Diary on the practice of a welding student who completed an internship at the Rostov metal structures plant "Yuzhtekhmontazh" in 2017.

Diary of educational practice of a 2nd year student of Vocational Lyceum No. 2 in Bataysk, Alexey Nikolaevich Krivoshlykov, specialty 150709.02: “Welder (electric and gas welding work).” The internship took place from 03/13/2017 to 04/03/2017 at the Rostov metal structures plant "Yuzhtekhmontazh".

period	types of jobs	marks
03/13/2017	Familiarization with working conditions, undergoing instructions, studying the rules of safe operation welding work, signing an employment contract.
03/14/2017	Performing standard metalworking procedures related to preparing metal for welding.
03/15/2017 -	Arc welding: Alloys and non-ferrous metals; Seams located in the ceiling position; Seams of complex configuration and circular. Studying the features of pipeline welding, performing pipe welding exercises.
03/17/2017 -	Arc surfacing of beads at weld position: Lateral; Oblique; Horizontal.
03/21/2017	Arc welding of plates located in different positions. Multilayer arc welding, performing welding exercises with an electrode located in an inclined and lying position.
03/22/2017	Gas surfacing and welding of non-carbon steel plates in vertical and horizontal positions. Gas welding of simple and complex components.
March 23, 2017	Automatic and semi-automatic welding of alloys, non-ferrous metals and low-alloy steels.
March 24, 2017	Performing oxygen and oxygen-flux cutting of metals.
March 27, 2017	Working with copper and its alloys - gas welding. Multilayer gas welding. Cold and hot welding of cast iron, welding cracks in cast iron products.
March 28, 2017	Independent preparation of semi-automatic machines for operation, performing arc welding on semi-automatic machines in shielding gas, self-shielding and flux-cored wire. Studying the rules for using two-pole holders when welding with three-phase current.
March 29, 2017	Arc welding on automatic machines in argon and nitrogen environments.
March 30, 2017	Welding of copper and aluminum alloys. Study and practical application of welding techniques with twin and beam electrodes.
03/31/2017	Studying a drawing of a welded structure. Together with the practice manager, manufacturing a metal structure using manual arc welding using a non-consumable and consumable electrode. Application in practice of methods for reducing deformation processes during welding, performing hot melting of welded structures.
04/03/2017	The final day of practice, submitting the final test to the supervisor, writing a report and preparing a diary.

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Abstract: Welding and the work of a welder

Graduate work

Welding and welder's work

Introduction

Welding history

Modern technical progress in industry is inextricably linked with the improvement of welding production. Welding as a high-performance process for manufacturing permanent joints is widely used in the manufacture of metallurgical, chemical and energy equipment, various pipelines, in mechanical engineering, in the production of building and other structures.

Welding is the same necessary technological process as metal processing, cutting, casting, and forging. The great technological capabilities of welding have ensured its widespread use in the manufacture and repair of ships, cars, aircraft, turbines, boilers, reactors, bridges and other structures. The prospects for welding, both scientifically and technically, are limitless. Its use contributes to the improvement of mechanical engineering and the development of rocket science, nuclear energy, and radio electronics.

About the possibility of using “electric sparks” for melting metals back in 1753. said Academician of the Russian Academy of Sciences G.R. Richman in his studies of atmospheric electricity. In 1802 Professor. St. Petersburg Military Surgical Academy V.V. Petrov discovered the phenomenon of the electric arc and indicated possible areas of its practical use. However, it took many years of joint efforts by scientists and engineers to create the energy sources necessary to implement the process of electric welding of metals. Discoveries and images in the fields of magnetism and electricity played a possible role in the creation of these sources.

In 1882 Russian scientist engineer N.N. Benardos, while working on the creation of rechargeable batteries, discovered a method of electric arc welding of metals with a non-consumable carbon electrode. He developed a method of gas-shielded arc welding and arc cutting of metals.

In 1888 Russian engineer N.G. Slavyanov proposed welding with consumable metallurgical electrodes. His name is associated with the development of the metallurgical foundations of electric arc welding, the development of fluxes to influence the composition of the weld metal, and the creation of the first electric generator.

In the mid-1920s. Intensive research into welding processes began in Vladivostok (V.P. Vologdin, N.N. Rykalin), in Moscow (G.A. Nikolaev, K.K. Okerblom). Academician E.O. played a special role in the development and establishment of welding in our country. Paton, who organized in 1992 laboratory, and then the Institute of Electric Welding (IEW).

In 1924 - 1934 Mostly, manual welding was used with electrodes with thin ionizing (chalk) coatings. During these years, under the leadership of Academician V.P. Vologdin, the first domestic boilers and hulls of several ships were manufactured. From 1935-1939 began to use thickly coated electrodes in which the rods were made of alloy steel, which ensured the widespread use of welding in industry and construction. In the 1940s Submerged arc welding was developed, which made it possible to increase the productivity of the process and the quality of welded products, and to mechanize the production of welded structures. In the early 1950s. at the Electric Welding Institute named after. E.O. Paton creates electroslag welding for the manufacture of large-sized parts from cast and forged workpieces, which has reduced costs in the manufacture of heavy engineering equipment.

Since 1948 Gas-shielded arc welding methods have become industrially used: manual welding with non-consumable electrodes, mechanized and automatic welding with non-consumable and consumable electrodes. In 1950-1952 at TsNIITMash with the participation of MSTU. N.E. Bauman and the E.O. Paton Electric Welding Institute have developed a high-performance process for welding low-carbon and low-alloy steels in a carbon dioxide environment, ensuring high quality welded joints.

In the last decade, the creation by scientists of new energy sources - concentrated electron and laser beams - has led to the emergence of fundamentally new methods of fusion welding, called electron beam and laser welding. These welding methods are successfully used in our industry.

Welding was also required in space. In 1969 found by cosmonauts V. Kubasov and G. Shonin and in 1984 S. Savitskaya and V. Dzhanibekov brought welding, cutting, and soldering of various metals in space.

Gas welding, in which the heat of a burning mixture of gases is used to melt the metal, also refers to fusion welding methods. The gas welding method was developed at the end of the 19th century, when the industrial production of oxygen, hydrogen and acetylene began, and is the main method of welding metals.

Gas welding using acetylene is most widely used. Currently, the volume of gas welding work in industry has been significantly reduced, but it is successfully used in the repair of products made of thin sheet steel, aluminum and its alloys, in soldering and welding of copper, brass and other non-ferrous metals; gas-thermal cutting is used in modern productive processes, for example workshop conditions and during installation.

Pressure welding includes resistance welding, which uses the heat generated in the contact of the parts being welded when an electric current passes. There are spot, butt, seam and relief contact welding.

The main methods of resistance welding were developed at the end of XlX. In 1887 N.N. Benardos received attention on the methods of spot and seam resistance welding between carbon electrodes.

Later, when electrodes made of copper and its alloys appeared, these resistance welding methods became the main ones.

Resistance welding occupies a leading place among mechanized welding methods in automobile construction when connecting thin-sheet stamped car body structures. Butt welding is used to connect joints of railway rails and joints of main pipelines. Seam welding is used in the manufacture of thin-walled containers. Relief welding is the most highly productive method of reinforcement for building reinforced concrete structures. Capacitor contact welding is widely used in the radio engineering industry in the manufacture of element bases and microcircuits. One of the most developing areas in welding production is the widespread use of mechanized and automatic welding. We are talking about both mechanization and automation of the welding processes themselves (i.e., the transition from manual labor of a welder to mechanized labor), as well as complex mechanization and automation, covering all types of robots associated with the manufacture of welded structures (blank, assembly, etc.) and the creation of continuous and automatic production lines. With the development of technology, the need arises for welding parts of various thicknesses from different materials; in connection with this, the range of types and methods of welding used is constantly expanding. Currently, parts with thicknesses ranging from several micrometers (microelectronics) to tens of centimeters and even meters (in heavy engineering) are welded. Along with structural carbon and low-carbon steels, it is increasingly necessary to weld special steels, light alloys and alloys based on titanium, molybdenum, chromium, zirconium and other metals, as well as dissimilar materials.

In conditions of continuous complication of structures and an increase in the volume of welding work, proper training - theoretical and practical - of qualified workers - welders - plays an important role.

1.1 Classification of welding types

There are more than 150 types of welding processes. GOST 19521-74 classifies welding processes according to basic physical, technical and technological characteristics.

The basis of the classification according to physical characteristics is the type of energy used to produce the welded joint. According to physical characteristics, all welding processes are classified into one of three classes: thermal, thermomechanical, and mechanical.

Thermal class – all types of fusion welding carried out using thermal energy (gas, arc, electroslag, plasma, electron beam and laser).

Thermo-mechanical class - all types of welding carried out using thermal energy and pressure (contact, diffusion, forging, gas and arc press).

Mechanical class - all types of welding, pressure welding, performed using mechanical energy (cold, friction, ultrasonic and explosion).

According to technical characteristics, welding processes are classified depending on the method of protecting the metal in the welding zone, the continuity of the process and the degree of its mechanization.

1.2 High-performance types of RDS

To make the welder’s work easier and to increase labor productivity, various high-performance types of welding are used.

Welding with an electrode beam - two or more electrodes are connected into a bundle (the contact ends are welded to each other in two or three places) and welding is carried out using an electrode holder. When welding with an electrode beam, contact occurs between the product being welded and one electrode rod as it melts, the contact passes to the next rod. When welding with an electrode beam, you can use increased current strength.

Welding with deep penetration - a thicker layer of coating is applied to the electrode rod, thereby increasing the thermal force of the arc and increasing its melting action, that is, increasing the depth of fusion of the base metal. Welding is carried out with a short arc, the combustion of which is maintained due to the support of the coating visor on the base metal; it is used when welding corner and T-joints.

Welding with inclined electrodes - the electrode is placed in the groove of the seam, copper pads are used to hold the electrode in the groove and to insulate and protect the arc; the length of the arc during the combustion process is equal to the thickness of the coating layer; the diameter of the electrode is 6-10 mm, and the length of the electrode is 800-1000 mm.

Welding an electrode with large diameters - 8-12mm and a current value of 350-600A, but has its drawbacks:

1. Difficult to perform in narrow places.

2. The welder gets tired quickly.

3. Significant magnetic blast occurs.

Pool welding is performed with one or more electrodes at an increased current; this ensures heating of the elements being welded to form a large pool of liquid metal, which is held in a special shape during the welding process; the deposited metal is constantly in a liquid state at the end of the welding process, to speed up and cool the weld pool, the arcs are periodically interrupted.

Flameless welding - the electrode is not fixed in the holder, but is welded to it end-on, which allows the entire rod to be used.

1.3 Types of welding

Manual arc welding.

Gas welding and cutting.

Semi-automatic welding

Automatic welding under a layer of flux and in a protective gas environment.

Argon - arc welding

Electric contact welding

2. Special part

2.1 Purpose and description of the design

The pipeline is used to transport cold and hot water in the room for heating, compressed gases, and steam. This work consists of two separate sections of pipe connected to each other using manual electric arc welding.

2.2 Material selection and description

For the manufacture of the structure, low-carbon steel grade 3 is used, which belongs to the group of well-welded ones. Carbon in it is up to 0.25%, manganese 0.5%, silicon 0.35%.

For welding low-carbon steels, electrodes of the following grades are used: OZS - 3; OZS – 4; MR – 3, the rod of these electrodes is made of wire grade SV – 08A. The coating composition includes: 30 - 50% titanium dioxide, feldspar, ferromanganese, liquid glass.

This electrode will give the lowest percentage of metal spattering, suitable for welding with direct and alternating current; it is not harmful to the human body, therefore it is widely used in industry.

2.3 Selection of equipment and technical characteristics of power supplies

I chose pipe welding. For welding pipes, the TDM-401 transformer is most convenient, since you can easily select the current strength. The transformer itself consists of a closed core, a primary and a secondary winding. When the primary and secondary windings of a transformer are connected in series, part of the turns of the primary winding is included in the electrical circuit, and a range of low currents is obtained.

When the windings are connected in parallel, all branches of the primary winding are included in the electrical circuit, resulting in a range of high currents.

The secondary winding is movable; it is used to regulate the current strength.

2.5 Preparing metal for welding

At the place where the pipeline is welded, the edges are carefully cleaned with an iron brush to remove dirt, oil, and rust, which lead to the formation of defects.

The quality of the welded seams largely depends on the condition of the surface of the welded edges.

2.6 Assembly of the structure

During assembly, it is important to ensure the required accuracy and coincidence of the edges of the elements being welded.

To accurately assemble parts for welding, you need to use measuring tools.

And great attention must be paid to the fact that when the metal is heated, it can become deformed. During welding, the root of the seam must be especially careful to thoroughly remove slag.

Tacks are made with an electrode with a diameter of 3 mm

2.7 Selecting welding mode

The diameter of the electrode is selected depending on the thickness of the metal, the leg of the weld, and the position of the seam in space.

The approximate relationship between the metal thickness (s) and the diameter of the electrode when welding a seam in the desired position is:

Smm 1 – 2 3 – 5 4 – 10 12 – 24 30 – 60

dmm 2 – 3 3 – 5 4 – 5 5 – 6 and more

The welding current is usually set depending on the selected electrode diameter.

When welding seams in the lower position, the current strength can be determined by the state Jd = (20+60) d Jw (40÷60) for electrodes with a diameter of less than 3 mm Jd = 30 d.

Arc voltage 18 – 20, weld width 15 – 16mm arc length 1 – 0.5mm from the base metal,

Jb ≈ 80 – 120 H

Lower position Jsv ≈ 120A

Horizontal position Jst ≈ 100A

Vertical position Jst ≈ 80A.

Ceiling position Jsv ≈ 60A

2.8 Consumption of welding material

The consumption of coated electrodes is determined by multiplying the mass of deposited metal by the consumption coefficient.

Gne = Gn * Kr (kg, g)

Gne – masses of coated electrodes.

Gн – masses of directed metal

Kr – electrode consumption coefficient

Kr = 1.5 – 1.8

for coated electrodes with RDS

Gн = 7.85 * F * L

Gn = 7.85 g/cm3 *0.32 cm2 *49.9 cm =125

Gne = 125*1*7 = 212*5≈212

G of one electrode =(4*970kg)/125pcs =39 *76 g

Number of electrodes 212g/(39*76) = 5*33 ≈ 6 pcs

The consumption of welding electrodes per product was 6 electrodes

2.9 Determination of standard time

Standard time for welding. T

t0 – main time

Kuch - a coefficient taking into account the organization of labor is accepted at RDS 0.25 - 0.40.

Arc burning time T0 is determined by the formula:

t0 = 7.85*F*L/hнj

where 7.85 is the specific density of steel g/cm2

F – cross-sectional area of ​​the seam – with a metal thickness of 8 mm

F = 64cm2/2 = 0.32 cm2

L*Fm = 1/2*a2 seam length

L = Ø * P L = 159 * 3.14 = 499.26 ≈ 499 mm

Lн – build-up coefficient for MR electrodes – 3 Lн = 16 g/nh

J – welding current, A J = 30*deK

K – coefficient of arc power reduction when welding on alternating current (0.7-0.97)

30 is amperes per mm of electrode

J = 87*3 ≈ 90A

t0 =(7.85 g/cm3 * 0.32 cm2 * 49.9 cm)/(16g*7 *90A) =(125 * 34mm)/1440= = 0.08 h

T = 0.08/0.25 = 0.68 = 32 min

It took 32 minutes.

2.10 Welding technique and sequence

For 170 pipes, according to calculations, I made three tacks, a tack 30mm long.

Tacks are applied every 30mm.

For welding the root of the seam, I chose an electrode with a diameter of 3 mm.

For welding the second seam, I chose 4mm.

To pass the second seam, you need to make oscillatory movements from side to side to capture (weld) both edges.

3. Technical control

3.1 Organization of quality control

Defects in welded joints can be caused by poor quality of welded materials, inaccurate assembly and preparation of joints for welding, violation of welding technology, low qualifications of the welder and other reasons. The task of quality control of connections is to identify possible causes of defects and prevent them.

Work on quality control of welding work is carried out in three stages:

Preliminary control carried out before the start of work:

Control during assembly and welding (operational).

Quality control of finished welded joints.

Preliminary control includes: checking the qualifications of welders, flaw detectors and personnel supervising assembly, welding and control work.

During the manufacturing process (operational control), the quality of edge preparation and assembly, welding modes, the order of seams, the appearance of the seam, its geometric dimensions, and the serviceability of welding equipment are checked.

The last control operation is checking the quality of welding in the finished product: external inspection and measurements of welded joints, density testing, ultrasonic testing, magnetic testing methods.

Checking the qualifications of the welder: the qualifications of welders are checked when establishing a discharge. The category is assigned in accordance with the requirements stipulated by the tariff and qualification reference books; tests of welders before admission to responsible work are carried out according to the rules for certification of welders and welding specialists.

Base metal quality control. The quality of the base metal must meet the requirements of the certificate sent by factories - suppliers, along with a batch of metal, must carry out an external inspection to establish the mechanical properties and chemical composition of the metal.

During an external inspection, the metal is checked for scale, rust, cracks and other defects.

Preliminary inspection of the metal in order to detect surface defects is a necessary and mandatory operation, thanks to which you can prevent the use of low-quality metal when welding the product.

The mechanical properties of the base metal are determined by testing standard samples on tensile machines, pessas and pile drivers in accordance with GOST 1497 - 73 metal tensile testing methods.

Quality control of welding wire: the grade and diameter of the welding wire, chemical composition, acceptance rules and test methods, requirements for packaging, labeling, transportation and storage are established on the steel surfacing wire.

Each coil of welding wire must have a metal tag on which the name and trademark of the manufacturer are indicated; welding wire that does not have documentation is subject to careful control.

Electrode quality control. When welding structures in which the type of electrode is indicated in the drawings, you cannot use an electrode that does not have a certificate. An electrode without a certificate is checked for the strength of the coating and the welding properties are also determined by the mechanical properties of the weld metal and welding joint of the electrode made from the tested batch.

Flux quality control. The flux is checked for uniformity in appearance and determined mechanical composition, grain size, volume, weight and moisture content.

Control of workpieces. Before the workpieces arrive for assembly, the cleanliness of the metal surface and the quality of edge preparation dimensions are checked.

Assembly control: the assembled assembly is controlled: the gap between the edges, the bluntness and the opening angle for butt joints: the width of the overlap and the gap between places for overlap joints.

Quality control of welding equipment and instruments. They check the serviceability of instrumentation, the reliability of contacts and insulation, the correct connection of the welding arc, the serviceability of closed devices, electrode holders, welding torches, gearboxes, and wires.

Control of the welding technological process: before starting welding, the welder gets acquainted with the technological maps, which indicate the sequence of operations, the diameter and brand of the electrodes used, welding modes and the required dimensions of the welds. Failure to follow the proper order of sutures can cause significant deformation.

4. Organization of the workplace

4.1 Requirements for workplace organization

When performing production operations, a worker or a team of workers is assigned a workplace in the form of a certain section of the production area, equipped in accordance with the requirements of the technological process, with the appropriate equipment and necessary supplies. The welder's workplace is called a welding station.

To protect workers from arc radiation in permanent welding areas, a separate cabin measuring 2x2.5 or 2x2 is installed for each welder.

The walls of the cabin can be made of thin iron or other fireproof material with a height of 1.8-2.0 m, for better ventilation, not reaching the floor by 0.2-0.3 m. The floor must be made of fire-resistant material: brick, concrete, cement. The walls are painted light gray with paints that absorb ultraviolet rays well. The cabin is equipped with local ventilation with an air exchange of 40 m3/hour per worker.

The ventilation suction is positioned so that the gases released during welding pass by the welder.

Welding of the part is carried out on a work table 0.5-0.7 m high. The table cover is made of cast iron 20-25mm thick; in some cases, various devices for assembling and welding products are installed on the table.

A steel bolt is welded to the bottom of the table cover or leg, which serves to secure the current-carrying wire from the welding current source and for the table grounding wire. There are slots for storing electrodes on the side of the table. Tools and technological documentation are stored in the drawer of the table. For ease of work, a metal chair with a lifting screw seat made of non-conductive material is installed in the cabin. The welder should have a rubber mat under his feet.

The welding station is equipped with a generator or welding transformer.

5. Safety precautions

5.1 Safety precautions during welding work

Persons at least 18 years of age are allowed to perform welding work after passing the technical minimum according to safety regulations.

The organization of each workplace must ensure the safe performance of the robot.

Workplaces must be equipped with various types of fences, protective and safety devices and adapted ones.

To create a safe environment for robot welders, it is necessary to take into account, in addition to the general provisions of industrial safety regulations, the specifics of performing various welding operations. Such features are possible electric shock, poisoning with harmful gases and vapors, burns from radiation from a welding arc and molten metal, injuries from explosions of cylinders with compressed and liquefied gases.

An electric welding arc emits bright visible light rays and invisible ultraviolet and infrared rays. Light rays have a blinding effect. Ultraviolet rays cause eye diseases, and with prolonged exposure lead to skin burns.

To protect eyesight and facial skin, shields, masks or helmets are used; light filters are inserted into the viewing holes to block and absorb rays. To protect welders’ hands from burns and splashes of molten metal, it is necessary to use protective gloves and wear a special tarpaulin cover over the body. clothes.

During the welding process, a significant amount of aerosol is released, which leads to poisoning of the body. The highest concentration of dust and harmful gases is in the cloud of smoke rising from the welding zone, so the welder must ensure that the flow does not fall behind the shield. To remove harmful dust gases from the welding zone, it is necessary to install local ventilation, exhaust and general supply ventilation. In winter, supply ventilation should supply heated air into the room. In case of poisoning, the victim must be taken out into fresh air, freed from tight clothing and given rest until a doctor arrives, and if necessary, artificial respiration should be used.

5.2 Electrical safety

Electric shock occurs when a person comes into contact with live parts of equipment. The resistance of the human body, depending on its condition (fatigue, skin moisture, health) varies over a wide range from 1000 to 20,000 Ohms. The open-circuit voltage of arc power sources reaches 90V, and the compressed arc voltage reaches 200V in accordance with Ohm’s law, if the welder’s condition is unfavorable, a current close to the limit can pass through it:

To prevent possible electric shock when performing electric welding work, you must follow the following basic rules:

The housings of equipment and apparatus to which electric current is supplied must be grounded;

All electrical wires coming from distribution panels and to workplaces must be reliably insulated and protected from mechanical damage;

It is prohibited to use the ground loop, metal structures of buildings, as well as pipes of water and heating systems as the return wire of the welding circuit;

When performing welding work inside closed vessels (boilers, tanks, tanks, etc.), wooden shields, rubber mats, gloves, galoshes should be used: Welding must be carried out with a handy person located outside the vessel. It should be remembered that for lighting purposes inside vessels, as well as in damp rooms, an electric current with a voltage of no higher than 12V is used, and in dry rooms - no higher than 36V; in vessels without ventilation, the welder should work for no more than 30 minutes with breaks for rest in the fresh air .

Installation, repair of electrical equipment and supervision of it must be performed by electricians. Welders are strictly prohibited from repairing power electrical circuits. In case of electric shock, it is necessary to turn off the current in the primary circuit, free the victim from its influence, provide access to fresh air, call a doctor, and, if necessary, perform artificial respiration before the doctor arrives.

5.3 Fire safety

The causes of fire during welding can be sparks or drops of molten metal and slag, careless handling of the torch flame in the presence of flammable materials near the welder’s workplace. The risk of fire should be especially taken into account at construction and installation sites and during repair work in rooms not suitable for welding.

To prevent fires, the following fire safety measures must be observed:

Do not store flammable or flammable materials near the welding site, or carry out welding work in rooms contaminated with rags, paper, wood waste, etc.;

It is prohibited to use clothing and gloves with traces of oils, fats, gasoline, kerosene and other flammable liquids;

Perform welding and cutting of structures with freshly painted oil paints until they are completely dry

It is prohibited to weld devices under electrical voltage and vessels under pressure;

You cannot weld or cut liquid fuel containers without special training;

When performing temporary welding work indoors, wooden floors, decks and platforms must be protected from ignition by sheets of asbestos or iron;

It is necessary to constantly have and monitor the working condition of fire-fighting equipment - fire extinguishers, sand boxes, shovels, buckets, fire hoses, etc., and also maintain the fire alarm in good working order;

After completing welding work, you must turn off the welding machine and also make sure that there are no burning objects. Fire extinguishing agents include water, foam, gases, steam, powder compounds, etc.

Special water pipelines are used to supply water to fire extinguishing installations. Foam is a concentrated emulsion of carbon dioxide in an aqueous solution of mineral salts containing foaming agents.

When extinguishing a fire with gases and steam, carbon dioxide, nitrogen, flue gases, etc. are used.

When extinguishing kerosene, gasoline, oil, or burning electrical wires, it is prohibited to use water or foam fire extinguishers. In these cases, carbon dioxide or dry fire extinguishers should be used.

6. Environmental protection

In accordance with the Constitution, in the interests of the living and future generations, measures are taken to protect and rationally use the earth and its subsoil, water resources and flora and fauna, to preserve clean air and water, ensure the reproduction of natural resources and improve the human environment. These activities in the annual plans of enterprises are grouped into sections: protection and use of water resources, protection of the air basin, protection and rational use of land, protection and use of mineral resources.

The protection and use of water resources include measures for the construction of structures for water intake and reservoirs, wastewater treatment, recycling water supply systems in order to reduce irretrievable water losses, etc.

In welding production, many enterprises use a reverse water supply system; water used to cool welding equipment is reused after its natural cooling.

Air protection involves measures to neutralize substances emitted with exhaust gases that are harmful to humans and the environment: the construction of treatment plants in the form of wet dry dust collectors, for chemical and electrical purification of gases, as well as for the capture of valuable substances, waste disposal, etc. For example. , liquefied carbon dioxide is produced from combustion waste products for welding and other purposes.

The protection and rational use of land involves measures aimed at reducing the exit of lands from agricultural use, protecting them from erosion and other destructive processes, land reclamation, etc.

The protection and rational use of mineral resources include measures to improve systems and methods for the development of mineral deposits and ore beneficiation schemes, the use of waste from metallurgical production and mechanical engineering, the extraction of purchased valuable components from ores, etc. The activities of the enterprise should not violate the normal conditions of the work of other enterprises and organizations , worsen the living conditions of the population. To this end, gas plans also provide for measures to combat production noise, vibration, and the effects of electric and magnetic fields. The noise generated by welding equipment should be minimal.

Welding arc power sources, as well as a number of electrical devices used in automatic and semi-automatic welding machines, interfere with radio and television reception. In order to eliminate this phenomenon, noise protection devices are installed in all types of welding equipment that creates such interference.

Weld defects

Name of defect	Detection method	Remedy
1. Lack of penetration of subfloats	External inspection.	Cutting out the defective area and subsequent welding.
2. Undercut	External inspection and measurement with a probe.	Cleaning, trimming areas and welding.
3. Waviness of the seam with sharply defined boundaries.	External inspection.	Cutting out the defective area.
4. Uneven formation of folds.	External inspection.	Cutting out the defective area.
5. Various sizes of fillet weld cassettes.	Measuring with a template.	1) with K and K seam processing. 2) with K and K X welding.
6. Incorrect seam height.	Measuring with a template. Note local deviations in the overlap height exceeding the tolerances should not be more than 10% of the total length of the seam; local deviations up to 15 mm	a) processing the seam to the main size. b) welding with preliminary cleaning.
7. Uneven overlap width.	Measuring with a template.	Hemming the seam.

Literature

1. Vinogradov V.S. Equipment and technology of automatic and mechanized arc welding, M: 1997;

2. Rybakov V.M. Arc and gas welding, M: VSh, 1986.

3. Stepanova V.V. Welder's Handbook, M: 1982.

4. Fominykh V.P. Electric welding, M: V.Sh..., 1978.

5. Chernyshev G.G. Welding business, M: 2003.

www.ronl.ru

Training program for the profession “Welder”

Ministry of Education of the Penza Region

State autonomous professional

educational institution of the Penza region

"Penza Multidisciplinary College"

I APPROVED

Head of Construction Department

GAPOU ON PMPK

WORKING PROGRAMM

EDUCATIONAL PRACTICE

profession 01/15/05 “Welder”

(electric welding and gas welding work)

duration of study 2.5 years

profession according to the general classifier (OK 016-94)

1. Electric and gas welder

Agreed:

_____________________

Penza, 2015

EXPLANATORY NOTE

This practice program is intended to train qualified workers in the profession of “Welder (electric welding and gas welding)” according to the secondary vocational education program.

The program includes: an explanatory note, professional and general competencies, a summary thematic plan for industrial training, and a curriculum.

The organization of training is carried out on the basis of the list of professions of primary vocational education and the federal state educational standard for primary vocational education (FSES SPO)

The program provides a specific nomenclature of professions that reflect the region’s labor market, and determines the content of professional competencies taking into account the specifics of the region.

Professional characteristics reflect the substantive parameters of professional competence: its main types, as well as their theoretical foundations.

Requirements for learning outcomes are the main parameters when assessing the quality of training of students in the Welder profession (electric welding and gas welding work).

Fulfillment of these requirements serves as the basis for issuing state-issued documents to graduates on the level of qualifications in the profession of “Welder” (electric welding and gas welding work).

The work program for vocational training was developed on the basis of the Federal State Educational Standard for the profession, the Regulations on educational practice (industrial training) and industrial practice of students mastering basic professional educational programs

Developer organization:

State Autonomous Professional Educational Institution of the Penza Region "Penza Multidisciplinary College" Construction Department (hereinafter referred to as GAPOU PO PMPK)

1. PASSPORT OF THE WORK PROGRAM

EDUCATIONAL PRACTICE

Scope of the program:

The work program of educational practice is part of the main professional educational program in accordance with the Federal State Educational Standard for Secondary Professional Education in the profession of Welder (electric welding and gas welding work) in terms of mastering the qualifications:

Gas welder,

Electric and gas welder,

Electric welder on automatic and semi-automatic machines,

Electric welder, manual welding,

Gas cutter

and main types of professional activity (VPA):

1. Preparatory and welding work.

3. Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure.

The work program of educational practice can be used in additional education and vocational training in the professions of workers:

19756 Electric and gas welder;

19906 Electric welder, manual welding;

11620 Gas welder.

1.2. Goals and objectives of industrial practice:

Formation of initial practical professional skills in students within the framework of OPOP SVE modules in the main types of professional activities for mastering a working profession, training in labor techniques, operations and methods of performing labor processes characteristic of the corresponding profession and necessary for their subsequent development of general and professional competencies in their chosen profession .

Requirements for the results of mastering industrial practice

As a result of completing educational practice in types of professional activity, the student should be able to:

	Skill Requirements
1. Preparatory and welding work	PC 1.1. Perform standard metalworking operations used in preparing metal for welding. PC 1.2. Prepare gas cylinders, control and communication equipment for welding and cutting. PC 1.3. Assemble products for welding. PC 1.4. Check assembly accuracy.
2. Welding and cutting of parts made of various steels, non-ferrous metals and their alloys, cast iron in all spatial positions.	PC 2.1. Perform gas welding of medium and complex complexity PC 2.2. Perform manual arc and plasma welding of medium complexity and complex parts of apparatus, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. PC 2.3. Perform automatic and mechanized welding using a plasmatron of medium complexity and complex devices, components, parts, structures and pipelines made of carbon and structural steels. PC 2.4. Perform oxygen, air-plasma cutting of metals of rectilinear and complex configurations. PC 2.6. Ensure safe performance of welding work at the workplace in accordance with sanitary technical requirements and labor protection requirements.
3. Surfacing of defects in parts and components of machines, structural mechanisms and castings for machining and test pressure.	PC 3.1. Weld over parts and assemblies of simple and medium-complex structures with hard alloys. PC 3.2. Weld complex parts and assemblies of complex tools. PC 3.3. Weld over worn simple tools, parts made of carbon and structural steels. PC 3.4. Fusing heated cylinders and pipes, defects in machine parts, mechanisms and structures. PC 3.5. Perform surfacing to eliminate defects in large iron and aluminum castings for machining and test pressure. PC 3.6. Perform surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity.
4. Defects of welds and quality control of welded joints.	PC 4.1. Clean seams after welding. PC 4.2. Determine the causes of defects in welds and joints. PC 4.3. Prevent and eliminate different kinds defects in welds. PC 4.4. Perform hot straightening of complex structures.

1.3. Number of hours for mastering the work program of educational practice (on-the-job training):

Total - 540 hours, including:

As part of mastering PM 01. – 72 hours

As part of the development of PM 02. – 270 hours

As part of the development of PM 03. – 162 hours

As part of the development of PM 04. –36 hours

1.4. Number of hours for mastering the work program of practical training:

PP - 52 weeks - 312 hours

As part of mastering PP 01. – 36 hours

As part of the development of PP 02. – 138 hours

As part of the development of PP 03. – 102 hours

As part of the development of PP 04. –36 hours

2. RESULTS OF MASTERING THE WORK PROGRAM OF TRAINING PRACTICE

The result of mastering the work program of industrial practice is the formation of students’ initial practical professional skills within the framework of the OPOP SPO modules in the main types of professional activities (VPA),

	Name of the result of mastering the practice
	Perform standard metalworking operations used in preparing metal for welding.
	Prepare gas cylinders, control and communication equipment for welding and cutting.
	Assemble products for welding.
	Check assembly accuracy.
	Perform gas welding of medium complexity and complex components, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys.
	Perform manual arc and plasma welding of medium complexity and complex parts of apparatus, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys.
	Perform automatic and mechanized welding using a plasmatron of medium complexity and complex devices, components, parts, structures and pipelines made of carbon and structural steels.
	Perform oxygen, air-plasma cutting of metals of rectilinear and complex configurations.
	Ensure the safe performance of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements.
	Weld over parts and assemblies of simple and medium-complex structures with hard alloys.
	Weld complex parts and assemblies of complex tools.
	Weld over worn simple tools, parts made of carbon and structural steels.
	Fusing heated cylinders and pipes, defects in machine parts, mechanisms and structures.
	Perform surfacing to eliminate defects in large iron and aluminum castings for machining and test pressure.
	Perform surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity.
	Clean seams after welding.
	Determine the causes of defects in welds and joints.
	Prevent and eliminate various types of defects in welds.
	Perform hot straightening of complex structures.

3. THEMATIC PLAN AND CONTENT OF PRODUCTION PRACTICE

3.1. Thematic plan of industrial practice

	Code and names of professional modules	Number of PM hours	Types of jobs	Names of industrial practice topics	Number of hours by topic
	Preparatory and welding work		Perform straightening and bending, marking, chopping, mechanical cutting, filing metal; prepare gas cylinders for use; assemble products for welding in assembly and welding fixtures using tacks; check assembly accuracy; be able to work on the MTDS-05 simulator.	Topic 1.1. Metalworking operations performed when preparing metal for welding
				Interim certification
	Welding and cutting of parts made of various steels, non-ferrous metals and their alloys, cast iron in all spatial positions		Perform technological methods of manual arc, plasma and gas welding, automatic and semi-automatic welding using a plasma torch of parts, assemblies, structures and pipelines of varying complexity from structural and carbon steels, cast iron, non-ferrous metals and alloys in all spatial positions of the seam; perform automatic welding of critical complex building and technological structures operating in difficult conditions; perform automatic welding in a shielded gas environment with a non-consumable electrode of hot-woven strips of non-ferrous metals and alloys under the guidance of a more highly qualified electric welder; perform automatic microplasma welding; perform manual oxygen, plasma and gas straight and shaped cutting and cutting with petrol and kerosene cutting devices on portable, stationary and plasma cutting machines of parts of varying complexity from various steels, non-ferrous metals and alloys according to markings; perform oxygen-flux cutting of parts made of high-chromium and chromium-nickel steels and cast iron; perform oxygen cutting of ship objects afloat; perform manual electric arc air planing of varying complexity of parts made of various steels, cast iron, non-ferrous metals and alloys in various positions; perform preliminary and accompanying heating when welding parts in compliance with the specified mode; set welding modes according to specified parameters; use materials and electricity sparingly, handle tools, equipment and equipment with care; comply with occupational safety and fire safety requirements; read working drawings of welded metal structures of varying complexity.	Familiarization with equipment for manual arc welding.
Cutting, assembly and arc welding of steel plates in inclined, vertical, horizontal seam positions.
Assembly and arc welding of simple parts and assemblies from low carbon steel
Gas surfacing of beads and welding of low-carbon steel plates in the lower, vertical position of the seam.
Intermediate Certification in the form of differential credit
Low carbon
Oxygen Metal cutting
Welding alloyed
Welding and soldering
Intermediate certification in the form of differential credit
	Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure		Carry out hardfacing of simple parts with hard alloys; perform surfacing with hard alloys using ceramic fluxes in protective gas of parts and assemblies of medium complexity; eliminate defects in large iron and aluminum castings for machining and test pressure surfacing; remove defects in components, mechanisms and castings of varying complexity by surfacing; perform fusing of heated cylinders and pipes; fuse cavities and cracks in parts, assemblies and castings of varying complexity.	Arc surfacing of plates in lower, inclined vertical and horizontal positions.
Topic 3.2. Gas-oxygen surfacing in all spatial positions.
Hard surfacing
	Weld defect detection and quality control of welded joints		Clean seams after welding; check the quality of welded joints by appearance and fracture; identify defects in welds and eliminate them; apply methods to reduce and prevent deformation during welding; perform hot straightening of welded structures.	Classification of defects and causes of their occurrence. Effect of defects on the strength of welds
Non-destructive types quality control of welds
Destructive type of weld quality control
Interim certification in the form of differentiated credit
	Total hours

Code and name professional modules and themes industrial practice			development
PM 01. Preparatory and welding work
Types of jobs: 1. Perform standard metalworking operations used in preparing metal for welding. 2. Performing assembly of welded structures in various ways. 3. Tack welding of assembled parts. 4. Perform operations to control the assembly of welded structures. 5. Preparation of gas cylinders, control and communication equipment for gas welding and metal cutting.
Metalworking operations performed when preparing metal for welding	1. Cleaning and straightening of metal. 2. Marking and cutting parts. 3. Preparing the edges of parts for welding.
Familiarization and work on the low-ampere arc welder simulator MDTS - 05. Safety precautions.	1. Manual arc welding (MAW). Practicing the technique of exciting and maintaining the arc. 2. Manual arc welding (MAW). Practicing techniques for maintaining arc length and specified welding speed. 3. Manual arc welding (MAW). Practicing techniques for maintaining arc length, specified welding speed and electrode angles. 4. Manual argon arc welding (TIG). Practicing techniques for maintaining arc length, specified welding speed and electrode angles. 5 Mechanized welding in shielding gases with a consumable electrode (MAG). Practicing techniques for maintaining arc length, specified welding speed and electrode angles. 6. Manual arc welding of pipeline joints. Development of techniques for maintaining arc length, specified welding speed and electrode inclination angles when welding fixed pipeline joints.
Product assembly and control	1. Assembling beams and frames 2.Assembly of lattice structures
Interim certification in the form of differentiated credit
PM 02. Welding and cutting of parts made of various steels, non-ferrous metals and their alloys, cast iron in all spatial positions
Types of jobs: 1. Instruction on the operation of assembly and welding devices. 2. Organization of the workplace and labor safety. 3. Assembly and welding of butt joints. 4. Assembling butt joints for welding (without beveled edges, with one-sided and double-sided beveled edges), setting the required gap during assembly. 5. Installation of tacks. 6. Assembly and welding of corner and T-joints. The procedure for performing assembly, tack welding, surfacing and welding techniques and technology. 7. Checking the quality of welded joints by appearance and fracture. Correction of weld defects. Cutting out the defective area and re-welding. 8. Arc cutting with carbon and metal electrodes: marking and cutting flanges, rings, various round and shaped holes; cutting corners and channels, punching holes on plates, cutting pipes. 9. Separating air-arc cutting of profile metal, burning holes, cutting pipes and channels. 10. Surface air-arc cutting of grooves performed on carbon and alloy steel plates, sampling of defective welds. 11. Plasma arc cutting of simple parts from alloy and non-ferrous metals. 12. Performing manual arc and plasma welding of medium complexity and complex parts of apparatus, assemblies, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys. 13. Performing automatic and mechanized welding using a plasma torch of medium complexity and complex devices, components, parts, structures and pipelines made of carbon and structural steels. 14. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configurations. 15. Reading drawings of medium complexity and complex welded metal structures. 16. Performing gas welding of units of medium complexity and complex units, parts and pipelines made of carbon, structural steel, non-ferrous metals and alloys. 17. Performing automatic and mechanized welding of components, parts, structures, pipelines from various structural materials 18. Performing oxygen, air and plasma cutting of metals of rectilinear and complex configurations. 19. Carrying out welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements. 20. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configurations. 21. Reading drawings of medium complexity and complex welded metal structures. 22. Reading instructional and technological maps, diagrams. 23. Butt welding of pipes in a rotating and non-rotating position. 24. Making circumferential seams in containers for storing various types of bulk materials. 25. Welding of various stiffeners. 26. Welding of transition areas, frames, fences, gratings. 27. Welding various kinds of gussets, planks to beams, trusses. 28. Welding of various building structures (beams, building frames, trusses, sheet structures, hull transport structures). 29. Pipeline welding. 30. Checking the quality of welds, eliminating defects in welds.
Familiarization with equipment for manual arc welding	Familiarization with welding equipment and equipment, rules for their maintenance. Instruction on workplace organization and occupational safety. Turns the DC arc power supply on and off. Regulation of current strength, connection of wires. Clamping the electrode into the electrode holder. Training in exciting the arc and maintaining its combustion until the electrode completely melts.
Cutting, assembly and arc welding of steel plates in the lower position of the seam.	1. Familiarization with the rules and techniques of surfacing and welding. Instruction on workplace organization and occupational safety. Surfacing of the bead onto the plate in the lower position of the seam. 2. Single-layer welding of sheet metal, lap welding of plates, corner welding, butt welding with edge cutting, tee welding. 3. Surfacing of beads on an inclined plate. Surfacing of adjacent parallel beads in different directions. 4. Cutting plates with coated electrodes in a straight line, along a curve and along markings. Cutting metal of various profiles. Cutting holes. 5. Cutting grooves, removing defective welds. Cutting out the root of the seam from the reverse side for welding
Cutting, assembly and arc welding of steel plates in inclined, vertical and horizontal seam positions	1. Cutting plates into plates in an inclined, vertical and horizontal position of the seam. Cutting metal of various profiles. 2. Surfacing of rollers on the ascent and descent on the plate installed at different angles. 3. Assembling parts for welding, setting the required gap, determining tack locations in various spatial positions. 4. Setting up tacks and cleaning them. 5. Butt welding of inclined plates in an inclined position.
Assembly and arc welding of simple parts and assemblies made of low-carbon steel.	1. Assembling parts for welding, setting the required gap, determining tack locations. 2.Tacking of assembled parts in various spatial positions. 3. Welding plates, gussets, stiffeners to simple products in the lower position of the seam. 4. Welding plates, gussets, stiffeners to simple products in a vertical position of the seam. 5. Welding plates, gussets, stiffeners to simple products in a horizontal position of the seam
Gas surfacing of beads and welding of low-carbon steel plates in the lower, vertical position of the seam	1.Selection of welding mode. Surfacing of filler material. 2. Surfacing of beads on steel plates in the lower position of the seam. 3. Surfacing of beads on steel plates in a vertical position of the seam. 4. Butt welding of plates in all spatial positions
Interim certification in the form of differentiated credit
Assembly and gas welding of simple products and assemblies from Low carbon	1. Assembling parts for welding, setting the required gap, determining the locations of tack welds and the sequence of their application. 2. welding of simple products in inclined, vertical and horizontal positions of seams. 3. Welding of shells and cracks in simple parts 4. Checking the quality of simple connections. Identification of defects and their elimination.
Oxygen cutting of metals	1. Oxygen cutting of plates. 2. Oxygen cutting of corners, channels
Welding of alloy steels.	1. Familiarization with the rules and techniques of welding alloy steels. 2. Surfacing of beads with coated electrodes on alloy steel plates. 3. Welding butt joints without cutting edges in various spatial positions 4.Instruction on workplace organization and labor safety during argon-arc welding. Familiarization with the techniques of welding alloy steels using argon-arc welding. 5. Practicing skills in surfacing beads using argon arc welding 6.Argon-arc welding of corner and T-joints in all spatial positions
Welding and soldering of cast iron	1. Instruction on workplace organization and labor safety. Familiarization with the methods and techniques of welding cast iron. 2. Cold welding of cast iron with steel electrodes on steel studs. 3. Surfacing of a layer of brass on a cast iron plate. 4. Cutting out defects and preparing the edges of products for welding.
Welding of non-ferrous metals and their alloys.	1. Gas surfacing of beads on aluminum plates 2. Gas butt welding of aluminum plates 3. Gas surfacing of beads on plates made of copper and their alloys 4. Gas butt welding of copper plates. 5. Argon-arc surfacing of beads on aluminum plates 6. Argon-arc surfacing of beads on plates made of copper and their alloys butt-end.
Interim certification in the form of differentiated credit
PM 03. Surfacing of defects in parts and assemblies of machines, mechanisms, structures and castings for machining and test pressure
Types of jobs: 1. Fusing of parts and assemblies of simple and medium complexity structures with hard alloys; fusing of complex parts and assemblies of complex tools. 2. Welding of worn-out simple tools, parts made of carbon and structural steels. 3. Performing surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. 4. Performing surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity; Carrying out surfacing with hard alloys using ceramic fluxes in protective gas on parts and assemblies of medium complexity. 5. Removal of defects in components, mechanisms and castings of varying complexity by surfacing; performing fusing of heated cylinders and pipes. performing surfacing to eliminate defects in large iron and aluminum castings for machining and test pressure. 6. Surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity.
Surfacing technique for eliminating defects in large iron and aluminum castings for machining and test pressure	1Fusing of parts and assemblies of simple and medium complexity structures with hard alloys 2. Deposition of complex parts and assemblies of complex tools 3. Welding of worn-out simple tools, parts made of carbon and structural steels 4. Performing surfacing to eliminate defects in large cast iron and aluminum castings for machining and test pressure. 5. Performing surfacing to eliminate cavities and cracks in parts and assemblies of medium complexity. 6. Performing surfacing with hard alloys. 7. Removal of defects in components, mechanisms and castings of varying complexity by surfacing. 8. Perform fusing of heated cylinders and pipes 9. Welding of complex parts and assemblies, complex tools
Gas-oxygen surfacing in all spatial positions	1.Operation of automatic welding machines for mechanized arc surfacing. 2. Regulation of welding modes for mechanized arc surfacing. 3. Gas surfacing of surfaces of parts made of various metals. 4. Development of techniques for eliminating defects in machined parts and assemblies by surfacing with a gas burner. 5. Surfacing of parts and assemblies of simple and medium complexity structures with hard alloys. 6. Surfacing of structures with hard alloy
Arc automatic and semi-automatic surfacing	1. Welding of complex parts and assemblies of complex tools. 2. Deposition of worn-out simple tools and parts made of carbon steel. 3. Application of technological methods of automatic and mechanized welding of defects in machine parts, mechanisms and structures. 4 Deposition of worn-out simple tools, alloy steel parts 5 Welding of worn-out simple tools, parts made of structural steels. 6. Surfacing with hard alloys
Surfacing with hard alloys.	1. Familiarization with the techniques of surfacing with hard alloys. 2. Fusing of simple parts and assemblies with hard alloys. 3. Welding of complex parts and assemblies with hard alloys. 4. Surfacing with powder alloys
Interim certification in the form of differentiated credit
PM 04. Weld defect detection and quality control of welded joints
Types of jobs: 1. Cleaning the seams after welding. 2. Determining the causes of defects in welds and joints. 3. Prevention and elimination of various types of defects in welds. 4. Hot straightening of complex structures.
Classification of defects and the cause of their occurrence.	1. Cleaning the seams after welding. 2. Defects in welded joints. Welding deformations. Causes of defect
Non-destructive types of welding seam testing	1. Visual control of the quality of the welded joint. 2. Ultrasonic inspection of welds
Destructive types of weld inspection	1.Hydraulic control of welds 2 Hot straightening of welded structures.
Interim certification in the form of differentiated credit

To characterize the level of mastery of educational material, the following designations are used:

2 - reproductive (performing activities according to a model, instructions or under guidance);

3 – productive (planning and independent execution of activities, solving problematic problems)

4. CONDITIONS FOR IMPLEMENTATION OF THE PRODUCTION PRACTICE WORK PROGRAM

4.1. Minimum logistics requirements

The implementation of the work program of educational practice presupposes the presence of enterprises and organizations in the Penza region that carry out electric welding and gas welding work on the basis of direct contracts with the State Budgetary Educational Institution of Secondary Professional Education PA "PMPC".

Equipment for enterprises or organizations:

1.Equipment:

1. Manual arc welding station.

2. Gas welding station.

3. Station for semi-automatic welding in shielding gas.

4. Welding stations for manual DC arc welding.

5. Welding stations for manual arc welding of alternating current.

6. Equipment and fixtures for performing assembly and welding work.

7. Electrodes for welding.

2. Tools and accessories:

1. A set of plumbing and measuring tools.

2. Tools for manual and mechanized metal processing.

3. Sets of control and measuring tools for checking edge cutting.

4. Sets of test tools for checking assembly accuracy.

5. Instruments for determining the hardness of metals.

6. Assembly and welding devices.

7. Universal and special devices.

8. Test tool and template.

9. Electric welder's tools.

10. Devices for straightening and straightening.

3. Teaching aids:

1. Technical documentation for various types of metal processing.

2. Journal of instructions on safe working conditions.

3. Technological documentation.

4. Personal and collective protective equipment.

4.2. General requirements for the organization of the educational process

Industrial training is carried out by industrial training masters and mentors at a professional cycle enterprise. Industrial training is carried out in a concentrated manner.

4.3. Staffing of the educational process

Industrial training masters who supervise the practical training of students must have a qualification level in the profession of 3-4, higher or secondary vocational education in the profile of the profession, and undergo mandatory internship in specialized organizations at least once every 3 years.

5. MONITORING AND EVALUATING THE RESULTS OF PROGRAM DEVELOPMENT

EDUCATIONAL PRACTICE

Monitoring and evaluation of the results of mastering educational practice is carried out by the practice manager in the process of conducting training sessions, students’ independent completion of tasks, and performing practical testing. As a result of mastering educational practice within the framework of professional modules, students undergo intermediate certification in the form of differentiated credit.

Learning outcomes (mastered skills within the framework of the VPA)	Forms and methods of monitoring and assessing learning outcomes
PC 1.1. Performing standard plumbing operations used in preparing metal for welding.
PC 1.2. Preparation of gas cylinders, control and communication equipment for welding and cutting.
PC 1.3. Assembling products for welding.	Expert assessment of the student’s activities
PC 1.4. Checking assembly accuracy.	Expert assessment of the student’s activities
PC 2.1. Performing gas welding of medium complexity and complex units, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys.	Expert assessment of completed work
PC 2.2. Performing manual arc and plasma welding of medium complexity and complex parts of apparatus, components, structures and pipelines made of structural and carbon steels, cast iron, non-ferrous metals and alloys.	Expert assessment of completed work
PC 2.3. Performing automatic and mechanized welding using a plasma torch of medium complexity and complex devices, components, parts, structures and pipelines made of carbon and structural steels.	Expert assessment of completed work
PC 2.4. Performing oxygen, air-plasma cutting of metals of rectilinear and complex configurations.	Expert assessment of completed work
PC 2.5. Reading of moderately complex drawings and complex welded metal structures.	Expert assessment of the student’s activities
PC 2.6. Ensuring the safety of welding work at the workplace in accordance with sanitary and technical requirements and labor protection requirements.	Expert assessment of the student’s activities

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Practical work program

STATE BUDGETARY PROFESSIONAL EDUCATIONAL INSTITUTION

MOSCOW REGION

"INDUSTRIAL AND ECONOMIC TECHNIQUE"

Working programm

industrial practice

150709.02 Welder (electric welding and gas welding work).

The practical training program was developed on the basis of the Federal State Educational Standard for the profession of primary vocational education (hereinafter referred to as NPO)

150709.02 Welder (electric welding and gas welding work).

PASSPORT OF THE PRODUCTION PRACTICE PROGRAM

STRUCTURE AND CONTENT OF THE PROGRAM

CONDITIONS OF IMPLEMENTATION OF THE PROGRAM

CONTROL AND EVALUATION OF DEVELOPMENT RESULTS

PRODUCTION PRACTICE

1. PASSPORT OF THE PRODUCTION PRACTICE PROGRAM

1.1.Scope of the program

The industrial practice program is part of the main professional educational program in accordance with the Federal State Educational Standard for the profession NPO 150709.02 Welder (electric and gas welding work).

The industrial practice program can be used in additional vocational education (in advanced training and retraining programs) and professional training of workers in the profession 150709.02 Welder (electric welding and gas welding work): with the initial level of education: secondary (complete) general, vocational without any experience requirements work.

1.3.Goals and objectives of industrial practice:

As a result of mastering the practical training program, the student should be able to:

Perform straightening and bending, marking, chopping, mechanical cutting, filing metal;

Prepare gas cylinders for use;

Assemble products for welding using assembly and welding fixtures and tacks;

Check assembly accuracy.

As a result of mastering the program, the student must have practical experience:

Assembly accuracy checks.

Perform standard plumbing operations used in welding;

Preparation of cylinders, control and communication equipment for welding and cutting;

Assembling products for welding;

Assembly accuracy checks.

1.4. The number of hours for mastering the industrial practice program is 216.

Explanatory note

This program has been compiled in order to provide practical assistance to the master of industrial training in conducting pre-graduation practical training for students of a vocational school for the training of electric and gas welders of 3-4 categories. The program recommends internships in workshops of enterprises, in construction and in private enterprises engaged in performing electric and gas welding work.

After acquiring the skills and abilities necessary to master and complete the program, students are given specific tasks that will help them complete trial qualifying work. Due to the improvement of production conditions, changes and additions may be made to the practice program.

The assignment of students to practice is formalized by an agreement with the enterprise, which reflects the timing of the work and the conditions for ensuring the safety of the work.

At the end of the internship, students are issued characteristics certified by a seal, which indicate: compliance with production standards, ability to handle technological tools, equipment and devices, knowledge of the technological process, recommended rank.

Students fill out a work practice diary, in which they indicate the types of work performed, the category, and the quality of work performed. At the end, the date of completion of the work is indicated, the signature of the person in charge and certified by a seal.

General provisions

Students undergo practical training at workplaces of enterprises, where, if possible, they will work after graduating from technical school.

The time fund for practical training is 216 hours over 6 weeks. Students of the study group, according to contracts, are distributed among the enterprises of the district, taking into account the specifics of the profession.

Students' work schedule: work under the guidance of a mentor or as part of teams in one or two shifts in accordance with the regime operating in workshops or at enterprise sites.

The length of the working day for students is determined by the Constitution of the Russian Federation and legislation on the labor of adolescents. For students over 18 years of age - 41 hours per week, under 18 years of age - 36 hours per week.

Graduates who have mastered the profession are awarded the third category of electric and gas welder. The best students, by decision of the State Examination Commission, may be assigned the fourth category.

The practice is supervised by a master of industrial training with the help of highly qualified workers. The progress of practice is monitored by the senior master and the deputy director of the school for educational and production work in accordance with the control schedule.

Goals and objectives

The purpose of pre-graduation practical training, as the final stage of the educational process, is to complete industrial training and prepare the future worker for independent, highly productive work at the enterprise.

The main objectives of pre-graduation practical training: Adaptation of students in specific production conditions.

Fostering conscious discipline, comradely mutual assistance, respect for the traditions of the enterprise and the desire to increase them.

Consolidation and improvement of professional knowledge, skills and abilities in the chosen profession.

Accumulation of experience in independent performance of work as an electric and gas welder of 3-4 categories.

Study of technical documentation, new production technologies.

Acquiring skills to operate modern equipment.

Formation of such professionally valuable qualities as speed of reaction, accuracy, coordination of actions, observation.

Types of jobs

Students must perform the work of an electric gas welder of 3-4 categories.

Occupational safety briefing, study of instructions on workplace organization and safe work practices. Inspection of the workplace, checking the availability and serviceability of tools and devices, signaling and protective devices, fire-fighting equipment. Clear and correct diary keeping.

Carrying out work at workplaces. Compliance with operating parameters, requirements, technological process. Periodic control of product quality and equipment operation.

Compliance with procedures in case of equipment malfunctions.

Study and application of advanced high-performance techniques and labor methods, tools, devices, equipment used in welding work.

Implementation of measures for the most efficient use of working time, prevention of defects, and economical use of materials.

Preparing the workplace for delivery. Fulfillment of obligations to maintain an exemplary workplace. Handing over the shift. Keeping entries in a diary.

Thematic plan

Name of topics

Number of hours

1. Introductory lesson. Learning objectives. Instruction on workplace organization, study of the technological process, documentation. Safe practices in the workplace.

2. Independent performance of work with a complexity of 3-4 categories of manual arc welding.

3. Independent performance of work with a complexity of 3-4 categories of gas welding.

4. Control of welding work.

5. Study and application of progressive technology and advanced techniques and methods of work.

6. Trial qualifying work and final qualifying exams.

Each time you move during an internship, it is necessary to conduct a three-hour briefing on occupational safety to develop and consolidate automatic skills for the impeccable implementation of occupational safety requirements (at the expense of time on each topic).

1. Instruction on safe working conditions and familiarization with the workplace (6 hours)2. Independent performance of manual arc welding work (150 hours)1) Welding beams and frames - Preparation operations - Assembling parts for welding - Welding I-beams - Welding box-section beams - Welding frames 2) Welding lattice structures - Preparation operations - Assembling parts for welding - Welding of lattice structures3) Welding of pipe structures - Preparation operations - Assembly of parts for welding - Welding of pipelines4) Welding of shell structures - Preparation operations - Assembly of parts for welding - Welding of tanks5) Surfacing and cutting of parts - Surfacing of parts for machining - Manual arc cutting - Cutting and fitting of parts from profiled metal; Cutting of alloy steel workpieces4. Control of welding work (36 hours)3. Independent performance of gas welding work (30 hours) - Welding of mufflers - Elimination of defects in car parts by surfacing - Elimination of cavities in castings - Welding of a tank for non-flammable liquids - Welding of ventilation pipes - Welding of free-flow water pipes - Elimination of defects in bronze and brass fittings - Surfacing of steels for defective forgings - Soldering of ductile iron parts - Oxygen cutting4. Control of welding work (6 hours)5. Study and application of progressive technology and advanced labor methods and techniques (30 hours) - Study of ways to increase productivity - Three-phase arc welding - Recumbent electrode welding - Deep penetration welding6. Qualifying exams (6 hours)

performing standard metalworking operations used in preparing metal for welding;

Preparation of cylinders, control and communication equipment for welding and cutting;

Assembling products for welding;

Assembly accuracy checks.

Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Part No. 1 of Issue No. 2 of ETKS
The issue was approved by Resolution of the Ministry of Labor of the Russian Federation dated November 15, 1999 N 45
(as amended by Order of the Ministry of Health and Social Development of the Russian Federation dated November 13, 2008 N 645)

Gas welder

§ 6. Gas welder 2nd category

Characteristics of work. Tack welding of parts and structural products in all spatial positions of the weld. Preparation of joints for welding and cleaning of seams after welding. Preparing gas cylinders for use. Maintenance of portable gas generators. Gas welding of simple parts, assemblies and structures made of carbon steels in the lower and vertical position of the weld. Surfacing of simple parts. Elimination of cavities and cracks by surfacing in simple castings. Heating of structures and parts during straightening.

Must know: design and principle of operation of serviced gas welding machines, gas generators, oxygen and acetylene cylinders, reducing devices and welding torches; types of welds and joints; rules for preparing simple products for welding; types of sections and designations of welds in drawings; handling rules and basic properties of gases and liquids used in welding; permissible residual gas pressure in cylinders; purpose and brands of fluxes used in welding; causes of defects during welding, characteristics of the gas flame; cylinder paint colors; arrangement of gas supply communications to places of consumption and rules for connecting to them.

Work examples

1. Axle-box, column and center bolts - fusing of excavation areas.

2. The necks of car gas tanks are soldered.

3. Details of the frames of the side awning - tack welding and welding.

4. Portholes and covers - welding.

5. Cones of oil pumps and car filters - fusing of shells in castings.

6. Protective casings - welding.

7. Covers for undercar lighting gutters - welding.

8. Brackets for attaching the muffler to the car frame - welding of cracks.

9. Moldings - welding of ears.

10. Pallets for machines - welding.

11. Reception pipes - welding of safety nets.

12. Car wing reinforcements - welding.

13. Corner sheets of the inner and outer skin of the tram - welding of cuts.

14. Clamps of hydraulic mechanisms of dump trucks - welding.

§ 7. Gas welder of the 3rd category

Characteristics of work. Gas welding of average complexity of units, parts and pipelines made of carbon and structural steels and simple parts made of non-ferrous metals and alloys in all spatial positions of the weld, except for ceiling ones. Elimination of cavities and cracks in parts and assemblies of medium complexity by surfacing. Surfacing of simple parts with hard alloys. Preliminary and accompanying heating when welding parts in compliance with a given regime.

Must know: installation of serviced gas welding equipment; structure of welding seams and methods of testing them; basic properties of welded metals; rules for preparing parts and assemblies for welding and surfacing; rules for choosing a heating mode for metal depending on its grade and thickness; causes of internal stresses and deformations in welded products and measures to prevent them; basic technological techniques for welding and surfacing parts made of steel, non-ferrous metals and cast iron.

Work examples

1. Fittings made of tin bronze and silicon brass under test pressure up to 1.6 MPa (15.5 atm.) - elimination of defects by fusing.

2. Crankshafts and cam shafts of automobiles - welding of defective semi-finished forgings with special steels.

3. Silencers - welding.

4. Internal combustion engines (fuel and air system) - welding.

5. Car parts (oil heater necks, gearbox housings, crankcase covers) - elimination of defects by fusion.

6. Bronze brake discs - elimination of cavities.

7. Casings of elastic couplings - welding.

8. Rear axles of cars - elimination of cavities in castings.

9. Car radiator lining - eliminating cracks.

10. Level regulator floats (fittings) - welding.

11. Profile window frames of the driver's cab - welding.

12. Pantograph frames - template welding.

13. Tanks for non-flammable liquids and brake systems of rolling stock - welding.

14. Bulkhead shaft seals - welding of the housing and pressure sleeve.

15. Rear wheel hubs, rear axle and other car parts - ductile iron soldering.

16. Ventilation pipes - welding.

17. Copper gas exhaust pipes - welding.

18. Connected smoke pipes in boilers and superheater pipes - welding.

19. Brake line pipes - welding.

20. Non-pressure pipelines for water (except main ones) - welding.

21. Pipelines of external and internal water supply and heating networks - welding in workshop conditions.

22. Brass gasifier balls (open) - welding.

§ 8. Gas welder of the 4th category

Characteristics of work. Gas welding of complex parts, structures and pipelines made of carbon and structural steels and parts of medium complexity made of non-ferrous metals and alloys in all spatial positions of the weld. Hard alloy surfacing with the use of ceramic fluxes in protective gas of parts and assemblies of medium complexity. Elimination of defects in large iron and aluminum castings for machining and test pressure surfacing. Elimination of cavities and cracks by fusing in processed parts and assemblies. Hot straightening of complex structures.

Must know: methods for establishing metal welding modes depending on the configuration and thickness of the parts being welded; methods of welding non-ferrous alloys, cast iron; testing of welds made of non-ferrous metals and alloys; basic rules for weldability of metals; general concepts about methods for producing and storing the most common gases used in gas welding (acetylene, hydrogen, oxygen, propane-butane, etc.); types of defects in welds and methods for their prevention and elimination; rules for reading drawings.

Work examples

1. Pipeline shut-off valves made of non-ferrous metals and alloys under test pressure over 1.6 to 4.9 MPa (over 15.5 to 48.4 atm) - elimination of defects by fusing.

2. Babbitt filling of bearings - fusion.

3. Cylinder blocks of automobile engines - elimination of cavities in castings.

4. Crankshafts - welding of journals.

5. Bronze and brass inserts - fusing onto steel bearings.

6. Parts and assemblies made of non-ferrous metals - welding followed by pressure testing.

7. Spool frames, pendulums - welding.

8. Teeth of cast iron gears - welding.

9. Thin-walled products made of non-ferrous alloys (air cooler covers, bearing shields, turbogenerator fans) - body welding with brass or silumin.

10. Large cast iron products (frames, pulleys, flywheels, gears) - elimination of cavities and cracks.

11. Crankcases of large engines and mechanical transmission housings of diesel locomotives - welding.

12. Pole coils electric machines from strip copper - welding of jumpers.

13. Brush holder housings, reverse segments, electric motor rotors - welding.

14. Aluminum furniture - welding.

15. Heaters - welding of a cage, a water-heating pipe with a cage, cone, rings and flanges.

16. Pistons of pneumatic hammers - elimination of cavities and cracks.

17. Bearings and liners for axle boxes, drawbars - fusing along the frame and fusing of cracks.

18. Porthole frames made of aluminum alloys - welding.

19. Air tanks for trolleybuses - welding.

20. Single and twisted metal mesh for pulp and paper production - soldering of ends with silver solder.

21. Tubes for sensors with a radioactive isotope - elimination.

22. Pipe elements of boilers, armor plates, etc. - hot edit.

23. Pipelines of external and internal water supply and heating networks - welding during installation.

24. Technological pipelines (category 5) - welding.

25. Pipelines of external and internal low-pressure gas supply networks - welding in workshop conditions.

26. Brass refrigerators - welding of seams for hydrotesting at pressures up to 2.5 MPa (24.2 atm).

27. Balls, floats and tanks made of special aluminum alloys - welding.

§ 9. Gas welder of the 5th category

Characteristics of work. Gas welding of complex parts, assemblies, mechanisms, structures and pipelines made of high-carbon, alloyed, special and corrosion-resistant steels, cast iron, non-ferrous metals and alloys designed to operate under dynamic and vibration loads and under pressure. Hard alloy surfacing of complex parts, assemblies, structures and mechanisms. Welding and elimination of cracks and cavities in thin-walled products and in products with hard-to-reach places for welding. Heat treatment of welded joints with a gas torch after welding.

Must know: mechanical and technological properties of welded metals, including high-alloy steels, as well as deposited metal; rules for choosing the technological sequence of seams and welding modes; methods for monitoring and testing welds; influence of heat treatment on the properties of the welded joint.

Work examples

1. Embrasures of blast furnaces - welding of shells and cracks.

2. Pipeline shut-off valves made of tin bronze and brass (silicon) - welded to a test pressure of over 5 MPa (48.4 atm).

3. Cylinders, caps, spheres operating in a vacuum - welding.

4. Lead baths - welding.

5. Bronze and brass propellers - correction of defects by fusion.

6. Parts of gas welding equipment - soldering with silver solders.

7. Copper coils - welding.

8. Caissons of open-hearth furnaces (hot repair) - internal welding.

9. Bellows-type expansion joints made of corrosion-resistant steel - soldering.

10. Collectors of complex configuration consisting of 20 or more parts made of corrosion-resistant steels and heat-resistant steel with verification of the macrostructure using radiography - welding.

11. Cast iron bodies, covers, tees, elbows, cylinders - elimination of defects by fusion.

12. Steam boilers - fusion of cracks.

13. Aluminum and bronze castings, complex and large - fusing of shells and cracks.

14. Molds - welding in hard-to-reach places.

15. Rotors of electrical machines - welding of short-circuited rings, rods, surfacing.

16. Complex beds, aprons of large lathes - welding, surfacing of cracks.

17. Tubes of pulse systems for instrumentation and automation - welding.

18. Pipe elements of steam boilers with pressure up to 4.0 MPa (38.7 atm.) - welding.

19. Pipelines of external and internal low-pressure gas supply networks - welding during installation.

20. Technological pipelines of categories 3 and 5 (groups), steam and water pipelines of categories 3 and 5 - welding.

21. Lead pipes - welding.

22. Pipelines for external gas supply networks of medium and high pressure - welding during installation.

23. Brass refrigerators - welding of seams for hydrotesting at pressures above 2.5 MPa (24.2 atm.).

24. Cylinders of internal combustion engines - welding of internal and external jackets.

25. Tires, tapes, expansion joints for them made of non-ferrous metals - welding.

§ 10. Gas welder of the 6th category

Characteristics of work. Gas welding of complex parts, mechanism components, structures and pipelines made of high-carbon, alloyed, special and corrosion-resistant steels, cast iron, non-ferrous metals and alloys designed to operate under dynamic and vibration loads and under high pressure. Hard alloy surfacing of complex parts, assemblies, structures and mechanisms.

Must know: variety of light and heavy alloys, their welding and mechanical properties; types of corrosion and factors causing it; metallography of welds; methods of special testing of welded products and the purpose of each of them.

Work examples

1. Separation units for air-oxygen workshops - welding of parts made of non-ferrous metals.

2. Parts and assemblies made of non-ferrous metals operating under pressure above 4.0 MPa (38.7 atm.) - welding.

3. Vacuum and cryogenic containers, caps, spheres and pipelines - welding.

4. Blades of turbine rotors and stators - soldering.

5. Pulse wiring of turbines and boilers - welding.

6. Pipe elements of steam boilers with pressures above 4.0 MPa (38.7 atm.) - welding.

7. Pipelines for external gas supply networks of medium and high pressure - welding during installation.

8. Technological pipelines of categories 1 and 2 (groups), as well as steam and water pipelines of categories 1 and 2 - welding.

§ 47. Electric and gas welder 4th category

Attention! This qualification characteristic is excluded by order of the Ministry of Labor of Russia dated April 9, 2018 N 215

Characteristics of the work. Manual arc, plasma and gas welding of medium complexity parts, assemblies, structures and pipelines made of structural steels, cast iron, non-ferrous metals and alloys and complex parts of assemblies, structures and pipelines made of carbon steel in all spatial positions of the weld. Manual oxygen, plasma and gas straight and shaped cutting and cutting with petrol and kerosene cutting devices on portable, stationary and plasma cutting machines, in various positions of complex parts from various steels, non-ferrous metals and alloys according to markings. Oxygen flux cutting of parts made of high chromium and chromium-nickel steels and cast iron. Oxygen cutting of ship objects afloat. Automatic and mechanical welding of medium complexity and complex devices, components, pipeline structures made of various steels, cast iron, non-ferrous metals and alloys. Automatic welding of critical complex building and technological structures operating in difficult conditions. Manual electric arc air planing of complex parts made of various steels, cast iron, non-ferrous metals and alloys in various positions. Welding of cast iron structures. Surfacing of defects in complex machine parts, mechanisms, structures and castings for machining and test pressure. Hot straightening of complex structures. Reading drawings of various complex welded metal structures.
Must know: installation of various electric welding and gas-cutting equipment, automatic and semi-automatic devices, features of welding and electric arc planing on alternating and direct current; basics of electrical engineering within the scope of the work performed; types of defects in welds and methods for their prevention and elimination; basics of metal welding; mechanical properties of welded metals; principles for selecting welding modes based on instruments; brands and types of electrodes; methods for producing and storing the most common gases: acetylene, hydrogen, oxygen, propane-butane, used in gas welding; gas cutting process for alloy steel.
Work examples
1. Equipment, vessels and containers made of carbon steel, operating without pressure - welding.
2. Equipment and vessels for chemical and petrochemical industries: tanks, separators, vessels, etc. - cutting holes with beveled edges.
3. Pipeline shut-off valves made of non-ferrous metals and alloys under test pressure over 1.6 to 5.0 MPa (over 15.5 to 48.4 atm) - fusing of defects.
4. Transformer tanks - welding of pipes, welding of terminal boxes, cooler boxes, current installations and tank covers.
5. Rudder stocks, propeller shaft brackets - welding.
6. Cylinder blocks of automobile engines - fusing of shells in castings.
7. Crankshafts - surfacing of journals.
8. Bronze and brass inserts - surfacing on steel bearings.
9. Fittings and boiler burner bodies - welding.
10. Parts made of stainless steel sheets, aluminum or copper alloys - gas-electric cutting with beveled edges.
11. Cast iron parts - welding, fusion with and without heating.
12. Parts made of sheet steel with a thickness of over 60 mm - manual cutting according to markings.
13. Parts and assemblies made of non-ferrous metals - welding followed by pressure testing.
14. Car retarders - welding and surfacing of components under operating conditions.
15. Cast iron gear teeth - welding.
16. Thin-walled products made of non-ferrous alloys (air cooler covers, bearing shields, turbogenerator fans) - welding with brass or silumin.
17. Large cast iron products: frames, pulleys, flywheels, gears - fusing of shells and cracks.
18. Chambers of hydraulic turbine impellers - welding and surfacing.
19. Blast furnace structures (casings, air heaters, gas pipelines) - cutting with beveled edges.
20. Frames of industrial furnaces and boilers - welding.
21. Crankcases of large engines and mechanical transmission housings of diesel locomotives - welding.
22. Lower engine crankcases - welding.
23. Pole coils of electric machines made of strip copper - welding and welding of jumpers.
24. Gas exhaust manifolds and pipes - welding.
25. Hydraulic turbine control rings - welding and surfacing.
26. Housings and axles of the header drive wheels - welding.
27. Compressor housings, low and high pressure cylinders of air compressors - crack fusion.
28. Rotor housings with a diameter of up to 3500 mm - welding.
29. Stop valve housings for turbines with power up to 25,000 kW - welding.
30. Brush holder housings, reverse segments, electric motor rotors - welding.
31. Fastening and supports for pipelines - welding.
32. Brackets and fastenings for diesel locomotive pivot bogies - welding.
33. Sheets of large thicknesses (armor) - welding.
34. Masts, drilling and production rigs - welding in workshop conditions.
35. Aluminum furniture - welding.
36. Fundamental plates of large electrical machines - welding.
37. Struts, axle shafts of aircraft landing gear - welding.
38. Heaters - welding of a cage, a water-heating pipe with a cage, cone, rings and flanges.
39. Bearings and liners for axle boxes, drawbars - fusion along the frame and fusion of cracks.
40. Pistons of pneumatic hammers - fusing of shells and cracks.
41. Dust-gas-air ducts, fuel supply units and electric precipitators - welding.
42. Spool frames, pendulums - welding.
43. Porthole frames made of aluminum alloys - welding.
44. Conveyor frames - welding.
45. Air tanks for trolleybuses - welding.
46. ​​Tanks for petroleum products with a capacity of less than 1000 cubic meters. m - welding.
47. Rail butt joints - welding under operational conditions.
48. Rails and prefabricated crosspieces - fusing ends.
49. Single and twisted metal mesh for pulp and paper production - soldering of ends with silver solder.
50. Crusher beds - welding.
51. Welded-cast frames and housings of electrical machines - welding.
52. Cast iron beds of large machine tools - welding.
53. Beds of working stands of rolling mills - surfacing.
54. Stators of air-cooled turbogenerators - welding.
55. Tubes for sensors with a radioactive isotope - fusing.
56. Pipe elements of boilers, armor plates, etc. - hot edit.
57. Pipelines of external and internal water supply and heating networks - welding during installation.
58. Pipelines of external and internal low-pressure gas supply networks - welding in workshop conditions.
59. Drill pipes - welding of couplings.
60. Technological pipelines of category 5 - welding.
61. Frameworks, connections, lanterns, purlins, monorails - welding.
62. Complex cutters and dies - welding and deposition of high-speed cutters and hard alloys.
63. Brass refrigerators - welding of seams for hydrotesting at pressures up to 2.5 MPa (24.2 atm.).
64. Cylinders of car blocks - fusing of shells.
65. Car tanks - welding.
66. Balls, floats and tanks made of special aluminum alloys - welding.

From July 1, 2016, employers are required to apply professional standards, if the requirements for the qualifications that an employee needs to perform a certain job function are established by the Labor Code, federal laws or other regulations (Federal Law of May 2, 2015 No. 122-FZ).
To search for approved professional standards of the Ministry of Labor of the Russian Federation, use

Gas welding is relatively simple and does not require complex, expensive equipment or a source of electricity.

The disadvantage of gas welding is the lower heating rate of the metal compared to arc welding and a larger zone of thermal influence on the metal. When gas welding, the heat concentration is less, and the warping of the parts being welded is greater.

Due to the relatively slow heating of the metal by the flame and the low heat concentration, the productivity of gas welding decreases with increasing thickness of the metal being welded. For example, with a steel thickness of 1 mm, the gas welding speed is about 10 m/h, with a thickness of 10 mm - only 2 m/h. Therefore, gas welding of steel with a thickness of over 6 mm is less productive than arc welding.

The cost of acetylene and oxygen is higher than the cost of electricity, so gas welding is more expensive than electric welding. Disadvantages of gas welding also include explosion and fire hazards if the rules for handling calcium carbide, flammable gases and liquids, oxygen, cylinders with compressed gases and acetylene generators are violated. Gas welding is used for the following work: manufacturing and repairing steel products with a thickness of 1-3 mm; welding of vessels and small tanks, welding of cracks, welding of patches, etc.; repair of cast products made of cast iron, bronze, silumin; welding joints of pipes of small and medium diameters; manufacturing products from aluminum and its alloys, copper, brass and lead; production of structural units from thin-walled pipes; surfacing of brass on parts made of steel and cast iron; joining ductile and high-strength cast iron using filler rods made of brass and bronze, low-temperature welding of cast iron.

Gas welding can be used to join almost all metals used in technology. Cast iron, copper, brass, and lead are easier to gas weld than arc welding.

GAS WELDING TECHNIQUE

Gas welding can be used to perform bottom, horizontal, vertical and ceiling seams. Ceiling seams are the most difficult to make, since in this case the welder must maintain and distribute liquid metal along the seam using the pressure of the flame gases. Most often gas welding is used to make butt joints, less often corner and end joints. It is not recommended to make lap and T-joints using gas welding, since they require intense heating of the metal and are accompanied by increased warping of the product.

Beaded joints of thin metal are welded without filler wire. Intermittent and continuous seams are used, as well as single-layer and multi-layer seams. Before welding, the edges are thoroughly cleaned of traces of oil, paint, rust, scale, moisture and other contaminants.

In table Figure 10 shows the preparation of edges when gas welding carbon steels with butt welds.

MOVEMENT OF THE TORCH DURING WELDING

The burner flame is directed at the metal being welded so that the edges of the metal are in the reduction zone, at a distance of 2-6 mm from the end of the core. It is impossible to touch the molten metal with the end of the core, as this will cause carburization of the metal of the bath. The end of the filler wire must also be in the reduction zone or immersed in the molten metal pool. In the place where the end of the flame core is directed, the liquid metal is slightly inflated to the sides by gas pressure, forming a depression in the weld pool.

The rate of heating of metal during gas welding can be adjusted by changing the angle of inclination of the mouthpiece to the metal surface. The larger this angle, the more heat is transferred from the flame to the metal and the faster it will heat up. When welding thick or good heat-conducting metal (for example, red copper), the angle of inclination of the nozzle a is taken greater than when welding thin or low thermal conductivity. In Fig. 86, and shows the angles of inclination of the mouthpiece recommended for left-handed (see § 4 of this chapter) welding of steel of various thicknesses.

In Fig. 86, b shows ways to move the mouthpiece along the seam. The main thing is to move the mouthpiece along the seam. Transverse and circular movements are auxiliary and serve to regulate the rate of heating and melting of the edges, and also contribute to the formation of the desired shape of the weld.

Method 4 (see Fig. 86, b) is used when welding thin metal, methods 2 and 3 - when welding metal of medium thickness. During welding, you must strive to ensure that the metal of the pool is always protected from the surrounding air by the gases of the reduction zone of the flame. Therefore, method 1, in which the flame is periodically drawn to the side, is not recommended, since it may oxidize the metal with atmospheric oxygen.

BASIC GAS WELDING METHODS

Left welding (Fig. 87, a). This method is the most common. It is used when welding thin and low-melting metals. The torch is moved from right to left, and the filler wire is led in front of the flame, which is directed to the unwelded section of the seam. In Fig. 87, and below shows a diagram of the movement of the mouthpiece and wire during the left-hand welding method. The flame power for left-hand welding is taken from 100 to 130 dm 3 acetylene per hour per 1 mm of metal (steel) thickness.

Right welding (Fig. 87, b). The torch is driven from left to right, the filler wire is moved after the torch. The flame is directed to the end of the wire and the welded area of ​​the seam. Transverse oscillatory movements are not performed as often as during left-hand welding. The mouthpiece makes slight transverse vibrations; When welding metal with a thickness of less than 8 mm, the nozzle is moved along the axis of the seam without transverse movements. The end of the wire is kept immersed in the weld pool and the liquid metal is mixed with it, which makes it easier to remove oxides and slags. The heat of the flame is dissipated to a lesser extent and is better utilized than in left-hand welding. Therefore, during right-hand welding, the opening angle of the seam is made not 90°, but 60-70°, which reduces the amount of deposited metal, wire consumption and warping of the product due to shrinkage of the weld metal.

It is advisable to use right-hand welding to connect metal with a thickness of more than 3 mm, as well as metal with high thermal conductivity with grooved edges, such as red copper. The quality of the seam in right-hand welding is higher than in left-hand welding because the molten metal is better protected by the flame, which simultaneously anneals the deposited metal and slows down its cooling. Due to best use heat, right-hand welding of metal of large thicknesses is more economical and more productive than left-hand welding - the speed of right-hand welding is 10-20% higher, and gas savings are 10-15%.

Right-hand welding connects steel up to 6 mm thick without bevel of edges, with full penetration, without welding on the reverse side. The flame power for right-hand welding is taken from 120 to 150 dm 3 acetylene per hour per 1 mm of metal (steel) thickness. The mouthpiece must be inclined to the metal being welded at an angle of at least 40°.

When right-hand welding, it is recommended to use filler wire with a diameter equal to half the thickness of the metal being welded. When left welding, use a wire with a diameter 1 mm larger than when welding right. Wire with a diameter of more than 6-8 mm is not used for gas welding.

Welding with a through bead (Fig. 88). The sheets are installed vertically with a gap equal to half the thickness of the sheet. The burner flame melts the edges, forming a round hole, the lower part of which is smelted with filler metal over the entire thickness of the metal being welded. Then the flame is moved higher, melting the top edge of the hole and applying the next layer of metal to the bottom side of the hole, and so on until the entire seam is welded. The seam is obtained in the form of a through bead connecting the sheets to be welded. The weld metal is dense, without pores, cavities and slag inclusions.

Welding with baths. This method is used to weld butt and corner joints of metal of small thickness (less than 3 mm) with filler wire. When a pool with a diameter of 4-5 mm is formed on the seam, the welder inserts the end of the wire into it and, having melted a small amount of it, moves the end of the wire into the dark, reducing part of the flame. At the same time, he makes a circular motion with the mouthpiece, moving it to the next section of the seam. The new bath should overlap the previous one by 1/3 of the diameter. To avoid oxidation, the end of the wire must be kept in the reducing zone of the flame, and the flame core should not be immersed in the bath to avoid carburization of the weld metal. Thin sheets and pipes made of low-carbon and low-alloy steel welded in this way (with lightweight seams) produce connections of excellent quality.

Multilayer gas welding. This welding method has a number of advantages compared to single-layer welding: a smaller metal heating zone is provided; annealing of underlying layers is achieved when surfacing subsequent ones; it is possible to forge each layer of the seam before applying the next one. All this improves the quality of the weld metal. However, multilayer welding is less productive and requires more gas consumption than single-layer welding, so it is used only in the manufacture of critical products. Welding is carried out in short sections. When applying layers, you need to ensure that the joints of the seams in different layers do not coincide. Before applying a new layer, use a wire brush to thoroughly clean the surface of the previous one from scale and slag.

Oxidizing flame welding. Low carbon steels are welded using this method. Welding is carried out with an oxidizing flame having the composition

To deoxidize the iron oxides formed in the weld pool, wires of the Sv-12GS, Sv-08G and Sv-08G2S grades in accordance with GOST 2246-60 are used, containing increased amounts of manganese and silicon, which are deoxidizers. This method increases productivity by 10-15%.

Welding with propane - butane-oxygen flame. Welding is carried out with an increased oxygen content in the mixture

in order to increase the flame temperature and increase the penetration and fluidity of the bath. For deoxidation of weld metal, wires Sv-12GS, Sv-08G, Sv-08G2S, as well as wire Sv-15GYU (0.5-0.8% aluminum and 1 - 1.4% manganese) according to GOST are used.

Research by A. I. Shashkov, Yu. I. Nekrasov and S. S. Vaksman established the possibility of using in this case conventional low-carbon filler wire Sv-08 with a deoxidizing coating containing 50% ferromanganese and 50% ferrosilicon diluted on liquid glass. Coating weight (excluding weight liquid glass) is 2.8-3.5% by weight of the wire. Coating thickness: 0.4-0.6 mm when using wire with a diameter of 3 mm and 0.5-0.8 mm when using a wire with a diameter of 4 mm. Propane consumption is 60-80 l/h per 1 mm of steel thickness, b = 3.5, the angle of inclination of the rod to the metal plane is 30-45°, the cutting angle of the edges is 90°, the distance from the core to the rod is 1.5-2 mm, to metal 6-8 mm. This method can weld steel up to 12 mm thick. The best results were obtained when welding steel with a thickness of 3-4 mm. Wire Sv-08 with the specified coating is a full-fledged substitute for more scarce grades of wire with manganese and silicon when welding with propane-butane.

Features of welding various seams. Horizontal seams are welded in the right way (Fig. 89, a). Sometimes welding is done from right to left, holding the end of the wire at the top and the mouthpiece at the bottom of the bath. The weld pool is positioned at a certain angle to the axis of the seam. This makes it easier to form a seam, and keeps the bath metal from dripping.

Vertical and inclined seams are welded from bottom to top using the left method (Fig. 89, b). When the metal thickness is more than 5 mm, the seam is welded with a double bead.

When welding ceiling seams (Fig. 89, c), the edges are heated until melting (fogging) begins, and at this moment a filler wire is introduced into the bath, the end of which is quickly melted. The metal of the bath is kept from flowing down by a rod and the pressure of the flame gases, which reaches 100-120 gf/cm2. The rod is held at a slight angle to the metal being welded. Welding is carried out in the right way. It is recommended to use multi-layer seams welded in several passes.

Welding of metal less than 3 mm thick with flanged edges without filler metal is carried out using spiral (Fig. 89, d) or zigzag (Fig. 89, e) movements of the nozzle.

Administration Overall rating of the article: Published: 2011.05.31

§ 55. Electric welder for manual welding (2nd category)

Characteristics of work

• Tack welding of parts, products and structures in all spatial positions of the weld.
• Manual arc and plasma welding of simple parts in the lower and vertical position of the weld, deposition of simple parts.
• Preparation of products and assemblies for welding and cleaning of seams after welding.
• Ensuring protection of the reverse side of the weld during shielding gas welding.
• Heating of products and parts before welding.
• Reading simple drawings.

Must know:

• design and principle of operation of electric welding machines and devices for arc welding in conditions of using alternating and direct current;
• methods and basic techniques of tack welding;
• shapes of the section of seams for welding;
• device of cylinders;
• colors, paints and rules for handling them;
• rules for welding in shielding gas and rules for ensuring protection during welding;
• rules for servicing electric welding machines;
• types of welded joints and seams;
• rules for preparing the edges of products for welding;
• types of grooves and designation of welds in the drawings;
• basic properties of the electrodes used and the metal and alloys being welded;
• purpose and conditions of use of instrumentation;
• causes of defects during welding and ways to prevent them;
• device of torches for welding with a non-consumable electrode in shielding gas.

Work examples

• 1. Transformer tanks - welding the walls for automatic welding.
• 2. Cradle beams, spring bars and bolsters for all-metal cars and power station cars - welding of reinforcing angles, guides and centering rings.
• 3. Rolling beams - welding of points and gripping wheels according to the markings.
• 4. Strikers, cylinders of steam hammers - fusion.
• 5. Diaphragms of platform frames and metal gondola cars and window frames of passenger cars - welding.
• 6. Frames of children's chairs, stools, greenhouses - welding.
• 7. Guardrail casings and other lightly loaded components of agricultural machines - welding.
• 8. Header brackets, brake control rollers - welding.
• 9. Brackets for dump truck subframes - welding.
• 10. Spring pads and linings - welding.
• 11. Steel flasks - welding.
• 12. Frames of transformer tanks - welding.
• 13. Bed mattress frames, armored and rhombic mesh - welding.
• 14. Simple cutters - fusing of quick cutter and hard alloy.
• 15. Steel and cast iron small castings - fusing shells in untreated areas.

Electric arc welding:

• 1. Lugs, bushings, cups - tack.
• 2. Structures not subject to testing - welding of the set on a stand and in the lower position.
• 3. Plates, racks, angles, corners, frames, simple flanges made of metal with a thickness of over 3 mm - tack.
• 4. Platforms and ladders - fusion of rollers (corrugation).
• 5. Racks, boxes, shields, frames made of squares and strips - potholders.
• 6. T-joints and cleaning of foundations for auxiliary mechanisms - welding.
• 7. Set to light partitions and baffles in the lower position - welding at the pre-assembly site.
• 8. Equipment fastening parts, insulation, technological ends, combs, temporary strips, bosses - welding to structures made of carbon and low-alloy steels.

Gas shielded welding:

• 1. Welded joints of critical structures - protection of the weld during the welding process.

§ 56. Electric welder for manual welding (3rd category)

Characteristics of work

• Manual arc and plasma welding of medium complexity parts, assemblies and structures made of carbon steels and simple parts made of structural steels, non-ferrous metals and alloys in all spatial positions of the weld, except for the ceiling.
• Manual oxygen arc cutting, planing of medium-complexity parts from low-carbon, alloy, special steels, cast iron and non-ferrous metals in various positions.
• Welding of worn-out simple tools, parts made of carbon and structural steels.

Must know:

• design of used electric welding machines and welding chambers;
• requirements for the weld seam and surfaces after oxygen cutting (planing);
• properties and significance of electrode coatings;
• main types of weld inspection;
• methods for selecting electrode grades depending on steel grades;
• causes of internal stresses and deformations in welded products and measures to prevent them.

Work examples

• 1. Beater and cutting drums, front and rear axles of a tractor trailer, drawbar and frame of a combine and header, augers and headers, rake and reel - welding.
• 2. Sidewalls, transition platforms, footboards, casing of railway cars - welding.
• 3. Raid buoys and barrels, artillery shields and pontoons - welding.
• 4. Electrical machine shafts - welding of journals.
• 5. Parts of the body frame of freight cars - welding.
• 6. Details of the rocker mechanism - fusing of holes.
• 7. Frames for switchboards and control panels - welding.
• 8. Support rollers - welding.
• 9. Keel blocks - welding.
• 10. Assembled casings, heating boilers - welding.
• 11. Truck brake pads, casings, rear axle axle shafts - welding.
• 12. Structures, components, parts of the gun mount - welding.
• 13. Housings of electrical explosive equipment - welding.
• 14. Lifting cranes - fusing of slopes.
• 15. Car dealership bodies - welding.
• 16. Diesel locomotive frames - welding of conductors, flooring sheets, parts.
• 17. Shaped cutters and simple dies - welding and surfacing of high-speed cutters and hard alloys.
• 18. Small machine beds - welding.
• 19. Racks, bunker grates, transition platforms, stairs, railings, decking, boiler casing - welding.
• 20. Smoke pipes up to 30 m high and ventilation pipes made of sheet carbon steel - welding.
• 21. Connected smoke pipes in boilers and steam superheater pipes - welding.
• 22. Heated pipes - welding of beads.
• 23. Non-pressure pipelines for water (except main ones) - welding.
• 24. Pipelines of external and internal water supply and heating networks - welding in stationary conditions.
• 25. Gears - fusing of teeth.

Electric arc welding:

• 1. Expansion tanks - welding, pipe welding.
• 2. Tanks, pipelines, vessels, containers made of carbon and low-alloy steels for filling with water - welding.
• 3. Buoys, raid barrels, artillery shields and pontoons - welding.
• 4. Rollers, bushings - fusing in the lower position.
• 5. Shafts and frames of electric motors - welding of shells and cracks.
• 6. Light barriers - welding on the slipway to each other and to internal structures.
• 7. Bushings on the front panels of the main distribution boards are welded to the conductor.
• 8. Doors and hatch covers are permeable - welding.
• 9. Doors are permeable, hatch covers are welded.
• 10. Parts of distribution boards: caps, substitutes, grooves, hinges, barrels, racks, welds, studs - welding to the body, frame or cover.
• 11. Parts of ship mechanisms - fusing the edges of sheets and other parts during assembly work.
• 12. Details of units, foundations, small metal thickness of 3 mm and higher, made of carbon steel - welding.
• 13. Diffusers of compensators of gas turbine units, fundamental frames - tack of parts.
• 14. Chimneys and chimneys of main and auxiliary boilers - welding of vertical and horizontal seams, welding of stiffeners.
• 15. Straight and angular gutters for laying cables - welding along the remote control route.
• 16. Round blanks for dies - welding.
• 17. Locks: wing, rack, lever, latch - welding of butt and overlap joints.
• 18. Sewing when installing equipment - welding in the lower position.
• 19. Lightweight portholes - welding.
• 20. Water chambers, compensator casings, frames, power units - welding.
• 21. Chambers for shot blasting machines, armor protection for shot blasting machines - welding.
• 22. Frames, brackets, beams and instrument frames of simple design - welding.
• 23. Frame and casing of auxiliary water-tube recovery boilers and air heaters - welding.
• 24. Frames, beds and other equipment for assembling large units - welding into volumetric units.
• 25. Pockets for photo circuits, pencil cases, spare fuses, fuse links - welding in power distribution devices.
• 26. Welded body structures made of carbon and low-alloy steels - air-arc planing in all spatial positions (removing temporary elements, melting defective areas of welds, cutting edges).
• 27. Fastening the ballast - welding on the slipway.
• 28. Covers of hermetic boxes - welding of shells, grooves.
• 29. Frames and lining of doors of power distribution devices - welding.
• 30. Frames of cabins, beds - welding into volumetric units.
• 31. Electric bridge crane rollers - welding.
• 32. Keel blocks and cages for slipways - welding.
• 33. Main body structures made of AK and YuZ steels - electric tack (removable) along the assembly joints.
• 34. Casings, gutters, panels, pallets made of carbon and low-alloy steels with a metal thickness of over 2 mm - welding.
• 35. High pressure turbine casings - tack.
• 36. Bodies, frames of mobile diesel power plants, frames, levers, angles - welding.
• 37. Fastening special coatings: studs, staples, combs - welding.
• 38. Spacer rings, counterweights, spacer beams - welding to OK with technological non-measurement.
• 39. Waterproof covers - welding under pressure from 0.1 to 1.5 MPa (1 -15 kgf/sq. cm).
• 40. Coamings of covers, doors, hatches, necks, grilles - welding.
• 41. Folding sheets, fairings, ship devices - welding in the workshop.
• 42. Light hatch - welding the body and welding the covers.
• 43. Superstructures - set welding, welding and welding to decks.
• 44. Superstructures - set welding, welding and welding to decks in lower and vertical positions.
• 45. Saturation of the metalwork building - welding.
• 46. ​​Outer casing - welding of technological seals that are not subject to control.
• 47. Simple hull structures - electric air gouging (surfacing of the weld root and removal of temporary fasteners).
• 48. Insulation purlins on sides and bulkheads - welding on the slipway and afloat.
• 49. Sheathing - welding in the ceiling position.
• 50. Butts and lifting products up to 5 tons - welding of the pre-assembly section.
• 51. Sheathing of frames, front panels - welding to structures.
• 52. Platform fencing, fan railings (storm railings, handrails for ladders) - welding to structures.
• 53. Supports, covers for distribution boards - welding.
• 54. Deck pipes - welding.
• 55. Suspensions of pipes, cables, fastenings of electrical appliances, brackets made of carbon and low-alloy steels - welding.
• 56. Support stands, pedestals, beams without cutting edges - welding.
• 57. Special devices for filling cable boxes - welding the bushing to the shaft.
• 58. Light bulkheads, baffles - welding of stiffeners in the lower position.
• 59. Rudder blade made of low-carbon steel - welding.
• 60. Transverse and longitudinal bulkheads, deck partitions - welding of units, panels along joints and grooves in the lower position in the pre-assembly area.
• 61. Planks, brackets, brackets, racks, suspension of pipes, cables, fastening of electrical appliances - welding on a slipway.
• 62. Protectors - welding.
• 63. Instrument frames and frames of complex configuration - welding.
• 64. Spacer beams, rings, crosspieces - welding to the main body.
• 65. Grilles made of tubes with a diameter of 10 to 15 mm - welding.
• 66. Rollers, hubs, couplings - welding and fusing of teeth.
• 67. Rudders - welding the flat part of the feathers.
• 68. Gas cutting tables, boxes for transporting parts and charge - welding.
• 69. Trawl brackets, transition bridges, platforms, bulwarks, numbers, letters - welding on the slipway.
• 70. Staples, fastening bags, pliers, panels - welding.
• 71. Gas cutting tables, boxes for transporting parts and couplings - welding.
• 72. Racks for storing documentation - welding.
• 73. Walls made of sheet metal with a thickness of 3 mm and above - welding in the lower and vertical position.
• 74. Vertical and inclined ladders (steel), gangways - welding.
• 75. Galley chimney pipes - welding.
• 76. Ship ventilation pipes made of carbon and low-alloy steels with a thickness of over 2 mm - welding.
• 77. Air guide device, air heaters for water tube boilers - welding.
• 78. Railing, loading, winches, views - welding.
• 79. Ventilation flanges - welding.
• 80. Foundations made of carbon and low-alloy steels: for auxiliary mechanisms, cylinders, boat and mooring devices, equipment fastenings - welding.
• 81. Shanks of oil seals, punches, dies - welding to metal structures.
• 82. Cylinders, pipes, glasses that do not require leak testing - welding of longitudinal and circumferential seams.
• 83. Cabinets and safes with locks - welding.
• 84. Frames made of carbon and low-alloy steels - welding and welding to the skin at the pre-assembly site.
• 85. Medium complexity dies with pressure up to 400 tons - welding.
• 86. Anchors, sternposts, stems - welding of defects.

Gas shielded welding:

• 1. Bosses, bottoms, crosses, partitions, strips, ribs, cups, angles, flanges, fittings in assembled welded assemblies made of aluminum, copper and other alloys - tack.
• 2. Light fences, platforms made of alloys - welded to each other and welded on a slipway to internal structures.
• 3. Sleeves for support made of copper and copper-nickel alloys - welding of bosses and extensions.
• 4. Insulation details of water tube boilers - welding.
• 5. Parts made of aluminum alloys, metal thickness over 3 mm - tack.
• 6. Frame parts made of aluminum alloys 6 mm thick - welding.
• 7. Parts for fastening furniture and products made of non-ferrous alloys - welding.
• 8. Products working under pressure - seam protection during the welding process.
• 9. Products made of aluminum alloys with a metal thickness of over 3 mm (casings, gutters, panels, screens, pallets, boxes, housings, covers, frames, brackets, various assemblies) - welding.
• 10. Products made of brass with metal thickness up to 1.5 mm - welding for chrome plating.
• 11. Frames, brackets, frames made of profile metal, alloys - welding.
• 12. Casings on the route of steam heating and electrical cables made of non-ferrous alloys - welding.
• 13. Boxes measuring 300x300x100 mm - tack welding.
• 14. Metal furniture - welding.
• 15. Set in sections made of aluminum alloys - tack during installation.
• 16. Castings from non-ferrous alloys, simple structures - welding of shells and cracks.
• 17. Non-ferrous castings - welding of defects.
• 18. Planks, cassettes, bracket-bridges, pendants, shanks and other saturation from alloys - welding.
• 19. Suspensions, foundations for electrical equipment - welding at the pre-assembly site.
• 20. Simple parts made of titanium and its alloys - welding.
• 21. Tanks made of alloys that do not require hydrotesting for tightness - welding.
• 22. Tanks that do not require hydrotesting for tightness - welding.
• 23. Railing devices (stands, railings, casings, grounding hooks) made of non-ferrous alloys - welding.
• 24. Main foundations, frames, deckhouses, tanks - protection of the weld during the welding process.
• 25. Studs, brackets made of alloys - welding to ship structures.

§ 57. Electric welder for manual welding (4th category)

Characteristics of work

• Manual arc and plasma welding of medium complexity of machine parts, assemblies, structures and pipelines made of structural steels, cast iron, non-ferrous metals and alloys and complex parts, assemblies, structures and pipelines made of carbon steels in all spatial positions of the weld.
• Manual oxygen cutting (planing) of complex parts made of high-carbon, special steels, cast iron and non-ferrous metals, welding of cast iron structures.
• Fusion of heated cylinders and pipes, defects in machine parts, mechanisms and structures.
• Welding of complex parts, assemblies and complex tools.
• Reading drawings of complex welded metal structures.

Must know:

• installation of various electric welding equipment;
• features of welding and arc cutting on alternating and direct current;
• technology for welding products in chambers with a controlled atmosphere;
• basics of electrical engineering within the scope of the work performed;
• methods for testing welds;
• types of defects in welds and methods for their prevention and elimination;
• principles for selecting welding modes based on instruments;
• brands and types of electrodes;
• mechanical properties of welded metals.

Work examples

• 1. Apparatuses, vessels, containers made of carbon steel, operating without pressure - welding.
• 2. Reinforcement of load-bearing reinforced concrete structures - welding.
• 3. Transformer tanks - welding of pipes, welding of terminal boxes, cooler boxes, current installations and tank covers.
• 4. Rudder stocks, propeller shaft brackets - welding.
• 5. Fittings and boiler burner bodies - welding.
• 6. Cast iron parts - welding, fusion with and without heating.
• 7. Chambers of hydraulic turbine impellers - welding and surfacing.
• 8. Frames of industrial furnaces and boilers DKVR - welding.
• 9. Engine crankcases - welding.
• 10. Gas exhaust manifolds and pipes - welding and welding.
• 11. Hydraulic turbine control rings - welding and surfacing.
• 12. Housings and axles of the header drive wheels - welding.
• 13. Compressor housings, low and high pressure cylinders of air compressors - crack fusion.
• 14. Rotor housings with a diameter of up to 3500 mm - welding.
• 15. Stop valve housings for turbines with power up to 25,000 kW - welding.
• 16. Fastenings and supports for pipelines - welding.
• 17. Brackets and pivot fastenings of the diesel locomotive bogie - welding.
• 18. Sheets of large thicknesses (armor) - welding.
• 19. Masts, drilling and production rigs - welding in workshop conditions.
• 20. Struts, axle shafts of aircraft landing gear - welding.
• 21. Foundation slabs for large electrical machines - welding.
• 22. Dust-gas-air ducts, fuel return units and electric precipitators - welding.
• 23. Transformer frames - welding.
• 24. Bed frames - welding in a rotary jig in all spatial positions, except for the ceiling.
• 25. Tanks for petroleum products with a capacity of less than 1000 cubic meters - welding.
• 26. Rails and prefabricated crosspieces - fusing ends.
• 27. Stators of air-cooled turbogenerators - welding.
• 28. Crusher beds - welding.
• 29. Welded-cast frames and housings of electrical machines - welding.
• 30. Beds of large-sized cast iron machines - welding.
• 31. Beds of working stands of rolling mills - surfacing.
• 32. Pipelines of external and internal water supply and heating networks - welding during installation.
• 33. Pipelines of external and internal low-pressure gas supply networks - welding in stationary conditions.
• 34. Technological pipelines (V category) - welding.
• 35. Complex cutters and dies - welding and surfacing of high-speed cutters and hard alloys.
• 36. Fachwerks, connections, lanterns, purlins, monorails - welding.
• 37. Car block cylinders - fusing of shells.
• 38. Car tanks - welding.

Electric arc welding:

• 1. Fittings, pipelines, branches, flanges, fittings, cylinders, tanks, tanks made of carbon steel, operating under a pressure of 1.5 to 4.0 MPa (from 15 to 40 kgf/sq.cm) - welding.
• 2. Beams and traverses of crane trolleys and mechanisms - welding.
• 3. Lugs, flanges, welds, fittings for high-pressure compressor cylinders - welding.
• 4. Cylinders, tanks, reservoirs, tanks, separators, filters, evaporators made of carbon steel - welding under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm).
• 5. Reflective tanks made of low-carbon steel with a thickness of 1.0 to 1.5 mm - welding in the lower position.
• 6. Banquettes, shaft housings, winch housings, winch gearbox housings, deck glasses - welding under pressure from 0.1 to 1.0 MPa (from 1 to 10 kgf/sq. cm) in the lower position.
• 7. Block sections - welding of baffles, saturation to the body.
• 8. Waterline beads - surfacing along the ship’s hull.
• 9. Medium-sized crankshafts - welding and fusing of worn parts.
• 10. Propellers, blades, hubs of normal accuracy class of all sizes and designs - air-arc planing of all surfaces.
• 11. Fences, bulkheads and deckhouses - welding and welding in various spatial positions.
• 12. Gas exhausts, air distributors, ventilation pipes in the superstructure - welding.
• 13. Silencers for high-pressure compensators, steel, metal thickness 1.5 mm and diameter up to 100 mm - welding.
• 14. Doors and hatch covers are water-gas-tight - welding.
• 15. Bottom, side, upper and lower decks, platforms, volumetric sections of ends, transverse and longitudinal bulkheads - welding of frame joints on a slipway.
• 16. Metalwork details for the main body and lining of the main tanks - welding.
• 17. Shelf parts - welding to intercompartment transverse bulkheads.
• 18. Doors, panels, angles, sheets, bushings with a metal thickness of 1.4 to 1.6 mm - welding.
• 19. Parts of complex configuration, intended for work under dynamic and vibration loads, material thickness from 10 to 16 mm - welding.
• 20. MSCh products - anti-corrosion deposits of AK type steels on surfaces for machining.
• 21. Casings, gutters, panels, pallets made of carbon and low-alloy steel with a thickness of up to 2 mm, of alloy steel with a thickness of over 2 mm - welding.
• 22. Cable boxes - welding under pressure testing from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) during unit assembly.
• 23. Casings, gutters, panels, pallets made of carbon and low-alloy steel with a thickness of up to 2 mm, of alloy steel with a thickness of over 2 mm - welding.
• 24. Ship ventilation ducts - welded to bulkheads on the slipway.
• 25. Anchor fairleads - welding.
• 26. Casings, gutters, panels, pallets made of alloy steel up to 2 mm thick - welding.
• 27. Ventilation valves - welding.
• 28. Cargo hold coamings - welding the set together.
• 29. Body structures made of carbon, low-alloy and high-alloy steels - air-arc gouging in hard-to-reach places (melting the weld root, removing temporary elements, smelting defective areas).
• 30. Ship-carrying train structures - welding.
• 31. Hull of a surface vessel: outer deck plating - welding of joints and grooves on the slipway in all positions.
• 32. Hulls of heavy portholes - welding and welding into the ship’s hull.
• 33. Hull structures and assemblies, up to 20% of the welds of which are subjected to ultrasonic or gammagraphic control - welding.
• 34. Brackets, edges, screens made of sheet and profile metal up to 2 mm thick - welding.
• 35. Caps and bearing housings made of castings - welded for tightness testing.
• 36. Removable sheets of carbon and low-alloy steels - welding.
• 37. Recess marks, cargo welding - welding to the ship's hull.
• 38. Masts, cargo booms, cargo columns - welding of assembly joints and face sheets on the slipway.
• 39. Signal masts - welding during assembly.
• 40. Metal structures of ships - welding of defective areas of seams when tested on a slipway and afloat in all positions.
• 41. Intercompartment transverse bulkheads - welding.
• 42. Saturation of fittings and hulls - welding on the transverse and longitudinal bulkheads of the superstructure.
• 43. A set of longitudinal and transverse bottom, side and deck (calculation) sections made of structural steel - welding to each other and welding to the outer plating and deck flooring on pre-stall assembly.
• 44. Set with grooved edges, joints and grooves of steel bulkheads - assembly and welding at the pre-assembly site.
• 45. A set of bottom sections with a height of 0.8 to 1.5 m - welding at the bow end, to the bottom flooring and welding to each other.
• 46. ​​Superstructures, deckhouses made of alloy steels - welding and welding to the main body.
• 47. Double bottom decking - welding joints and grooves on the slipway.
• 48. Saturation of cargo masts, booms (heads, foundations, control platforms with railings) - welding to structures.
• 49. Butts for transporting sections with a lifting capacity of up to 20 tons - welding and welding to sections.
• 50. Butts with a lifting capacity of over 20 tons - welding and welding.
• 51. Steel rudder blade - welding of the flat part.
• 52. Transverse and longitudinal bulkheads, external walls of superstructures - welding of joints and grooves of panels in all positions on the slipway.
• 53. Reinforcements for foundations, construction device supports, side keels, outer walls of tanks, outer walls chimney- welding on the slipway.
• 54. Other tanks - welding of seams with cutting of edges and structural lack of penetration on sectional assembly.
• 55. Rails of workshop electric trolleys - welding.
• 56. Joints and grooves of the aft end skin, brackets and stabilizers - welding.
• 57. Joints of sheets of walls, roofs and a set of internal tanks - welding and welding to the casing, bulkheads and to each other.
• 58. Assembly joints of reinforced concrete vaults - welding.
• 59. Tambour, airlock, bathrooms - welding and welds.
• 60. Ship ventilation pipes made of carbon and low-alloy steels up to 2 mm thick - welding and welding of flanges to them.
• 61. Pipelines made of carbon steels operating under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) with a pipe wall thickness of more than 2 mm - welding.
• 62. Pipelines - welding of joints on backing rings with quality control of seams by radiography.
• 63. Pipelines - welding of pressurized joints with quality control of seams by radiography.
• 64. Anchor, towing, launching and mooring devices, construction device stops - welding.
• 65. Flanges, pipes, fittings, welds, nozzles, nipples - welding to the pipeline under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm).
• 66. Foundations made of alloy steel for auxiliary mechanisms, cylinders, boat and mooring devices - welding.
• 67. Frames - welding of joints during heat treatment on a HDTV installation.
• 68. Dies for presses with pressures over 400 tons - welding.

Gas shielded welding:

• 1. Tin bronze fittings under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) - fusing of exposed casting defects after machining.
• 2. Fittings, casting, parts made of aluminum-magnesium alloys - welding, welding of defects.
• 3. Fans - welding of disks with a brush made of aluminum alloys.
• 4. Views made of non-ferrous alloys - welding.
• 5. Flame pipe heads, aluminum alloy flame pipe - welding.
• 6. Gas exhausts, mufflers made of stainless steel, copper-nickel alloys - welding.
• 7. Silencers for high-pressure compressors made of aluminum alloys with a metal thickness of 2 to 3 mm - welding.
• 8. Details of saturation of the body made of aluminum alloys - welding in the ceiling position.
• 9. Parts and assemblies made of aluminum-magnesium alloys of medium complexity, operating under pressure from 0.1 to 1.0 MPa (from 1 to 10 kgf/sq.cm) - welding.
• 10. Parts and assemblies of current distribution devices made of aluminum alloys: hermetic boxes, shells, angles, hinges, cans, brackets, racks, frames, shoulders, welds, gaskets, grooves - welding to the body and welding.
• 11. Hull structures after hydraulic tests - tacking, welding, correction of seam defects; binding of temporary fastenings.
• 12. Rings and branches of pipe sections made of non-ferrous alloys under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) - welding.
• 13. Structures made of aluminum, titanium and non-ferrous alloys - welding of holes, tack welding in vertical and ceiling positions.
• 14. Impellers, flanges, covers of electrical appliances made of aluminum alloys - welding cracks, attaching broken parts.
• 15. Alloy structures - tack in all spatial positions.
• 16. Structures made of aluminum and titanium alloys - straightening using the method of applying blank rollers.
• 17. Composite structures (steel - aluminum alloy) - welding using bimetallic inserts.
• 18. Masts made of aluminum alloys - welding of joints and grooves of the mast barrel and welding of components.
• 19. Superstructures, deckhouses made of aluminum alloys - welding of volumetric units, set joints at intersections.
• 20. Castings with a wall thickness of up to 10 mm - welding of shells and cracks under pressure testing of 0.1 to 1.0 MPa (from 1 to 10 kgf/sq.cm).
• 21. Castings from aluminum alloys - welding of defects.
• 22. Castings with a wall thickness of over 10 mm, operating under pressure over 1.0 MPa (10 kgf/sq.cm) - welding of defects.
• 23. Hydraulic cylinder pistons and other products (hooks of anchor devices, winch seals) - cladding with copper alloys.
• 24. Frames, sashes made of non-ferrous metal - welding of incoming parts.
• 25. T-joints - with full penetration of the outer skin sheet made of aluminum alloys.
• 26. Joints of pipes not working under pressure, made of aluminum and non-ferrous alloys - welding of rotary joints.
• 27. Vertical and inclined ladders made of aluminum alloys - welding.
• 28. Reinforcement units made of non-ferrous metals - welding of parts, welding of parts under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm).
• 29. Flanges, rollers, housings, boxes, covers, blocks - fusing and welding with bronze, alloys, corrosion-resistant steels.
• 30. Foundations for mechanisms and devices - editing.
• 31. Seams after automatic welding in shielding gases - making fillets and finishing rollers.
• 32. Alloy scuppers - welding.
• 33. Copper busbar with a metal thickness of 12 mm - welding with preheating of the metal.

§ 58. Electric welder for manual welding (5th category)

Characteristics of work

• Manual arc and plasma welding of complex building and technological structures operating in difficult conditions.
• Manual oxygen arc cutting (planing) of complex parts made of high-carbon, alloy and special steels and cast iron.
• Fusion of defects in various machine parts, mechanisms and structures.
• Welding of complex parts and assemblies.

Must know:

• electrical circuits and designs of various types of welding machines;
• technological properties of welded metals, metal deposited with electrodes of various brands and castings subjected to planing;
• technology for welding critical products in chambers with a controlled atmosphere;
• selection of technological sequence for applying seams and welding modes;
• methods for monitoring and testing critical welds;
• rules for reading drawings of complex welded spatial metal structures.

Work examples

• 1. Apparatuses and vessels made of carbon steels operating under pressure and alloy steels operating without pressure - welding.
• 2. Fittings for open hearth furnaces - welding during repair of existing equipment.
• 3. Reinforcement of load-bearing and critical reinforced concrete structures: foundations, columns, floors, etc. - welding.
• 4. Tanks of unique powerful transformers - welding, including welding of lifting hooks, jacking brackets, stainless steel plates operating under dynamic loads.
• 5. Center beams, buffer beams, pivot beams, locomotive and wagon bogie frames, wagon body trusses - welding.
• 6. Beams and traverses of crane trolleys and balancers - welding.
• 7. Span beams for bridge cranes with a lifting capacity of less than 30 tons - welding.
• 8. Boiler drums with pressure up to 4.0 MPa (38.7 atm) - welding.
• 9. Blocks of building and technological structures made of sheet metal (air heaters, scrubbers, blast furnace casings, separators, reactors, blast furnace flues, etc.) - welding.
• 10. Cylinder blocks and water manifolds of diesel engines - welding.
• 11. Large crankshafts - welding.
• 12. Gas tanks and tanks for petroleum products with a volume of 5000 cubic meters and more - welding in stationary conditions.
• 13. Gas and oil product pipelines - welding on a rack.
• 14. Parts of machines and mechanisms (charging devices of blast furnaces, propellers, turbine blades, rolls of rolling mills, etc.) - for melting with special, hard, wear-resistant and corrosion-resistant materials.
• 15. Parts of machines, mechanisms and structures forged, stamped and cast (propellers, turbine blades, cylinder blocks of parts, etc.) - fusing of defects.
• 16. Caissons for open-hearth furnaces operating at high temperatures - welding.
• 17. Columns, bunkers, trusses and sub-trusses, beams, trestles, etc. - welding.
• 18. Structures of radio masts, television towers and power line supports - welding in stationary conditions.
• 19. Head housings, traverses, bases and other complex components of presses and hammers - welding.
• 20. Rotor housings with a diameter of over 3500 mm - welding.
• 21. Stop valve housings for turbines with power over 25,000 kW - welding.
• 22. Housings of cutters, loading machines, coal combines and mine electric locomotives - welding.
• 23. Covers, stators and lining of blades and hydraulic turbines - welding.
• 24. Masts, drilling and production derricks - welding during installation.
• 25. Bases made of high-alloy drill pipes for drilling rigs and three-diesel drives - welding.
• 26. Foundation slabs for a walking excavator unit - welding.
• 27. Frames and components of cars and diesel engines - welding.
• 28. Kingpin and diesel locomotive frames - welding.
• 29. Tanks for petroleum products with a capacity from 1000 to 5000 cubic meters. - welding during installation.
• 30. Rods for cold rolling mills, pipes and pipe drawing mills - welding of individual elements.
• 31. Joints of reinforcement outlets of elements of load-bearing prefabricated reinforced concrete structures - welding.
• 32. Pipe elements of steam boilers with pressure up to 4.0 MPa (38.7 atm.) - welding.
• 33. Pipelines of external and internal low-pressure gas supply networks - welding during installation.
• 34. Pipelines of external and internal gas supply networks of medium and high pressure - welding in stationary conditions.
• 35. Technological pipelines of III and IV categories (groups), steam and water pipelines of III and IV categories - welding.
• 36. Assemblies of sub-engine frames and shock absorber cylinders of aircraft landing gear - welding.
• 37. Tires, expansion joints for them made of non-ferrous metals - welding.

Electric arc welding:

• 1. Fittings, pipelines, branches, flanges, fittings, cylinders, tanks, tanks made of corrosion-resistant steels operating under pressure from 1.5 to 4 MPa (from 15 to 40 kgf/sq.cm.) - welding.
• 2. Sternposts, stems - welding of joints and welding of the outer skin.
• 3. Intermediate shafts, propeller and stern tubes - welding.
• 4. Propellers - welding steel, cast or forged blades.
• 5. Propellers, hub blades of medium, high and special accuracy classes of all sizes and designs - air-arc planing of all surfaces of the propeller, blades and hubs.
• 6. Vertical keels and impermeable stringers - welding of installation joints.
• 7. Gas-tight steel decking - welding and welding to the main body.
• 8. Metalwork details for the main body and lining of the main tanks - welding.
• 9. Shelf parts - welding to the main hull and to the end transverse bulkheads.
• 10. Steel parts - air-arc gouging (melting the root of the weld and removing temporary fasteners).
• 11. Parts operating under vibration loads - welding of sections.
• 12. Ship hulls made of carbon and low-alloy steels - welding of joints and grooves of the outer plating in all spatial positions.
• 13. Boat hulls (repair) - welding.
• 14. Brackets, mortars and propeller shaft fillets - welding, welding of joints, welding to the hull.
• 15. Stabilizing columns, braces, connections of tubular and box-shaped forms of floating drilling rigs - welding during installation afloat.
• 16. Structures made of low-magnetic steel with a metal thickness of 1.5 to 3 mm, planned steels - welding.
• 17. Ship pump housings, nozzle segments with milling blades, ship steering gears (cylinders, plungers, valve boxes) - welding.
• 18. Brackets, mortars, propeller cores - welding and welding on type vessels.
• 19. Hatch coamings made of alloy steel - welded to the hull skin (under the supervision of a technologist).
• 20. Steel structures SW - welding of joints and grooves.
• 21. End and intercompartment bulkheads - welded to the main body.
• 22. Stern and bow extremities in confined spaces in workshop conditions - welding of the set to each other and to the skin of the extremities.
• 23. Set with grooved edges, joints and grooves of steel bulkheads - assembly and welding at the pre-assembly site.
• 24. Anchor fairlead niches - welded to the outer skin on the slipway.
• 25. Butts, traverses, beams of overhead bridge cranes with a lifting capacity of up to 30 tons - welding and welding.
• 26. Sheathing and set of ORs, superstructure of fairings and ends of the NK - welding to OK.
• 27. Supporting parts of the foundations for opening the shields - welding to each other and welding to the structures of the bow end.
• 28. Sheathing and set of stabilizers - welding to mortars.
• 29. Main tanks - welding and tacking them to the main body.
• 30. Sheathing of the outer casing made of steel - welding of installation joints.
• 31. Decks and platforms - welding of joints and grooves in the ceiling position on the slipway.
• 32. Welded joints, welded joints made of alloy steel, container cups - welding on a slipway.
• 33. Sheets and sets of bulkheads and tanks located inside the vessel and of unequal strength to it - welding.
• 34. Spacer platform sheets - welding to bulkheads.
• 35. Transverse and longitudinal brackets of stabilizers - welding to each other.
• 36. Foundation frames of high pressure compressors - welding.
• 37. Joints and grooves of the outer plating of technological structures of the ship's hull - welding on a welding assembly.
• 38. Sections of the stern and main ends at the pre-assembly site and slipway - welding of joints and grooves.
• 39. Welding and set of impermeable bulkheads and stringers, stabilizers, rudders, nozzles, nacelles - welding on site.
• 40. Joints and grooves of the shells of the main body - welding.
• 41. Joints and grooves of the outer skin made of AK and YUZ type steels, stringers, vertical keel, frames - welding of the seam in all spatial positions with a through wire.
• 42. Pipelines made of low-alloy and corrosion-resistant steels operating under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) with a pipe wall thickness of over 2 mm - welding.
• 43. Foundations for main mechanisms, reinforcements for intercompartment bulkheads, internal tanks - welding.
• 44. foundations for retractable devices - welding to base plates, platforms and impulse tank.
• 45. Shafts, other deckhouses, coamings of entrance and loading hatches - welding to the main hull.
• 46. ​​Frames - welding joints and welding to the main body.
• 47. Mines, other cuttings - welding of joints and grooves.
• 48. Dies - hard alloy deposition.
• 49. Dies of complex configuration, plates, rods, tips, spindles - fusing edges with hard alloys.

Gas shielded welding:

• 1. Heat exchangers and other coils made of light and non-ferrous alloys, as well as tanks, reservoirs and vessels made of aluminum alloys under hydraulic pressure from 1.5 to 4.0 MPa (from 15 to 40 kgf/sq.cm) - welding.
• 2. Fittings made of alloys, pipelines and fittings made of aluminum alloys - welding of flanges, fittings, nozzles, nipples.
• 3. Fittings for bellows expansion joints made of corrosion-resistant steels and titanium alloys - welding with 100% gammagraphy.
• 4. Blocks, frames, boxes, covers, panels made of non-ferrous metal - welding under pressure testing from 0.1 to 1.0 MPa (from 1 to 10 kgf/sq.cm).
• 5. Propellers made of non-ferrous alloys - fusing, welding of cracks, welding of fittings.
• 6. Doors and components with metal thickness up to 1.5 mm from homogeneous and dissimilar aluminum alloys - welding.
• 7. Parts of complex configuration made of dissimilar aluminum alloys and corrosion-resistant steels with a wall thickness of up to 2 mm - welding.
• 8. Casings, fairings made of alloys - welding under pressure testing up to 4.0 MPa (40 kgf/sq.cm).
• 9. Compensators and other critical components of water tube boilers made of alloys - welding.
• 10. Housings made of corrosion-resistant steels operating under pressure from 1.5 to 4.0 MPa (from 15 to 40 kgf/sq.cm) - welding.
• 11. Alloy superstructures - welded to the hull.
• 12. Saturation of the hull and end bulkheads from alloys - welding.
• 13. Pipelines made of copper-nickel and aluminum alloys operating under pressure from 0.1 to 1.5 MPa (from 1 to 15 kgf/sq.cm) - welding.
• 14. Pipes made of copper, copper-nickel, aluminum alloys, corrosion-resistant steels and alloys - welding of joints, welding of flanges, pipes, fittings, welds under pressure from 1.5 to 4.0 MPa (from 15 to 40 kgf/ sq.cm).
• 15. Stern tubes, propeller shafts, sealed closure covers - cladding with non-ferrous alloys and corrosion-resistant steels.
• 16. Assemblies of units made of alloys with a metal thickness of 0.3 mm - welding.

§ 59. Electric welder for manual welding (6th category)

Characteristics of work

• Manual arc and plasma welding of complex devices, components, structures and pipelines made of various steels, non-ferrous metals and alloys.
• Manual arc and gas-electric welding of complex building and technological structures operating under dynamic and vibration loads, and structures of complex configuration.
• Welding of experimental structures made of metals and alloys with limited weldability, as well as titanium and titanium alloys.
• Welding of complex structures in block design in all spatial positions of the weld.

Must know:

• design of the equipment being serviced;
• types of titanium alloys, their welding and mechanical properties;
• types of corrosion and factors causing it;
• methods of special testing of welded products and the purpose of each of them;
• diagrams of pumping systems of chambers with controlled atmosphere;
• main types of heat treatment of welded joints;
• basics of weld metallography.

Work examples

• 1. Beams of working platforms of open-hearth shops, structures of bunkers and unloading platforms of metallurgical enterprises, crane beams for heavy-duty cranes, booms of walking excavators - welding.
• 2. Span beams of bridge cranes with a lifting capacity of 30 tons and above - welding.
• 3. Boiler drums with pressure over 4.0 MPa (38.7 atm.) - welding.
• 4. Gas tanks and tanks for petroleum products with a volume of 5000 cubic meters and more - welding during installation.
• 5. Main gas and oil product pipelines - welding during installation.
• 6. Vacuum and cryogenic containers, caps, spheres and pipelines - welding.
• 7. Spherical and drop-shaped containers and coatings - welding.
• 8. Locks of drill pipes and couplings - double seam welding.
• 9. Working wheels of gas turbine compressors, steam turbines, powerful blowers - welding of blades and vanes.
• 10. Ammonia synthesis columns - welding.
• 11. Structures of radio masts, television towers and power line supports - welding during installation.
• 12. Steam turbine boxes - welding and fusing of shells.
• 13. Stator housings of large turbogenerators with hydrogen and hydrogen-water cooling - welding.
• 14. Housings of heavy diesel engines and presses - welding.
• 15. Ship steam boilers - welding of bottoms, welding of critical components with a one-sided butt weld.
• 16. Structures made of light aluminum-magnesium alloys - welding.
• 17. Feet and rustles of drill bits, drilling steam conductors - welding.
• 18. Oil and gas pipelines - welding to eliminate gaps.
• 19. Pipeline piping of oil and gas wells and edge flooding wells - welding.
• 20. Tanks and structures made of two-layer steel and other bimetals - welding.
• 21. Reinforcement bars of reinforced concrete structures in split forms - welding using the hot tub method.
• 22. Span structures of metal and reinforced concrete bridges - welding.
• 23. Pipe elements of steam boilers with pressure over 4.0 MPa (38.7 atm.) - welding.
• 24. Pressure pipelines; spiral chambers and impeller chambers of hydroelectric turbines - welding.
• 25. Pipelines for external gas supply networks of medium and high pressure - welding during installation.
• 26. Technological pipelines of I and II categories (groups), steam and water pipelines of I and II categories - welding.

Electric arc welding:

• 1. Heat exchangers and other vessels made of special steels under test pressure over 20.0 MPa (over 200 kgf/sq.cm) - welding.
• 2. PC brackets - welding to the casing.
• 3. Necks made of alloy steel - welding with a sealed seam under pressure over 4.0 MPa (over 40 kgf/sq.cm).
• 4. Doors and entrance hatch collars with bulkhead panels - welded.
• 5. Buffer tanks for air pressure of 40.0 MPa (400 kgf/sq.cm) - welding.
• 6. Plugs for hydraulic testing of the block - welding.
• 7. Collectors, chambers, pipes, cylinders, tanks, tanks made of carbon and low-alloy steels under pressure over 4.0 MPa (over 40 kgf/sq.cm) - welding.
• 8. Cable boxes - welding under pressure testing over 4.0 MPa (over 40 kgf/sq.cm).
• 9. Housings of flaps and TA pipes - welding to the main body, item 21.
• 10. Special purpose tank bodies (bottom sheets, transverse bulkheads, roof) - welding.
• 11. Support columns of floating drilling rigs - welding during installation.
• 12. Structures made of high-strength special steels - welding of installation joints OK in vertical and ceiling positions.
• 13. Hull structures and assemblies, 100% of the welds of which are subjected to ultrasonic or gammagraphic control - welding.
• 14. Sheets of removable housing made of high-strength steel - welding after hydraulic tests.
• 15. Interhull transitions, coaming platforms, TA and stern tubes - welding and straightening.
• 16. Mortars, necks, fillets, chairs, glasses and others - welding and welding.
• 17. Butts, traverses, beams of overhead cranes with a lifting capacity of over 30 tons - welding.
• 18. Sheathing OK, PR - welding of joints and grooves.
• 19. Sheathing of external durable tanks and enclosures - welding and sealing.
• 20. Sheathing and frames of rescue devices, as well as coamings welded into them, rod devices - welding and welding.
• 21. Sheathing and frames of containers - welding.
• 22. Sheathing of internal durable tanks, recesses, partitions and sheets of impenetrable bulkheads (stringers) - welding together and welding.
• 23. Other capsules, chambers, gondolas, etc., operating at full outboard pressure - welding.
• 24. Shelf panels and a set of end strong bulkheads - welding and welding.
• 25. Fabrics and a set of inter-hull connections OK and equal-strength structures - welding and welding to OK.
• 26. Sheets and sets of spacer platforms and impermeable bulkheads - welding and sealing.
• 27. Walls and stiffeners of the PTU frame, foundations of the main mechanisms - welding and welding.
• 28. Removable sheets and seals of the main body ed. 21 - welding.
• 29. The ends of a set of end bulkheads, external and internal tanks - welding to the casing of OK and PTs.
• 30. Main and auxiliary steam pipelines - welding of fittings and jets under pressure over 4.0 MPa (over 40 kgf/sq.cm).
• 31. Boiler pipes under test pressure over 4.0 MPa (over 40 kgf/sq.cm), fixed joints under solid pressure over 2.5 MPa (over 25 kgf/sq.cm) - welding.
• 32. Pipelines - welding in hard-to-reach places with quality control of seams by radiography.
• 33. High-pressure pipelines with a working pressure of 40.0 MPa (400 kgf/sq.cm) and higher on floating drilling rigs - welding.
• 34. Bimetallic pipes under pressure over 20.0 MPa (over 200 kgf/sq.cm) - straightening flanges and welding.
• 35. Welded seams - welding in hard-to-reach places using a mirror.

Gas shielded welding:

• 1. Heat exchangers made of aluminum and copper alloys under hydraulic pressure over 4.0 MPa (over 40 kgf/sq.cm) - welding.
• 2. Fittings made of tin bronze and silicon brass - welding of defects under pressure over 4.0 MPa (over 40 kgf/sq.cm).
• 3. Cylinders made of titanium alloys and corrosion-resistant steels under pressure over 4.0 MPa (over 40 kgf/sq.cm) - welding.
• 4. Portholes made of special alloys and steels under pressure over 20.0 MPa (over 200 kgf/sq.cm) - preliminary welding and welding into the body.
• 5. Caps, shells, housings, covers, pipes made of non-ferrous metals - welding under pressure testing over 4.0 MPa (over 40 kgf/sq.cm).
• 6. Structures made of alloys and corrosion-resistant steels operating under pressure over 20.0 MPa (over 200 kgf/sq.cm) - welding.
• 7. Special structures made of corrosion-resistant steels up to 2 mm thick, subjected to x-ray gammagraphy, hydro- and pneumatic tests under pressure over 5.0 MPa (over 50 kgf/sq.cm) - welding.
• 8. Containers, housings made of corrosion-resistant steels - welding under pressure testing over 5.0 MPa (over 50 kgf/sq.cm).
• 9. Pipes made of corrosion-resistant steels - welding of fixed joints.
• 10. Joints of pipes made of copper-nickel, copper, aluminum, titanium alloys, corrosion-resistant steels in systems with pressure over 4.0 MPa (over 40 kgf/sq.cm) - welding, welding of fittings.
• 11. Joints of mounting housings made of special steels and alloys - welding in hard-to-reach places.
• 12. Pipelines made of corrosion-resistant steels under pressure over 5.0 MPa (over 50 kgf/sq.cm) - welding in hard-to-reach places using a mirror.
• 13. Copper water desalination plants - welding under pressure 0.6 MPa (6 kgf/sq.cm).