ITI's which provides courses for Welder (Gas & Electric)

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.
- Setting up of Arc and gas Apparatus.
- Lighting and setting of flame.
- Striking an arc

- General discipline in the Institute
- Elementary First Aid.
- Importance of Welding in Industry
- Safety in Manual
- Metal Arc Welding, Oxy-Acetylene Welding and Cutting.

2

- Hack sawing, filing square to dimensions.
- Marking out on MS plate and punching

- Arc and Gas Welding Equipments, tools and accessories
- Various Welding Processes and its applications
- Arc and Gas Welding terms and definitions

3

- Fusion run with and without filler rod on M.S. sheet 1.6 mm thick in flat position by Gas welding Edge joint on M.S sheet 1.6 mm thick in flat position without filler rod by Gas welding

- Different process of metal joining bolting, riveting, soldering, brazing, seaming etc.
- Types of welding joints and its applications. Edge preparation and fit up for different thickness.

4

- Straight line beads on M.S. 10 mm thick in flat position by 3.15 mm 9 electrode by arc welding
- Weaved bead on M. S 10mm in flat
position by 4 mm 0 electrode in D/H
position by arc welding

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

- Principle of Manual Metal Arc Welding arc welding

5

- Marking and Straight line cutting on MS flats by Gas cutting
- Square butt joint on M.S. sheet. 2 mm thick in flat Position by gas welding.
- Fillet Tee joint on M.S.10 mm in flat position by Arc welding.

- Oxy-Acetylene Cutting Equipment principles, cutting parameters and applications
- Common gases used for welding, their flame temperatures and uses.
- Chemistry of oxy-acetylene flame.
- Types of oxy-acetylene flames and uses.

6

- Marking and circular cutting on MS plates 10 mm thick by Gas cutting
- Outside corner joint on M S 2 mm in flat Position by gas welding
- Fillet lap joint on M.S. 10 mm in flat position by Arc welding

- Arc welding power sources-Transformer, Motor Generator set, Rectifier and Inverter type welding machines
- Advantages and disadvantages of A.C. and D.C. welding machines

7

- Bevelling of MS flats on MS plates 10 mm thick by Gas cutting
- Fillet Tee joint on M S 2 mm in flat position by gas welding

- Welding positions - flat-horizontal-vertical and over head position. Weld slope and rotation.

8

Fillet Lap joint on M S 2 mm in flat position by gas welding
- Single Vee Butt joint on M S 12 mm in flat position by arc welding

- Arc length - types - effects of arc length.
- Polarity and its uses.

9

- Square Butt joint on M.S. sheet. 3 mm in Horizontal vertical position by gas welding
- Straight line beads on M.S. 10 mm in Horizontal vertical position by arc welding

- Calcium carbide properties and uses
- Manufacture of calcium carbide. –Acetylene gas Generators and manufacturing methods and properties

10

- Outside Corner joint on M S 2 mm in horizontal position by gas welding
- Fillet Lap joint on M.S. 10 mm in horizontal position by arc welding.

- Acetylene gas Purifier, Hydraulic back pressure valve. Charging methods of oxygen and acetylene gases

11

- Fillet Tee joint on MS 2 mm in horizontal position by gas welding
- Outside Corner joint on M S 10 mm in horizontal position by arc welding

- Oxygen and Acetylene gas cylinders and color coding for different gas cylinders

12

- Fillet Lap joint on M S 2 mm in horizontal position by gas welding
- Single Vee Butt joint on MS 12 mm in horizontal position by arc welding

- Gas regulators, types and uses.
-Welding and gas cutting torches and types.

13

- Square Butt joint on M.S. sheet. 3 mm in vertical position by gas welding
- Straight line Beads on M.S. 10 mm in vertical position by arc welding

- Arc blow - causes and methods to control arc blow.
- Distortion in welding and methods employed to minimize distortion

14

- Outside Corner joint on MS sheet 2 mm in vertical position by gas welding
- Fillet Lap joint on M.S. 10 mm in vertical position by arc welding

- Electrode - types - functions of flux, coating factor, sizes of electrode.
Coding of electrode as per BIS, AWS, and BS.
- Effects of moisture pick up on electrodes and backing.

15

- Fillet Tee joint on M S sheet 2 mm in vertical position by gas welding
- Outside Corner joint on MS plate 10 mm in vertical position by arc welding

- Gas welding filler rods, specifications and sizes. Welding techniques - right and leftward methods

16

- Fillet lap joint on M S sheet 2 mm in vertical position by gas welding.
- Single Vee Butt joint on MS plate12 mm in vertical position by arc welding

- Resistance welding- principle of resistance welding - types and applications.

17

- Square Butt joint on M.S. sheet. 3 mm in over head position by gas welding
- Fillet Tee joint on M.S. 6 mm in over head position by Arc welding

- Brass - types - properties- uses.
- Copper - types - properties and uses.

18

- Outside Corner joint on M S sheet 2 mm in over head position by gas welding
- Fillet Lap joint on M.S. plate 10 mm in over head position by arc welding

- Aluminium - properties- weld ability of aluminium by different welding process.
- Cast iron- types and fusion welding of cast iron and bronze welding of cast iron.

19

- Fillet Tee joint on M S sheet2 mm in over head position by gas welding - Single Vee Butt joint on M S plate 10mm in over head position by arc welding

- Stainless steel - types- uses - welds decay and stainless steel welding by gas
- Welding Technique-Right Hand-Left Hand - Explanation

20

- Square Butt joint on Brass sheet. Sheet 2 mm in flat position by gas welding

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

21

- Square Butt joint on M.S. sheet 1.6mm by brazing.
- Tee joint on M.S. sheet 1.6 mm by brazing

- Weldability of metals, importance of pre heating, post heating and maintenance of interpass temperature

22

- Square Butt joint on Aluminium sheet. 3 mm in flat position by gas welding

- Effects of alloying elements on steel

23

- Bronze welding on cast iron (Single vee butt joint) 6mm by oxy-acetylene process

- Pipe welding - specification of pipes, various types of pipe joints and welding procedure such as up-hill and downhill method

24

- Square Butt joint on S.S. sheet. 1.6 mm in flat position by gas welding

- Pipe welding - specification of pipes, various types of pipe joints and welding procedure such as up-hill and downhill method

Project Work

Sem. II

Trade Practical

Trade Theory

1

- Depositing bead on M.S (10mm thick) in flat position (1.2mm wire and Dip transfer)
- Fillet weld - Lap joint on M.S (10mm thick) in flat position (1.2mm wire and Dip transfer).
- Fillet weld - Tee joint on M.S (10mm thick) in flat position (1.2mm wire and Dip transfer).
- Fillet weld - corner joint on M.S (10mm thick) in flat position (1.2mm wire and Dip transfer).

- Introduction to CO2 welding -equipment - accessories.
- Description of CO2 welding set with diagram.

2

- Fillet weld - Lap joint on M.S. (3mm thick) in flat position (0.8 mm wire and Dip transfer).
- Fillet weld - Tee joint on M.S. (3mm thick) in flat position (0.8 mm wire and Dip transfer).
- Fillet weld - corner joint on M.S. (3mm thick) in flat position (0.8 mm wire and Dip transfer).

- Advantages of CO2 welding over MMAW , limitations and applications
- Process variables and modes of metal transfer - dip or short circuiting transfer, spray transfer (free flight transfer) and globular transfer (intermittent transfer) etc.

3

Fusion run with and without filler rod on M.S. sheet 1.6 mm thick in flat position by Gas welding Edge joint on M.S sheet 1.6 mm thick in flat position without filler rod by Gas welding

- Different process of metal joining bolting, riveting, soldering, brazing, seaming etc.
- Types of welding joints and its applications. Edge preparation and fit up for different thickness.

4

Straight line beads on M.S. 10 mm thick in flat position by 3.15 mm 9 electrode by arc welding - Weaved bead on M. S 10mm in flat position by 4 mm 0 electrode in D/H position by arc welding

- Basic electricity applicable to arc welding and related electrical terms & definitions.
- Principle of Manual Metal Arc Welding arc welding.

5

-Marking and Straight line cutting on MS flats by Gas cutting
- Square butt joint on M.S. sheet. 2 mm thick in flat Position by gas welding.

- Oxy-Acetylene Cutting Equipment principles, cutting parameters and applications
- Common gases used for welding, their flame temperatures and uses.

6

- Marking and circular cutting on MS plates 10 mm thick by Gas cutting
- Outside corner joint on M S 2 mm in flat Position by gas welding.

- Arc welding power sources-Transformer, Motor Generator set, Rectifier and Inverter type welding machines.
- Advantages and disadvantages of A.C. and D.C. welding machines

7

- Bevelling of MS flats on MS plates 10 mm thick by Gas cutting
- Fillet Tee joint on M S 2 mm in flat position by gas welding

Welding positions - flat-horizontal-vertical and over head position. Weld slope and rotation.

8

- Fillet Lap joint on M S 2 mm in flat position by gas welding

- Arc length - types - effects of arc length
- Polarity and its uses.

9

- Square Butt joint on M.S. sheet. 3 mm in Horizontal vertical position by gas welding
- Straight line beads on M.S. 10 mm in Horizontal vertical position by arc welding

- Calcium carbide properties and uses
- Manufacture of calcium carbide. –Acetylene gas Generators and manufacturing methods and properties.

10

- Outside Corner joint on M S 2 mm in horizontal position by gas welding
- Fillet Lap joint on M.S. 10 mm in horizontal position by arc welding

- Acetylene gas Purifier, Hydraulic back pressure valve. Charging methods of oxygen and acetylene gases

11

- Fillet Tee joint on MS 2 mm in horizontal position by gas welding
- Outside Corner joint on M S 10 mm in horizontal position by arc welding.

- Oxygen and Acetylene gas cylinders and colour coding for different gas cylinders.

12

Fillet Lap joint on M S 2 mm in horizontal position by gas welding
- Single Vee Butt joint on MS 12 mm in horizontal position by arc welding

- Gas regulators, types and uses. -Welding and gas cutting torches and types.

13

- Square Butt joint on M.S. sheet. 3 mm in vertical position by gas welding
- Straight line Beads on M.S. 10 mm in vertical position by arc welding

- Arc blow - causes and methods to control arc blow
- Distortion in welding and methods employed to minimize distortion

14

- Outside Corner joint on M S sheet 2 mm in vertical position by gas welding
- Fillet Lap joint on M.S. 10 mm in vertical position by arc welding

- Electrode - types - functions of flux, coating factor, sizes of electrode. Coding of electrode as per BIS, AWS, and BS

15

- Fillet Tee joint on M S sheet 2 mm in vertical position by gas welding
- Outside Corner joint on MS plate 10 mm in vertical position by arc welding

- Gas welding filler rods, specifications and sizes. Welding techniques - right and leftward methods.

16

- Fillet lap joint on M S sheet 2 mm in vertical position by gas welding
- Single Vee Butt joint on MS plate12 mm in vertical position by arc welding

- Resistance welding- principle of resistance welding - types and applications.

17

- Square Butt joint on M.S. sheet. 3 mm in over head position by gas welding
- Fillet Tee joint on M.S. 6 mm in over head position by Arc welding

- Brass - types - properties- uses
- Copper - types - properties and uses.

18

- Outside Corner joint on M S sheet 2 mm in over head position by gas welding.
- Fillet Lap joint on M.S. plate 10 mm in over head position by arc welding

Aluminium - properties- weld ability of aluminium by different welding process
- Cast iron- types and fusion welding of cast iron and bronze welding of cast iron.

19

- Fillet Tee joint on M S sheet 2 mm in over head position by gas welding
- Single Vee Butt joint on M S plate 10mm in over head position by arc welding

Stainless steel - types- uses - welds decay and stainless steel welding by gas.
- Welding Technique-Right Hand-Left Hand - Explanation

20

- Square Butt joint on Brass sheet. Sheet 2 mm in flat position by gas welding

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

21

- Square Butt joint on M.S. sheet 1.6mm by brazing.
- Tee joint on M.S. sheet 1.6 mm by brazing.

-Weldability of metals, importance of pre heating, post heating and maintenance of interpass temperature.

22

- Square Butt joint on Aluminium sheet. 3 mm in flat position by gas welding

- Effects of alloying elements on steel

23

- Bronze welding on cast iron (Single vee butt joint) 6mm by oxy-acetylene process

- Pipe welding - specification of pipes, various types of pipe joints and welding procedure such as up-hill and downhill method

24

Square Butt joint on S.S. sheet. 1.6 mm in flat position by gas welding

- Pipe welding - specification of pipes, various types of pipe joints and welding procedure such as up-hill and downhill method

Project Work