Welder (Welding & Inspection)

ITI Welder (Welding & Inspection) Syllabus (English)

Course Overview

• Trade Name: Welder (Welding & Inspection)
• Duration: 1 Year (2 Semesters)
• NSQF Level: Level 4
• Eligibility: 10th Grade Pass
• Objective: To train candidates in advanced welding techniques and weld quality inspection methods, equipping them for roles as welders, welding inspectors, or quality control technicians in industries like manufacturing, oil and gas, aerospace, or construction, or for self-employment in welding and inspection services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Welding and Inspection: Role of welders and inspectors, importance in critical industries.
• Safety Practices: PPE (welding helmets, gloves, respirators), fire safety, arc flash protection, confined space safety.
• Welding Processes: Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW/MIG), Gas Welding; electrodes and shielding gases.
• Metallurgy Basics: Properties of metals (carbon steel, stainless steel), heat-affected zones, weldability.
• Weld Imperfections: Porosity, cracks, incomplete fusion; causes and prevention.
• Inspection Basics: Visual inspection, weld measurement, introduction to non-destructive testing (NDT) methods (dye penetrant, magnetic particle).
• Engineering Drawing: Weld symbols, joint designs (butt, fillet, groove), inspection checkpoints in blueprints.

Trade Practical

• Safety Drills: Using PPE, handling welding gases, practicing confined space entry, setting up fire extinguishers.
• SMAW Practice: Welding mild steel plates (6-10 mm) in flat position, achieving uniform beads.
• GMAW/MIG Practice: Setting up MIG equipment, welding fillet joints, adjusting voltage and wire feed.
• Gas Welding: Performing oxy-acetylene welds on thin sheets, ensuring proper flame control.
• Visual Inspection: Checking welds for surface defects, measuring weld dimensions with gauges (±0.5 mm).
• Joint Preparation: Grinding edges, preparing V-groove and butt joints for welding.
• Project Work: Welding and inspecting a multi-pass butt joint on mild steel, documenting defects.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Advanced Welding Techniques: Tungsten Inert Gas (TIG/GTAW), Flux-Cored Arc Welding (FCAW), plasma arc welding.
• Non-Destructive Testing (NDT): Ultrasonic testing, radiographic testing, principles and applications.
• Destructive Testing: Tensile testing, bend testing, hardness testing for weld strength.
• Welding Standards: AWS D1.1, ASME Section IX, BIS codes; procedure qualification records (PQR).
• Weld Imperfection Analysis: Root cause analysis for defects, corrective actions, repair welding techniques.
• Equipment Maintenance: Troubleshooting welding machines, calibrating inspection tools.
• Entrepreneurship: Starting a welding inspection service, costing, trends in quality assurance.

Trade Practical

• TIG Welding: Welding stainless steel or aluminum, controlling heat input, achieving clean welds.
• FCAW Practice: Welding thick plates (12-20 mm) in vertical position, ensuring deep penetration.
• NDT Exercises: Performing dye penetrant and magnetic particle tests, interpreting results.
• Destructive Testing: Conducting guided bend tests, checking weld ductility, documenting fractures.
• Inspection Tasks: Verifying welds against AWS/ASME standards, preparing inspection reports.
• Maintenance Work: Repairing welding torches, calibrating ultrasonic flaw detectors.
• Project Work: Welding a critical joint (e.g., pressure vessel seam), performing NDT, and submitting a quality report.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
   
  • Calculations: Weld volume, electrode consumption, heat input calculations.
  • Science: Metallurgical changes during welding, electrical circuits in welding, acoustics in ultrasonic testing.
  • Hours: 80 hours/year
• Engineering Drawing
   
  • Drawings: Weld imperfection sketches, inspection templates, PQR documentation layouts.
  • Hours: 80 hours/year
• Employability Skills
   
  • Communication: Writing inspection reports, liaising with quality teams, client interactions.
  • IT Literacy: Using NDT software, CAD for weld design, online standards databases.
  • 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 critical joints, conducting NDT, preparing inspection reports.
• Evaluation Criteria: Weld quality, inspection accuracy, compliance with standards, safety adherence.
• Certification: NCVT National Trade Certificate (NTC) upon passing both semesters, globally recognized.

Career Opportunities

• Employment: Welder, welding inspector, quality control technician in manufacturing, oil and gas, aerospace, or construction.
• Self-Employment: Welding and inspection services, freelance NDT consultancy, weld repair contracts.
• Further Studies: Diploma in Welding Technology, certifications in NDT (Level I/II), or coded welding.