Welder (Fabrication & Fitting)

ITI Welder (Fabrication & Fitting) Syllabus (English)

Course Overview

• Trade Name: Welder (Fabrication & Fitting)
• Duration: 1 Year (2 Semesters)
• NSQF Level: Level 4
• Eligibility: 10th Grade Pass
• Objective: To train candidates in welding techniques, fabrication, and fitting operations for joining metals, equipping them for roles as welders, fabricators, or fitters in industries like construction, manufacturing, automotive, or shipbuilding, or for self-employment in welding and fabrication services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Welding: Types (arc, MIG, TIG), applications in industries, role of welders.
• Safety Practices: PPE (welding helmets, gloves, aprons), fire safety, ventilation, electric shock prevention.
• Welding Processes: Shielded Metal Arc Welding (SMAW), Gas Welding, electrodes, and filler materials.
• Metallurgy Basics: Properties of metals (steel, aluminum), effects of heat on metals, weld imperfections.
• Tools and Equipment: Welding transformers, regulators, torches, grinders; maintenance and setup.
• Fabrication Basics: Cutting, bending, shaping metals; reading fabrication drawings.
• Engineering Drawing: Weld symbols, joint types (butt, fillet), blueprints for fabrication.

Trade Practical

• Safety Drills: Using PPE, handling gas cylinders, setting up fire extinguishers, ensuring ventilation.
• Arc Welding Practice: Striking arc, depositing straight beads, maintaining arc length (2-3 mm).
• Gas Welding: Setting up oxy-acetylene torches, performing fusion welds on mild steel.
• Cutting Tasks: Using gas cutting torches to cut mild steel plates (5-10 mm thickness).
• Fabrication Exercises: Measuring, marking, and cutting metal sheets for simple structures.
• Joint Preparation: Preparing butt and fillet joints, grinding edges for welding.
• Project Work: Fabricating and welding a small metal frame (e.g., angle iron stand) with butt joints.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Advanced Welding Techniques: MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), plasma arc welding.
• Fitting Operations: Drilling, tapping, reaming, assembling components, alignment techniques.
• Weld Imperfections: Porosity, cracks, undercuts; causes and remedies, non-destructive testing (dye penetrant).
• Fabrication Techniques: Jigs, fixtures, templates; assembling complex structures.
• Quality Control: Weld inspection, BIS standards, ensuring dimensional accuracy (±1 mm).
• Maintenance: Repairing welding equipment, troubleshooting power supply issues.
• Entrepreneurship: Starting a welding workshop, costing, trends in fabrication industries.

Trade Practical

• MIG/TIG Welding: Welding aluminum/stainless steel sheets, adjusting gas flow and voltage.
• Fitting Tasks: Drilling holes (6-12 mm), tapping threads, assembling bolted joints.
• Advanced Fabrication: Using jigs to fabricate a multi-part structure (e.g., pipe frame).
• Weld Testing: Inspecting welds for porosity, performing dye penetrant tests.
• Maintenance Practice: Overhauling welding transformers, replacing torch tips, checking cables.
• Quality Checks: Measuring fabricated parts with calipers, ensuring alignment and strength.
• Project Work: Fabricating and welding a complex structure (e.g., a gate or ladder) with multiple joints and fittings.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
   
  • Calculations: Weld length estimation, material consumption, electrode requirements.
  • Science: Heat transfer in welding, thermal expansion, electrical principles in arc welding.
  • Hours: 80 hours/year
• Engineering Drawing
   
  • Drawings: Fabrication blueprints, sectional views of welded joints, assembly diagrams.
  • Hours: 80 hours/year
• Employability Skills
   
  • Communication: Reporting weld quality, client interaction, teamwork in workshops.
  • IT Literacy: Using CAD for fabrication designs, online welding resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
   
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like welding joints, fabricating structures, fitting assemblies, quality inspections.
• Evaluation Criteria: Weld strength, joint accuracy, fabrication precision, safety adherence.
• Certification: NCVT National Trade Certificate (NTC) upon passing both semesters, globally recognized.

Career Opportunities

• Employment: Welder, fabricator, fitter in construction, manufacturing, automotive, or shipbuilding industries.
• Self-Employment: Welding workshop, freelance fabrication services, repair and maintenance contracts.
• Further Studies: Diploma in Welding Technology, certifications in advanced welding (TIG, underwater welding).