Lesson 1:

Introduction Welding and Fabrication

1. What is welding? 2. Use of welding? 3. What is the function of welding? 4. What are the types of welding? 5. What is a welding joint? 6. What are the types of welding joints? 7. What is Fabrication? 8. What is fabrication study? 9. What is drawing in fabrication? 10. What is fabrication module? 11. What are the different types of fabrication process?

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Lesson 2:

Welding and Fabrication Equipment

1. Welding Machine: ● Arc Welding in Total ● Stick Welding ● MIG or MAG Welding ● Flux-Cored Arc Welding ● TIG Welding ● Plasma Arc Welding ● Carbon Arc Welding ● Submerged Arc Welding ● Atomic Hydrogen Welding ● Electroslag Welding and Drawn Arc (DA) Stud Welding. 2. Welding Electrode, 3. Welding Table 4. Welding gloves 5. Angle grinder 6. Welding clamp 7. Measuring tools 8. Welding Plier 9. Auto Darkening mask 10. Welding Jacket 11. Welding shoe 12. Gas cylinder Trolley 13. Die-cutting 14. Finishing 15. Hydroforming 16. Roll forming 17. Shrinking 18. Spinning Stamping 18. Stretching. 19. Different Tools: ● Saws ● Hammers ● Grinders ● Cutters ● Plasma Torch ● Welding Clamps ● Magnets ● Gauges ● Vices ● Electrodes.

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Lesson 3:

Symbols and Joints

Types of Welding Symbols: ● Reference Line, ● Arrow and Other Side, ● Weld Symbols, ● Dimensions and Other Data, ● Supplementary Symbols, ● Finish Symbols, ● Tail Slot weld Plug weld Types of Welding Joints: 1. Joining Metals 2. Joining Plastics 3. Joining Wood. 4. Common Joint Configurations: ● Corner Joint, ● Edge Joint, ● Lap Joint, ● Tee Joint, ● Butt Joints ● Cruciform Joint

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Lesson 4:

Welding and Fabrication Safety

Welding Safety: ● Creating a Safe Workshop Environment ● Electrical Safety ● Fumes ● Noise and Noise Cancelling Provisions ● Eye Protection and Safety ● Mechanical Hazards and Burn Risks ● Welding in Difficult Situations Personal Safety: ● Respiratory protective equipment (RPE). ● Anyone welding outdoors must wear RPE when welding. ● Welding helmets with side-shields ● Fire resistant clothing ● Hearing protection. ● Boots and gloves.

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Lesson 5:

Welding and Fabrication Processes

1. What is Fabrication? 2. Types of Fabrication: ● Location: On Site and Factory Site. Welding Processes: ● Gas welding ● Arc welding ● Resistance welding ● Energy beam welding ● Solid-state welding ● Glass welding ● Plastic welding. Metal Fabrication Processes: ● Cutting: 1. Mechanical, 2. Thermal, 3. Hydraulic. ● Forming: 1. Rolling 2. Extrusion 3. Die Forming 4. Forging. ● Joining: 1. Welding 2. Soldering 3. Brazing 4. Fasteners 5. Adhesive Bonding. ● Machining: 1. Drilling 2. Turning 3. Milling. ● Casting: 1. Sand Casting 2. Investment Casting 3. Plastic Castings. Fabrication Service: ● Customization ● Quality control ● Reduce lead time ● Cost-Saving.

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Lesson 6:

Welding and Fabrication Inspection and Quality Control

1. What is Quality Assurance (QA)? 2. What is Welding Quality Control (QC)? 3. Methods of Welding Inspection: ● Visual Inspection ● Radiographic Testing (RT) ● Ultrasonic Testing (UT) ● Magnetic Particle Testing (MT) ● Liquid Penetrant Testing (PT).

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Lesson 7:

Structural Steel Layout Welding and Fabrication

● Manual & Automated (CNC) Thermal Cutting & Forming Applications: 1. Portable Flame and Plasma Cutting Equipment 2. Automated Plasma Cutting Equipment 3. Flame Straightening & Bending. ● Structural Shapes & Layout Methods: 1. Steel Plate Classification 2. Structural Steel Configuration & Classification 3. Squaring, Diagonal Measurement &Triangulation 4. Square, Mitered & Coped Tie-In Joints. ● Hand & Bench Tool Practices: 1. Saws, 2. Files, 3. Vises, 4. Hammers, 5. Punches, 6. Metal Stamps, 7. Screwdrivers Wrenches, 8. Pliers, 9. Clamps & Hydraulic Presses. ● Drilling, Thread Cutting & Joining: 1. Drill Classification Stationary Drill Press Practices 2. Thread Cutting (Tap & Die Practices) 3. Fastening Processes. ● Power Sawing: 1. Types of Power Saws & Maintenance 2. Coolants & Cutting Fluids. ● Shearing, Punching & Rolling Practices: 1. Power Equipment Tonnages, Tolerances & Limitations 2. Power Shear Set up & Practices 3. Press Brake Set up & Practices 4. Metal Rolling Set up & Practices.

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Lesson 8:

Gas Tungsten Arc Welding

● Introduction to GTAW Process: 1. Advantages and Disadvantages of GTAW Process, Applications. 2. Types of GTAW power source, torch assembly, gas regulator, flow 3. Meter and electrode preparation. 4. Execution of GTAW in mild steel in fat, horizontal and vertical 5. Location in the following joints: ■ Angle ■ Lap ■ Tee Fillet ■ Butt. ● GTAW electrode, filler metal and shielding gas: 1. Identification of basic GTAW workstation components. 2. Welding currents and settings, filler metals, and electrodes. 3. Designation. ● GTAW welds on stainless steel: 1. Perform GTAW on stainless steel, fat, horizontal and vertical in the following joints: ■ corner ■ lap ■ tee fillet ■ butt. ● GTAW welds on aluminum: 1. Execution of GTAW on aluminum in fat, horizontal and vertical positions in the following joints: ■ Corner ■ Lap ■ T Fillet ■ Butt. ● GTAW Troubleshooting: 1. Diagnose and troubleshoot power source output current problems. 2. Diagnose and solve torch and wire assembly problems. 3. Diagnose and solve sealing gas coverage problems.

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Lesson 9:

Pipe and Pressure Vessel Layout & Fabrication

● Line Pipe Drawings and Symbols: 1. Reading isometric and orthographic pipe drawings 2. Drawing isometric single line piping arrangements for piping spools with proper orientation 3. Lettering and labelling on isometric and orthographic drawings. ● Pipe Offsets: 1. Pipe sizes and schedules 2. Pipe layout tools 3. Calculating angle of cut, measure-back and length of pieces for various pipe turns 4. Marking out pipe using a wraparound to calculate dimensions 5. Calculating offsets using Pythagorean Theorem. ● Piping Spools: 1. Terms and fitting symbols used for piping spools 2. Material lists with numbering on piping spools 3. Drawing piping spools for specified lab projects. ● Joint Fit-up and Assembly Methods: 1. Alignment clamps and appliances 2. Joint tacking 3. Two Square Method 4. Spirit Level Method. ● Welded and Flanged Pipe Fittings: 1. Code interpretation of pipe fittings 2. The fabrication process for welded pipe and fittings 3. Gasket preparation and joining techniques for flanged joints. ● Parallel Line Development: 1. Developing pipe joining patterns using parallel line development process. ● Pipe Welding Joint Configuration Testing Positions and Weld Sequencing: 1. Joint face profiles 2. Root welds 3. Intermediate welds 4. Cover welds. ● Pipe Welding Techniques: 1. Start and stop techniques 2. Downhill techniques 3. Uphill techniques. ● Semiautomatic and Automated Pipe Applications: 1. Semiautomatic application 2. Orbital application 3. Robotic application.

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Lesson 10:

Welding and Fabrication Operations Management

● Assessing Required Welding Project Work Environment: 1. Shop vs field welding 2. Equipment and tools required for safe and effective project completion 3. Fixturing 4. Code vs non-code requirements. ● Calculating Material Costs: 1. Review of material shape designations 2. Calculating material shape weights & costs 3. Comparing weld process operating costs 4. Calculating weld deposition rates & costs 5. Miscellaneous post welding expenses (painting, plating and shipping). ● Calculating Laboure Costs: 1. Calculating fabrication and installation hours 2. Payroll costs (CPP, WCB & EI) 3. Benefits. ● Calculating Overhead Costs: 1. Office staff 2. Office equipment and maintenance 3. Rent, fuel, electricity and communications 4. Shop vehicles, tools and equipment. ● Profit Margin Factors and Calculations: 1. Size and complexity of the project 2. Previous project experience 3. Sub-contracting 4. Timelines.

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Exam

Final Exam

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