Fabricaiton and Welding Engineering

7/30/2019 Fabricaiton and Welding Engineering

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ED/STV/2001/PI/10

Fabrication and Welding Engineering

National Technical Certificate (NTC) andAdvanced National Technical Certificate (ANTC)

Curriculum and Course Specifications

NATIONAL BOARD FOR TECHNICAL EDUCATION

Federal Republic of Nigeria

UNESCO Nigeria Project

2001


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Fabrication and Welding Engineering - National

Technical Certificate (NTC) and Advanced National

Technical Certificate (ANTC)


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General Information.............................................................................................................3

Curriculum Table (NTC).......................................................................................................7

Curriculum Table (ANTC) ....................................................................................................8

National Technical Certificate ..............................................................................................9

General Metalwork I .........................................................................................................9

General Metalwork II ......................................................................................................27

Sheet metal Work...........................................................................................................33

Gas Welding and cutting ................................................................................................42

Metal Arc Welding ..........................................................................................................51

Structural Steel Work .....................................................................................................62

Advanced National Technical Certificate ...........................................................................72

Welding ..........................................................................................................................72

Structural Mechanics and Specification..........................................................................87

Structural Steel Work .....................................................................................................91

Sheet metal work ...........................................................................................................95

List of tools and equipment for welding and fabrication engineering................................100

Guideline for textbooks development...............................................................................103

Recommended books for fabrication and welding engineering craft practice ..................105

List of Participants ...........................................................................................................106


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To give training and impart the necessary skills leading to the production of craftsmen, technicians and other

skilled personnel who will be enterprising and self-reliant.

Candidates must not be less than 14 years of age and should have successfully completed three years of

Junior Secondary education or its equivalent. Special consideration may be given to sponsored candidates

with lower academic qualifications who hold trade test certificates and are capable of benefiting from the

programme.

Candidates should possess the National Technical Certificate or its equivalent and should have had a

minimum of two years post qualification cognate industrial experience.

The Curriculum of each programme is broadly divided into three components:

a. General Education, which accounts for 30% of the total hours required for the programme.

b. Trade Theory, Trade Practice and Related Studies which account for 65% and

c. Supervised Industrial Training/Work Experience, which accounts for about 5% of the total

hours required for the programme. This component of the course which may be taken in

industry or in college production unit is compulsory for the full-time students.

Included in the curriculum is the teacher's activity and learning resources required for the guidance of the

teacher.

A Course/Module is defined as a body of knowledge and skills capable of being utilized on its own or as a

foundation or pre-requisite knowledge for more advanced work in the same or other fields of study. Each

trade when successfully completed can be used for employment purposes.


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These are educational objectives, which identify precisely the type of behaviour a student should exhibit at

the end of a course/module or programme. Two types of behavioural objectives have been used as the

curriculum. They are:

a. General Objectives

b. Specific learning outcomes

General objectives are concise but general statements of the behaviour of the students on completion of a

unit of week such as understanding the principles and application in:

a. Orthographic projection in engineering/technical drawing;b. Loci in Mathematics

c. Basic concepts of politics and government in Political Science

d. Demand and supply in Economics

Specific learning outcomes are concise statements of the specific behaviour expressed in units of discrete

practical tasks and related knowledge the students should demonstrate as a result of the educational

process to ascertain that the general objectives of course/programme have been achieved. They are more

discrete and quantitative expressions of the scope of the tasks contained in a teaching unit.

The General Education component of the curriculum aims at providing the trainee with complete secondary

education in critical subjects like English Language, Economics, Physics, Chemistry, Biology,

Entrepreneurial Studies and Mathematics to enhance the understanding of machines, tools and materials of

their trades and their application and as a foundation for post-secondary technical education for the above

average trainee. Hence, it is hoped that trainees who successfully complete their trade and general

education may be able to compete with their secondary school counterparts for direct entry into the

polytechnics or colleges of education (technical) for ND or NCE courses respectively. The Social Studies

component is designed to broaden the trainee's social skills and his understanding or his environment.

For the purpose of certification, only the first three courses in mathematics will be required. The remaining

modules are optional and are designed for the above average students.

The NTC and ANTC programmes are run by Technical Colleges accredited by NBTE.

NABTEB conducts the final National examination and awards certificates.


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Trainees who successfully complete all the courses/modules specified in the curriculum table and passed

the national examinations in the trade will be awarded one of the following certificates:

S/NO LEVEL CERTIFICATE

1. Craft Level National Technical Certificate

2. Advanced Craft Level Advanced National Technical Certificate

The number of hours stated in the curriculum table may be increased or decreased to suit individual

institutions' timetable provided the entire course content is properly covered and the goals and objectives of

each module are achieved at the end of the term.

The maximum duration of any module in the new scheme is 300 hours. This means that for a term of 15

weeks, the course should be offered for 20 hours a week. This can be scheduled in sessions of 4 hours in a

day leaving the remaining hours for general education. However, (properly organized and if there are

adequate resources), most of these courses can be offered in two sessions a day, one in the morning and

the other one in the afternoon. In so doing, some of these programmes may be completed in lesser number

of years than at present.

The sessions of 4 hours include the trade theory and practice. It is left to the teacher to decide when the

class should e held in the workshop or in a lecture room.

The traditional approach of teaching trade science and trade calculation as separate and distinct subjects in

technical college programmes is not relevant to the new programme as it will amount to a duplication of the

teaching of mathematics and physical science subjects in the course. The basic concepts and principles in

mathematics and physical science are the same as in the trade calculation and trade science. In the new

scheme therefore, qualified persons in these fields will teach mathematics and physical science and the

instructors will apply the principles and concepts in solving trade science and calculation problems in the

trade theory classes. To this end, efforts have been made to ensure that mathematics and science modules

required to be able to solve technical problems were taken as pre-requisite to the trade module.


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For the programme to achieve its objectives, any course started at the beginning of a term must terminate at

the end of the term.

Instructors should therefore device methods of accurately assessing the trainees to enable them give the

student's final grades at the end of the term. A national examination will be taken by all students who have

successfully completed their modules. The final award will be based on the aggregate of the scores attained

in the course work and the national examination.


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T P T P T P T P T P T P T P T P T P 216

1 CMA 12-

15

Mathematics 2 - 2 - 2 - 2 - 2 - 2 - 2 - 2 - 2 - 288

2 CEN 11-

17

English 2 - 2 - 2 - 3 - 3 - 3 - 3 - 3 - 3 - 288

3 CPH 10-

12

Physics 2 - 2 - 2 - 2 1 2 1 2 1 2 1 2 1 2 1 288

4 CCH 11-

12

Chemistry 2 - 2 - 2 - 2 1 2 1 2 1 2 1 2 1 2 1 288

5 CEC 11-

13

Economics 2 - 2 - 2 - 2 - 2 - 2 - 2 - - - - - 216

6 CBM 11 Entrepreneurship - - - - - - 2 - 2 - 2 - - - - - - - 72

7 CTD 11-

13

Drawing - 3 - 3 - 3 - 3 - 3 - 3 - 2 - 2 - 2 288

8 ICT 11-

15

Computer Studies - - - - - - 1 2 1 2 1 2 1 2 1 2 - - 180

9 CME 11 General Metal Work I 2 5 2 5 - - - - - - - - - - - - - - 168

10 CME 12 General Metal Work

II

- - - - 2 3 - - - - - - - - - - - - 60

11 CFW 11 Sheet Metal Work - - - - - - - - - - - - 3 6 3 6 - - 216

12 CFW 12 Gas Welding and

Cutting

- - - - - - - - - - - - 3 6 3 6 - - 216

13 CFW 13 Metal Arc Welding - - - - - - - - - - - - - - 3 6 3 6 216

14 CFW 14 Structural Steel Work - - - - - - - - - - - - - - 3 6 3 6 216

15 CFW 11 Sheet metal Work - - - - - - - - - - 2 6 2 5 - - - - 180


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1. CMA 21-22 Mathematics 2 - 2 - 2 - 72

2 CEN 21-22 English and Communication 2 - 2 - 2 - 72

3 CTD 21 Engineering Drawing and Design - 3 - 3 - - 72

4 CTD 22 Fabrication Drawing - - - 3 - 3 72

5 CEC 21-23 Economics 2 - 2 - 2 - 72

6 CBM 21 Entrepreneurship 2 - 2 - 2 - 72

7 ICT 21-22 Computer Studies 1 2 2 2 - - 72

8 CFW 21 Welding 2 5 2 6 - - 180

9 CFW 22 Structural Mechanics & Specification - - 2 5 2 6 180

10 CFW 23 Structural Steel work 2 5 2 6 - - 180

11 CFW 24 Sheet metal work - - 2 5 2 6 180

TOTAL 13 15 17 30 12 15 1044


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General Objective: On completion of this module the student will be able to:

Understand workshop safety rules and their application in machine shop.

1. Know the physical properties, manufacturing process and application of ferrous and non-

ferrous metals in common use

2. Select and use common measuring, marking out, cutting and striking tools.3. Understand the basic working principles of drilling machine and be able to use it for

various types of screws treads rivets, and be able to rivet and cut screws by hand.

4. Understand the application of various types of screw threads and rivets, and be able to

rivet and cut screws by hand.

5. Understand the ISO system of tolerances and fits, and their application in engineering

production.

6. Produce simple engineering components on the bench.

7. Understand the essential features and working principles of the center lathe and carry out

basic operations such as turning, stepped turning facing, taper turning., knurling, chamfering

and undercutting.

Practical Competence: On completion of this module, the student will be able to:

1. Use all tools correctly ensuring the machinery guards and protective eye shields are used

at all times.

2. Comply with the general rules for safe practice in the work environment at all this.

3. Use and select handtools for carrying out various bench fitting and assembly tasks

4. Tools: hacksaws, taps, reamers, drills, dividers, surface gauge

5. Produce threads using taps and dies6. Correctly grind drill point angles: Drills: Twist and flat drills

7. Select and set drilling machine speeds to carryout a range of operations using the

appropriate coolants. Drilling, reaming, counter sinking, counterboring

8. Perform metal joining by a range of processes. Cut through the joints and investigate the

depth of penetration of the metals at the interface. Processes: Soldering, brazing, and fusion

welding.

9. Mark out on metals and other materials, datum lines, angles, radii/circles and hole

positions using a range of tools.


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1-3

1.1 Using and handling hand tools,

portable power tools and machine

1.2 Lifting, moving and storing materials or

job

1.3 Demonstrate first aid application in

cases of minor cuts, electric shock, burns.

Demonstrate safe ways of

handling basic hand tools

Show a film on industrial

safety

Demonstrate how to treat

energy cases like artificial

respiration cold compress,

etc

Assess student

Hand tools files, hacksaw

Television, Video

machines

Posters on artificial

respiration


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4-6

2.1 Describe the essential features

and use of the followinga. micrometer

b. vernier caliper

c. Venier height

gauge

d. combination set

2.2 Maintain and care for the

instruments listed above

2.3 Perform marking out exercise

on plane surfaces including profiles

2.4 File a piece of metal to given

specifications using any of the

following: Cross filing, draw filing,

filing square and flat surfaces

2.5 Test surface for flatness using

surface plate and try square and

state precautions to be taken to

avoid pinning

2.6 Maintain files in good working

conditions

2.7 Apply various hammers and

mallets e.g ball pein, rubber

mallets, etc for engineering

purposes

2.8 Select and insert hacksaw

blade correctly

2.9 Cut metal and other

engineering materials to given

specification using the adjustable

hacksaws, junior hacksaws,

piercing saw, etc drills and Drilling.

Demonstrate how to use

micrometer, venier caliper,vernier height gauge,

combination set

Demonstrate the maintenance

and care of the instruments

listed above

Perform marking out for the

students to learn and practice till

they become competent

Demonstrate how flat surface

can be tested using surface plate

and try square

Demonstrate how files are

cleaned and state the

precautions to be taken against

pinning. Students to practice till

competent

Demonstrate the application of

hammers and mallets for

engineering purposes

Demonstrate how a hacksaw

blade can be inserted correctly

Demonstrate how to use

adjustable hacksaw, junior

hacksaw piercing

Students should be allowed to

practice till competent

Guide students to produce

simple engineering components

like open ended spanner,

engineers square, tool makers

clamp, center square, etc.

Make a simple precision fitting

project like hexagonal mild steel

bar making push fit through a

mild steel plate

Micrometer, vernier

calipers, vernier heightgauge, combination sets

Steel rules, dividers,

punches, trammel, scribe

angle plate, vee block

center square

Flat file, hand file, try

square

File card, flat file

Ball pein hammers, mallet

Hacksaw blade, Hacksaw

frame.


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3.1 Setting up and operate a drilling machine

in given situationsNote Setting up drilling machine should

include

a. change of spindle speed

b. adjustment of drilling table

to required height and angle,

holding of work on drilling

table to required height and

angle, holding of work on

drilling table using

appropriate clamping device

c. Install the drill bit in chuck

3.2 Sharpen a twist drill correctly to

manufactures' specification

3.3 Perform with facility the following

operations:

a. drilling blind holes

b. drilling round stock

c. counterboring and

counter-sinking

d. drilling large diameter

holes

3.4 List the operation sequence and cut

internal (through and blind) and external

threads by hand method and state

precautions to be taken when taping on the

bench

3.5 Rivet metals together in any given

situations

3.6 Mark out only given bench work using

datum points, datum lines, datum faces,

chalk or marking solution center or dot

punch, scribing block or measurement

transfer.

Demonstrate how to set

up and operate a drillingmachine in given situation

Students to practice till

competent

Demonstrate how a twist

drill can be sharpened

correctly

Demonstrate with the

appropriate facility how to

perform all the drilling

operations



Give notes as well as

demonstrate the operation

sequence in cutting

internal (through and

blind) and external

threads by hand method

Demonstrate how

riveting can be done and

let the students practice

same till they become

competent

Demonstrate the

marking out procedures

on bench working using

datum lines datum faces,

etc



Assess the student.

Bench drill pillar drill, drill

bits Bench drill, pillar drill, twist

drill, flat drill, counter sink

drill, counterbore drill, center

drill

Drills, taps, tap wrench, die

and die stock

Rivets and sets of drill bits

Surface table, surface

plate, marking solution,

center/dot punches, scribing

block


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10-12

4.1 Sharpen cutting tool for plain turning,

shouldering, parting off and facingoperations

4.2 Set up rough and turned stock in 3-

jaw-chuck

4.3 Select appropriate cutting tool and set

them up to center height for turning or

facing operations

4.4 Carryout chuck work involving facing,

step turning, undercutting radiusing,

chamfering, parting off and knuring

Note Components should be produced to

specified tolerance and finish

4.5 Produce simple components involving

taper turning using the compound slide

Guide the students to

sharpen cutting tool for plainturning shouldering, parting

off and facing operations

and allow students to


Demonstrate how to set-up

rough and turned stock in a

3-jaw-chuck and operate

lathe. Allow students to


Guide the students to

select appropriate cutting

tools and set them up to

center height for lathe work

(turning or facing)

Students should be

allowed to practice till they

become competent

Prepare simple exercises

that will guide students to

produce components

involving taper turning using

the compound slide. Assess

the students

Point tools, grinding

machine, lathe machine 3-jaw chuck and lathe

machine

Point tools and lathe

machine

Lathe machine and

accessories

Centre lathe and

accessories like catch plate,

face plate, dog lathe, lathe

centers fixed steady and

traveling steading

Round nose turning tool,

fine finishing tool, form tool,

parting off tool, boring tool,

bar of good length and 4mm

diameter, Live/dead centers

catch plates

Standard exercises or

prepared


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1

On completion of this module, the trainee

should be able to:

Workshop safety rules and

practice

1.1 State sources of hazards in the workshop

and how to prevent them.e.g.

a. handling and using hand

tools, portable power tools and

machines;

b. stepping on or striking

obstructions left on floors or

benches;

c. lifting, moving and storing

materials or jobs;

d. using inflammable or

corrosive liquids and gases;

e. inhaling vapours or fumes;

1.2 Explain the application of factory safety

regulations in the machine shop.

1.3 Name safety equipment and wears

essential in the machine shop, and state their

application in working situations.

Note:

Example of safety wears and

equipment should include

overall, eye goggles, gloves,

safety boots, helmet, fire

extinguishers, etc

State sources of hazards

in the workshop.

Through questions and

answer, determine whether

the students grasped the

topic Show a film on industrial

safety.

Through question and

answer determine

comprehension.

Demonstrate how to treat

emergency cases

like artifical respiration,

cold compress etc.

List the safety equipment

and wears that are

essential in the workshop.

Give detail notes and

explanation in each topic a-

e.

Use questions and

answer to determine

comprehension.

Assess the students

Safety posters, common

hard tools like files

hacksaw

Television, Video

machine.

Overall, goggles, gloves,saftyboots, head shield,

fire extinguishers.


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1.4 Outline safety rules and

regulations relating to:-

a. clothing and health

hazards;

b. workshop hygiene;c. movement and

other behaviour of

workers in the

workshops;

d. materials handling;

e. tool handling,

storage and usage;

f. machine operation;

g. fire protection.

1.5 Understand appropriate

procedures in the events of a

workshop accident

1.6 Examples of procedures may

include:

a. application of first

aid to the victim;

b. removal or

rectification of the

accident;

c. reporting the

accident to the

appropriate authority;

d. keeping a record of

accidents for

management use.

Explain safety rules and regulation in the

workshop, highlighting a - g in 1.4.

Explain appropriate procedures to be

taken in the event of workshop accident.


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2

2.1 Explain the meaning of the following

general physical properties of metals:

ductility, malleability, strength,

roughness, brittleness, elasticity,plasticity.

Give detail notes and explanations to

explain the meaning of the following

general physical properties of metals:

ductility, malleability, strength,toughness, brittleness, elasticity,

plasticity. Assess the students

Give detailed notes and explanations

for the topics in 2.1

2.3 Describe the basic composition and

properties of plain carbon steels, cast

iron and alloy steel and state their

application in the engineering industry.

Note: Specific examples of tools and

equipment made from the various steel

and cast iron should be mentioned.

Examples of steels and cast irons should

include: plain carbon steels, dead mild

steels, mild steel, medium carbon steel,

high carbon steel.

Cast Irons - gray cast

iron malleable cast iron,iron carbide, alloy cast

irons (spheroidal and

acicular)

Alloy Steels - High

speed steels, high

tensile steels, tungsten,

stainless steels, stellite

2.4 Outline:

a. the copula process of

manufacture of cast iron;

Give notes and specific examples of

tools and equipment made from the

various steels and cast iron.

Examples of steels and cast irons

should include plain carbon steels,

dead mild steels, mild steel, medium

carbon steel high carbon steel, gray

cast iron, malleable cast iron, iron

carbide, alloy cast iron high speed

steels, high tensile steels, tungsten,

stainless steels.

Give notes and explanation on the

cupola process, the blast furnace andthe direct reduction process of

manufacture of steel.

This can be preceded by film show

and a visit to be manufacturing plant.

Give detail notes and explanations

describing the physical properties and

applications of the following non-ferrous

metals: copper, tin, zinc, aluminium,

aluminium alloys, brass, (muntzmetal,

cartridge brass, gilding metal) etc.

Video and

television including

cassettes on

production

processes.


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b. the blast furnace

process of manufacture

of pig iron;

c. the direct reduction

process of manufacture

of steel.

Note:

A visit to a steel

manufacturing plant is

recommended.

2.5 Describe the physical properties and

applications of non-ferrous metals below:

copper, tin, zinc,aluminium and

aluminium alloys brass

(muntz metal, cartridge

brass, gilding etc)

metal,bronze

(manganese bronze

tunmetal, bell metal,

aluminium bronze,

phosphor bronze and

lead.

Benchwork and Tools:

bronze, manganese bronze bell metal,

aluminium bronze phosphor bronze and

lead. Assess the students


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3

3.1 Explain with examples the

difference between "line" and

"end" measurement.

3.2 Explain the use of datum

points, datum lines and datumfaces in marking out.

3.3 Describe, the functions and

application of the following

instruments used in metal-work,

steel rule, dividers, calipers

(inside, outside and odd-legs),

trammel, scriber angle plate,

vee-block, centre square.

3.4 Describe the various types

of files, stating their grades and

applications.

Note:

Types of files

should include:

flat, square,

round, half

round, three

square, warding

pollar, mill and

rasp.

3.5 Classify the common files

use in metal work and state their

composition of material used for

their manufacture.

3.6 Sketch the bench vise,

explain its clamping power and

demonstrate the technique of

Prepare notes that will clearly differentiate

between "line" and "end" measurement.

Prepare notes and examples that will explain

the use of datum points, datum lines, and

datum faces in marking out. Give explanations regarding the functions

and application of: steel rule, dividers, calipers

(inside, outside and oddleg) trammel, scriber,

angle plate, vee block, centre square

Prepare notes that will describe the various

types of files, stating their grades and

applications. By type it means: flat, square

round, halfround, three square, warding, mill

and rasp.

Prepare detail notes that will classify the

common files used in the metal work as well as

stafing the composition of materials used for

their manufacture.

Show a bench vice and demonstrate the work

ithe vice for

Show a bench vice and demonstrate the

technique of holding work in the vice for filing,

tapping and designing operations.

Prepare detail notes that will describe the

functions of the various parts of a bench vice,

its holding power while performing various

operations.

filing, tapping and designing operations

Prepare detail notes that will describe the

functions of the various parts of a bench vice,

its holding power while performing various

operations

Steel rule, dividers

calipers, trammel,

scribe angle plate

vee block, centre

square. Micrometer

vernier callipers

vernier height

gauge combination

set

Flat file, hard file,

round file square,

half round,

triangular warding,

mill file, rasp file.

Flat file, handfile

engineers square.

Surface plate try

square (engineers

square)

File card

Flat file

Bench vice.

Bench vice.

Ball pein hammers

mallets.


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holding work in the vise for

filing, tapping and designing

operations.

3.7 Describe the functions of the

various parts of a bench vice, its

holding power while performing

various operations on its, such

as filing, tapping sawing etc.

3.8 Describe and use the

following tools:

a. cold chisels

(flat, cross, cut

half round,

diamond-point)b. centre punch

and dot punch

c. scrappers

(flat, triangular,

half round)

d. power hack

saw

Assess the students

Prepare detail notes and demonstrations that

will describe and uses of: cold chisels, centre

punch dot punch, scrapers and power

hacksaw.


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4

3.9 Describe the various parts of a hack saw

and their function.

3.10 Describe the common types of hacksaw

blades, their range of pitches and their

applications.3.11 State the safety precautions to be

observed when using a hand hacksaw

Prepare notes that will describe

the various parts of a hacksaw

and their functions.

Show sample of hacksaw blades

as well as prepare notes that willdescribe the common types of

hacksaw blades, their range of

pitches and their applications.

Prepare notes that will show

correct way of inserting blades.

Prepare detail notes and

explanation, stating the safety

precautions to be observed when

using a hand hacksaw.

Prepare notes that will describe

the uses of various hacksaws.

Assess the students

Cold chisels,

centre punches, dot

punch, scrapers

power hacksaw

blades. Hacksaw blade

Hacksaw frame

Adjustable

hacksaw junior

hacksaw piercing

saw.

5-6

4.1 Identify the various types of drilling

machines.

4.2 Describe, with sketches, the main

features of a bench or pillar drilling machine.

4.4 Describe with sketches and state where

each of the following types of drills are best

suited.

e.g. twist drill (taper shank, parallel shank

and jobbers drill, and their relative merits),

flat drill, countersink drill, counter bore drill,

combination centre drill.

4.5 Explain the effects of the following faults

Show different types of drilling

machines

Make notes and drawings that will

identify the various types of drilling

m/cs.

Prepare detail notes and drawings

that will describe the main

features of a bench or pillar drilling

machine.

Solve many problems for students

to practice.

Prepare notes and drawings that

Bench drill

Pillar drill.

Twist drill, flat drill

counter sink drill,

counter bore drill

combination centre

drill.

Drilling machines

and its accessories.


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in a ground twist drill bit:

a. point angle too acute;

b. point angle too obtuse;

c. cutting edges at unequal

angles;

d. insufficient lip clearance;

e. excessive lip clearance.

4.6 Calculate spindle revolution or cutting

speed for specified size of drill using the

formulae:-

N = 1000S/

S = dN/1000

Where S = cutting speed

(m/min)N = revolution/minute

D = diameter of drill (mm)

= 3.142

4.8 State the cause and remedy of drilling

faults such as:-

a. drill breaking;

b. drill coloured blue;

c. walls of drilled hole left

rough;

d. chipped cutting lips.

4.9 State the safety precautions to be

observed when using a drilling machine.

4.10 Explain the purpose of reaming and

describe different types of hand and machine

reamers.

4.11 Ream to given specification by hand

and machine method.

will describe where each of the

following drills are best suited

Twist drill (taper shank, parallel

shank, jobber drill and their

relative merits), flat drill,

counterbore drill and combination

center drill.

Assess the students.


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5.4 State precautions to be taken when

taping on the bench.

5.5 Describe and differentiate types of

rivets.e.g. Snap and pan head, mushroom

and counter-sunk head, flat head, dod

rivet, etc.

5.6 Sketch the rivet set and state its

use.

5.7 Calculate the diameter of rivet and

riveting allowance in given situations.

Prepare notes that will state precautions

to be taken when tapping on bench.

Give notes and diagrams that will describe

and differentiate types of rivets, rivet sets,and its uses and guide to calculate the

diameter of rivet and riveting allowance.


Rivet sets,

drills.

8

6.1 Differentiate between the following:-

a. nominal size

b. limits (upper and

lower)

c. tolerance (unilateral

and bilateral)

d. fit (clearance,

transition interference).

6.2 Explain the importance of tolerance

and fit in engineering production and

describe briefly the ISO system of limits

and fits.

6.3 Determine by calculation the

amount of tolerance and types of fit in

given situations.

Give detailed notes that will differentiate

between nominal size, limits, tolerance and

fits.

Prepare detailed note and diagrams that

will explain the important of tolerance and

fits in engineering production as well as

describing the ISO systems of limits and

fits.

Give notes and explanations that will

guide in calculating the amount of tolerance

and types of fits in given situations.


Charts on

tolerances, limits

and fits.


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24

9

7.1 Explain layout procedures

from working drawing of simple

engineering components or

tools such as:-

a. open endedspanner

b. engineer's try

square

c. tool maker's

clamp

d. plate bracket

or gusset

(involving

rounds, angles,

holes)

e. centre

square.

7.2 Explain how to produce any

simple engineering component

to given specifications including

dimensions, tolerance and finish

7.3 Explain how to carry out

simple precision fitting project.

e.g. hexagonal mild steel bar

making push fit through a mild

steel plate.

Teachers to prepare notes and explanations

to guide the students in producing simple

engineering components as in 7.1


Lesson notes

Diagrams and

charts.


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10

8.1 Describe the essential features of a

centre lathe and state their functions

e.g lathe bed, headstock, tailstock, saddle or

carriage, etc.8.2 Explain the working principles of the

centre lathe.

8.3 Identify and state the functions of centre

lathe accessories such as: catch or driving

plate, face plate, lathe dog or carrier, lathe

centres, fixed and travelling steadies.

8.4 Explain the difference between the

centre lathe, capstan lathe, in terms, of their

main features and functions.

8.5 Name types of cutting fluids used for

lathe turning operations and state their

composition and purposes.

8.6 Outline safety precautions to be

observed when working on the lathe

8.7 Sketch and describe common tools:

e.g butt-brazed tool, tipped tool, bit and

holder.

Note:

Tool description should

include tool materials e.g

plain carbon steel, high

speed steel, stellite,

cemented carbide, diamond.

8.8 Explain with sketches the functions of

tool angles rake, clearance, and state their

values for different metals to be machined.

With the aid of a diagram explain the

essential features of a lathe machine

Explain the working principles and basic

operations of a lathe machine Demonstrate some basic operations on

lathe machine.

Prepare detailed notes that will describe

the essential features of center lathe and

their functions.

Give notes and diagrams that will explain

the working principles of center lathe and

functions of its accessories.

Give explanations that will show the

difference between center lathe and

capstan lathe in terms of their main features

and functions.

Prepare notes that will list types of cutting

fluid use for lathe turning operations and

their composition and purposes.

Prepare detailed notes and explanation

that will outlines safety precautions,

common tools and materials used in

marking them.

Give detailed notes and diagrams that will

explain the functions of too angles (rake,

clearance) stating their values for different

metals to be machined.

Assess the students

Centre lathe

and accessories

like catch plates,

face plates,centers, fixed

and traveling

steadies.

Charts of

center lathe and

capstan lathe.

Round nose

turning tool,

finishing tool,

site finishing,

knife tool, form

tool, parting off

tool, and boring

tool.


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11-12

8.9 Differentiate between various tool shapes

and state their uses e.g. Round nose rougher,

fine finishing, side finishing, knife tool, formtool, parting off tool, boring tool, etc.

8.10 Explain with sketches the effects of

wrong setting of cutting tool: e.g. vibration and

chatter, tool rubbing against or digging into the

job.

8.11 Define cutting speed and feed with

respect to lathe operation.

8.12 Calculate the cutting speed and feed for

given turning operation.

8.13 Estimate the rate of metal removal and

time required for carrying out specified turning

operations

8.14 State precautions to be observed when

turning between centres.

8.15 Set up the lathe for and carry out basic

turning operations between centres.

8.16 Compute required taper dimensions from

given data using taper ratic angle formulae i.e.

8.17 Taper Ratio = [d2 - d1]/L

OR

where = taper angle

d1 - small and diameter

d2 = large end diameter

L = length of taper

Give notes and diagrams of

various tool shapes and their

uses. Prepare detailed notes and

explanations to cover 8.10 to

8.15

Solve many problems for the

students practice.

Assess the students

Charts on tool

height

Charts anddiagrams of

different machining

operations.


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GENERAL METAL WORK

CME 12 GENERAL METAL WORK II

CME 11

2 HRS THEORY 3 HRS PRACTICAL

The module is designed to introduce the trainee to basic processes in mechanical

engineering such as forging, sheet-metal work and welding.

On completion of this module, the trainee should be able to:

1. Understand the basic principles and processes of heat treatment of metal in the

workshop.

2. Produce simple engineering components by forging.

3. Understand the basic principles and techniques of gas and metal arc welding and apply

them in fabricating simple metal components.

On completion of this module students will be able to:

1. Carry out heat treatment of metal in the workshop

2. Produce simple engineering components by forging

3. Carryout gas/arc welding and apply them in fabricating simple engineering components


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Week

1-2

1.1 Carry out the following heat

treatment processes Hardening,

tempering, annealing normalizing,

case hardening on given plain carbon

steel, engineering component or tool

1.2 Anneal copper, brass and

aluminium for various purposes

Demonstrate heat treatment

processes and explain the

stages

Demonstrate the annealing

process on brass, copper and

aluminium for various

purposes.


Furnace, Forge tongs


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3-4

5-8

2.1 Select appropriate forging tools

and produce to specification givenengineering components by forging

processes

a. upsetting - drawing

down

b. setting down -

twisting

c. forge welding

(scarf and spice

welds)

d. bending, turning

closed ring

e. forming an eye

Demonstrate with appropriate

forging tools how to producesome engineering components

and let the student practice till


Assess the students

Anvil, swage block, leg vice,

forging hammers, hot set coldset, sets of hammer, punchers,

drifts, fillers, top swage,

bottom swage, flatter, open

tongs, hallow bit

9-12

3.1 Set up and operate gas or metal

arc welding equipment in given

situations.

Note: Equipment operation should

include choice of correct nozzles or

electrode. Adjustment for correct gas

pressure/flame or voltage

3.2 Prepare joints for welding in given

situations

3.3 Weld given components by arc or

gas welding methods, and state

safety precautions to be observed

List and identify gas and

metal arc welding equipment

Demonstrate the use of both

gas and metal welding

equipment; and all the

students to practice

Demonstrate to the students

how to prepare joints for

welding purposes

Guide students to weld

various components using

both gas and arc welding

process and state safety

precautions to students to


Oxygen, cylinders and

acetylene, regulations arc,

welding set goggles, shield,

electrodes, diagrams and

charts various welding joints

Practical - 60% of overall assessment


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1-4

1.1 Explain briefly the structural behaviour of

plain carbon steel as it is heated from room

temperature to about 1000oC.

a. hardeningb. tempering

c. annealing

d. normalising

e. case-hardening.

1.2 Explain the meaning of hardening metal

work.

1.3 Outline safety precautions relating to heat

treatment processes apply them in given

situations.

Prepare detail notes that will

explain the structural

behaviour of plain carbon

steel as it is heated from roomtemperature to about 1000oC.


explain the meaning of

hardening in metalwork.

Prepare notes that will

outline safety precautions

relating to heat treatment

processes.

Assess the students

Recommended Text

books

Lesson notes, etc


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5-6

7-8

2.1 Explain with outline sketch the main

features and working principles of the black

smith's forge.

2.2 Describe and state the functions of

common forging tools. e.g anvil, swage block,

leg vice, forging hammers, hot and cold sets,

set hammer, punches and drifts, hardie,

fullers, top and bottom swages flatter, tongs

(open mouth, closed mouth, hollow bit, etc.).

2.3 Describe with sketches the following

forging operations:

a. upsetting

b. drawing down

c. setting down

d. twisting

e. forge welding (scarf and

splice welds)

f. bending

g. forming closed ring

h. forming an eye.


diagrams that will explain the

main features and working

principles of the black smith's

forge.

Prepare notes and diagrams

that will describe the functions

of common forging tools.


describe the following forging

operations: upsetting, drawing

down, setting down, twisting,

forge welding, bending,

forming closed ring, forming

an eye.


Forge and forging tools.


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9 - 12

3.1 Describe the equipment and explain the

basic principles and application of gas and

metal arc welding.

3.2 State the safety precautions to beobserved and apply them in given welding

situations.


diagrams that will describe the

equipment and explain the

basic principles andapplication of gas and metal

arc welding.

Prepare diagrams of joints

that the students will practice.


state the safety precautions to

be observed during welding.


Charts

Oxygen cylinder

acetylene cylinder

regulations arc weldingset goggles, shield

electrode.

Diagrams and charts

of various welding

joints, and techniques.


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This module is designed to produce a skilled sheet metal work who has good knowledge

of the use and application of sheet metal working equipment, material, processes,

techniques and safety practices.

On completion of this module, the trainee should be able to:

1. Apply appropriate workshop processes, techniques and tools to mark out and form

projects in sheet metal work

2. Solder and braze various sheet metal projects with maximum safety.

3. Produce finished sheet metal project involving: edge stiffening, beading, finished, either

as part of the corporate production process or as an independent process.

4. Draw, develop and produce templates for production of sheet metal projects.

On completion of this module the student will be able to

1. Mark out and form projects in sheet metal work

2. Solder and braze various sheet metal project with maximum safety

3. Produce finished sheet metal projects involving various production processes

4. Draw, develop and produce templates for production of sheet metal projects.


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34

Year 3

Term 1

1.1 Mark out the following projects

on sheet metal material applying

appropriate tools, techniques and

safety practices:a. rectangular

container

b. funnels

c. cylindrical

container

Demonstrate the marking out of

projects on sheet metal by applying

the appropriate techniques and

safety practices. Demonstrate marking out items

listed on sheet of metal

Lesson plan

Appropriate Tools and

Equipment

Steel rule, divider,scriber, compass and

chalkboard

1.2 Cut sheet metal to given sizes

using appropriate tools/machines

Demonstrate sheet metal cutting

to given sizes using appropriate

tools and machine

Lesson Plan


Machines

1-2 1.3 Form sheet metal to given

shapes using appropriate tools,

machines and techniques

Demonstrate the formation of

sheet metal

Demonstrate methods of forming

these shapes.

Lesson plan

Appropriate Tools,

Machines and Equipment

3

1.4 Calculate allowance for joint

using the formula: grooved seam =

11/2x width of groover.

Calculate allowance for joint using

the formula: grooved seam = 11/2x

width of groover, panned down and

knock-up joints.

Lesson plan Chalkboard

31.5 Sketch the joint allowances on

the materials and notch the joints

Sketch joint allowances on the

materials and notch

Lesson plan Appropriate

Tools and equipment


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4-5

1.6 Make the following joints in

sheet metal:

a. solid corner joint

b. grooved seam

joint

c. panned down

joint

d. knocked up joint

Demonstrate the process of

making the following joints:

solid corner

groove seam

panned down

knock-up

Lesson plan


Equipment

6

1.7 Name common rivets used in

metal work and state their

properties

List and explain types of rivets

used in sheet metal and their

properties


Samples of rivets.


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36

6

1.8 State common faults in riveting

e.g.

a. overlapping

b. cracked rivetc. uneven ends,

etc.

Explain common faults in riveting

Show the listed defect to student

Lesson plan

Charts/Posters

7

1.9 Drill and punch holes on joints

for riveting making sure that burrs,

are removed

Demonstrate drilling and punching

of holes on sheet metal including

removal of burrs.


Tools, Machine and

Equipment

7

1.10 Rivet joints satisfactorily using

correct sets

Demonstrate riveting by using

appropriate rivet sets

Lesson plan

Charts/Posters Various

Types of rivet Sets.

8

2.1 Identify the types of solders

used in sheet metal work and state

their compositions: e.g.

- tinman's solder,

grade

- self-flux solder

- resin-core solder,

etc

List and identify types of solders

show various types of solders

used in sheet metal work and state

their composition

Lesson plan Charts

Various Types of solders


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6

3.1 State the meaning of the

following terms:

a. edge-stiffening

b. beadingc. work hardening

d. beating

e. annealing

f. hollowing

g. raising

h. blocking

i. planishing

j. sand blasting

k. picking

l. lacquering

m. galvanizing

n. plating

o. painting

p. other items used

Explain the meaning of the terms

listed in 3.1 (a - p)

Give details note on the above.

Show samples to students

Lesson plan Posters

Chalkboard

Finished sheet metal

projects involving termslisted in 3,1 (a - p)

11 - 12

3.2 Calculate allowances for edge-

stiffening which include:

a. helmingb. wiring, using the

formula for wiring

allowance: 2D + 4T

(where D is the

diameter of wire

and T is the

thickness of metal)

Solve problems involving

calculations of allowances for edge-

stiffening using the formula forwiring allowance: 2D+4T (where D

is the diameter of wire and T is

thickness of metal

Lesson plan Charts

Chalkboard


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Year 3

Term 2

1 - 2

3.3 Mark out for edge-stiffening

using the calculated allowance

3.4 Produce projects involving

edge-stiffening such as:a. beading

b. swaging

3.5 Know the mechanical properties

of the following materials used in

beating metal work:

a. brass

b. copper

c. aluminium

d. low carbon steel

3.6 Develop discs for making bowls

using workshop method

Ask students to demonstrate the

marking out for edge-stiffening

Ask students to demonstrate

projects involving edge-stiffeningafter sample demonstration.

Explain the mechanical properties

of materials used in beating sheet

metal work


development of discs for making

bowls using workshop method


Tools and Equipment


Tools and Equipment Lesson plan Chalkboard


Tools and Materials

3 - 4

3.7 Describe the processes of

raising, sinking, hollowing,

planishing and polishing sheet

metal work in copper or brass.

3.8 Estimate size of blank for

raising and polishing sheet metalwork in copper or brass.

3.9 Layout and cut out blanks for

raising, sinking or hollowing

process.

Ask students to explain the

process of raising, sinking,

hollowing planishing and polishing

sheet metal work in copper or

brass.

Ask students to draw the size ofblank for raising and polishing sheet

metal work in copper or brass


laying out and cutting out blanks for

raising, sinking or hollowing

Lesson plan, Chalkboard

Posters.


Compasses Dividers, etc.


Dividers Scribers, etc


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3 - 7

3.10 Select appropriate tools and equipment and apply

correct procedures to produce to specification by

raising, sinking or hollowing, given metal forming job.

Note: Sheet metal forming procedures should involve:a. blank size estimation

b. blank preparation

c. heat treatment (annealing)

d. application of appropriate forming

process

e. cleaning

f. polishing; and

g. edge trueing

3.11 Produce bowls by the following process:

a. raising, using oval head wooden

mallet and repeated beating and

annealing;

b. hollowing, using a hollowed pipe or

cylinder, hollowing hammer and a

bossing mallet

c. blocking, using wooden block,

bossing mallet and blocking hammer.

Note: Safety precautions should be emphasized in the

processes

3.12 Remove dents from metal surfaces using the

following tools:

a. wheeling machine

b. dent eraser

c. planishing hammer and dollies

Note: Metal surfaces to be worked on include: bowls,

car fenders, metal boxes and other containers.

Demonstrate and

explain process of

producing bowls by

raising, hollowing andblocking using necessary

tools.

list the safety precaution.

Give student

project/assignment to

produce bowl.

Explain and demonstrate

removal of dents from

metal surface.

Give student assignment

on dent removal

Ask students to

demonstrate removal of

dents using appropriate

tools and equipment

Lesson plan

Chalkboard

Lesson plan,

ChalkboardAppropriate Tools

and Equipment

Such as wheeling

machine,

planishing harmer,

dollies dent eraser

etc.

Lesson plan,

Appropriate Tools

and Equipment.


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8 - 9

3.13 Prepare surfaces for finishing

by applying the following

processes:

a. sand blasting thesurface

b. pickling with acid

c. sanding

3.14 Finish sheet metal projects by

using the following techniques:

a. lacquering

b. galvanizing

c. plating

d. painting


preparation of surfaces for finishing

using appropriate tools and

equipment. Ask students to demonstrate

finishing of sheet metal project by:

i. laquiring

ii. galvanizing

iii. plating

iv. painting etc.

Lesson plan, Related

Tools and Equipment.

Lesson plan Related

Tools and Equipment


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10 - 12

4.1 State materials used for templates

a. Wood

b. Cardboard, etc

4.2 Produce and read blue-prints (which

include working drawings) of sheet metalprojects

4.3 Develop templates by using the

following methods for the indicated items:

a. Parallel line method - for

elbows and T-pieces,

square and rectangular

trays etc.

b. Radial line method - for

right cone, oblique cone,

etc

c. Triangulation method -

for transition piece and

ductings.

d. Cutting plane method -

for inclined plane, branch 'T'

pieces.

e. Development of

complicated irregular

shape.

4.4 Produce various sheet metal items, e.g.

ductings to central air-conditioning systems,

buckets for water, drawer cabinets

(furniture), etc.

4.5 Produce at least two project in sheet

metal work

Explain materials used for

making templates

Demonstrate the production

and reading of blue-prints of

sheet metal projects Develop templates using the

methords listed for indicated

items in 4.3 (a - e)

Ask students to produce

various sheet metal project

using templates methods


the production of various

sheet metal projects

Test and evaluate the

trainee in production

processes

Lesson plan

Chalkboard related

Materials

Lesson plan

chalkboard ChartsAppropriate Tools and

Equipment

Lesson plan

Chalkboard Instrument

Lesson plan Related

Tools, Equipment and

Materials

Lesson plan

Tool, Equipment and

materials


43/107

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: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice

CFW 12 Gas Welding and Cutting

CFW 11

18 hours/Week 6 theory, 12 Practical

: This module is designed to equip the trainee with the knowledge, attitude and skills to carry

out gas welding and cutting jobs on all types of metals

1. Understand and apply the general safety precautions related to gas welding

2. Know and apply successfully various gas welding processes/operations including the

acetylene and oxy-fuel gas cutting processes.

3. Know and weld together different types of non-ferrous and ferrous metals

4. Understand the process of building up worn metallic shafts or surfaces

5. Understand and apply the fuel gas cutting process in cutting metals to given specifications

6. Know the various welding defects and rectify them

On completion of this module, the student will be able to:

1. Apply general safety precaution

2. perform various gas welding operations

3. Weld together different types of ferrous and non-ferrous metals

4. Build up worn shaft or surfaces

5. Apply fuel gas cutting process in cutting metals to given specification

6. Identify and rectify various welding defects


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Year 3

Term 11

1.1 Carry, transport and store full and

empty gas cylinders safety using

appropriate equipment

Explain how to carry

transport and store full and

empty gas cylinders

Explain how to carry,transport and store full and

empty gas cylinder safety

using appropriate equipment

Lesson plan Charts

or Posters and

appropriate equipment

1.2 Apply appropriate safety precautions

while carrying out the following:

a. Gas welding operations

on containers which have

been emptied of chemicals,

inflammable or explosive

liquids.

b. Gas welding near

containers with inflammable

materials, e.g. petrol tank;

and

c. Gas welding in confined

spaces.

List and explain safety

precautions involved in gas

welding operations

List and explain the use of

protective wears for carrying

out gas welding operations


appropriate safety precaution

while carrying out items 1.2 (a-

c)

Lesson plan Charts

etc.

1.3 Select, use and care for protective

wears for carrying out gas welding

operations. E.g.

a. welding goggles

b. welding shields

c. gloves

d. boots etc.

Ask students to identify the

use and care for protective

wears for carrying out gas

welding operations e.g.

welding goggles, welding

shield, globes and boots etc.

Chalkboard, Lesson

plan and Protective

wears


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4

5

6

2.1 Identify the following gas welding

equipment, describing their features, functions,

applications and care:a. generators

b. regulators

c. blow pipes

d. nozzles

e. hoses

f. gas cylinders and their

colours

g. economizers

h. check valves

2.2 Differentiate between the following types of

generators, stating their merits and demerits

a. water-to-carbide generator

b. carbide-to-carbide

generator

2.3 Identify the main parts of the generator

e.g. hydraulic back pressure valve purifiers,

carbide trays etc.

2.4 Distinguish between high and low pressure

systems of welding

2.5 State the composition of calcium carbide

2.6 Generate acetylene using calcium carbide

guiding against danger of over-charge

2.7 Identify types of welding rods stating their

properties, compositions, and uses.

2.8 Differentiate between welding and cutting

torches

Show the students items

listed in 2.1

Identify and explain thefeatures and functions and

applications listed in 2.1

Explain the difference

between the two types of

generators stating advantages

and disadvantages

Explain the main part of

generator

e.g. hydraulic back pressure

valves, purifiers, carbide trays

etc.

State the difference between

low and high pressure

systems of gas welding

Explain the composition of

calcium carbide

Demonstrate how to

generate acetylene using

calcium carbide

Show and explain the types

of welding rods to students

stating their properties,

composition and uses.

With the aid of torches

explain the difference between

welding and cutting torches.

Chalkboard and

Lesson plan

Chalkboard,Lesson plan,

sketches/Charts

Chalkboard

Lesson plans

leveled drawings.

Lesson plan, low

and high pressure

gas welding sets.

Lesson plan,

Chalkboard and

calcium carbide

Lesson plan,

calcium carbide

motor and generator

Lesson plan

Chalkboard and

different types of

welding rods.

Lesson plan,

chalkboard Welding

and Cutting torches.


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7

8

9

10

2.9 Identify the following flames and

describe how they are derived in the

oxy-acetylene welding processes:

a. oxidizing flame

b. carbonizing flame

c. neutral flame

2.10 state the instances of the

application/uses of the type of flames

named in 2.9 above

2.11 Light the welding torch and

adjust the flame to each of the types

named in 2.9 above

2.12 Prepare plate surfaces and run

beads:

a. without filler rods

b. with filler rods

2.13 Make neat labeled sketches

indicating the conventional symbols

for the welder joints. E.g.:

a. butt joint

b. fillet joint

c. lap joint

2.14 Prepare plate surfaces for the

following welding joints and tack

weld:

a. butt joint

b. fillet jointc. lap joint

2.15 Weld metals together in down-

hand or flat position

2.16 State the functions of backing

bars and strips

2.17 Apply backing bars and strips

according to instructions on the side

of a weld to control penetration.

Explain the three types of flame in gas

welding:- oxidizing, carbonizing and

neutral

Describe uses of the types of flame

named in 2.9 above

Demonstrate the lighting and setting up

of the flames named in 2.9 above

Demonstrate plate surface preparation

for running beds, with and without filler

rods

Draw neat labeled sketches showing

the conventional symbols for welded

joints:

i. butt

ii. fillet

iii. lap. etc

demonstrate running of beads with and

without filler rods on plate surfaces

show students sketches of weld joints

listed in 2.13

give students detailed notes on the

above and work to practice

Demonstrate tack welding and joints

listed in 2.1

Explain the preparation of plate

surfaces for

i. buttii. fillet and

iii. lap joints

Set up and tack weld the prepared

pieces

Give detailed notes

Ask students to demonstrate how to

weld metal together in down-hand or flat

position

Explain the function of backing bars

and strips Demonstrate the use of backing bars

and strips for controlling penetration.

Lesson plan,

chalkboard,

Sketches/charts.

- do -

- do -

Lesson pla,

plates and related

equipment/tools

Lesson plan,

Sketches/charts

and Chalkboard

Lesson plan,

materials and

appropriate tools

and equipment

Sample of weld

jionts


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11

12

3.1 Identify the following types of non-ferrous and ferrous

metals

a. copper

b. aluminiumc. brass

d. bronze

e. tin

f. zinc

g. lead

h. iconel and monel

a. wrought iron

b. mild steel

c. stainless steeld. cast iron

And state their composition

3.2 Describe the general characteristics of materials used in

fabrication engineering including simple consideration of

physical properties such as:

a. strength

b. ductility

c. malleability

d. hardness

e. tenacity

f. fusion

g. distortion

h. toughness and resistance to impact in

relation to uses and common manufacturing

processes, and weldability of materials.

3.3 State the common fabrication engineering uses of cast

iron, mild steel, high yield steel, cast steel, austenite stainless

steel, copper and common copper alloys, aluminium and

common aluminium alloys, common forms or supply and the

general limitations of cast forms.

3.4 State the properties and composition of fluxes used for

welding non-ferrous metals

Show students

samples of metals

listed in 3.1

Explain the

different types ofnon-ferrous and

ferrous metals and

their composition,

as listed in 3.1

Explain the

characteristics

listed in 3.2

Ask students to

explain the general

characteristic ofmetal s used

fabrication with

particular reference

to mechanical and

physical properties

in items 3.2 (a - h)

List and explain

the properties and

composition of

fluxes used forwelding non

ferrous metals

Explain the

properties and

composition of

fluxes used for

ferrous and non-

ferrous metals

Lesson plan,

Chalkboard

Samples

Ferrous and

Non-ferrousMetals listed in

3.1

Lesson plan,

Chalkboard

and Charts

Fabricated

samples of

items listed in

3.3


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Year 3

Term 2

1 - 2

3

3.5 Enumerate two functions of

fluxes in the welding of non-ferrous

metals

3.6 Prepare and weld non-ferrous

metals using appropriate fluxes.3.7 Identify cast-iron in terms of:

a. types

b. its composition

c. its properties

3.8 Prepare cast-iron for welding by:

a. chamfering or

beveling of edges to

specification

b. pre-heating to

specification

3.9 Fusion weld cast iron

components

3.10 Identify suitable flux for bronze

welding and state its composition

3.11 Prepare bronze to specifications

3.12 Weld bronze to specifications

3.13 State reasons for post-heating

bronze welds

3.14 Identify and state the type,

composition and properties of

common stainless steels used in

metal work.

3.15 Prepare stainless steel

components for welding

Explain two function of fluxes used in

the welding of ferrous and non-ferrous

metals using appropriate fluxes

Demonstrate the welding of ferrous

and non-ferrous metals usingappropriate fluxes

Show students the different types of

cast iron

Explain their composition and

properties

Demonstrate preparation of cast iron

for welding

Demonstrate the fusion welding of

cast iron components

Explain the composition of suitable

flux for bronze welding

Demonstrate preparation of bronze

components for welding, avoiding

sharp edges

Demonstrate the welding of bronze

to specification

Ask the student to demonstrate

above

Explain the purpose for post-heating

bronze welds

Explain and state the types of

composition and properties of

common stainless steels

Demonstrate the preparation of

stainless steel components for

welding

Ask students to practice above

Lesson plan,

Charts, Appropriate

Tools and

Equipment

Lesson plan,Chalkboard and

Sample of Cast

Irons

Lesson plan,

Charts, Pieces of

Cast iron, Related

Tools and

Equipment

- do -

Lesson plan,

Chalkboard

Lesson plan,

chalkboard bronze

related tools and

equipment

Lesson plan,

charts, Pieces of

Bronze, Related

Tools and

Equipment.

Lesson plan

Chalkboard

- do -

Lesson plan,

Chalkboard

Stainless Steel,

Tools and

Equipment


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4 - 6

3.16 Weld stainless steel using appropriate

welding rods and techniques and observing

safety practice.

3.17 Apply appropriate treatment to thewelded joint e.g. washing in soapy water,

brushing off lux residue, etc. to avoid weld

decay

3.18 Explain the effect of welding together

two different metals

3.19 Identify dis-similar metals such as:

a. copper and brass

b. steel and cast-iron

c. aluminium and steel, etc

3.20 State the effect of dilusion in welding

3.21 Explain the principles of the following

welding processes:

a. cladding

b. stelliting

c. hard surfacing

d. brazing

3.22 Prepare and weld dis-similar metals

using correct techniques and observing the

correct safety practice.

Demonstrate the welding of

stainless steel using

appropriate welding rods and

observing safety practices Demonstrate the appropriate

treatment to the welded joint

to avoid weld decay

State the effects of welding

together two different metals

Explain dissimilar metal

listed in 3.19 (a-c)

Describe the effect of

dilusion in welding

State the principles of the

following welding process in

3.21 (a-d) giving examples

Demonstrate the welding of

dissimilar metals observing

correct techniques and safety

practices

Give detailed notes on all of

the above

Students should be asked to

carryout projects involving all

of the above

Lesson plan, Charts

Pieces of Stainless

Steel, related Tools

and Equipment Soapy cold water,

Worm Water Wire

brushes

Lesson plan,

Chalkboard and

sketches/Charts

Lesson plan

Chalkboard

- do -

- do -

Lesson plan,

materials tools and

equipment.

Sample of metals


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4.1 Identify the composition of given worn

metallic shafts or other worn metallic

objects

4.2 Discuss the properties of the metal usedfor given worn metallic shafts or other

objects

4.3 Build up given worn metallic surfaces to

specifications using suitable filler rods and

applying the correct technique/sequence of

operation

Explain the composition of

given worn metallic shaft or

objects

Describe the properties ofthe metal used for given worn

metallic shaft or other objects

Demonstrate how to built up

worn metallic surfaces to

specification, using suitable

techniques and filler rods

Lesson plan,

Chalkboard, Worn out

Metallic Part or Shaft

- do - Lesson plan and

Appropriate materials,

related tool and

equipment


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8

9

10 - 12

5.1 Describe the following defects in gas

welded joints:

a. undercut

b. lack of fusion (side, root,

inter-run)

c. porosity

d. slag inclusion

e. unequal leg length

(uneven alignment)

f. lack of reinforcement

5.2 State how the weld defects in (5.1)

above can be avoided in oxy-acetylene

welding

5.3 Beware of the following test to detect

defect in welded joint

a. Non-destructive test

such as visual inspection,

x-ray test, gamma ray test,

ultrasonic tests

5.4 Apply the following tests to detect

defects in welded joints:

a. Destructive test such as

bend test, macro and micro

examination sulphur prints,

mick and tee fillet test

5.5 Rectify welded joints defects

enumerated in 5.1 above

5.6 Produce project involving the fabrication

of:

a. General safety

precaution

b. Ferrous and non-ferrous

metal welding

c. Various joints defect and

their rectification

List and identify various

welding defects to students

Explain the defects in gas

welded joint as listed in 5.1 (i-

vi) Give detailed notes on all of

the above

Explain how the weld defects

in (5.1) above can be avoided

in oxy-acetylene welding

Explain the use of test to

detect defect in welded joint a

non-destructive test

Give detailed notes

Explain and Demonstrate

how to use of test to detect

defects in welded joints:

destructive and non-

destructive test


correction of welding defects

enumerated in (5.1) above

Test and evaluate the

students in production process

Lesson plan

Chalkboard

Sketches/charts

Lesson plan,

Chalkboard,Sketches/Charts

Lesson plan

Films

Video taper

Industrial

visit/execution etc.

Lesson plan, Test

piece Related Tools

and Equipment

do -

Lesson plan

Tools, equipment

and materials


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National Technical Certificate in Fabrication AND Welding Engineering Craft Practice

CFW 13 Metal Arc Welding

CFW 12

18 hours/Week 6 theory, 12 Practical

: This module is designed to equip the trainee with the knowledge, attitude and skills to carry

out Metal arc welding job involving various ferrous and non ferrous metals in positions

1. Understand And Apply Safety Precautions Related To Metal Arc Welding

2. Understand the construction, features and working principles of arc welding machines and

accessories

3. Make different types of welded joints in all positions

4. Know the properties of various types of ferrous and non-ferrous metals and weld them

together

5. Build up worn metallic shafts; air surfaces using metal arc welding

6. Cut Metals to various specifications using metal Arc Cutting process

7. Know various welding defects and rectify them

On completion of this module, the student will be able to:

1. Apply general safety precaution related to arc welding

2. Use the Arc welding machine in fabricating simple engineering projects involving different

types of joints and position involving different welding techniques

3. cut metals to various specification using metal arc cutting processes

4. identify and rectify various welding defects


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Year 3

Term 21

1.1 List and explain the hazards related to

metal arc welding, e.g.

a. arc eye

b. burningc. radiation

d. electric shock

e. toxic fumes, etc

Explain the hazard related to

metal arc welding as listed in 1.1

Discuss how these listed

hazards can be avoided Give detailed notes

Lesson plan

Chalkboard and

Charts

2

1.2 Select, use and care for protective

wears required while carrying out metal

arc welding operations, e.g.

a. head and hand shield

b. hand gloves

c. apron

d. spats

e. boots and leggings, etc.

List and Describe the use and

care for protective wears while

metal arc welding as listed in 1.2

Show these items to students

and give detailed notes

- do -

items listed in 2.1

chalkboard, charts

3

1.3 Apply appropriate safety precautions

while carrying out:

a. arc welding in confined

spaces

b. arc welding empty

vessels or drums that had

contained inflammable or

toxic materials

c. arc welding near

inflammable materials

Discus Safety precautions while

carrying out a - c


appropriate safety precaution

while carrying out arc welding as

listed in 1.3

Lesson plan Arc

Welding Equipment


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4

5

2.1 Differentiate between A.C and D.C arc

welding machine

2.2 Know the working principles of a.c.

and d.c. welding machines

2.3 List and state the functions of the

welding accessories, e.g.

1. welding load

2. earth load

3. electrode holder

4. chipping hammer

5. wire brush, etc.

2.4 Know the advantages and

disadvantages of a.c. and d.c. welding

systems

2.5 set and use the a.c. and d.c. welding

machines for specified voltage/amperage

operation, observing safety precaution

2.6 Explain the following processes of

electrode manufacture:

a. solid extrusion process

b. extruded with re-

enforcing coating

c. dipped process

Show students the different

features in the construction of the

arc welding machine

Explain the differences between

a.c. and d.c. arc welding

machines

State the working principles of

a.c. and d.c. welding machines

Explain the function of welding

accessories as listed in 2.3

Show students these items

List and explain the advantages

and disadvantages of a.c. and

d.c. welding machines

Demonstrate the use of a.c. d.c.

welding machines for specified

voltage and amperage observing

safety precautions

Describe the processes of

electrode manufacturing as listed

in 2.6

6. Chalkboard Lesson

plan Arc Welding

Equipment

7. Lesson plan

Chalkboard Chart

Chalkboard Arc

Welding Accessories

etc.

Chalkboard Lesson

plan ac/dc welding

machine etc.

- do -

- do -


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6

2.7 Describe with sketches the material

composition of different types of

electrodes

2.8 State the conventional electrode

classification system

2.9 Select electrode materials according

to parent system

2.10 State the basic methods of electrode

care, e.g.

a. dry storage

b. oven storage

c. safe handling

2.11 Strike metal arc and maintain the arc

Explain with sketches, material

composition of different types of

electrode

Explain the conventional

electrode classification system

Explain the selection of

electrode materials according to

parent metals

Explain the basic method of

electrode care with reference to

i. dry storage

ii. oven storage

iii. safe handling

Demonstrate how to strike and

maintain the arc

Ask students to practice striking

metal arc and maintaining the arc

Lesson plan,

Chalkboard

Sketches/Charts

- do -

Lesson plan,

Appropriate Electrode

etc.

Electrode drying

oven, lesson plan etc.

Lesson plan,

Appropriate Arc

Welding Equipment

and tools

7

2.12 Carry out with proficiency the

following arc welding

techniques/operations:

a. weaving

b. laying of multi-runs, etc.

Note: Safety regulations and requirements

must be observed.

Demonstrate with proficiency

the following arc welding

techniques/operations:

i. weaving

ii. laying of multi-

runs etc

observing safety

regulations as

required

Lesson Plan,

Welding Machine

Tools and

Accessories


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8

9

3.1 Describe with sketches the application

of the following joints in metal fabrication:

a. square butt

b. single vee

c. double vee

d. single U Fillet

e. open corner, etc.

3.2 Know the factors that govern the

selection of joints to be used for a project

e.g.

a. type of metal

b. thickness of metal

c. shape of plate

d. position of joint

3.3 Interpret the various arc welding

symbols and conventions used in

engineering working drawings

3.4 Prepare edges for welding the

following joints:

a. square butt

b. single vee

c. double vee

d. single U

e. double U

f. open corner

3.5 Weld the prepared joints in (3.4)

above in flat positions observing

necessary safety precautions.

Explain with sketches the

application of the following joints

in metal fabrication:

i. square butt

ii. single vee

iii. double vee

iv. single U

v. fillet and

vi. open corner

etc

Describe the factors that govern

the selection of joint to be used

for a project with reference to 3.2

(a-d)

Show and explain the various

arc welding symbols use in

engineering working drawing

Demonstrate preparation of

edges f

Fabricaiton and Welding Engineering

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