WELDING AND FABRICATION ENGINEERING CRAFT PRACTICE

Transcription

1 WELDING AND FABRICATION ENGINEERING CRAFT PRACTICE SCHEME OF EXAMINATION There will be three papers, Papers, and 3, all of which must be taken. Papers and will be a composite paper to be taken at one sitting. Paper : Paper : Paper 3: will consist of forty multiple-choice objective questions all of which are to be answered in hour for 40 marks. will consist of five questions out of which candidates will be required to answer any four in ½ hours for 60 marks. will be practical test of 3 hours, 0 minutes duration. It will consist of one compulsory question for 00 marks. A list of materials for the test shall be made available to schools not less than two weeks before the paper is taken for material procurement and relevant preparations. ALTERNATIVE TO PRACTICAL TEST The Council may consider testing candidates ability in practical work as prescribed in the syllabus in the event that materials for the actual practical test cannot be acquired. For this alternative test there will be one question to be answered in 3 hours for 00 marks. DETAILED SYLLABUS S/NO. TOPIC CONTENT PRACTICAL Workshop and standard workshop practices... Introduction to fabrication and welding practice... Safety precautions in welding and fabrication workshop. - Types and causes of accident in the workshop (fire, explosion, sharp objects, hazardous gases, etc). - Accident prevention measures. - Types and causes of environmental pollution. - Methods of preventing... Demonstration of the use of protective wears in welding and fabrication.

2 Properties of metals and selection. environmental pollution. - Safety facilities and protective wears..3. Workshop layout (fabrication and welding)..4. Standard welding codes and symbols..5. First-Aid administration in the workshop.. Ferrous and non-ferrous metals (steel, aluminum, cast iron, copper and zinc, tin, alloy steel)... Properties of metals (ductility, hardness, toughness, malleability, fusion and tenacity, brittleness, elasticity and plasticity)..3. Sheet metal (aluminum, mild steel, brass) - concept of sheet metal - gauges of sheet metal.4. Selection of suitable metals for specific jobs..5.. Demonstration of the use of first aid in the workshop... Identification of ferrous and nonferrous metals. 3 Tools and Equipment in Fabrication and Welding..5 Heat treatment of metals (hardening, annealing, normalizing, tempering and case- hardening, etc.) 3.. Identification of tools and equipment for fabrication and 3.. Equipment set-up for gas, arc welding and fabrication Job holding devices for fabrication and 3.4. Measuring instruments, marking out and cutting tools Identification of parts and.5.. Annealing, Hardening and Normalizing of metals 3... Student to set up oxy acetylene equipment Demonstration of the use of measuring, marking out and cutting tools Demonstration of the

3 4 Operations and Techniques in Welding and Fabrication. accessories for gas and arc 3.6. Maintenance procedure for arc and gas (oxy-acetylene) welding equipments Preparation of acetylene gas from carbide Types of electrodes and their composition, their application, gauges of electrodes, selection of appropriate electrode for a specific job Equipment for fault detection and trouble shooting in fabrication and 4.. Types of welding (Gas and Arc welding), explanation of the principles of gas and arc welding and their differences preparation of ace-tylene gas from carbide. 4.. Description of a typical fabrication process Types of joints, joint methods and application in welding and fabrication 4.4. Classification of marking out techniques in welding and fabrications Description of the use of templates for fabricated and welded assemblies Welding techniques and application Techniques in fabrication work - Description of folding techniques and its importance in fabrication work. 5 Fasteners 5.. Permanent fasteners Demonstration of various jobs cutting techniques Students to weld using both leftward and rightward methods Students to work on wire-edge projects.

4 (a) Classification of fasteners. (b) Rivet and its application (c) Bolt and nuts (d) Screws 6 Forging Process - Introduction to forging 7 Preparation of welding surfaces and environment. 5.. Temporary fasteners Types of rivets Uses of rivets Description of bolts and nuts Uses of bolts and nuts 5.7. Classes of rivets and screws. 6.. Definition of forging 6.. Forging tools and equipment (furnace, swages, fullers, flatters and tongs) Forging process - upsetting. - drawing down - twisting - bending - forging an eye. 7.. Preparation of welding surfaces by cleaning with wire brush, emery cloth, files, scrappers and grinding machine. 7.. Preparation of edges for welding e.g. single V, double V, fillets Post surface preparation - cleaning surface with wire brush - oiling surface to protect from corrosion or rusting Defect in welding surfaces (causes and remedies) Definition of welding environment - awkward, unventilated, flammable material - slipery floor (oil/grease on floor) 7.6. Surface furnishing for fabrication and welding (painting, metal spraying, galvanizing and oiling). 8 Practical Work/Project 8.. Marking of shapes (triangle, square and rectangle) Students to produce rivets joints Students to produce bolts and nuts Students to form an eye Preparation of single V surface for

5 S/N 9 Business Entrepreneurship Opportunity 8.. Cutting and bending of triangles, square and rectangles Soldering of sheet metals 8.4. Welding of steel using arc 8.5. Welding of steel using gas 8.6. Fabrication of ferrous and nonferrous metals into required shapes. 8.7 Suggested projects (students to produce the following): - named plate - trinket box - funnel - kitchen stool - car stopper - metal rake - scoop - hinges - charcoal stove, etc. 9.. Definition of - entrepreneurship - employer - employee. 9. Enterprises - small scale enterprise - medium scale enterprise - large scale enterprise 9.3. Factors for setting a workshop (cost, site, weather, material, manpower, market, source of power, transportations. LIST OF FACILITIES AND MAJOR EQUIPMENT/MATERIALS REQUIRED: Hammers (various types) Q T Y S/N QTY S/N QT Y 0 7 Bending rollers 33 Combined set of cutting welding outfits Site visitations to existing enterprise (small, medium or large scale enterprise) S/N 5 48 Bench grinding Try squares 0 8 Bench mounted 34 Regulators with 6 49 Electrode 0 QTY

6 cone roller flow meters Holders 3 Chisels 5 9 Bench shares 50 Electrode 35 Water to drying oven 4 Punches 5 0 Power hacksaw carbide generator 5 Pillar Drilling 5 Hand gloves 30 Vee blocks 5 36 Anvil 3 5 Smith open forge 6 Straight edges 0 Aprons Swage block 53 Vice (bench) 7 Trammel 5 3 O CYLINDERS 3 38 Chipping 0 54 Bench type drivers hammers grinding 8 Left and right snips 0 4 Transformers with rectifiers 9 Straight snips 5 5 Hand shield and Head caps 0 Rule, Scriber and dividers 0 ea ch 6 Gas welding goggles Hand nibbling machine 5 7 Double cylinder Trolley Wire brushes 50 8 Oxygen regulators 3 Pliers-assorted 0 9 Acetylene regulators 4 Tongs 5 30 Hoses, Clips and Assorted all attachments 5 Hacksaws and blades accessories 60 3 DC generators with all connections 6 Guillotine 3 AC Transformers 5 39 Flatters 5 55 Double ended buffer and polisher 0 each 40 Mole grip 5 56 Blow pipes (low and high pressure) 0 4 Sledge Hammers 5 57 Files assorted 5 4 Plain goggles 0 58 Acetylene Cylinder G clamp 5 50 Parallel 5 Clamp 5 44 First-aid box 60 Toolmakers 5 clamp 45 Magnetic clamp 6 Mallets Self grip pliers 5 6 Work bench Folding bars 63 Fire 4 Extinguishe r 64 Sand 4 bucket 65 Cramp 0 Folding 66 Riveting 5 Pliers 67 Riveting set 0

7 RECOMMENDED BOOKS S/NO. BOOKS AUTHOR Welding and Fabrication The Science and Practice of Welding Fabrication and Welding Basic Welding The Theory and Practice of Metalwork Metal Craft Theory and Practice Metalwork Motivate Series W. Kenyon A. C. Davis F. J. M. Smith P. Somsky George Love John R. Bedford J. K. N. Sackey & S. K Metalwork Technology Workshop Processes and Materials Ilesanmi Metalwork for Senior Secondary School Books 3 Amoakohene G. H. Thomas J. V. Courtney Adejuyigbe S. B. and S. K. Akinlosose Practical Welding Motivate Series S. W. Gibson and B. K. Amoako-Awuah