realcareer - amazon web services · realcareer realcareer s greetings from realityworks®, inc....

Weld Defects KitBend TesterguideWELD® VR now with StickEmployability Skills Program

RealCareer™ Program Catalog 2016

855.351.8936 | www.realityworks.com

NEW

2

DECREASED

TRAINING

TIME

21st Century Welding Training Method

2

Simulate Replicate Evaluate

guideWELD® VR welding simulator• Engage users in a safe, virtual

welding environment • Advance basic welding skills and build

correct muscle memory techniques • Save on classroom consumables

FOR MORE INFORMATION, SEE PAGES 4-5

guideWELD® LIVE real welding guidance system• Provide in-helmet instruction for

consistent welding technique during live welding

• Enable self-learning through immediate technique correction

• Build welders’ confidence and reduce classroom management concerns


RealCareer™ Weld Defects Kit and Bend Tester• Inspect common weld defects

and discontinuities • Prepare welders to conduct and

qualify welds • Teach welders how to correct

defects when welding



INCREASED

PROFICIENCY

DECREASED

TRAINING

TIME

DECREASED

CONSUMABLE

COSTS

Greetings from Realityworks®, Inc.Realityworks is an experiential learning technology company whose award-winning programs provide realistic learning experiences. The RealCareer™ line of products combines hands-on learning experiences with comprehensive curricula for various career areas. The gap between the skills job-seekers have and the skills employers need is continuously widening. We want to do our part in preparing students for the future workforce by engaging and training them early.

Our products are 100% owned by our company. Our employees have led the conception, development and ultimately the creation of each product.

For more information on Realityworks, visit: www.realityworks.com

21st Century Welding Training Method . . . . . . . . . . . . .2-3

guideWELD® VR welding simulator . . . . . . . . . . . . . . . . . .4-5

guideWELD® LIVE real welding guidance system . . . .6-7

RealCareer™ Weld Defects Kit . . . . . . . . . . . . . . . . . . . . . . . . .8

RealCareer™ Bend Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

RealCareer™ Employability Skills Program . . . . . . . . . . 10

RealCareer® Business Education Simulations. . . . . . . . 10

HOW TO ORDER and Package Options . . . . . . . . . . . . . . 11

What’s inside

NEW

NEW

NEW

Why the 21st Century Welding Training Method?The 21st Century training method can be used not only to improve welding techniques so users become more proficient, but to engage participants and encourage them to enter welding careers.

The system gives them real-time feedback on what they’re doing and if it is right or wrong, and it builds their confidence.

Greg Siepert Welding InstructorHutchinson Community CollegeHutchinson, KS

“

“


4

guideWELD® VR welding simulatorEnable users to refine basic welding skills, learn proper welding techniques and explore welding career paths while saving on costly consumables.

Users experience:• MIG and/or Stick welding methods• A safe, virtual practice environment• Welding on different joints, metal types and metal thicknesses• Immediate feedback on work angle, travel angle, speed and

nozzle-to-plate distance• Instant assessment on individual welds

Features:• Recorded weld assessments• 27 default Welding Procedure Specifications (WPS)• Create custom WPS assignments for classroom needs• 3 difficulty levels: Novice, Intermediate and Advanced• Easy installation on Windows and MAC operating systems

Package includes:*• Online access to: 13-lesson curriculum, teacher guide, administrator

guide and student guide• 1 guideWELD® VR workstation with choice of 1 interchangeable

MIG or Stick welding simulator gun** • 3 welding joints (tee, lap and butt) • 1 pair of welding gloves

Call for pricing guideWELD VR (1 welding gun option) – 56010101

Call for pricing guideWELD VR (both welding gun options)

Notice: shipping and handling is 1.5 percent of the order total

**Option to add additional MIG or Stick welding gun. See package

pricing on page 11 for details.

Curriculum Spotlight:• FOCUS: Introduction to welding safety, equipment,

proper welding techniques and careers• Standards-based curriculum written by a certified

welding inspector and educator (CWI/CWE) • Lessons: 13• Teaching hours: 30 • Presentation slides: 292• Aligns to: Common Core State Standards, Common

Career Technical Core Standards

Curriculum alignments can be found at www.realityworks.com/alignments-crosswalk-docs

4 NOTICE: Combo and Quantity Options on page 11

Software SpecificationsFor complete hardware and software specifications, visit: www.realityworks.com/guideweldvr-systemrequirements

Stickand MIGoptions!

Student weld assessment and replay screen*NOTICE: Monitor not included


RealCareer™ Welding Training

Meet your organizational needs and learn ways to maximize your program’s effectiveness with professional development training!

Each personalized session covers:

• Hands-on practice using Realityworks’ welding solutions

• Operating training tools and interpreting assessment results

• Best practices for participants

Call for pricing

2.5-Hour Webinar Training – 51080250

Call for pricing

On-Site Live Training – 51080600

Learn more online: www.realityworks.com/realcareertraining


6

Product Support

Realityworks’ online Product Support Center offers a variety of support resources for your welding program 24 hours a day, including:

• Video tutorials• Support documentation• FAQs• System requirements• Software details

Our Product Support Team is available Monday-Friday from 7:30 a.m. - 5:00 p.m. Central Standard Time. Contact them directly at [email protected] or call 800.830.1416, option 2. Learn more online: www.realityworks.com/support/

6


Live welding in-helmet guidance displays

Same corrective guidance icons displayed

in guideWELD® VR

NOTICE: Combo and Quantity Options on page 11

guideWELD® LIVE real welding guidance systemTransition users from the classroom to the shop floor by providing corrective in-helmet training during live welding on the core techniques needed to weld effectively.

Users experience:• A periphery-view display inside the welding helmet• Live MIG welding with guidance• Instant feedback on work angle, travel angle and travel speed

Features:• Real-time feedback during live welding on core

welding techniques• 9 default Welding Procedure Specifications (WPS)• Custom WPS creation available• Works with any MIG welding machine

Package includes:• 1 auto-darkening welding helmet with in-helmet guides• 1 speed sensor board with base• 1 angle sensor• Online access to 16-lesson curriculum

Call for pricing guideWELD LIVE – 55010901

Notice: shipping and handling is 5 percent of the order total

Curriculum Spotlight:• FOCUS: Introduction to weld correction techniques,

welding procedure specifications and weld testing• Standards-based curriculum written by a certified

welding inspector and educator (CWI/CWE) • Lessons: 16• Teaching hours: 30 • Presentation slides: 318• Aligns to: Common Career Technical Core Standards


Work angle, travel angle and speed guidance

Hardware SpecificationsFor complete hardware specifications, visit: www.realityworks.com/products/guideweld

Welding gloves not included

8 NOTICE: Combo and Quantity Options on page 11

Specifications:• 21” L x 7” W x 16” H

• Coupons: 5” L x 2 ¾” W• Weight: 9.5 lbs.

RealCareer™ Weld Defects KitTeach users how to identify, correct and prevent common weld defects.

Users will:• Examine and inspect common weld defects examples• Learn how common weld defects occur• Understand how to correct common weld

defects by adjusting both their machine and their technique

Features:• Portable, lightweight kit• 13 plastic models: 12 weld defects and 1 quality weld• Flashcards, posters and defects identification

sheet included

Package includes:• 1 quality weld and 12 weld defect models in case• Welding defect definition insert • Instructor guide • 10 sets of flash cards• 5 classroom posters• Online access to 5-lesson curriculum

Call for pricing Weld Defects Kit Classroom Package – 52510200

Notice: 5 percent shipping surcharge applies

Curriculum Spotlight:• FOCUS: Identifying and correcting common weld defects

and discontinuities• Standards-based curriculum written by a certified welding

inspector and educator (CWI/CWE) • Lessons: 5• Teaching hours: 10 • Presentation slides: 151• Aligns to: Common Career Technical Core Standards


Example: Spatter and lack of fusion defect models

© 2015 Realityworks, Inc. All rights reserved. | RealCareer® is a registered trademark of Realityworks, Inc. |

1035271-01A

WELD TYPES

RealCareer® Welding Solutions

Quality Fillet Weld

(No visual defects)

A weld joining two surfaces at right

angles to each other, as in a lap or tee

joint, with a triangular cross section.

Quality Groove Weld

(No visual defects)

A weld made in a preformed groove between two

base metal pieces, as in a butt or groove joint.

Fille

t Wel

d

Groo

ve W

eld

© 2015 Realityworks, Inc. All rights reserved. | RealCareer® is a registered trademark of Realityworks, Inc. | 1035274-01A

WELD POSITIONS


Fille

t Wel

ds

1FFLAT POSITION

2FHORIZONTAL POSITION

3FVERTICAL POSITION

4FOVERHEAD POSITION

1GFLAT POSITION

2GHORIZONTAL POSITION

3GVERTICAL POSITION

4GOVERHEAD POSITION

Groo

ve W

elds

1G FLAT

Pipe is turned or rolled

while welding.

2G HORIZONTAL5G POSITION

Pipe is not turned or

rolled while welding.

6G POSITION


WELD PARTS RealCareer® Welding Solutions

Fille

t Wel

ds

Gro

ove

Wel

ds

Face Toe

Root Reinforcement

Toe

Throat

Root

Throat Toe

Toe Face

LegLeg

Face: The exposed surface of the weld.

Leg: The distance from the root to the toe of the weld.

Reinforcement: Excess filler required to fill the throat of a weld.

Root: The area of the weld or throat opening where the nearest base metals contact is located. This may be a point, line or area.

Throat: The open area required to be filled by the weld.

Toe: The intersection between the face of the weld and the base metal.Terms &

Definitions

Ideal Path

Ideal Path


WELD SAFETY RealCareer® Welding Solutions

Personal Protective GearWelding Helmet

Safety Glasses

Fume Extractor

Leather Boots

Welding Skull Cap

Welding Jacket

Welding Gloves

Denim Pants(No Cuffs)

Ear Plugs

InconsistencyThe weld bead is not constant and varies throughout the weld, leading to different filler metal thicknesses, penetration depths and fusion issues.

Excessive ReinforcementWhen the weld metal has too much build-up above the base metal (groove welds only).

SpatterThe metal particles expelled during arc and gas welding that do not form part of the weld.

UndercutAn indentation or channel melted into the base metal adjacent to the toe or root of a weld and left unfilled by weld metal. Insufficient ReinforcementWhen the weld metal lacks sufficient build-up above the base metal (groove welds only).

Slag InclusionsWhen foreign material is trapped in the weld metal or between the weld and the base metal, the most common is slag, a non-metallic solid material.

OverlapThe protrusion or overhang of weld metal beyond the bond at the toe or root of a weld without fusing to the base metal.

PorosityThe presence of inclusions or gas pockets in a weld.

ConvexityThe maximum distance from the weld face perpendicular to a line joining the weld toes. In this instance, the weld has a rounded profile (fillet welds only).

Lack of FusionThe failure of a welding process to fuse or join together layers of weld metal, or weld metal and base metal.

Arc StrikeAccidental striking of an arc outside the welding area (zone).

ConcavityWhen the distance from the weld face perpendicular to a line joining the weld toes curves inward toward the weld joint (fillet welds only).


WELD DEFECTS RealCareer® Welding Solutions

NEW

PROD

UCT

Flashcards: 8.5” L x 5.5” W

Posters: 36” L x 25” W

1033495-01

Causes of Defect

• Improper machine settings

• Improper Work Angle

• Improper Wire Feed Speed

• Fast Travel Speed

Correction of Defect - Check Your Machine

• Decrease voltage or increase Wire Feed Speed (GMAW)

• Decrease amperage (SMAW)

Correction of Defect - Check Your Technique

• Keep Work Angle around 45º for a fillet weld and 90º for a groove weld

• Decrease Travel Speed

• Contact to Work Distance (CTWD) may be too short; try staying 1/4 – 1/2 inches from

metal (GMAW)

• Arc Length may be too long; try staying around 1/8 inches from metal (SMAW)

• Clean base metal before welding

Undercut

An indentation or channel melted into the base metal adjacent to the toe

or root of a weld and left unfilled by weld metal.

#2

• Arc Length is too long

• High amperage settings

• Rust on metal

RealCareer® Welding Solutions - Defect #2Define, then check your welder and technique

WELD DEFECTS


FLASH CARDS

www.realityworks.com


RealCareer™ Bend TesterHelp users prepare for and safely conduct guided bend tests in a classroom or welding lab.

Users will:• Conduct destructive bend tests on

1/8” plates, 1/4” plates and 3/8” plates• Learn how to qualify a bend-tested weld• Understand qualification standards and

why they are important

Features:• Tabletop size for shop or off-site portability• Manual hydraulic jack• Auto-close safety cover with auto latch• Bends 1/8” plates, 1/4” plates and 3/8” plates• Conforms to AWS D1.1 bend test specifications

Package includes:• Bend tester• Plungers: 1/2”, 1” and 1 1/2”• Jack handle• 2 posters• Instructor guide• 1-year limited warranty• Online access to 8-lesson curriculum

Call for pricing Bend Tester – 53510100

Notice: contact Realityworks as additional shipping surcharges are required

Curriculum Spotlight:• FOCUS: Destructive testing, preparing, bending and

qualifying welds • Standards-based curriculum written by a certified

welding inspector and educator (CWI/CWE)• Lessons: 8• Teaching hours: 15 • Presentation slides: 167• Aligns to: Common Career Technical Core Standards



NEW

PROD

UCT

© 2015 Realityworks, Inc. All rights reserved. | RealCareerTM is a trademark of Realityworks, Inc. | 1036381-02A

RealCareerTM Bend Tester

QUALIFICATIONS Face BendOccurs when bend places Plunger is

against the Root, stressing the Face

Follow all Welding Procedure Specifications.

Ensure that plates are cut at a minimum of 7” x 2 7/8” and grain is longitudinal with bend.

Bevel plates to ensure standard dimensions are maintained.

Clamp weld to ensure it stays flat while welding.

Preheat test plates if needed.

Between passes, check temperature of base metal, chip slag and wire brush passes, and inspect for discontinuities or defects.Weld PreparationBest practices for weld preparation:3

Conduct a visual inspection of the weld. If the weld does not pass, it is already disqualified.

Cut and grind bend test strips to ensure standard dimensions are maintained.

Stamp bend test specimen with: initials/welder stamp number, test plate position and joint design.

Radius edges of weld specimen to prevent edges from cracking.

Ensure bend test specimen dimensions are a minimum of 6” long and 1 ½” wide and a maximum of 1/8” radius and 3/8” thick.Weld Bending Best practices for bend testing:3

1. AWS D1.1: 2015 – Structural Steel, paragraph 4.9.3.3.

2. Except when that corner crack results from visible slag inclusion or other fusion type discontinuity. Corner cracks exceeding ¼” (6 mm) with no evidence of slag inclusions

or other fusion type discontinuity shall be disregarded, and a replacement test specimen from the original weldment shall be tested

3. These best practices do not encompass all preparation and performance requirements.

NOTICE: Illustration not to scale

Root BendOccurs when bend places Plunger

against the Face, stressing the Root

Examples of Face Bend Testing

Examination Tools:• Steel Ruler with increments ≤ 1/32”

• Caliper• Magnifying Glass

• Flashlight

The Sum of all Weld Surface

Discontinuities Should Not Exceed:1

• 3/8” [10 mm] – the sum of the greatest dimensions

of all discontinuities exceeding 1/32” [1 mm],

but ≤ 1/8” [3 mm] discontinuities

• 1/4” [6 mm] – the maximum corner crack, except when that

corner crack results from visible slag inclusion or other fusion type

discontinuity, then the 1/8” [3 mm] maximum shall apply2

Discontinuity Examples:

1/32” = Acceptable

1/8” = Test Fail3/4” = Test Fail1/4” = Acceptable

(corner)

Individual Discontinuities

Should Not Exceed:1

• 1/8” [3 mm] measured in any direction on the surface

References:

© 2015 Realityworks, Inc. All rights reserved. | RealCareerTM is a trademark of Realityworks, Inc. | 1036380-02A

RealCareer TM Bend TesterBENDING BASICS Movable Roller Positions:• Top: 1/8” plate• Center: 1/4” plate• Bottom: 3/8” plate

Conduct a visual inspection of the weld. If the weld does not pass, it is already disqualified.

Stamp or identify the root or face of the weld. I.D. the weld with your mark.

With the direction of the weld, grind any excess so the bend area is smooth and cut test specimens to size.

Grind excess weld flush in the lengthwise direction of the test specimen, and a slight radius along the edges.

Weld PreparationFollow these steps before bending:

InterchangeablePlunger Sizes:• 1 1/2”• 1/2”

• 1”

Ensure that the bend tester machine is securely positioned on a flat surface.

Ensure that the rollers are securely in place.

Keep fingers and other extremities clear of the plunger and rollers when metal is in place.

Pump the bend lever slowly to keep metal in place.

SafetyBest practices:*

*These best practices do not encompass all safety requirements. Be sure to follow all lab safety procedures at all times.

Safety Cover

Hydraulic Jack

Bend LeverLever Handle

NOTICE: Illustration not to scale

Plunger/Roller SetupMetal Thickness

Plunger Size Roller

Location1/8”1/2”

Top1/4”1”

Center3/8”1-1/2” Bottom

Specifications:• Weight: 93 lbs (42.1 kg)• Height: 24.5” (622 mm) H x 13.75” (350 mm) W x 11” (280 mm) D

Posters: 30” L x 20” W

10

1035934-01

Points of view to consider

• You, the employee

• Monica, the HR Director

• David, the co-worker

Key questions

• Has Monica shown active listening behavior? What non-verbal cues

has she shown the employee about her level of interest?

• What could Monica do to be a better active listener in the future? Do a

short role-play between Monica and the employee, where Monica uses

active listening strategies in the meeting.

• How do you, the employee, feel after your meeting? Do you feel that

your concerns were heard?

RealCareer™ Employability Skills Program

ListeningScenario: You have been employed at a new company for about six months. A co-worker,

David, has been repeatedly sexually harassing you. You finally decide you’ve had enough and decide to file a complaint with Human Resources. You meet with the HR Director,

Monica. During your meeting, she never takes any notes as you speak. She keeps checking her phone and also her Facebook on her laptop. You

notice that she is doodling on her notepad. At the end of the conversation, you wonder if she

really understood your concern at all.

RealCareer™ Employability Skills Program

WORKPLACE

SCENARIO CARDS

www.realityworks.com

CAREER-READY

RealCareer™ Employability Skills ProgramHelp users develop the soft skills they will need they will need to be career- and college-ready.

Users are able to:• Identify and discuss 20 soft skills• Practice using those soft skills in real-life situations• Understand the importance of soft skills in various environments

Package includes:• 19-lesson curriculum/teacher guide and presentation slides• Set of 20 hard-copy student workbooks • 19 Career-Ready Workplace Scenario Cards

Call for pricing Employability Skills Program – 11130945

Notice: 5 percent shipping surcharge applies

School-Wide Site License includes:• Unlimited use for 5 years• Online access to teacher guide, student workbooks, Career-Ready

Workplace Scenario Cards and presentation slides

Call for pricing Employability Skills Program Site License – 11130947

RealCareer® Business Education SimulationsGive users hands-on experience making business decisions while applying classroom lessons.

Users are able to:• Hone skill development by practicing on 3 different online simulations:

Business Management, Entrepreneurship and Business Finance• Learn how to make critical business decisions and use problem-solving skills• Understand how their decisions can impact business outcomes

Package includes:*• 15-lesson curriculum• 3 simulations: Business Management, Entrepreneurship and Business Finance• 5-year site license

Call for pricing 3 Business Education Simulations – 80050117

Curriculum Spotlight:• FOCUS: Train and develop soft skills for

career employment• Lessons: 19• Teaching hours: 19-30• Presentation slides: 33• Student workbooks• Career-Ready Workplace Scenario Cards


Curriculum Spotlight:• FOCUS: Business concepts, knowledge

and skills• Lessons: 15• Teaching hours: 13• Presentation slides: 99


Scenario Cards: 5.5” W x 8.5” H

10 *Individual simulations are available for purchase online: store.realityworks.com

NEW PRODUCT


Contact us for a customized quote to meet your program needs.Our Account Managers are ready to connect with you! Give them a call at 855.351.8936 or email [email protected]

How to Order Order supplies and software online at: www.realityworks.com

Orders can be emailed to: [email protected]

Call with credit card: 855.351.8936

Fax orders to: 715.830.2050

Mail purchase orders to: 2709 Mondovi Road Eau Claire, WI 54701All orders must be accompanied by a check, credit card number or purchase order. Returns may be subject to a restocking fee. Product availability and prices subject to change without notice.

*Shipping and handling is 1.5 percent of the order total with a minimum charge of $12.00 (applies to 48 contiguous U.S. only). Bulky and oversized items require additional shipping surcharges. Contact Realityworks®, Inc. for details. See product pages for specific shipping charges.

HI + AK please contact for shipping quote.

Contact Realityworks for accelerated or special shipping requirements.

RealCareer™ Package OptionsguideWELD® VR - specify either

MIG or Stick option SKU #

VR Unit - 3 56010103

VR Unit - 5 56010105

VR Unit - 10 56010110

VR Unit - 15 56010115

VR Unit - 20 56010120

MIG ADD-ON 55510100

Stick ADD-ON 56010100

NOTICE: Single unit options can be found on each product page

guideWELD® LIVE SKU #LIVE Unit - 3 55010253

LIVE Unit - 5 55010255

LIVE Unit - 10 55010260

LIVE Unit - 15 55010265

LIVE Unit - 20 55010270

RealCareer™ Weld Defects Kit SKU #Weld Defects Kit only

(posters, flashcards, curriculum not included)52510100

Classroom Package (3 Kits) 52510200



Defects Flashcards (10 Sets) 52520010

Defects Posters (5 Posters) 52520050

Call for pricing

Realityworks, Inc.2709 Mondovi RoadEau Claire, WI 54701

855.351.8936www.realityworks.com© 2016 Realityworks, Inc. All rights reserved.1026910-04 | 01/2016

JOIN US ON Be part of the conversation about engaging learners, technology tips, issues facing all areas of education and much more.

RealCareer®Welding Solutions21st Century Welding Training Method (see pages 2-3)

• Simulate• Replicate• Evaluate

realcareer - amazon web services · realcareer realcareer s greetings from realityworks®, inc....

Documents