GMAW NC II study plan

Identify the OHS controls that apply to a GMAW workstation by listing the hierarchy of controls for fume, arc radiation, spatter, and electric shock, and match each control to a specific piece of equipment or practice.

Select and justify the correct PPE for a given GMAW task (helmet shade, respirator type, gloves, sleeves, footwear) and state the standard or rule of thumb behind each choice.

Demonstrate 5S housekeeping on a simulated or real weld bay by sorting, setting in order, and labeling consumables, cables, and gas cylinders, then record the before-and-after state.

Set up a GMAW machine from a nameplate and front-panel reading: connect polarity for solid wire with DCEN/electrode positive as specified, set wire feed speed, voltage, and gas flow, and record every setting on a setup sheet.

Prepare base metal for welding by removing mill scale, rust, oil, and moisture from a 150 mm test area on two coupons, then verify cleanliness against a written checklist.

Fit up a butt joint and a T-joint to within 1 mm root gap and 1 mm misalignment using tack welds, and measure each with a gap gauge or feeler set.

Explain how wire feed speed, voltage, and travel speed interact to control arc length and bead shape, and predict the effect of raising or lowering each parameter.

Produce a bead-on-plate stringer pad in the flat position at three parameter sets (low, recommended, high) and label each bead with its recorded values.

Adjust shielding gas flow to the recommended range for the wire being used and identify signs of too little and too much flow in a test bead.

Set up and align jigs or fixtures so the workpiece is restrained without distorting the joint, and state one clamping rule that limits distortion.

Execute a flat-position butt weld (single-V or square groove) with consistent travel angle and work angle, keeping bead width and reinforcement uniform along the length.

Weld a flat-position T-joint fillet with equal leg lengths and correct throat, and measure leg size with a fillet gauge.

Demonstrate correct torch manipulation: push vs. drag angle for the given transfer mode, correct stick-out, and steady travel without whipping.

Troubleshoot two common process faults (porosity from gas loss, burn-through from excess current or slow travel) by diagnosing the cause and correcting the parameter.

Record all settings and observations for each weld in a log that ties parameters to visual outcome.

Weld in the horizontal (2F/2G) position and adapt travel angle and heat input to control sagging and undercut.

Inspect your own welds against acceptance criteria for undercut, overlap, porosity, spatter, and bead profile, and classify each defect found.

Correct one identified defect by grinding out and rewelding, then re-inspect and document the correction.

Apply the correct visual inspection sequence (clean, light, examine, measure) and record which defects are surface-visible versus internal-only.

Define what each common NDT method (visual, penetrant, magnetic particle, ultrasonic, radiographic) can and cannot detect in a GMAW joint.

Weld in the vertical (3F/3G) position, using a weave or step technique to control puddle and prevent undercut at the toes.

Weld in the overhead (4F) position with correct body position, torch angle, and reduced current as needed for control.

Identify the causes and prevention of lack of fusion, lack of penetration, and crater cracks in multi-pass welds.

Perform a bend test or destructive break test on a practice coupon and interpret the failure location and appearance.

Compare your vertical and overhead results against the flat-position baseline and state which parameter changes were needed and why.

Read a welding symbol and extract every element: reference line, arrow, tail, groove or fillet type, size, length, pitch, contour, and all-around or field-weld marks.

Locate and interpret the essential variables in a WPS (process, base metal, filler, gas, current type and polarity, voltage range, travel speed, preheat, interpass) and state how a deviation is handled.

Read dimensions and tolerances on a fabricated-part drawing and identify the datum and the dimensions that govern fit-up of a welded assembly.

Map the safety and housekeeping requirements of the work area to the job being planned, including ventilation for the chosen process and gas, and fire watch duties.

Explain how a WPS qualification and a welder qualification differ and what each one proves.

Build a defect catalogue from your own practice welds, listing each defect with its visual signature, root cause, and the parameter or technique fix.

Perform a dimensional check on a finished weldment (leg length, throat, reinforcement height, angular distortion) and compare each reading with the drawing tolerance.

Carry out post-weld operations: spatter removal, slag and oxide cleaning, wire cut and tip replacement, and liner and drive-roll inspection.

Perform routine GMAW maintenance: check contact tip wear, nozzle condition, gas hose leaks, ground clamp contact, and wire spool drag, and record the findings.

Complete a weld inspection and maintenance record that would let another welder reproduce the job.

Complete a timed full mock assessment covering one weld to a given WPS and drawing, from fit-up through final inspection and documentation.

Self-score the mock against a rubric weighted to the exam domains and identify the two weakest areas.

Re-drill the two weakest areas with targeted practice and record the before-and-after result.

Assemble a final portfolio: setup sheets, parameter logs, inspection reports, maintenance records, and decoded WPS and symbol worksheets.

Write a short reflection stating which domains you can now perform independently and which still need supervised practice.