STEM - WELDING
STEM Welding helps 4-H members learn the basics of welding. In addition, 4-H members get the opportunity to present their knowledge on the topic and display what they have made. Involvement in STEM Welding gives participants a first-hand experience in a skill that can be used for a lifetime.
4-H Welding Project Tips and Suggestions
CLASS 1
All welds should be made with the same electrode/wire/rod size and number.
Welds should be made only on one side of metal so penetration can be judged.
Welds should be cleaned with chipping hammer and wire brush. Apply a coat of light oil (penetrating oil) to the metal to prevent rusting. Wipe off excess oil.
It is suggested that all welds be of the same size and thickness of metal. These pieces, referred to as coupons, should be 1.5 to 2 inches wide and 3.5 to 4 inches long. A good way to get this size is to buy a new cold rolled strap iron and cut it to length.
The extra width is needed to provide enough metal to absorb the heat from the welding process and prevent the coupons from becoming too hot before the bead is completed. Narrower coupons will become very hot, making an average welder setting too cold at the bead start, just about right in the middle, and too hot at the end. The correct way to weld narrow strips is to make short beads and allow time to cool, however this project requires a full length bead.
Stick welding
Suggested coupon thickness - 1/4” if using 1/8” rod
Suggested rod - AC and DC straight or reverse polarity - first E-7014, second E-6013
MIG welding
Suggested coupon thickness - 1/4” if using .035 wire and 1/8” if using .023 wire
Oxy-Acetylene
Suggested coupon thickness - 1/8”
Suggested rod - 1/8” mild steel rod
CLASS 2
It is suggested that all welds be of the same size and thickness of metal. These pieces are referred to as coupons. The welds can be on one coupon that is about 4” x 4” or on individual coupons that are about 2” x 4” and 1/4” thick. Suggested rods for this class of position welds for AC and DC straight or reverse polarity is, first E-6013, second E-7014 and E-6010 for DC reverse polarity only.
Welds should be cleaned with a chipping hammer and wire brush. Apply a coat of light oil (penetrating oil) to the metal to prevent rusting. Wipe off excess oil.
CLASS 3 & 4
All welds should be cleaned and protected from rust with paint or light oil. Plans are to be complete enough that if they were given to a welding shop, the item could be made without further instructions. Bill of materials should include a cost for all items used including steel, electrodes, paint, wheels, etc.
PREMIUMS: Purple-$3.00; Blue-$2.00; Red-$1.50; White-$1.00
DIVISION 920 - WELDING
H920001* WELDING JOINTS - A display of one butt, one lap and one fillet weld. (SF281)
H920002* POSITION WELDS - A display showing three beads welded in the vertical down, horizontal and overhead positions. (SF281)
H920003* WELDING ART - Any art created using tack welds to hold the metal pieces together (examples include horseshoe projects). Type of welder, welder settings, all plans, plan alterations, and a bill for material must be attached to the article. Protect plans with a cover. If project is designed to be outside, it is required to have appropriate outdoor finish. (SF283)
H920004* WELDING ARTICLE - Any shop article where welding is used in the construction. 60% of the item must be completed by 4-H member and notes regarding laser welding or machine welding must be included. Type of welder, welder settings, all plans, plan alterations, and a bill for material must be attached to the article. Protect plans with a cover. If project is designed to be outside, it is required to have appropriate outdoor finish because project may be displayed outside. (SF281)
H920005* WELDING FURNITURE - Any furniture with 75% welding is used in the construction. 60% of the item must be completed by 4-H member and notes regarding laser welding or machine welding must be included. Type of welder, welder settings, all plans, plan alterations, and a bill for material must be attached to the article. Protect plans with a cover. If project is designed to be outside, it is required to have an appropriate outdoor finish because project may be displayed outside. (SF282)
H920006* PLASMA CUTTER/WELDER DESIGN - Plasma cutters/welders allowed for detailed design(s) to butt cut into metal. 4-H members will create a notebook describing the design process to create the “artwork” to butt cut into the metal. In the notebook include:
A photo (front and back) of the finished project.
Instructions on how the design was created (include software used), this allows for replication of the project.
Lessons learned or improvements to the project.
Steps to finish the project. (SF279)
H920007* COMPOSITE WELD PROJECT - 60% of the project must be welded and 40% made from other materials such as wood, rubber, etc. Type of welder, welder settings, all plans, plan alterations, and a bill for material must be attached to the article. Protect plans with a cover. If project is designed to be outside, it is required to have an appropriate outdoor finish because project may be displayed outside. (SF280)