ITI Welder (GMAW & GTAW) Syllabus (English)

Course Overview

• Trade Name: Welder (GMAW & GTAW)

• Duration: 1 Year (2 Semesters)

• NSQF Level: Level 4

• Eligibility: 10th Grade Pass with Science and Mathematics

• Objective: To train candidates in Gas Metal Arc Welding (GMAW) and Gas Tungsten Arc Welding (GTAW) techniques for joining metals, preparing them for roles as welders, fabricators, or self-employment in welding services across industries like manufacturing, construction, and automotive.

• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Welding: Types of welding processes (GMAW, GTAW, SMAW), applications in industries.

• Safety Practices: PPE (welding helmets, gloves, aprons), fire prevention, ventilation, electrical safety.

• Welding Materials: Metals (steel, aluminum, stainless steel), filler wires, shielding gases (argon, CO2).

• GMAW Basics: Equipment (MIG welding machine, wire feeder), process parameters (voltage, wire speed).

• Welding Joints: Butt, lap, fillet, corner; joint preparation techniques (beveling, cleaning).

• Welding Imperfections: Porosity, cracks, incomplete fusion; causes and prevention.

• Basic Metallurgy: Effects of heat on metals, weldability, distortion control.

Trade Practical

• Safety Drills: Wearing PPE, handling gas cylinders safely, practicing emergency shutdowns.

• GMAW Setup: Assembling MIG welding machine, setting voltage (18-24V), wire speed (±0.5 m/min).

• Bead Welding: Depositing straight beads on mild steel plates (3-6 mm thick), ensuring uniform width.

• Joint Welding: Performing butt and fillet welds in flat position, achieving penetration (±1 mm).

• Cleaning Tasks: Removing slag, grinding welds, preparing surfaces with wire brushes.

• Inspection: Checking welds for porosity, cracks using visual inspection techniques.

• Project Work: Weld a mild steel T-joint (200x100 mm) using GMAW, ensuring defect-free fillet welds.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• GTAW Basics: Equipment (TIG welding machine, tungsten electrodes), process parameters (current, gas flow).

• Advanced GMAW: Multi-pass welding, welding in vertical/horizontal positions, pulse MIG techniques.

• Welding Positions: 1G, 2G, 3G, 4G; challenges and techniques for out-of-position welding.

• Welding of Alloys: Aluminum, stainless steel; selecting appropriate filler wires and gases.

• Quality Control: Non-destructive testing (dye penetrant, magnetic particle), weld acceptance standards.

• Maintenance: Servicing welding machines, replacing nozzles, sharpening tungsten electrodes.

• Entrepreneurship: Starting a welding workshop, market trends (e.g., robotic welding).

Trade Practical

• GTAW Setup: Preparing TIG machine, selecting tungsten (1.6-2.4 mm), setting argon flow (6-10 L/min).

• GTAW Welding: Welding beads on stainless steel (2-4 mm), ensuring clean fusion.

• Multi-Position Welding: Performing GMAW fillet welds in vertical (3G) position, maintaining arc stability.

• Alloy Welding: Welding aluminum butt joints using GTAW, achieving smooth bead appearance.

• Testing Welds: Conducting dye penetrant tests, identifying surface defects.

• Machine Maintenance: Cleaning contact tips, replacing liners, calibrating gas regulators.

• Project Work: Fabricate a stainless steel box frame (300x200x100 mm) using GTAW, ensuring precise joints.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science

  • Calculations: Welding current, electrode consumption, gas flow rate, heat input.

  • Science: Thermal conductivity, arc physics, gas shielding principles.

  • Hours: 80 hours/year

• Engineering Drawing

  • Drawings: Weld symbols, joint designs, fabrication blueprints.

  • Hours: 80 hours/year

• Employability Skills

  • Communication: Coordinating with supervisors, reading welding procedures, client interaction.

  • IT Literacy: Using welding software, digital weld inspection tools, online material catalogs.

  • Soft Skills: Time management, teamwork, resume writing, interview preparation.

  • Hours: 60 hours/year

Assessment and Certification

• Exams:

  • Theory: Written exams per semester (MCQs, descriptive questions).

  • Practical: Performing GMAW/GTAW welds, joint preparation, defect analysis, equipment setup.

• Evaluation Criteria: Weld quality (strength, appearance), adherence to standards, safety practices.

• Certification: NCVT National Trade Certificate (NTC), globally recognized.

Career Opportunities

• Employment: Welder, fabricator, or quality inspector in manufacturing, construction, automotive, or shipbuilding industries.

• Self-Employment: Welding workshop, freelance welding services, metal art fabrication.

• Further Studies: Diploma in Welding Technology, certifications in robotic welding or NDT.