Aluminum GTAW/TIG Fabrication Process 1

Course Number:
MFG 281
Transcript Title:
Aluminum GTAW/TIG Fabrication Process 1
Created:
Aug 15, 2022
Updated:
Jul 12, 2023
Total Credits:
3
Lecture Hours:
0
Lecture / Lab Hours:
60
Lab Hours:
0
Satisfies Cultural Literacy requirement:
No
Satisfies General Education requirement:
No
Grading Options
A-F, P/NP, Audit
Default Grading Options
A-F
Repeats available for credit:
0
Prerequisites

MFG 280

Course Description

Builds on the knowledge of MFG 280 by beginning structural code welding practice and deepening knowledge of GTAW AC processes as they pertain to welding aluminum and alloys. Provides experience creating multipart assemblies as in a production manufacturing environment. Corequisites: MFG 280. Audit available.

Course Outcomes

Upon successful completion of this course, students will be able to:

  1. Create Position 2 Fillet weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.
  2. Create Position 2 Groove weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.
  3. Identify and recognize the oxidation processes of aluminum components as they pertain to weld quality.
  4. Identify common GTAW AC weld errors and their corrections.
  5. Demonstrate knowledge of procedural changes needed for welding different alloys of aluminum.
  6. Create multi-part assemblies from aluminum components with attention to tolerance and appropriate interpretation of a weld process sheet (WPS).

Suggested Outcome Assessment Strategies

Outcomes are assessed through a mixture of hands on and written assessments.  Priority is given to hands-on proficiency based assessment in an environment that rewards demonstration of skill needed for success in industry.

  1. Lecture and in booth coaching and direct instruction.
  2. Direct instruction in full class demonstration of skills.
  3. Written exams.
  4. Student proficiency through demonstration of learned strategies and skills in industry standard environment.
  5. Mock AWS Testing procedure (destructive testing) or mock local industry supported on-site testing procedures.
  6. Job readiness based on performance.
  7. In class lab experiments and testing using the scientific process with written result reporting.

Course Activities and Design

The determination of teaching strategies used in the delivery of outcomes is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: lecture, small group/forum discussion, flipped classroom, dyads, oral presentation, role play, simulation scenarios, group projects, service learning projects, hands-on lab, peer review/workshops, cooperative learning (jigsaw, fishbowl), inquiry based instruction, differentiated instruction (learning centers), graphic organizers, etc.

Course Content

Outcome #1: Create Position 2 Fillet weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.

  • Understand American Welding Society (AWS) D1.2 structural code for aluminum GTAW fillet weld process in position 2.
  • Prepare plate for welding according to structural standard.
  • Weld plate to code specification.
  • Prepare plate for destructive testing per AWS Code.
  • Interpret destructive testing results.

Outcome #2: Create Position 2 Groove weldments using AC GTAW processes suitable for destructive testing as per AWS D1.2 code.

  • Understand American Welding Society (AWS) D1.2 structural code for aluminum GTAW groove weld process in position 2.
  • Prepare plate for welding according to structural standard.
  • Weld plate to code specification.
  • Prepare plate for destructive testing per AWS Code.
  • Interpret destructive testing results.

Outcome #3: Identify and recognize the oxidation processes of aluminum components as they pertain to weld quality.

  • Understand the chemical changes / reactions that happen when aluminum is exposed to oxygen in the air.
  • Show understanding of appropriate cleanup and prep procedures based on type and extensiveness of oxidation formation on aluminum.
  • Identify mechanical and chemical processes used to both prevent oxidation of different aluminum alloys and to clean up existing oxidation on aluminum surfaces.
  • Recreate chemical reactions that cause oxidation, and reverse those oxidation reactions.

Outcome #4: Identify common GTAW AC weld errors and their corrections

  • Look at different welds and identify problems in procedure, practice or weldment that have created poor weld quality.
  • Find problems in weldment using destructive testing and determine cause.
  • Using rubric, grade weld quality of peer’s work in position 2 fillet and groove weldments, and recommend corrective actions to improve weld quality. 
  • Find problems in commercially available welded product and produce a corrective action report as a weld engineer or inspector would.

Outcome #5: Demonstrate knowledge of procedural changes needed for welding different alloys of aluminum.

  • Demonstrate knowledge of different frequencies and AC balance to use for welding of 6061 aluminum alloy.
  • Demonstrate knowledge of different frequencies and AC balance to use for welding 5052 aluminum alloy.
  • Identify oxidation correction changes between 5000 series aluminum alloys and 6000 series aluminum alloys.
  • Understand necessary procedural changes to avoid centerline cracking in 5000 series aluminum alloys.
  • Identify oxidation correction procedures and pre-weldment treatment procedures for cast aluminum weldments.
  • Understand procedural differences and best practices for welding “dirty” cast   aluminum.

Outcome #6: Create multi-part assemblies from aluminum components with attention to tolerance and appropriate interpretation of a weld procedure specification (WPS).

  • Demonstrate aluminum specific design processes in creation of a fabricated multi-part assembly
  • Identify possible problems in the assembly and manufacturing of multi-part assemblies as they pertain to GTAW AC aluminum.
  • Create a mock weld procedure specification (WPS) for a multi-part assembly, correctly identifying procedures for removal of oxidation and weldment prep and process preparation.
  • Assemble to tolerance an aluminum multi-part assembly.

Suggested Texts and Materials

Resources are available openly on the web, but largely the curriculum adaptation needs to be done based on the instructors existing skill set.  Since there are many ways to teach the content, the “teach what you know, and teach well what you do” is very appropriate for courses like this.

The following books are recommended:
  • Welding Skills, 5th Edition, B.J. Moniz
  • Welding Skills Workbook, 5th Edition, Jonathan F. Gosse
Some Suggested resources:
  • AWS Structural Code Book 2020
  • Aeorspacewelding.com
  • Thefabricator.com
  • Aws.org
  • Millerwelds.com
  • Lincolnelectric.com

Department Notes

Safety glasses are required at all times in the welding lab and are provided for students. Students may also purchase their own safety glasses from a local supplier. Long pants and closed toed shoes are required in the welding lab at all times. Appropriate clothing must be worn to work in the lab (no synthetic materials, ect.). Safety requirements are covered prior to work in the lab.