Fabrication and Welding

course outline

Topics

• Marking, Cutting and Forming of Sheet Metals

  This module covers the essential processes of marking, cutting, and forming sheet metals, including the calculation and creation of joints, and the identification and rectification of riveting faults. It details the tools, techniques, and types of rivets used in sheet metal work.

• Soldering and Brazing

  This module focuses on soldering and brazing techniques, covering the identification and properties of solders and fluxes, the preparation of joints, and the associated hazards. It also differentiates between hard and soft soldering and details the brazing process.

• Sheet Metal Operation

  This module delves into various sheet metal operations, including annealing, raising, sinking, and finishing techniques. It covers the calculation of allowances, the development of discs for bowl making, and the removal of dents from metal surfaces.

• Templates

  This module focuses on the creation and interpretation of templates for sheet metal projects. It includes understanding blueprints, developing templates using various methods, and preparing patterns on sheet metal with necessary allowances and modifications.

• Safety Precautions (Structural Steel Work)

  This module emphasizes safety in structural steel work, covering the selection and use of protective wear, as well as specific safety rules for handling gas cylinders, lifting steel, transportation, and welding in hazardous environments.

• Tools and Equipment (Structural Steel Work)

  This module covers the essential tools and equipment used in structural steel work, including their classification, uses, and maintenance. It details various types of hand and power tools, as well as procedures for oiling, greasing, and regrinding equipment.

• Specifications and Calculations (Structural Steel Work)

  This module focuses on the specifications and calculations relevant to structural steel work. It covers the description of steel materials, symbols, standard specifications, Hooke's law, and the differentiation of various stresses.

• Steel Project (Structural Steel Work)

  This module covers the practical application of structural steel work through project development. It includes calculating allowances for forming, developing templates, reproducing jobs, and creating simple working jigs.

• Iron and Steel Manufacturer

  This module explains the manufacturing processes of iron and steel, focusing on the sketch and working principles of a blast furnace, the role of fuel, the Bessemer process, and the characteristics of pig iron and cast iron.

• Assembly (Structural Steel Work)

  This module covers the assembly of simple structural components, detailing the uses of fixtures and bolts, and providing examples of structural assemblies like rafters and roof trusses.

• Corrosion (Structural Steel)

  This module identifies the common causes of corrosion in structural steel and describes its detrimental effects on the integrity and appearance of steel structures.

• General safety Precautions (Gas Welding)

  This module focuses on general safety precautions for gas welding, covering the safe handling and storage of gas cylinders, safety measures for welding in confined or hazardous areas, and the use of appropriate protective wear.

• Gas Welding Process

  This module covers the gas welding process, including the identification and function of equipment, acetylene generation, types of flames, welding joints, and material preparation. It also differentiates between welding and cutting torches.

• Non-Ferrous and Ferrous Metal (Welding)

  This module covers the welding of both non-ferrous and ferrous metals. It includes identifying non-ferrous metals, understanding fabrication material properties, welding cast iron, bronze welding, and preparing and welding stainless steel. It also details the properties and welding of various non-ferrous metals.

• Building up of Worn Mechanic Parts

  This module focuses on the process of rebuilding worn mechanical parts. It covers identifying the composition and properties of worn parts, selecting suitable materials, and detailing the step-by-step procedure for building up surfaces to specification.

• Welded Joints, Defects and Rectification

  This module addresses common defects in gas welded joints, their causes, and methods for avoidance. It also covers various tests, both non-destructive and destructive, used to detect these defects.

• Safety Precautions (Arc Welding)

  This module outlines the hazards associated with arc welding, including arc eye and electric shock, and specifies the protective wears required. It also details crucial safety precautions for welding in confined or dangerous areas.

• Welding Machines and Accessories

  This module compares AC and DC welding machines, detailing their functions, principles, advantages, and disadvantages. It also covers electrode classification, selection, handling, and techniques for striking and maintaining an arc.

• Welding Joints in all positions

  This module covers welding joints in all positions, including preparing and welding various joint types like butt, fillet, and V-joints. It also addresses welding pipes and flanges in different positions and explains factors governing joint selection and welding symbols.

• Arc Welding Ferrous and Non-Ferrous Metal

  This module focuses on arc welding of both ferrous and non-ferrous metals. It covers identifying metal types, understanding their properties and welding behavior, preparing cast iron for welding, and performing welding operations on non-ferrous metals.

• Building up worn metallic parts (Arc Welding)

  This module details the process of building up worn metallic parts using arc welding. It covers identifying the composition and properties of worn components and outlines the steps for rebuilding them to specifications, including cleaning, joint formation, and heat treatment.

• Arc cutting of metal

  This module explains the principles and applications of various arc cutting methods, including plasma-arc cutting. It identifies different arc cutting electrodes, their compositions and uses, and outlines the procedures for cutting metals.

• Welding Defects (Arc Welding)

  This module covers major defects in arc welding joints, methods for testing (both non-destructive and destructive), and techniques for rectification. It emphasizes proper welding procedures and precautions to avoid defects.