TSUEISHI@eoocceccercecesereceeeccercesecoe TRAINING MODULES Cee cecceccececeerecceccercceccoe TSUNEISHI HEAVY INDUSTRIES PRACTICAL TRAINING Welding equipment setup, handling, operation, and fundamentals are easy to understand. Training programs aid in quick parameter discovery and lay the groundwork for real application optimization The training program is broken down into distinct modules, allowing for the creation of unique training packages to satisfy a variety of objectives. Basic modules are identified with an A include the basic principles of welding and 2015 DAIHEN Welding Machine. Modules identified with B include the parts and its description. C-modules include safety instructions and installation. D includes operation recommendation and maintenance instructions. E covers the preventive and curative measures for quality control (e.g. blow holes). COURSE MATRIX PRINCIPLES. OF WELDING 2015 DAIHEN oo WELDING MACHINE PARTS AND DESCRIPTION SAFETY ane — INSTRUCTIONS INSTALLATION OPERATION RECOMMENDATION|* | MAINTENANCE QUALITY CONTROLCeoecec cer ceceeerecceccoerccevccce SCOPE OF TRAINING MODULE A MODULE Course Content Duration A Basic Principles of Welding |. Outline of the Welding Process a. Manual Welding (SMAW) 41 WEEK Il. Positions of Application to Hull Construction Ill. Edge Preparation A. BASIC PRINCIPLES 1, OUTLINE OF THE WELDING PROCESS MANUAL WELDING It is also known as Stick Welding. The entire electrode is coated with an inert gas (flux). The key advantages of SMAW are its flexibility, simplicity, and cost. Welders require minimal equipment to get started and while the manual process does require some training, SMAW is far more forgiving and easy on beginners. A POSITIONS OF APPLICATION TO HULL CONSTRUCTION FABRICATION Butt joints for skin plates, inner bottom plating, deck plating and other structural member. Flat surface shall be welded by Submerged Arc Welding (SAW), CO2 one side welding, and Submerged Arc Welding & CO2 combined. Curve surfaces shall be welded by CO2 one side welding. Fillet joints shall be welded by CO2 gas shielded welding, manual arc welding, and automatic fillet welding 8-line electrode shielded by CO2. Butt joints for other members shall be welded CO2 one side welding and manual arc welding. Repairs shall be done by either manual arc welding or CO2 gas. shielded welding.SCOPE OF TRAINING MODULE A © ee cee cee ce cee eeecec cee ce ec eee Il. POSITIONS OF APPLICATION TO HULL CONSTRUCTION ERECTION . Butt joints for inner bottom plating and deck plating shall be welded by CO2 one side welding and Combined CO2 & Submerged Arc Welding. Butt joints for skin plates, bulkhead joints and other structural members shall be welded by CO2 one side welding. Fillet joints of internal and structural members shall be welded by CO2 gas shielded welding and manual arc welding. Butt joints for other members shall be welded by CO2 gas shielded welding or manual arc welding. Repairs shall by done by either CO2 gas shielded welding or manual arc welding. . . OTHER AREAS Mainly CO2 gas shielded welding and/or manual arc welding are used for the construction/fabrication of ship’s parts. TIG welding shall be done in the pipe shop for the penetration pass (ist pass) of pipe then welded by CO2 gas shielded welding or manual welding to complete the process.SCOPE OF TRAINING MODULE A © ee cee cee ce cee eeecec cee ce ec eee Ill. EDGE PREPARATION STANDARD RULE FOR EDGE PREPARATION (TO BE APPLIED EXCEPT WHEN SPECIFIC PROCEDURE IS MENTIONED.) Stendara Renee Shape of Edge Preparation ee ee Sera | erent footie | ent |SCOPE OF TRAINING MODULE A CO Ill. EDGE PREPARATION STANDARD RULE FOR EDGE PREPARATION (TO BE APPLIED EXCEPT WHEN SPECIFIC PROCEDURE IS MENTIONED.) A. MANUAL ARC WELDING Manual Arc Welding (7) Thickness | Flat Vertical Overhead Horizontal Remarks t<6 r 7 wy | feo To 6 ~42— ‘opty cpresnd a telecon components at cos Gisance FOR NON-PERIODIC MAINTENANCE * The Wire FeedingMechanism must be kept clean,and the rollersurfaces must not be lubricated. * Always remove any deposits on the mechanism with dry air each time you replacea welding wire. * The consumables on the torch should be cleaned regularly. It should be replaced if necessary. Make sure that these materials are original products for long-term use. FOR ERROR CODES It gives an error message when the mains voltage is wrong or thermal. If you do not want the welding performance to be affected during installation, the parameters such as wire diameter, torch, consumables used in the torch, wire type, wire diameter and gas type should be considered. ln a | cRISTMG, [-pearcrdarenwons |" Sea eas cage Sane sap con Steen mn Se ee tighrtine |+Taremaybeantnceasin | Chek mas vag = ‘fi most See cme 7SCOPE OF TRAINING MODULE E © ee cee cee ce cee eeecec cee ce ec eee E. QUALITY CONTROL ‘ON-LINE WELDING QUALITY CONTROL, a ‘ny Gonm tae Cone Pgs) [Non carens — uma |} Weiegites | even msi coe | Luray: ed erie, valtage, welding i a “ Emission spectroscopy, S| woszome |_[nccgenemens er, Levelt 5} dentition ‘chemical composition, speed [~) iMffared emission, acoustic welding, ete. proces, Lo | | Oninetoea—] [Reval wlig rent vangrewmie | [ouiesrianers” |] cormmapens Levelt | "to assure proper ‘chemical compostion, speed - seme || Ste citeetaste BLOW HOLES PREVENTIVE MEASURES: THEORETICAL PART ‘10 Welding Safety Rules ° ° On, 0 © * Proper welding procedure @ a a Coes” * Maintaining positive workspace conditions.@eoeocceccerceceserecseccerscececoe SCOPE OF TRAINING MODULE E © ee cee cee ce cee eeecec cee ce ec eee MODULE Course Content Duration E Quality Control 3 WEEKS BLOW HOLES PREVENTIVE MEASURES: PRACTICAL PART * Use low Hydrogen electrode. * Baking of electrodes before welding as per the recommended procedure. * Thorough cleaning of the joint surface and adjacent area before welding * Preheat the joint before welding. * Ensure sufficient flow of shielding gases if using TIG or MIG welding ¢ Use correct arc distance (within recommended voltage range). 23SCOPE OF TRAINING MODULE E ee oeececeeerccecccecec ce ccce © 0 000 0 00 0 00 0 00 00 000 0 00 0 oe coe MODULE Course Content Duration E Quality Control 3 WEEKS, BLOW HOLES REPARATION MEASURES This section of this module focuses on fixing the blowholes or porosity in welding. One of the multiple problems in welding is the existence of blowholes, sometimes called porosity (Kobelco, nd). Porosity refers to cavity-type discontinuities or pores formed during the solidification of the molten weld metal by gas entrapment (Kobelco, nd). Porosity can occur in the internal and external parts of the metal workspace (Silva, 2020). The existence of blow holes results in frail weld parts and is detrimental to weld quality. Multiple gases may be present in the molten weld pool including hydrogen, oxygen, nitrogen, carbon monoxide, and many more (Kobelco, nd). But hydrogen plays a major part in why porosity in weld metals exists. Several factors are also considered why porosity and blowholes exist in the weldment: CAUSES: REMEDIES: * use of improper electrode * proper electrode and filler * faster arc travel speed material selection * too low and too-high arc currents * reduce the welding * gas entrapment during current solidification use smaller arc length unclean job surface remove rust or oil from the incorrect surface treatment surface improper use of shielding gas preheat the weld area rust or oil on the weld surface reduce welding speed using a longer are ecco BEFORE: AFTER: * Clean the metal surface before * Filling the blow hole using welding metals * Use a chipping hammer/steel brush/grinder * Maintain a current that is equivalent to the stencil strength of the metal * Positioning 24e@coce eeeececceeccce eecccce SUMMARY OF TRAINING MODULES x TSUNEISHI HEAVY INDUSTRIES (CEBU), Inc. TOP MESSAGE