Course: WELDING AND FABRICATION. Qualification: 7 th Pass (or) Formal education who can read and write in telugu. Duration: 3 months

Transcription

1 Course: WELDING AND FABRICATION Qualification: 7 th Pass (or) Formal education who can read and write in telugu Duration: 3 months Number of hours: hours for evaluation Number of hours per week: 12 hours (Theory 4 hours and Practical 8 hours) S N Content Hours 1 Arc welding 80 2 Gas welding 35 3 Basic Fitting work 20 4 Basic Sheet metal work 10 5 Introduction to modern welding methods 05 Some important core competencies to be developed are: 1. Safety consciousness and safe working practices 2. Care of equipment and tools 3. Punctuality, discipline and honesty 4. Concern for quality 5. Respect for rules and regulations 6. Concern for health and hygiene 7. Cordial relationship and Cooperation with co-workers and team Work 8. Positive attitude and behavior 9. Responsibility and accountability 10. Communication Skills 11. Concern for environment and waste disposal

2 Week Theory Practical Objectives 1 st -Introduction to welding -Basic safety precautions -Purpose and use of tools and equipment of Arc welding -Simple electrical terms and their importance - Necessity, care and maintenance of AC, DC welding machines, earth clamp, electrode holder, cables, lugs -Safe working process to be observed during welding -setup of arc welding equipment -use and purpose of safety clothing such as Apron, hand gloves, welding shield, goggles on shop floor -selection of welding lens -striking of arc -able to operate the controls of welding machine -able to connect the welding machine and cables -able to use safety equipment -able to start welding arc and start laying beads 2 nd -Principles of Manual Metal Arc welding (MMAW), advantages and limitations -Types of welding joints and edge preparation -laying of straight line beads on MS Plate in flat position -Butt and Lap joint preparation -Identification of weld for defects by visual inspection like porosity, slag inclusion, blow holes and remedies -necessity and usage of chipping hammer and wire brush -able to lay uniform beads on MS plate without defects in flat position -able to know the usage of welding accessories like wire brush, chipping hammer etc., -able to identify the defects by visual inspection 3 rd -Identify measuring tools, marking tools, cutting tools and equipment used in fitting shop -Safety related to cutting tools -Need and usage of marking tools like scriber, try square, prick punch, number punch, letter punch -Need and measuring procedure of measuring tools like Steel rule, inside and outside calipers, vernier caliper, inside and outside micrometer and practice. -Operation and care of work holding devices like bench vice, pipe vice -Hack sawing and chipping -able to identify various types fitting tools like cutting tools, measuring tools, marking tools used in welding shop floor - able to know use of hack saw and its adjustment

3 4 th -Fitting operations Sawing, chipping, filing, scrapping, grinding, marking, drilling and tapping -Filing for accurate flatness, right angle, perpendicularity and edge preparation for T-joint, H-joint -Selection of electrode depending on thickness of metal -Adjustment of welding machine current based on thickness of material to weld -able to identify various types of files and their usage, safety -able to file work pieces as per requirement -able to set the required weld current as per the thickness of material 5 th -Welding positions -Welding distortion and methods to control -Preparation of Corner joint, single V-butt joint, double V-butt joint, T-joint, H-joint in horizontal position -able to read and interpret simple drawings -able to prepare the edge for corner joint, V-joint, T-joint, H-joint -able to fill the joints with complete penetration and complete the weld 6 th -care to be taken while welding pipes -use of pipe vice -measurement of angles -Fillet lap joint (single and double) -Edge joints -Welding practice in horizontal and vertical positions -Pipe welding (butt) at 90 o and 45 o -able to prepare the lap joint, edge joint without any defects -able to join the MS pipes at required angle without any holes -able to deposit weld metal in horizontal and vertical positions without any falling of molten metal 7 th -Advantages, disadvantages and applications of gas welding -Safety in oxy acetylene welding -Gas welding hand tools -gas welding equipment and assembly -common gases used in gas welding -generation of acetylene -safe handling of oxygen and acetylene cylinder -Use of protective devices on shop floor -Identification of tools and accessories used for Gas welding -Setting up of Gas Welding Plant -Lighting up the blow pipe. Adjusting the flame. -Heating the base metal to its molten. -Fusion run on sheet with and without filler rod -usage of weld flux - able to operate the controls of gas welding equipment like regulator -able to connect the high pressure and low pressure cylinders and hoses -able to use safety equipment -able to detect gas leakages -able to initiate flame and start heating the base metal -able to hold the blow pipe and filler rod in correct position

4 8 th -Principle of gas welding -Filler rods and fluxes for brazing -Types of blow pipes -types of nozzles -types of oxy acetylene flame -Weld techniques RHS and LHS -Lap weld of 2 mm sheets -Butt weld of sheets -Edge joint -Fillet joint -able to make weld in LHS and RHS -able to make weld on sheets -able to prepare different types of gas weld joints -able to know the usage of flux 9 th -welding techniques LHS & RHS -Function of regulator and types -Soldering and brazing -Welding of dissimilar metals -Metal cutting by gas flame -Pipe welding by gas at 90 o and 45 o -able to know the importance of soldering and brazing -able to know the purpose and use of soldering and brazing -able to weld the pipes at required angle without any holes 10 th Sheet metal work -Introduction and application of marking tools. -Safety, proper handling and use of marking tools. -Introduction to sheet metal hand tools and machine tools and safety precautions to be observed while using them. -Marking of layouts as per drawing on sheet metal -Identification of sheet metal tools like sheet metal gauge, divider, trammel, punches, snips and stakes -Perform sheet metal operations like shearing, blanking, punching, piercing, Bending, drawing, riveting -able to identify different types of sheet metals -able to check thickness by sheet metal gauge -able to cut the sheet with snips -able to bend the sheet metal -able to perform various sheet metal operations 11 th -Types of sheet metals and their applications. Different sizes of sheet metal commercially available -Metal joining method -Types of rivets and riveting methods -Sheet Metal Joints like single hem, double hem, Seam joint lap seam, grooved seam, single seam, double seam, -Perform riveting operation by single riveted lap, double riveted lap joint, single butt and double butt joint -able to join two sheets with hemming And solder them to prevent leakage -able to join sheets by riveting

5 12 th -Modern welding methods TIG, MIG, Co 2 welding, -Submerged arc welding -Plasma, laser welding -Preparation of small sized window grills, gates, collapsible gates, steel alma rah at least one item per each batch -able to method to fabricate window grills, collapsible gates, ordinary gates, steel almarah, stools, shoe racks etc to the real sizes -To give an idea about modern welding methods to be used industrially to create the awareness and learn further EVALUATION: Max marks: 100 Theory: Multiple choice questions: 20 each one mark Practical: Fabrication 80 marks