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Taking plasma cutting training to the next level

Hypertherm develops material for educators

Facing a wave of baby boomers exiting the manufacturing workforce, some metal fabricating equipment developers have stepped up to help support the education of next-generation fabricators. Industrial cutting tools manufacturer Hypertherm has produced a training program focused on plasma cutting. The company's Marketing Manager, Betsy Van Duyne, shared her thoughts with thefabricator.com about this effort.

fabricator.com: Why did Hypertherm decide to develop "Plasma Cutting Technology: Theory and Practice," the first commercially available training material specifically for plasma cutting and gouging?

Van Duyne: During visits to schools, our associates noticed a good percentage of welding and metal fabrication educators didn't have a thorough understanding of plasma or the resources to help them teach the subject. As a result, their students were not getting a consistent, complete, or accurate education on the plasma arc cutting process.

Instructional materials were being gleaned from manufacturer's websites, on educator user groups, from previous instructors, and from associations like AWS [American Welding Society] and NCCER [National Center for Construction Education and Research]. A comprehensive survey of welding educators reinforced these assumptions.

As a manufacturer of advanced industrial cutting systems, Hypertherm felt compelled to create a comprehensive curriculum that would make it easy for any welding educator, no matter their background or experience, to teach plasma arc cutting technology consistently and completely.

fabricator.com: What is included in the program, and what does it involve?

Van Duyne: The curriculum includes the following:

  • 132-page "Facilitator's Guide."
  • 85-page "Student Workbook."
  • Hands-on classroom teaching tools, including three consumable stacks on wires so students can become familiar with how consumables get loaded into a torch and three mock torches and a consumable kit for use during consumable building activities.
  • A resource CD that contains all teaching materials—six theory lessons, teacher and student guides, operator manual, and additional reading material.
  • An e-learning CD with a 30 minute e-learning module and additional reading material.
  • Powermax65/85 operator manual used for reference throughout the theory and application lessons.

The course can run up to 10 hours, depending on how thoroughly the instructor chooses to cover content. The facilitator guide contains everything needed to teach, and the course is a mix of reading, hands-on classroom exercise, seminar instruction (with PowerPoint slides and guidance), section quizzes, and lab activity time.

fabricator.com: What do participants learn?

Van Duyne: Using this step-by-step approach to plasma cutting education ensures consistency in training and student outcomes. Students who complete the course are able to:

  • Describe what plasma is and how it cuts metal.
  • Identify common industrial uses for plasma systems.
  • Articulate the differences among various thermal cutting methods.
  • Properly set up and operate a plasma system.
  • Correctly install and use plasma consumables.
  • Demonstrate proper plasma safety procedures.
  • Evaluate cut quality.
  • Execute a variety of cuts and gouges.

fabricator.com: What types of organizations currently use the program (who is it designed for)?

Van Duyne: "Plasma Cutting Technology: Theory and Practice" currently is being used in high schools, postsecondary institutions, and colleges and universities. Any student that requires a general knowledge of plasma cutting can benefit from this course, whether they are in eighth grade or an adult training for a new career.

fabricator.com: What kind of feedback is the program getting?

Van Duyne: Joel Johnson, associate professor of welding technology at North Dakota State College of Science, said that he likes the curriculum kit because students learn what the consumables do, how they go into the torch, and where to look up cut charts, so that they load the right consumables – all before they put their hands on a live torch. He said this saves them dollars on consumables, metal, system downtime, and repairs. He also said that the curriculum is easy to teach and use.

CWI/CWE and Professor Manufacturing Engineering Technology Philip McNew, Pittsburg State University, said, "This is a turnkey teaching tool. Instructors can teach with little preparation and appreciate the multimedia format. Students enjoy the interactive lab/lecture approach and attention to today's technologies."

David Gilliam, director of training, Tulsa Welding School, said, "The curriculum is easy to use, up-to-date, and contains the right academic information and hands-on exercises.  I highly recommend it."

fabricator.com: Who created the program?

Van Duyne: The program was created by Hypertherm's internal Corporate Training Team in conjunction with an advisory panel of postsecondary and university welding and metal fabrication instructors over a period of two years.

Our first education advisory panel meeting consisted of gathering input on course layout and contents. The second panel meeting was dedicated to reviewing the draft kit. Following that, each adviser received a copy of the kit to use in their classroom so that they could provide suggestions for improvements.

fabricator.com: Where can those interested learn more about it?

Van Duyne: Those who want to learn more about the course and other free educational resources from Hypertherm can go to www.plasmaeducation.com or call 800-643-0030, ext. 2349, for more information.

Virginia Hilton, PR counselor, The Meridian Group, virginia@themeridiangroup.com, assisted with this article.