KOLEJ VOKASIONAL LIKAS

KOTA KINABALU

TEACHING OUTLINE

PROGRAMME

WELDING TECHNOLOGY

COURSE NAME

GMAW (GAS METAL ARC WELDING) PROCESS

1

CODE NAME

MTK 303

LEVEL

2 SEMESTER 3

CREDIT UNIT

2.0

CONTACT HOUR

FACE TO FACE

: 4.0 HOURS / WEEK

NON FACE TO FACE :

COURSE TYPE

VOCATIONAL

PRE-REQUISITE

MTK 103 : SMAW (SHIELDED METAL ARC

WELDING) PROCESS 1
MTK 302 : SMAW (SHIELDED METAL ARC
WELDING

CORE REQUISTE

NO. OF CONTENT STANDARD

COURSE OUTCOMES
At the end of the course, the students should be able to:1. Select filler wire & shielding gas
2. Set up GMAW equipment and accessories
3. Weld carbon steel plate of thickness range 3-9 mm in 2F position
4. Weld carbon steel plate of thickness range 3-9 mm in 1G position
COURSE DESCRIPTION
This unit identifies the competence required to select filler wire and shielding gas, set
up GMAW equipment and accessories, weld carbon steel plate of thickness range 3mm to
9mm in 1G and 2F position by preparing the plate, setting up the equipment and welding
using GMAW process so that the plate is welded according to a given procedure and the
weldment is free from defect and meet the specific welding standard.

CONTENT STANDARD 1

SELECT FILLER WIRE & SHIELDING GAS

LEARNING STANDARD
1.1 Check parent metal
1.2 Describe type of shielding gas
1.3 Identify and choose filler wire

PERFORMANCE CRITERIA
1.1.1

Identify type of metals and its specification according to BS/AWS codes and
standards.
1.1.2 Identify different type of common base metals visually according to BS/AWS codes
and standards
1.2.1 Describe type of shielding gases use in GMAW welding process such as carbon
dioxide, argon, helium and other mixed mixture gases according to BS/AWS codes
and standards
1.2.2 Practise safety precaution according to OSHA.
1.3.1
1.3.2

Identify type of filler wires used in GMAW process according to BS/AWS codes and
standards.
Install wire to wire feeder securely set and safe to operate according to manufacturer
recommendation.

TEACHING STRATEGIES
A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI
B. MENYATAKAN OBJEKTIF PEMBELAJARAN:
- Identify the information to be delivered.
- Prepare notes for briefing.
- Deliver briefing to welders.
C. AKTIVITI PENGAJARAN:
1.1 Check parent metal
1.1.1 Identify type of metals and its specification according to BS/AWS codes and
standards.
1.1.2 Identify different type of common base metals visually according to BS/AWS codes
and standards
1.2 Describe type of shielding gas

1.2.1
1.2.2

Describe type of shielding gases use in GMAW welding process such as carbon
dioxide, argon, helium and other mixed mixture gases according to BS/AWS codes
and standards
Practise safety precaution according to OSHA.

1.3 Identify and choose filler wire

1.3.1 Identify type of filler wires used in GMAW process according to BS/AWS codes and
standards.
1.3.2 Install wire to wire feeder securely set and safe to operate according to manufacturer
recommendation.
D. REFLEKSI

CONTENT STANDARD 2

SET UP GMAW EQUIPMENT AND

ACCESSORIES

LEARNING STANDARD
2.1 Identify and select welding machine.
2.2 Install regulators, flow meters, nozzle/tips
2.3 Fix welding hoses
2.4 Identify and select safety accessories

PERFORMANCE CRITERIA

2.1.1
2.1.2
2.1.3
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.3.1
2.3.2
2.3.3

Apply safety precaution related to handling and operating of GMAW equipment

according to standard operational procedures.
Define principle of GMAW process according to BS/AWS welding standards.
Identify GMAW equipment according to manufacturer recommendation.
Apply procedure of installing regulators and flow meter according to manufacturer
recommendation.
Determine gas regulators for the required welding process.
Identify size of tip/nozzle according to manufacturer specifications.
Identify regulator and flow meter at welding machine according to manufacturer
recommendation.
Install regulators to flow meters and welding set according to manufacturer
recommendation.
Practise safety precaution in accordance to Occupational Safety & Health Act
(OSHA) to minimise accidents and injuries at work site.
Apply Safety precaution related to handling of welding hoses.
Identify type of welding hoses for the required welding process.
Assemble and connect welding hoses to equipment for the required welding process.

2.4.1
2.4.2

Identify potential hazards in welding operation for the required welding process.
Identify and select safety equipment/accessories for the required welding process.

TEACHING STRATEGIES
A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI
B. MENYATAKAN OBJEKTIF PEMBELAJARAN:
- Identify the information to be delivered.
- Prepare notes for briefing.
- Deliver briefing to welders.
C. AKTIVITI PENGAJARAN:
2.1 Identify and select welding machine.
2.1.1 Apply safety precaution related to handling and operating of GMAW equipment
according to standard operational procedures.
2.1.2 Define principle of GMAW process according to BS/AWS welding standards.
2.1.3 Identify GMAW equipment according to manufacturer recommendation.
2.2 Install regulators, flow meters, nozzle/tips
2.2.1 Apply procedure of installing regulators and flow meter according to manufacturer
recommendation.
2.2.2 Determine gas regulators for the required welding process.
2.2.3 Identify size of tip/nozzle according to manufacturer specifications.
2.2.4 Identify regulator and flow meter at welding machine according to manufacturer
recommendation.
2.2.5 Install regulators to flow meters and welding set according to manufacturer
recommendation.
2.2.6 Practise safety precaution in accordance to Occupational Safety & Health Act
(OSHA) to minimise accidents and injuries at work site.
2.3
2.3.4
2.3.5
2.3.6

Fix welding hoses

Apply Safety precaution related to handling of welding hoses.
Identify type of welding hoses for the required welding process.
Assemble and connect welding hoses to equipment for the required welding process.

2.4
2.4.1
2.4.2

Identify and select safety accessories

Identify potential hazards in welding operation for the required welding process.
Identify and select safety equipment/accessories for the required welding process.

D. REFLEKSI

CONTENT STANDARD 3

LEARNING STANDARD

WELD CARBON STEEL PLATE OF THICKNESS

RANGE 3-9 MM IN 2F POSITION

3.1 Prepare carbon steel plate

3.2 Set up welding machine
3.3 Set up filler wire to wire feeder
3.4 Set up tip nozzle and gas flow rate
3.5 Set up current and speed
3.6 Set up work piece
3.7 Carry out welding
3.8 Inspect welded joint

PERFORMANCE CRITERIA

3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.2.1
3.2.2
3.2.3
3.3.1
3.3.2
3.3.3
3.3.4
3.4.1
3.4.2
3.4.3
3.5.1

Identify material classification according to manufacturer recommendation.

Identify type, basic properties and weldability of carbon steel according to BS/AWS
codes and standard.
Identify type of joint design and its preparation according to BS/AWS codes and
standard.
Measure and mark plate for intended welding process.
Prepare cutting tools and equipment and cut carbon steel for welding work according
to SOP.
Apply safety precaution related to handling and operating welding machines
according to manufacturer specification.
Identify type of welding machine and its applications according to manufacturer
specification.
Install securely all accessories and hoses at welding machine according to
manufacturer recommendation.
Identify various types of filler wires, classification, composition and application
according to manufacturer specification.
Set filler wire to wire feeder
Describe function of anti spatter for GMAW welding machine according to
manufacturer specification.
Identify type of filler wire and install it according to manufacturer recommendation.
Determine and setting contact tip, nozzle and gas flow rate according to
manufacturer recommendation.
Install contact tip and nozzle according to manufacturer recommendations.
Practise safety precaution in compliance with OSHA requirement

3.5.5

Apply safety precaution related to handling and operating electrical equipment

according to OSHA.
List basic electricity related to welding work according to work requirement.
List units of current ampere, volt and watt according to work requirement.
Set welding current/amperage and travel speed for welding work according to work
requirement.
Prepare work piece to welding circuit according to SOP.

3.6.1
3.6.2
3.6.3

Fix welding material to positions required for intended welding work.

Describe importance of welding alignment.
Align work piece for welding.

3.5.2
3.5.3
3.5.4

3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.8.1
3.8.2

Define GMAW principle and process in accordance to BS/AWS codes and standards.
Describe technique of welding using GMAW process according to BS/AWS welding
standards.
Set up GMAW equipment according to manufacturer recommendation
Perform technique of welding carbon steel plate, in 2F horizontal position using
GMAW in accordance to BS/AWS standards.
Practise safety precaution related to GMAW according to OSHA.
Identify welding defects related to GMAW process in accordance to BS/AWS codes
and standards.
Inspect welding defect visually according to BS/AWS codes.

TEACHING STRATEGIES
A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI
B. MENYATAKAN OBJEKTIF PEMBELAJARAN:
- Identify the information to be delivered.
- Prepare notes for briefing.
- Deliver briefing to welders.
C. AKTIVITI PENGAJARAN:
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5

Prepare carbon steel plate

Identify material classification according to manufacturer recommendation.
Identify type, basic properties and weldability of carbon steel according to BS/AWS
codes and standard.
Identify type of joint design and its preparation according to BS/AWS codes and
standard.
Measure and mark plate for intended welding process.
Prepare cutting tools and equipment and cut carbon steel for welding work according
to SOP.

3.2 Set up welding machine

3.2.1 Apply safety precaution related to handling and operating welding machines
according to manufacturer specification.
3.2.2 Identify type of welding machine and its applications according to manufacturer
specification.
3.2.3 Install securely all accessories and hoses at welding machine according to
manufacturer recommendation.

3.3 Set up filler wire to wire feeder

3.3.1 Identify various types of filler wires, classification, composition and application
according to manufacturer specification.
3.3.2 Set filler wire to wire feeder
3.3.3 Describe function of anti spatter for GMAW welding machine according to
manufacturer specification.
3.3.4 Identify type of filler wire and install it according to manufacturer recommendation.

3.4
3.4.1
3.4.2
3.4.3

Set up tip nozzle and gas flow rate

Determine and setting contact tip, nozzle and gas flow rate according to
manufacturer recommendation.
Install contact tip and nozzle according to manufacturer recommendations.
Practise safety precaution in compliance with OSHA requirement

3.5 Set up current and speed

3.5.1 Apply safety precaution related to handling and operating electrical equipment
according to OSHA.
3.5.2 List basic electricity related to welding work according to work requirement.
3.5.3 List units of current ampere, volt and watt according to work requirement.
3.5.4 Set welding current/amperage and travel speed for welding work according to work
requirement.
3.5.5 Prepare work piece to welding circuit according to SOP.
3.6 Set up work piece
3.6.1 Fix welding material to positions required for intended welding work.
3.6.2 Describe importance of welding alignment.
3.6.3 Align work piece for welding.
3.7 Carry out welding
3.7.1 Define GMAW principle and process in accordance to BS/AWS codes and standards.
3.7.2 Describe technique of welding using GMAW process according to BS/AWS welding
standards.
3.7.3 Set up GMAW equipment according to manufacturer recommendation
3.7.4 Perform technique of welding carbon steel plate, in 2F horizontal position using
GMAW in accordance to BS/AWS standards.
3.7.5 Practise safety precaution related to GMAW according to OSHA.
3.8 Inspect welded joint
3.8.3 Identify welding defects related to GMAW process in accordance to BS/AWS codes
and standards.
3.8.4 Inspect welding defect visually according to BS/AWS codes.
D. REFLEKSI

CONTENT STANDARD 4

LEARNING STANDARD

4.1 Prepare carbon steel plate

4.2 Set up welding machine

WELD STAINLESS STEEL PLATE OF

THICKNESS RANGE 6 TO 9mm IN 2G POSITION.

4.3 Set up filler wire to wire feeder

4.4 Set up contact tip, nozzle and gas flow rate
4.5 Set up current and speed
4.6 Set up work piece
4.7 Carry out welding
4.8 Inspect welded joint
PERFORMANCE CRITERIA

4.1.1
4.1.2
4.1.3
4.1.4
4.1.5

Identify material classification according to manufacturer recommendation

Identify type, basic properties and weldability of carbon steel.
Identify type of joint design and its preparation.
Measure and mark plate for intended welding process.
Prepare cutting tools and equipment and cut carbon steel for welding work.

4.2.1

Apply safety precaution related to handling and operating welding machines

according to manufacturer specification.
Identify type of welding machine and its applications.
Install securely all accessories and hoses at welding machine.

4.2.2
4.2.3
4.3.1
4.3.2
4.3.3
4.3.4

4.4.1
4.4.2
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.6.1
4.6.2
4.6.3
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5

Identify various types of filler wires, classification, composition and application

according to BS/AWS codes and standard.
Set filler wire to wire feeder according to manufacturer recommendation.
Describe function of anti spatter for GMAW welding machine feeder according to
manufacturer recommendation.
Identify type of filler wire and install it according to manufacturer recommendation.

Determine and setting contact tip, nozzle and gas flow rate according to
manufacturer recommendation.
Install contact tip and nozzle according to manufacturer recommendations.
Apply safety precaution related to handling and operating electrical equipment.
List basic electricity related to welding work.
List units of current ampere, volt and watt related to welding work
Set welding current/amperage and travel speed for welding work according to work
requirement.
Prepare work piece to welding circuit according to SOP.
Fix welding material to positions required for intended welding work.
Describe importance of welding alignment according to BS/AWS codes and
standard.
Align work piece for welding according to SOP.
Define GMAW principle and process in accordance to BS/AWS codes and standards.
Describe technique of welding using GMAW process according to BS/AWS welding
standards.
Set up GMAW equipment according to manufacturer recommendation
Perform technique of welding carbon steel plate, in 1G flat position using GMAW in
accordance to BS/AWS codes and standards.
Practise safety precaution related to GMAW process according to manufacturer
recommendation

4.8.1
4.8.2

Identify welding defects related to GMAW process in accordance to BS/AWS codes

and standards.
Inspect welding defect visually according to BS/AWS codes.

TEACHING STRATEGIES
A. MEMULAKAN DENGAN SET INDUKSI YANG SESUAI
B. MENYATAKAN OBJEKTIF PEMBELAJARAN:
- Identify the information to be delivered.
- Prepare notes for briefing.
- Deliver briefing to welders.
C. AKTIVITI PENGAJARAN:
4.9 Prepare carbon steel plate
4.1.6 Identify material classification according to manufacturer recommendation
4.1.1 Identify type, basic properties and weldability of carbon steel.
4.1.2 Identify type of joint design and its preparation.
4.1.3 Measure and mark plate for intended welding process.
4.1.4 Prepare cutting tools and equipment and cut carbon steel for welding work.
4.2 Set up welding machine
4.2.1 Apply safety precaution related to handling and operating welding machines
according to manufacturer specification.
4.2.2 Identify type of welding machine and its applications.
4.2.3 Install securely all accessories and hoses at welding machine.
4.3 Set up filler wire to wire feeder
4.3.1 Identify various types of filler wires, classification, composition and application
according to BS/AWS codes and standard.
4.3.2 Set filler wire to wire feeder according to manufacturer recommendation.
4.3.3 Describe function of anti spatter for GMAW welding machine feeder according to
manufacturer recommendation.
4.3.4 Identify type of filler wire and install it according to manufacturer recommendation.

4.4 Set up contact tip, nozzle and gas flow rate

4.4.1 Determine and setting contact tip, nozzle and gas flow rate according to
manufacturer recommendation.
4.4.2 Install contact tip and nozzle according to manufacturer recommendations.
4.5 Set up current and speed
4.5.1 Apply safety precaution related to handling and operating electrical equipment.
4.5.2 List basic electricity related to welding work.
4.5.3 List units of current ampere, volt and watt related to welding work
4.5.4 Set welding current/amperage and travel speed for welding work according to work
requirement.

4.5.5

Prepare work piece to welding circuit according to SOP.

4.6 Set up work piece

4.6.1 Fix welding material to positions required for intended welding work.
4.6.2 Describe importance of welding alignment according to BS/AWS codes and
standard.
4.6.3 Align work piece for welding according to SOP.
4.7 Carry out welding
4.7.1 Define GMAW principle and process in accordance to BS/AWS codes and standards.
4.7.2 Describe technique of welding using GMAW process according to BS/AWS welding
standards.
4.7.3 Set up GMAW equipment according to manufacturer recommendation
4.7.4 Perform technique of welding carbon steel plate, in 1G flat position using GMAW in
accordance to BS/AWS codes and standards.
4.7.5 Practise safety precaution related to GMAW process according to manufacturer
recommendation
4.8 Inspect welded joint
4.8.1 Identify welding defects related to GMAW process in accordance to BS/AWS codes
and standards.
4.8.2 Inspect welding defect visually according to BS/AWS codes.

D. REFLEKSI

SUGGESTED LEARNING ACTIVITIES

1. Student reports by individuals

2. Class discussion conducted by teacher.
3. Presentations by student panels from the class.
4. Lecture by teacher.
5. Practical

SUGGESTED ITEM EVALUATION

To Develop Item Construction Assessment Guidelines Based On
Assessment Instruments That Are To Be Determined By The Examination Board:
Quiz / Observation / Theory short test / Oral test / Assignment / Practical

REFERENCES
Journals / Text Books / Website / Specification and manuals (Kaedah APA)
1. A Guide to the Occupational Health and Safety Act (OHSA). (2012) dari laman Web
http://www.labour.gov.on.ca/english/hs/pubs/ohsa/
2. C. Ray Asfahl. (1995). Industrial safety and health management. Prentice Hall, Inc. ,
New Jersey.
3. Jabatan Pendidikan Teknik dan Vokasional, Fakulti Pendidikan. (2003). Keselamatan
bengkel. SPE 1032 / SPK 2032, UTM.
4. Jawatankuasa Keselamatan Bengkel Sekolah, Kementrian Pelajaran Malaysia. (1977).
Panduan keselamatan bengkel sekolah. DBP, Kuala Lumpur.
5. Phil Hughes, Ed Ferrett. (2008). Health and Safety in Construction. Elsevier Ltd. All
rights reserved.Uk
6. Mohd. Nasir Ahmad. (1987). Teori asas kimpalan arka. Kuala Lumpur: Dewan Bahasa
dan Pustaka.
7. Nicholas, C.W & Gorman, C.V .(1977). The heart of instruction: classroom and
laboratory management. Ohio Deparment of Education-Division of Vocational.
8. Keselamatan di Makmal & Bengkel - OSH in School dari laman web:
http://www.oshinschool.net.my/index.php
9. Panduan keselamatan bengkel sekolah dari laman web:
http://elib.uum.edu.my/kip/Record/upm000118
10. Shielded metal arc welding. Horbart school of welding technology (1982) : Projek link