Weld Defects Kit Bend Tester guideWELD® VR now with Stick Employability Skills Program RealCareer™ Program Catalog 2016 855.351.8936 | www.realityworks.com NEW
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
FOR MORE INFORMATION, SEE PAGES 6-7
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
FOR MORE INFORMATION, SEE PAGES 8-9
3855.351.8936 | www.realityworks.com
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 Pricing . . . . . . . . . . . . . . . 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
“
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3855.351.8936 | www.realityworks.com
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
$4,900.00 guideWELD VR (1 welding gun option) – 56010101
$6,400.00 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 Discount Pricing 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
5855.351.8936 | www.realityworks.com
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
$499.00 2.5-Hour Webinar Training – 51080250
$3,459.00 On-Site Live Training – 51080600
Learn more online: www.realityworks.com/realcareertraining
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
5855.351.8936 | www.realityworks.com
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
7855.351.8936 | www.realityworks.com
Live welding in-helmet guidance displays
Same corrective guidance icons displayed
in guideWELD® VR
NOTICE: Combo and Quantity Discount Pricing 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
$6,500.00 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
Curriculum alignments can be found at www.realityworks.com/alignments-crosswalk-docs
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 Discount Pricing 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
$995.00 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
Curriculum alignments can be found at www.realityworks.com/alignments-crosswalk-docs
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
RealCareer® Welding Solutions
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
© 2015 Realityworks, Inc. All rights reserved. | RealCareer® is a registered trademark of Realityworks, Inc. | 1035272-01A
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
© 2015 Realityworks, Inc. All rights reserved. | RealCareer® is a registered trademark of Realityworks, Inc. | 1035273-01A
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).
© 2015 Realityworks, Inc. All rights reserved. | RealCareer® is a registered trademark of Realityworks, Inc. | 1035270-01A
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
RealCareer® Welding Solutions
FLASH CARDS
www.realityworks.com
9855.351.8936 | 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
$2,500.00 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
Curriculum alignments can be found at www.realityworks.com/alignments-crosswalk-docs
9855.351.8936 | www.realityworks.com
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
$499.00 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
$999.00 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
$1,500.00 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 alignments can be found at www.realityworks.com/alignments-crosswalk-docs
Curriculum Spotlight:• FOCUS: Business concepts, knowledge
and skills• Lessons: 15• Teaching hours: 13• Presentation slides: 99
Curriculum alignments can be found at www.realityworks.com/alignments-crosswalk-docs
Scenario Cards: 5.5” W x 8.5” H
10 *Individual simulations are available for purchase online: store.realityworks.com
NEW PRODUCT
11855.351.8936 | www.realityworks.com
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 PricingguideWELD® VR - specify either
MIG or Stick option SKU # Pricing Price/Unit
VR Unit - 3 56010103 $14,250.00 $4,750.00
VR Unit - 5 56010105 $23,500.00 $4,700.00
VR Unit - 10 56010110 $45,000.00 $4,500.00
VR Unit - 15 56010115 $64,750.00 $4,315.00
VR Unit - 20 56010120 $85,000.00 $4,250.00
MIG ADD-ON 55510100 $1,500.00
Stick ADD-ON 56010100 $1,500.00
NOTICE: Single unit pricing can be found on each product page
guideWELD® LIVE SKU # Pricing Price/UnitLIVE Unit - 3 55010253 $18,900.00 $6,300.00
LIVE Unit - 5 55010255 $30,875.00 $6,175.00
LIVE Unit - 10 55010260 $59,800.00 $5,980.00
LIVE Unit - 15 55010265 $85,800.00 $5,720.00
LIVE Unit - 20 55010270 $110,500.00 $5,525.00
RealCareer™ Weld Defects Kit SKU # Pricing Price/UnitWeld Defects Kit only
(posters, flashcards, curriculum not included)52510100 $795.00
Classroom Package (3 Kits) 52510200 $2,835.00 $945.00
Classroom Package (5 Kits) 52510200 $4,475.00 $895.00
Classroom Package (10 Kits) 52510200 $8,450.00 $845.00
Defects Flashcards (10 Sets) 52520010 $125.00
Defects Posters (5 Posters) 52520050 $35.00
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