CRT 2020 - Welding

WELDING, CUTTING AND JOINING

A. Safety Precautions

1. Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations. HP-I 
2. Locate OEM procedures to identify materials and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, etc.). HP-I
3. Locate procedures and precautions that may apply to the vehicle being repaired. HP-I
4. Identify vehicle system precautions and/or inspections to include but not limited to supplemental restraint system (SRS), advanced driver assistance systems (ADAS), hybrid/electric/alternative fuel vehicles), locations and recommended procedures before inspecting or replacing components. HP-I
5. Perform vehicle clean-up; complete quality control using a checklist on operations performed. HP-I

B. Metal Welding, Cutting, and Joining

1. Identify the considerations for cutting, removing, and welding various types of steel, aluminum, and other metals. HP-G
2.  Determine the correct GMAW welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation. HP-I
3. Set up, attach work clamp (ground), and adjust the GMAW welder to “tune” for proper electrode stick out, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded. HP-I
4. Store, handle, and install high-pressure gas cylinders; test for leaks. HP-I
5. Determine the proper angle of the gun to the joint and direction of gun travel for the type of weld being made. HP-I
6. Protect adjacent panels, glass, vehicle interior, etc. from welding and cutting operations. HP-G
7. Identify hazards; foam coatings and flammable materials prior to welding/cutting procedures. HP-G
8. Protect computers and other electronics/wires prior to welding procedures. HP-G
9. Clean and prepare the metal to be welded, assure good metal fit-up, apply weld through primer if necessary, clamp or tack as required. HP-I
10. Determine the joint type (butt weld with backing, lap, etc.) for weld being made. HP-I
11. Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation. HP-I
12. Perform the following welds: plug, butt weld with and without backing, and fillet etc., in the flat, horizontal, vertical, and overhead positions. HP-I
13.  Perform visual evaluation and destructive test on each weld type. HP-I
14. Identify the causes of various welding defects; make necessary adjustments.  HP-I
15. Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments. HP-I
16. Identify cutting process for different substrates and locations; perform cutting operation. HP-I
17.  Identify different methods of attaching structural components (squeeze type resistance spot welding (STRSW), riveting, structural adhesive, MIG bronze, rivet bonding, weld bonding, etc.).  HP-G