Duration: I year

Eligibility Criteria: Madhyamik

This course aims in acquainting the students with the working knowledge through theoretical as well as practical orientation. The contents are sequenced according to the practical exercises contained in the manual of trade practical. This corelation is maintained to help the students to develop the perceptional capabilities needed for performing the skills.
It is the process of joining metal or thermoplastic parts with the use of high-temperature heat and molten metal, filler metal or metallic rod. If you want a quick job after 1 or 2 years then you can go for the Welder
Trade

Employment of welders, cutters, solderers, and brazers is projected to grow 3 percent from 2019 to 2029, about as fast as the average for all occupations. The nation’s aging infrastructure will require the expertise of welders, cutters, solderers, and brazers to help rebuild bridges, highways, and buildings.

Welder (Gas & Electric) is a mechanical engineering vocational trade. Trade duration is one year one year with two semesters of six months each.

Job Opportunity
  • Mechanical Company
  • Construction Industry
  • Mining Industry
  • Education
Job Role
  • Technician
  • Assistance Technician
  • Supervisor
  • Faculty
  • Service executive

TRADE THEORY
1 st sem & 2 nd sem (1Year)

  • Importance of trade Training.
  • General discipline in the Institute
  • Elementary First Aid.
  • Importance of Welding in Industry
  • Safety precautions in Shielded Metal Arc Welding, and Oxy Acetylene Welding and Cutting.
  •  Introduction and definition of welding.
  • Arc and Gas Welding Equipments, tools and accessories.
  • Various Welding Processes and its applications.
  • Arc and Gas Welding terms and definitions.
  • Different process of metal joining methods: Bolting, riveting, soldering, brazing, seaming etc.
  • Types of welding joints and its applications. Edge preparation and fit up for different thickness.
  • Surface Cleaning.
  • Basic electricity applicable to arc welding and related electrical terms &  definitions.
  • Heat and temperature and its terms related to welding
  • Principle of arc welding. And characteristics of arc .
  •  Common gases used for welding & cutting, flame temperatures and uses.
  •  Chemistry of oxy-acetylene flame.
  • Types of oxy-acetylene flames and uses.
  • Oxy-Acetylene Cutting Equipment principle, parameters and application.
  •  Arc welding power sources: Transformer, Motor Generator set, Rectifier and Inverter type welding machines and its care & maintenance..
  •  Advantages and disadvantages of A.C. and D.C. welding machines.
  •  Welding positions as per EN & ASME : flat, horizontal, vertical and over head position.
  • Weld slope and rotation.
  •  Welding symbols as per BIS & AWS.
  •  Arc length – types – effects of arc length.
  •  Polarity: Types and applications.
  •  Weld quality inspection, common welding mistakes and appearance of good and defective welds
  •  Weld gauges & its uses
  •  Calcium carbide properties and uses.
  • Acetylene gas properties and generating methods.
  •  Acetylene gas Purifier, Hydraulic back pressure valve and Flash back arrestor
  •  Oxygen gas and its properties
  •  Production of oxygen by Air liquefaction .
  •  Charging process of oxygen and acetylene gases
  • Oxygen and Dissolved Acetylene gas cylinders and Color coding for different gas cylinders.
  •  Gas regulators, types and uses.
  •  Oxy acetylene gas welding Systems (Low pressure and High pressure). Difference between gas welding blow pipe(LP & HP) and gas cutting blow pipe
  •  Gas welding techniques. Rightward and Leftward techniques.
  • Arc blow – causes and methods of controlling.
  •  Distortion in arc & gas welding and methods employed to minimize distortion
  •  Arc Welding defects, causes and Remedies.
  • Specification of pipes, various types of pipe joints, pipe welding all positions, and procedure.
  •  Difference between pipe welding and plate welding.
  •  Pipe development for Elbow joint, “T” joint, Y joint and branch joint
  •  Manifold system
  •  Gas welding filler rods, specifications and sizes.
  •  Gas welding fluxes – types and functions.
  •  Gas Brazing & Soldering : principles, types fluxes & uses
  •  Gas welding defects, causes and remedies.
  • – Electrode : types, functions of flux, coating factor, sizes of electrode Coding of electrode as per BIS, AWS,
  •  Effects of moisture pick up.
  •  Storage and baking of electrodes.
  •  Special purpose electrodes and their applications.
  • Weldability of metals, importance of pre heating, post heating and maintenance of inter pass temperature.
  •  Classification of steel.
  •  Welding of low, medium and high carbon steel and alloy steels.
  •  Effects of alloying elements on steel
  • Stainless steel : types- weld decay and weldability.
  •  Brass – types – properties and welding methods.
  •  Copper – types – properties and welding methods.
  •  Aluminium and its alloys,properties and weldability, Welding methods
  •  Arc cutting & gouging,
  •  Cast iron and its properties types.
  • Welding methods of cast iron.
  •  Types of Inspection methods
  •  Classification of destructive and NDT methods
  •  Welding economics and Cost estimation.
  • Safety precautions in Gas Metal Arc Welding and Gas Tungsten Arc welding.
  •  Introduction to GMAW – equipment – accessories.
  •  Various other names of the process. (MIG/MAG/CO2 welding.)
  •  Advantages of GMAW welding over SMAW , limitations and applications
  •  Process variables of GMAW.
  •  Modes of metal transfer – dip or short circuiting transfer, spray transfer (free flight transfer) and globular transfer (intermittent transfer)and Pulsed metal transfer.
  •  Wire feed system – types – care and maintenance.
  •  Welding wires used in GMAW, standard diameter and codification as per AWS.
  • Types of shielding gases and gas mixtures used in GMAW and its applications.
  •  Flux cored arc welding – description, advantage, welding wires, coding as per AWS.
  •  Edge preparation of various thicknesses of metals for GMAW.
  •  GMAW defects, causes and remedies
  •  Heat input and techniques of controlling heat input during welding.
  • Heat distribution and effect of faster cooling
  •  Pre heating & Post Weld Heat Treatment
  •  Use of temperature indicating crayons.
  •  Submerged arc welding process
  •  principles, equipment, advantages and limitations
  •  Electro slag and Electro gas welding processes–principles, equipments, advantages and Limitations
  •  Thermit welding process- types,principles, equipments, Thermit mixture types a applications.
  •  Use of backing strips and backing bars
  •  GTAW process – brief description. Difference between AC and DC welding, equipments, polarities and applications.
  •  Various other names of the process (TIG, Argonarc)
  • Power sources for GTAW – AC & DC
  •  Tungsten electrodes –types & uses, sizes and preparation
  •  GTAW Torches- types, parts and their functions
  •  GTAW filler rods and selection criteria
  •  Edge preparation and fit up.
  •  GTAW parameters for welding of different thickness of metals
  •  Pulsed TIG welding – brief description, pulse parameters slope up and slope down.
  •  – Argon / Helium gas properties –uses.
  •  GTAW Defects, causes and remedy.
  •  Friction welding process- equipment and application
  •  Laser beam welding (LBW)and Electron beam welding(EBW)
  • Plasma Arc Welding (PAW) and cutting (PAC) process – equipments and principles of operation.
  •  Types of Plasma arc, advantages and applications.
  •  Resistance welding process – types, principles, power sources and welding parameters.
  • Applications and limitations.
  •  Metalizing – types of metalizing principles, equipments, advantages and applications
  •  Manual Oxy – acetylene powder coating process- principles of operation and applications
  •  Welding codes and standards
  •  Reading of assembly drawing
  •  Welding Procedure Specification (WPS) and Procedure Qualification Record ( PQR)
  •  Hard facing/ surfacing necessity, surface preparation, various hard facing alloys and advantages of hard facing.

EMPLOYABILITY SKILLS

Part- A

Basic Training

Workshop Calculation & Science

Unit, Fractions

  1. Classification of Unit System
  2. Fundamental and Derived Units F.P.S, C.G.S, M.K.S and SI Units
  3. Measurement Units and Conversion
  4. Factors, HCF, LCM and Problems
  5. Fractions – Addition, Subtraction, Multiplication and Division
  6. Decimal Fractions – – Addition, Subtraction, Multiplication and Division
  7. Solving Problems by using calculator

Square Root: Ratio and Proportions, Percentage

  1. Square and Square Root
  2. Simple problems using calculator
  3. Application of Pythagoras Theorem and related problems
  4. Ratio and Proportions
  5. Direct and Indirect proportion
  6. Percentage
  7. Changing percentage to decimal

Material Science

  1. Types of metals
  2. Physical and Mechanical Properties of metals
  3. Types of ferrous and non-ferrous metals
  4. Introduction of iron and cast iron
  5. Difference between iron and steel, alloy steel and carbon steel
  6. Properties and uses of rubber, timber and insulating materials

Mass, Weight, Volume, and Density

  1. Mass, volume, density, weight & specific gravity
  2. Related problems for mass, volume, density, weight & specific gravity

Speed and Velocity, Work Power and Energy

  1. Rest, motion, speed, velocity, difference between speed and velocity, acceleration and retardation
  2. Related problems on speed and velocity
  3. Potential energy, Kinetic Energy and related problems with related problems
  4. Work, power, energy, HP, IHP, BHP and efficiency

Heat & Temperature and Pressure

  1. Concept of heat and temperature, effects of heat, difference between heat and temperature
  2. Scales of temperature, Celsius, Fahenhiet, Kelvin and Conversion between scales of temperature
  3. Temperature measuring instruments, types of thermometer, pyrometer and transmission of heat – Conduction, convection and radiation
  4. Co-efficient of linear expansion and related problems with assignments
  5. Problem of Heat loss and heat gain with assignments
  6. Thermal conductivity and insulators
  7. Boiling point and melting point of different metals and Non metals
  8. Concept of pressure and its units in different system

Basic Electricity

  1. Introduction and uses of electricity, molecule, atom, how electricity is produced, electric current AC, DC and their comparison, voltage, resistance and their units
  2. Conductor, Insulator, types of connections- Series and Parallel, Ohm’s Law, relation between VIR & related problems
  3. Electrical power, energy and their units, calculation with assignments
  4. Magnetic induction, self and mutual inductance and EMF generation
  5. Electrical Power, HP, Energy and units of electrical energy

Mensuration

  1. Area and perimeter of square, rectangle and parallelogram
  2.  Area an Perimeter of Triangle
  3.  Area and Perimeter of Circle, Semi-circle , circular ring, sector of circle, hexagon and ellipse
  4. Surface area and Volume of solids- cube, cuboids, cylinder, sphere and hollow cylinder
  5.  Finding lateral surface area , total surface area and capacity in liters of hexagonal, conical and cylindrical shaped vessels

Levers and Simple Machines

  1.  Simple machines, Effort and load, mechanical advantage, velocity ratio, efficiency of machine, relation between efficiency, velocity ratio and mechanical advantage
  2.  Lever and its types

Trigonometry

  1.  Measurement of Angle, Trigonometrical Ratios, Trigonometric Table
  2.  Trigonometry-Application in calculating height and distance (Simple Applications)

ENGINEERING DRAWING

Engineering Drawing – Introduction

Introduction to Engineering Drawing and Drawing Instruments –

  1. Conventions
  2. Viewing of engineering drawing sheets.
  3. Method of folding of printed drawing sheets as per BIS SP: 46-2003

Drawing Instrument

  • Drawing board, T-square, Drafter (Drafting M/c), Set squares, Protector, Drawing Instrument Box (Compass, Dividers, Scale, Diagonal Scales etc.), pencils of different grades, Drawing pins/ Clips

Free hand drawing of –

  1. Lines, polygons, ellipse etc.
  2. Geometrical figures and blocks with dimension
  3. Transferring measurement from the given object to the free hand sketches.
  4. Solid objects – Cube, Cuboids, Cone, Prism, Pyramid, Frustum of Cone with dimensions.
  5. Free hand drawing of hand tools and measuring tools, simple fasteners (nuts, bolts, rivets etc.) trade related sketches

Lines

  1. Definition, types and applications in drawing as per BIS: 46-2003
  2. Classification of lines (Hidden, centre, construction, extension, Dimension, Section)
  3. Drawing lines of given length (Straight, curved)
  4. Drawing of parallel lines, perpendicular line
  5.  Methods of Division of line segme

Drawing of Geometrical figures

Definition, nomenclature and practice of –

  1. Angle: Measurement and its types, method of bisecting.
  2. Triangle: different types
  3. Rectangle, Square, Rhombus, Parallelogram.
  4. Circle and its elements
  5. Different polygon and their values of included angles. Inscribed and circumscribed polygons

Lettering & Numbering

  1. Single Stroke, Double Stroke, Inclined

Dimensioning and its Practice

  1. Definition, types and methods of dimensioning (functional, non-functional and auxiliary)
  2.  Position of dimensioning (Unidirectional, Aligned)
  3. Types of arrowhead
  4. Leader line with text
  5. Symbols preceding the value of dimension and dimensional tolerance

Sizes and layout of drawing sheets

  1. Selection of sizes
  2. Title Block, its position and content
  3. Item Reference on Drawing Sheet (Item list)

Method of presentation of Engineering Drawing

  • Pictorial View
  • Orthographic View
  • Isometric View

Symbolic representation – different symbols used in the trades

  1. Fastener (Rivets, Bolts and Nuts)
  2. Bars and profile sections
  3. Weld, Brazed and soldered joints
  4. Electrical and electronics element
  5. Piping joints and fitting

Projections

  • Concept of axes plane and quadrant
  • Orthographic projections
  • Method of first angle and third angle projections (definition and difference)
  • Symbol of 1st angle and 3rd angle projection.

Orthographic projection from isometric projection

Reading of fabrication drawing

 

 

TRADE PRACTICAL

1 st sem & 2 nd sem (1Year)

  1. Demonstration of Machinery used in the trade.
  2. Identification to safety equipment and their use etc.
  3.  Hack sawing, filing square to dimensions.
  4.  Marking out on MS plate and punching.
  5.  Setting of oxy-acetylene welding equipment, Lighting and setting of flame.
  6.  Perform fusion run without filler rod on MS sheet 2mm thick in flat position.
  7.  Setting up of Arc welding machine & accessories and Striking an arc.
  8.  Deposit straight line bead on MS plate in flat position.
  9.  Depositing bead with filler rod on M.S. sheet 2 mm thick in flat position.
  10.  Edge joint on MS sheet 2 mm thick in flat position without filler rod.
  11.  Straight line beads on M.S. plate 10 mm thick in flat position.
  12.  Weaved bead on M. S plate 10mm thick in flat position.
  13.  Setting up of oxy-acetylene and make straight cuts (freehand)
  14.  Perform marking and straight line cutting of MS plate 10 mm thick by gas. Accuracy within ±2mm.
  15.  Beveling of MS plates 10 mm thick, cutting regular geometrical shapes and irregular shapes, cutting chamfers by gas cutting.
  16.  Circular gas cutting on MS plate 10 mm thick by profile cutting  machine.
  17.  Marking and perform radial cuts, cutting out holes using oxyacetylene gas cutting.
  18.  Identify cutting defects viz., distortion, grooved, fluted or ragged cuts; poor draglines; rounded edges; tightly adhering slag.
  19.  Square butt joint on M.S. sheet 2 mm thick in flat Position. (1G)
  20.  Fillet “T” joint on M.S. Plate 10 mm thick in flat position.
  21.  Open corner joint on MS sheet 2 mm thick in flat Position (1F)
  22.  Fillet lap joint on M.S. plate 10 mm thick in flat position. (1F)
  23. Fillet “T” joint on MS sheet 2 mm thick in flat position. (1F)
  24.  Open Corner joint on MS plate 10 mm thick in flat position. (1F)
  25.  Fillet Lap joint on MS sheet 2 mm thick in flat position. (1F)
  26.  Single “V” Butt joint on MS plate 12 mm thick in flat position (1G) .
  27.  Testing of weld joints by visual inspection.
  28.  Inspection of welds by using weld gauges.
  29.  Square Butt joint on M.S. sheet. 2 mm thick in Horizontal position. (2G)
  30.  Straight line beads and multi layer practice on M.S. Plate 10 mm thick in Horizontal position
  31.  Fillet
  32. Fusion run with filler rod in vertical position on 2mm thick M.S sheet.
  33.  Square Butt joint on M.S. sheet. 2 mm thick in vertical position (3G)
  34.  Single Vee Butt joint on M.S. plate 12 mm thick in horizontal position (2G).
  35.  Weaved bead on M.S Plate 10mm in vertical position.
  36. Structural pipe welding butt joint on MS pipe Ø 50 and 3mm WT in 1G position.
  37.  Open Corner joint on MS plate 10 mm thick in vertical position. (2F)
  38.  Pipe welding –
  39.  Straight line beads on M.S. plate 10mm thick in over head position.
  40.  Single “V” Butt joint on MS plate 10mm thick in over head position(4G)
  41.  Pipe butt joint on M. S. pipe Ø 50mm WT 6mm (1G Rolled).
  42.  Square Butt joint
  43.  Single “V” butt joint C.I. plate 6mm thick in flat position. (1G)
  44.  Arc gouging on MS plate 10 mm thick.
  45.  Square Butt joint on Aluminium sheet. 3 mm thick in flat position.
  46.  Bronze welding of cast iron (Single “V” butt joint) 6mm thick plate (1G).
  47.  Dye penetrant test.
  48.  Magnetic particle test.
  49.  Nick- break test.
  50.  Free bend test.
  51.  Fillet fracture test.
  52.  Introduction to safety equipment and their use etc.
  53.  Setting up of GMAW welding machine & accessories and striking an arc.
  54.  Depositing straight line beads on M.S Plate.
  55.  Tee Joints on MS Pipe Ø 60 mm OD x 3 mm WT 1G position – Arc constant (Rolling)
  56.  Depositing bead on S.S sheet in flat position.
  57.  Butt joint on Stainless steel 2 mm thick sheet in flat position by Dip transfer.
  58.  Depositing bead on Aluminium sheet 2 mm thick in flat position.
  59.  Square butt joint on Aluminium sheet 1.6mm thick in flat position.
  60.  Fillet weld
  61.  Butt weld
  62.  Pipe butt joint on Aluminium pipe Ø 50 mm x 3 mm WT in Flat position
  63. “T” Joints on MS Pipe Ø 50 mm OD x 3 mm WT, position – Flat
  64.  Straight cutting on ferrous and non ferrous .
  65.  Lap joint on Stainless steel sheet by Resistance Spot welding .
  66.  MS sheets joining by Resistance Spot welding .
  67.  Square butt joint on Copper sheet 2mm thick in flat position.
  68.  “T” joint on Copper to MS sheet 2mm thick in flat position by Brazing
  69.  Hard surfacing practice on M.S round rod Ø 25 mm by using Hard facing electrode in flat position.

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