ITI's which provides courses for Welder (Structural)

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

- Induction training:
- Familiarisation with the Institute.
- Importance of trade Training
- Machinery used in the trade.
- Introduction to safety equipment and their use etc.
- Hack sawing, filing square to dimensions.
- Marking out on MS plate and punching

-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

2

- Setting up of Arc welding machine & accessories and Striking an arc
- Setting of oxy-acetylene welding equipment, Lighting and setting of flame.

-Introduction and definition of welding
- Arc and Gas Welding Equipments, tools and accessories
- Various Welding Processes and its applications
- Arc and Gas W

3

- Fusion run without and with filler rod on M.S. sheet 2 mm thick in flat position.
- Edge joint on MS sheet 2 mm thick in flat position without filler rod.
- Marking and straight line cutting of MS plate. 10 mm thick by gas

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

4

-Straight line beads on M.S. plate 10mm thick in flat position.
- Weaved bead on M. S plate 10mm thick in flat position.

-Basic electricity applicable to arc welding and related electrical terms & definitions.
- Heat and temperature and its terms related to welding

5

Square butt joint on M.S. sheet 2 mm thick in flat Position

-Common gases used for welding & cutting, flame temperatures and uses.
- Chemistry of oxy-acetylene flame

6

-Bevelling of MS plates 10 mm thick. By gas cutting
- Open corner joint on MS sheet 2 mm thick in flat Position

-Arc welding power sources: Transformer, Motor Generator set, Rectifier and Inverter type welding machines and its care & maintenance.
- Advantages and disadvantages of A.C.

7

- Circular gas cutting on MS plate 10 mm thick by profile cutting machine. Fillet “T” joint on MS sheet 2 mm thick in flat position

-Welding positions as per EN & ASME: Flat, horizontal, vertical and over head position.
- Weld slope and rotation.

8

Fillet Lap joint on MS sheet 2 mm thick in flat position.

Arc length – types – effects of arc length

9

- Square Butt joint on M.S. sheet. 2 mm thick in Horizontal position
- Straight line beads and multi layer practice on M.S. Plate 10 mm thick in Horizontal position.

-Calcium carbide properties and uses.
- Acetylene gas properties and generating methods.

10

-Fillet Lap joint on M.S. sheet 2 mm thick in horizontal position
- Fillet Lap joint on M.S. plate 10 mm thick in horizontal position

-Oxygen gas and its properties - Production of oxygen by Air liquefaction
- Charging process of oxygen and acetylene gases

11

Fusion run with filler rod in vertical position on 2mm thick M.S sheet - Square Butt joint on M.S. sheet. 2 mm thick in vertical position

Oxy acetylene gas welding Systems (Low pressure and High pressure). Difference between gas welding blow pipe(LP & HP) and gas cutting blow pipe

12

-Weaved bead on M.S Plate 10mm in vertical position.
- Fillet “T” joint on M.S sheet 2 mm thick in vertical position

-Arc blow – causes and methods of controlling
- Distortion in arc & gas welding and methods employed to minimize distortion

13

-Structural pipe welding butt joint on MS pipe Ø 50 and 3mm WT in 1G position.
- Fillet Lap joint on M.S. Plate 10 mm in vertical position

-Specification of pipes, various types of pipe joints, pipe welding positions, and procedure.
- Difference between pipe welding and plate welding.

14

-Open Corner joint on MS plate 10 mm thick in vertical position.
-Pipe welding - Elbow joint on MS pipe Ø 50 and 3mm WT. 

Pipe development for Elbow joint, “T” joint, Y joint and branch joint - Manifold system

15

-Pipe welding “T” joint on MS pipe Ø 50 and 3mm WT.
- Single “V” Butt joint on MS plate12 mm thick in vertical position (3G) 

-Gas welding filler rods, specifications and sizes
- Gas welding fluxes – types and functions.
- Gas Brazing & Soldering: principles, types fluxes & uses

16

Pipe welding 45 ° angle joint on MS pipe Ø 50 and 3mm WT.

Electrode : types, functions of flux, coating factor, sizes of electrode Coding of electrode as per BIS, AWS

17

Pipe Flange joint on M.S plate with MS pipe Ø 50 mm X 3mm WT

Weldability of metals, importance of pre heating, post heating and maintenance of inter pass temperature.

18

-Pipe welding butt joint on MS pipe Ø 50 and 5 mm WT. in 1G position.
- Fillet Lap joint on M.S. plate 10 mm thick in over head position

-Classification of steel
- Welding of low, medium and high carbon steel and alloy steels.

19

- Single “V” Butt joint on MS plate 10mm thick in over head position (4G)
- Pipe butt joint on M. S. pipe Ø 50mm WT 6mm (1G Rolled).

-Effects of alloying elements on steel
- Stainless steel: types- weld decay and weldability

20

- Square Butt joint on S.S. sheet. 2 mm thick in flat position.
- Square Butt joint on

-Brass – types – properties and welding methods
- Copper – types – properties and welding methods

21

- Square Butt & Lap joint on M.S. sheet 2 mm thick by brazing.
- Single “V” butt joint C.I. plate 6mm thick in flat position.
- Arc gouging on MS plate 10 mm thick

- Aluminium and its alloys, properties and weldability, Welding methods
- Arc cutting & gouging,

22

-Square Butt joint on Aluminium sheet. 3mm thick in flat position
- Bronze welding of cast iron (Single “V” butt joint) 6mm thick plate

-Cast iron and its properties types.
- Welding methods of cast iron.

Project Work

Sem. II

Trade Practical

Trade Theory

1

-Familiarisation with the machinery used in the trade
- Introduction to safety equipment and their use
- Setting up Gas cutting equipment and cutting MS Flats to required size

-Outline of the subjects to be covered
- Importance of structural welding
- Welding processes – brief description, Classification and application
- Welding terms and definitions

2

-Setting up SMAW Welding equipment and making straight and weaving bead on MS in all positions
- Practice on plasma cutting
- Practice on gouging techniques 

-Principles of Oxy-Acetylene Cutting and equipments required
- Principles of shielded metals arc welding, its advantages and limitations
- Types of weld joints

3

-Weld joint preparation for fillet weld (Cutting to size, fit up, tack weld etc.)
- Fillet, Lap and T joint on MS flat by SMAW, position - 1F 

-Basic Electricity applicable to welding
- Arc welding power source AC / DC
-advantages and disadvantages
- Types of metal and their characteristics
- Classification of steel and their Weldability

4

-Weld joint preparation for fillet welds (Cutting to size, fit up, tack weld etc.)
- Fillet, lap and T joint on MS flat by SMAW position - 2F

-Welding symbols and their importance
- Welding positions and necessity of positional welding
- Weld joint edge preparation
- Welding procedure and techniques

5

-Weld joint preparation for fillet welds (Cutting to size, fit up, tack weld etc.)
- Fillet, lap and T joint on MS flat by SMAW, position - 3F

-Welding tools and accessories
- Arc and its characteristics
- Polarity types and application
- Arc length
- Welding fixtures and clamps

6

-Weld joint preparation for fillet welds (Cutting to size, fit up, tack weld etc.)
- Fillet, lap and T joint on MS flat by SMAW position - 4F 

-Coated electrodes - Types, description and coding as per BIS, AWS etc.
- Standard size and length of electrodes
- Selection of electrodes and coating factor

7

-Weld joint preparation for pipe fillet welding
- Pipe to pipe fillet weld on MS pipes by SMAW, position -5F

-Effect of Heat on Weldments
- Welding distortion and stresses

8

-Weld joint preparation for plate groove welding
- Full penetration Single "V" butt joint on MS Flat by SMAW in 1G Positions

-Methods of controlling distortion by various methods
- Methods of relieving stress on Weldments

9

-Weld joint preparation for plate groove welding
- Full penetration Single "V" butt joint on MS Flat by SMAW in 2G Positions

-Types of Steel sections/forms used in structural fabrication and their standard sizes
- Importance of structural welding and workmanship
- Necessity of Qualifying welders, welding operators and tack welders

10

-Full penetration single "V" butt joint on MS Flat by SMAW in 3G Positions
- MS Flat by SMAW in 4G Positions
- Root pass welding & LPI testing
- Cover pass welding & inspection

-Types of Fillet welded and groove welded joints on statically loaded structures
- Types of fillet welded and groove welded joints on dynamically loaded structures

11

-Setting up GTAW welding equipment and making beading practice on MS in down hand position
- Square butt joint on M.S Sheet in down hand position

-GTAW equipments
- Advantages of GTAW Welding process
- Power source types AC/DC
- Types of polarity and application
- Accessories - HF unit and DC Suppressor

12

-Square butt joint on S.S Sheet in down hand position - Square butt joint on Aluminium in down hand position

-Tungsten electrode, types, sizes and Uses
- Types of shielding gases
- Preparation for TIG Welding under drift conditions
- Necessity of back purging

13

M.S square butt Tube (Square or rectangular) welding

Types of Tubular structures used on structural fabrication

14

T,Y,K tube (Square or rectangular) joints by TIG welding

Development of templates for marking and preparation of pipe elbow, - T, Y and K joints ( Similar and dissimilar diameter pipe connections)

15

Double bevel butt joint on MS Flats in dissimilar thickness in down hand positions by SMAW
- Root Inspection

Types of welding defects causes and remedy

16

-Pipe Elbow and T joints on MS pipes by SMAW in flat position
- Pipe Y and K connection on M.S. pipe by SMAW, positions - Horizontal

Procedure of rectifying, weld defects -Gouging methods , grinding, testing with die penetrate, pre-heating and rewelding

17

- Practice on C02 welding
- Lap, T , Corner joints on GMAW process in down hand position

-Introduction to GMAW, Flux cored arc welding - Advantages - Power source - Wire feeder - Electrode wires
- shielding gases - Types of metal transfer and welding parameters

18

Practice on Automatic Submerged Arc Welding machine – butt joint

Introduction to Submerged arc welding (SAW). Advantage, limitation, Equipment and operating conditions

19

-Manufacturing of simple structures with L angles, I section and channel sections using welding fixture by SMAW.
- Correction of distortion by cold & hot method

-Procedure of structural fabrication
- Planning for structural members, marking and edge preparation, assembling, tack welding, measurement of weldment size, root pass

20

-Manufacturing of structures using M.S. Flat by SMAW
- Adapting skip welding & back step welding method for controlling distortion

-Inspection and testing of weldments
- Visual inspection kits and Gauges

21

Fabrication of pipe/cone on M.S. sheet by SMAW.

-Non-destructive testing methods
- Structural welding codes and standards
- Writing procedure for WPS and PQR
- Requirement for qualification in different codes 

22

Weld test specimen - preparation as per a standard - Inspection & Testing

-Qualification procedure under various codes
- Different tests and inspection involved in qualification

Project Work