Steels 10 Lab 140.8 10
Week 6 –Ch. 43 SMAW Dissimilar
Dissimilar Metal Welding Metal Welding 10 Lab 140.9 10
Week 6 – Ch. 12 Flat, SMAW Flat and
Ch. 13 Horizontal Horizontal Plate 10 Lab 140.10 10
Week 7 – Ch. 14 SMAW Vertical and
Vertical, Ch. 15 O.H. Overhead Plate 10 Lab 140.11 10
Week 7 – Ch. 27 Pipe SMAW Pipe – All
Welding positions 10 Lab 140.12 10

Week 8 (Review) Final Review Lab Final

Week 8 FINAL 25 FINAL 25

TOTAL POINTS POSSIBLE 180 170 = 350

Grade Percentile Scale Grade Points Scale

465 to 500 A
450 to 464 A-
435 to 449 B+
415 to 434 B
400 to 414 B-
385 to 399 C+
365 to 384 C
350 to 364 C-
335 to 349 D+
315 to 334 D
300 to 314 D-
0 to 299 F