Welder - Assistant 2

Course Description

PMT0071C – Welder Assistant 2 is the second Postsecondary Adult Vocational (PSAV) clock-hour course in the Florida Welding Technology program (CIP 48.0508), continuing the foundational training begun in PMT0070C (Welder Assistant 1). The course expands students' competencies in welding processes through introductory hands-on practice with the major arc welding processes (SMAW, GMAW, FCAW, GTAW), with emphasis on developing fundamental welding technique, position welding, and weld quality assessment.

Students develop the practical skills needed to produce sound welds in fillet and groove configurations across welding positions (1F, 2F, 3F flat, horizontal, vertical for fillets; 1G, 2G for groove welds — with overhead and out-of-position work generally reserved for advanced courses). Coursework integrates classroom instruction with extensive hands-on shop practice using industry-standard equipment, building toward AWS performance qualification testing in subsequent specialty courses.

This course is offered at approximately 35 Florida technical colleges as the second major module of the Florida PSAV Welding Technology program. Hours invested in PMT0071C count toward the program total and prepare students for the SMAW specialty modules (PMT0072C and PMT0073C) and additional specialty courses in GMAW, FCAW, and GTAW.

Learning Outcomes

Required Outcomes

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

• Apply welding shop safety practices consistently in all production work, demonstrating habituated safe behavior.
• Set up and adjust SMAW (stick) welding machines for given electrode types, sizes, and amperage; understand polarity (DCEP, DCEN, AC) and amperage range for common electrodes.
• Perform SMAW fillet welds in the flat (1F), horizontal (2F), and vertical-up (3F) positions on carbon steel using common electrodes (E6010, E6011, E6013, E7018).
• Perform SMAW groove welds at an introductory level in the flat (1G) and horizontal (2G) positions on carbon steel.
• Set up and adjust GMAW (MIG) welding machines for given wire types, sizes, voltage, and wire feed speed; understand short-circuit transfer for common applications.
• Perform GMAW fillet welds in the flat and horizontal positions on carbon steel using ER70S-6 wire and 75/25 (Ar/CO₂) shielding gas (or similar).
• Set up and adjust FCAW (flux-cored) welding machines for self-shielded and gas-shielded wires; understand applications.
• Perform FCAW fillet welds in the flat and horizontal positions on carbon steel.
• Set up and adjust GTAW (TIG) welding machines for AC and DC operation; select tungsten electrode type and grind to appropriate point.
• Perform GTAW fusion runs and basic GTAW welds at the introductory level on carbon steel and (where included) stainless steel and aluminum.
• Identify common weld discontinuities and defects (porosity, undercut, lack of fusion, lack of penetration, slag inclusions, cracks, overlap) and their causes.
• Perform visual inspection of welds per AWS criteria, including the use of weld gauges (fillet weld size, undercut, reinforcement, throat thickness).
• Apply destructive testing at the introductory level — bend tests, break tests — to evaluate weld quality.

Optional Outcomes

• Perform SMAW vertical down welds with E6010 or E6011 (open root, fast-fill electrodes).
• Perform GTAW on stainless steel and aluminum at an introductory level, including back purging on stainless and AC welding parameters for aluminum.
• Apply weld appearance and contour requirements per AWS D1.1 for visual inspection.
• Begin introductory pipe welding practice in fixed positions (typically more extensive in advanced courses).
• Earn OSHA 10-Hour certification (where included in or alongside the program).

Major Topics

Required Topics

• Continued Welding Safety: Reinforcement of PPE habits; safe machine operation; safe practice in busy production shop; recognizing and responding to safety incidents.
• SMAW (Shielded Metal Arc Welding) — Setup and Operation: Power source selection (constant current — transformer, inverter, engine-driven); polarity (DCEP, DCEN, AC); amperage selection; electrode angle and travel angle; arc length; stringer beads vs. weave beads; restarting; welding cable handling.
• SMAW Electrode Selection: AWS classification (E6010, E6011, E6012, E6013, E7016, E7018, E7024 — the most common); fast-fill vs. fast-freeze; cellulosic vs. low-hydrogen; storage of low-hydrogen electrodes (rod ovens); choosing the right electrode for the job.
• SMAW Fillet Welds: 1F (flat); 2F (horizontal); 3F vertical-up; weld bead formation; stringer beads; weave patterns; multi-pass technique; managing slag between passes.
• SMAW Groove Welds (Introductory): 1G (flat) butt joints; 2G (horizontal) butt joints; root pass; fill passes; cap pass; back gouging where included.
• GMAW (Gas Metal Arc Welding) — Setup and Operation: Power source (constant voltage); wire feeder; gun and contact tip selection; voltage and wire feed speed; shielding gas selection (75/25 Ar/CO₂, 100% CO₂, tri-mix); short-circuit transfer; spray transfer (introductory awareness); proper gun angle and travel.
• GMAW Welding: Fillet welds in flat (1F) and horizontal (2F) positions; lap joints; T-joints; understanding burn-through and how to prevent it on thin material.
• FCAW (Flux-Cored Arc Welding) — Setup and Operation: Self-shielded (FCAW-S) vs. gas-shielded (FCAW-G) wires; applications; setup; high deposition rate; outdoor use of self-shielded wire.
• FCAW Welding: Fillet welds; outdoor work considerations.
• GTAW (Gas Tungsten Arc Welding) — Setup and Operation: Power source (DC for steel and stainless; AC for aluminum); high-frequency start; tungsten electrode selection (2% thoriated, 2% lanthanated, ceriated, pure tungsten); grinding tungsten; gas cup selection; shielding gas (argon for steel and aluminum; argon-helium mixes for aluminum thicker materials); back purging for stainless steel.
• GTAW Welding: Fusion runs (no filler); autogenous welds; introductory filler-rod welds on carbon steel; introductory work on stainless and aluminum (where included).
• Weld Discontinuities and Defects: Porosity (causes, prevention); undercut; lack of fusion; lack of penetration; incomplete fusion; slag inclusions; cracks (longitudinal, transverse, throat, root); overlap; convexity/concavity; arc strikes; spatter.
• Visual Inspection: Visual inspection per AWS D1.1; weld gauges (fillet size, undercut depth, reinforcement); inspection criteria; documentation.
• Destructive Testing (Introductory): Bend tests (face bend, root bend, side bend); break tests for fillet welds; macro etch testing.

Optional Topics

• SMAW Vertical Down: Open-root work with E6010/E6011 for pipeline applications.
• GTAW Specialty Materials: Stainless steel (with back purge); aluminum (AC GTAW, cleaning action).
• Weld Quality and Appearance Standards: AWS D1.1 visual inspection criteria in greater depth.
• Introductory Pipe Welding: Fixed-position pipe practice; rolling pipe welds.
• Cost Estimation: Welding costs (filler metal, gas, labor, overhead); productivity calculations.

Resources & Tools

• Common Texts: Continuation of Welding: Principles and Applications (Jeffus), Welding Skills (Giachino/Weeks), Modern Welding (Althouse/Turnquist/Bowditch); NCCER Welding Level 1 and 2 modules
• Personal Equipment: Same as PMT0070C, plus consumables (electrodes for SMAW practice; potentially personal MIG gun if program requires)
• Shop Equipment: SMAW machines (Lincoln, Miller, ESAB); GMAW/FCAW machines; GTAW machines (with high-frequency start); welding tables; clamps; angle grinders; weld inspection gauges; bend test fixtures
• Reference Standards: AWS D1.1 (Structural Welding Code—Steel); AWS A2.4 (welding symbols); AWS B4.0 (Standard Methods for Mechanical Testing of Welds); AWS QC1 (Standard for AWS Certification of Welding Inspectors); FLDOE Curriculum Framework for Welding Technology
• Online Resources: AWS website (aws.org); Lincoln Electric education; Miller Electric education; weld.com (popular online welding training)

Career Pathways

PMT0071C continues preparation for welding careers — see PMT0070C for the full list of career pathways. With completion of PMT0071C, students have introductory exposure to all major arc welding processes and are positioned for entry-level production welding work in many industries, particularly with continued specialization in subsequent program modules. The combination of broad introductory exposure (PMT0070C, PMT0071C) plus specialty depth (PMT0072C, PMT0073C SMAW; additional GMAW, FCAW, GTAW courses) positions graduates for the diverse welding work available in Florida's construction, manufacturing, marine, and aerospace sectors.

Special Information

Position in the Program Sequence

PMT0071C is the second major module of the Florida PSAV Welding Technology program. Successful completion of PMT0071C is typically required before entering the SMAW specialty modules (PMT0072C and PMT0073C). Hours invested count toward the program total.

Industry Certification Preparation

PMT0071C provides foundational welding skill across multiple processes. Industry credentials (AWS performance qualifications, AWS Certified Welder, NCCER Welding) are typically pursued in or after the specialty welding process modules where students develop the focused proficiency needed to pass qualification tests in specific positions and processes.

Skill Development Expectations

Welding is a manual skill that develops through repetition and practice. PMT0071C exposes students to the major processes; mastery in any one process develops over hundreds to thousands of hours of practice. Students should plan for the substantial out-of-class practice time many programs encourage to develop muscle memory and consistency.

Articulation

See PMT0070C — Florida technical college PSAV welding programs may articulate to Florida college Welding Technology A.S./A.A.S. programs at participating institutions.