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Welding Technology (257)
1. INTRODUCTION
Welding is a process of joining two or more parts of metal.
It provides a permanent joint. Most of the materials can be welded by one
process or the other. Welding is comparatively a new comer amongest the fabrication
processes. Though there are a number of well-established welding processes
but arc welding with coated electrodes is still the most popular welding process
in all over the world.
Arc welding in its present form started in 1880’s however, the demand for
large scale production of heavy items like ships, pressure vessels, construction
of bridges etc. provided the necessary impetus for welding to come of age.
Welding processes widely used in the industry include Oxy-acetylene as manual
metal arc required welding.
2 OBJECTIVES
After going through this course the student will be able to:
understand Gas and Arc Welding processes to join metal pieces for various
applications in industry.
carry out skillfully Gas and Arc Welding Processes to join materials for different
applications in Industry.
3. JOB OPPORTUNITIES
The pass outs of this programme have ample scope for self employment,
as there is sufficient market demand for trained and skilled technicians in
Gas and Arc Welding. They can also get wage employment as welder in private
and government sector industries, Research & Development Organisations,
Defence Sector, I.T.I.s and Vocational Training Institutes etc.
4. Course duration
One Year
4.1 Scheme of study – Theory 40%, Practical 60%
5. Entery Qualification
Class 8th Pass
6. SCHEME OF EXAMINATION
Maximum Weightage in Theory–30% Time – 2 hours
Maximum Weightage in Practical–70% Time – 3 hours
Passing Criteria – 33% aggrigate in Public Examination in secondary level
or Grade 'E' as for independent vocational course or Grade 'G' when combined
with academic stream.
7. COURSE CONTENT
1. Importance of Welding and its application in industry and rural areas.
Safety in manual Metal Arc Welding. Safety in Oxy-Acetylene welding and cutting.
Elementary knowledge of working & measuring tools.
2. Gas and Arc welding equipment, Their uses, care and maintenance.
3. Different processes of metal joint - bolting, rivetting, soldering, brazing
and welding.
4. Oxy-Acetylene welding and cutting equipment and their application
5. Common gases used for Welding - Oxygen, Hydrogen and Acetylene. Type of
Oxy-Acetylene flames their Setting and uses. Various gas combinations, flame
temperatures and their uses.
6. Types of welding joints - Explanation with simple sketches
7. Acetylene - its properties and dissolved Acetylene in cylinder
8. Oxygen - its properties and Oxygen cylinders, Safety precautions in handling
cylinders.
9. Regulators and Welding blow pipes, types, construction and uses.
10. Defects in Gas and Arc welding.
11. Welding of Aluminium, Flame and angle of blow pipe, Filler rod and Flux.
12. Welding of dissimilar metals, Flame setting, use of filler rod and flux,
Precautions.
13. Different flame cutting equipment, manual and machines, Flame setting
for Mild Steel. Precautions to be observed during cutting.
14. Different Arc Welding processes.
15. Polarity and its importance in Arc Welding and its application.
16. Welding positions - Flat, Horizontal, Vertical and Overhead.
17. Electrodes, Types of Flux coating, Precautions in handling & storage
of electrodes.
18. Cast Iron - its properties and welding.
19. Copper - its properties and welding
20. Inspection and testing of welds, Destructive and Non Destructive tests.
21. Introduction to Advance Welding methods
(i) Submerged Arc Welding
(ii) Tungsten Insert Gas Welding
(iii) CO2 Welding
(iv) Electron Beam Welding
(v) Friction Welding
(vi) Arc Brazer
(vii) Thermal welding
(viii) Resistance welding