Fabrication and Welding Engineering National Technical Certificate (NTC) and Advanced National Technical Certificate (ANTC)

Transcription

1 ED/STV/2001/PI/10 Fabrication and Welding Engineering National Technical Certificate (NTC) and Advanced National Technical Certificate (ANTC) Curriculum and Course Specifications NATIONAL BOARD FOR TECHNICAL EDUCATION Federal Republic of Nigeria UNESCO Nigeria Project 2001

2 Fabrication and Welding Engineering - National Technical Certificate (NTC) and Advanced National Technical Certificate (ANTC) Curriculum and Module Specifications OFFICE: PLOT B, BIDA ROAD, P.M.B. 2239, KADUNA NATIONAL TECHNICAL CERTIFICATE AND ADVANCED NATIONAL TECHNICAL CERTIFICATE PROGRAMMES 1

3 Table of Contents 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 Guideline for textbooks development Recommended books for fabrication and welding engineering craft practice List of Participants

4 General Information AIM 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. ENTRY QUALIFICATIONS Craft Programme 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. Advanced Craft 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 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. Unit Course/Modules 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. 3

5 Behavioural Objectives 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. General Education In Technical Colleges 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. National Certification The NTC and ANTC programmes are run by Technical Colleges accredited by NBTE. NABTEB conducts the final National examination and awards certificates. 4

6 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 Technical Programme 1. Craft Level National Technical Certificate 2. Advanced Craft Level Advanced National Technical Certificate Guidance Notes For Teachers Teaching The Curriculum 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. Integrated Approach In The Teacher Of Trade Theory, Trade Science And Trade Calculation 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. 5

7 Evaluation Of Programme/Module 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. 6

8 Curriculum Table (NTC) NTC FABRICATION AND WELDING ENIGINEERING CRAFT PRACTICE YEAR 1 YEAR 2 YEAR 3 S/No Subject Module Term Term Term Term Term Term Term Term Term Total Code Hours for each T P T P T P T P T P T P T P T P T P CMA 12- Mathematics CEN CPH English Physics CCH 11- Chemistry CEC Economics CBM 11 Entrepreneurship CTD ICT Drawing Computer Studies CME 11 General Metal Work I CME 12 General Metal Work II CFW 11 Sheet Metal Work CFW 12 Gas Welding and Cutting CFW 13 Metal Arc Welding CFW 14 Structural Steel Work CFW 11 Sheet metal Work GRAND TOTAL

9 Curriculum Table (ANTC) ANTC FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE YEAR 1 S/No Subject Code Module Term 1 Term 2 Term 3 Total Hours for each T P T P T P 1. CMA Mathematics CEN English and Communication CTD 21 Engineering Drawing and Design CTD 22 Fabrication Drawing CEC Economics CBM 21 Entrepreneurship ICT Computer Studies CFW 21 Welding CFW 22 Structural Mechanics & Specification CFW 23 Structural Steel work CFW 24 Sheet metal work TOTAL

10 National Technical Certificate General Metalwork I PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Module Specification: PRACTICAL/KNOWLEDGE REQUIREMENTS 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 nonferrous 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 dies 6. 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. 9

11 PRACTICAL TASKS General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the following abilities: 1.1 Using and handling hand tools, Demonstrate safe ways of Hand tools files, hacksaw portable power tools and machine handling basic hand tools Television, Video 1.2 Lifting, moving and storing materials or Show a film on industrial machines job safety Posters on artificial Demonstrate first aid application in Demonstrate how to treat respiration cases of minor cuts, electric shock, burns. energy cases like artificial respiration cold compress, etc Assess student 10

12 General Objective 2.0: Measuring, Marking, Cutting and Striking Describe the essential features and use of the following a. 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, vernier micrometer, venier caliper, calipers, vernier height vernier height gauge, gauge, combination sets combination set Steel rules, dividers, Demonstrate the maintenance punches, trammel, scribe and care of the instruments angle plate, vee block listed above center square Perform marking out for the Flat file, hand file, try students to learn and practice till square they become competent File card, flat file Demonstrate how flat surface Ball pein hammers, mallet can be tested using surface plate Hacksaw blade, Hacksaw and try square frame. 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 11

13 General Objective 3.0: Machine Tools Setting up and operate a drilling machine in given situations Note 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 drilling machine in given situation Students to practice till competent Demonstrate how a twist drill they become competent 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 Students to practice till they become competent Assess the student. Bench drill pillar drill, drill bits Bench drill, pillar drill, twist drill, flat drill, counter sink drill, counterbore drill, center drill can be sharpened Drills, taps, tap wrench, die correctly and die stock Demonstrate with the Rivets and sets of drill bits appropriate facility how to Surface table, surface perform all the drilling plate, marking solution, operations center/dot punches, scribing Students to practice till block 12

14 General Objective 4.0: Lathe and Lathework Sharpen cutting tool for plain turning, shouldering, parting off and facing operations 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 Point tools, grinding sharpen cutting tool for plain machine, lathe machine turning shouldering, parting 3-jaw chuck and lathe off and facing operations machine and allow students to Point tools and lathe practice till competent machine Demonstrate how to set-up Lathe machine and rough and turned stock in a accessories 3-jaw-chuck and operate Centre lathe and lathe. Allow students to accessories like catch plate, practice till competent face plate, dog lathe, lathe Guide the students to centers fixed steady and select appropriate cutting traveling steading tools and set them up to Round nose turning tool, center height for lathe work fine finishing tool, form tool, (turning or facing) parting off tool, boring tool, Students should be bar of good length and 4mm allowed to practice till they diameter, Live/dead centers become competent catch plates Prepare simple exercises Standard exercises or that will guide students to prepared produce components involving taper turning using the compound slide. Assess the students Assessment profile: Practical to take 60% of the overall assessment 13

15 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective: 1.0 understand workshop safety rules and application in machine shop 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 Safety posters, common in the workshop. hard tools like files Through questions and hacksaw answer, determine whether Television, Video the students grasped the machine. topic Overall, goggles, gloves, Show a film on industrial saftyboots, head shield, safety. fire extinguishers. 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 14

16 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective: 1.0 understand workshop safety rules and application in machine shop 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. 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. 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. 15

17 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 2.0: Know the physical properties, manufacturing process and application of ferrous and non-ferrous metals in common use 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 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. 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 Video and television including cassettes on production processes. Examples of steels and cast irons should cast iron, malleable cast iron, iron 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; carbide, alloy cast iron high speed steels, high tensile steels, tungsten, stainless steels. Give notes and explanation on the cupola process, the blast furnace and the 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. 16

18 b. the blast furnace process of manufacture of pig iron; c. the direct reduction process of manufacture of steel. bronze, manganese bronze bell metal, aluminium bronze phosphor bronze and lead. Assess the students 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: 17

19 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools Explain with examples the difference between "line" and Prepare notes that will clearly differentiate between "line" and "end" measurement. Steel rule, dividers calipers, trammel, "end" measurement. Prepare notes and examples that will explain scribe angle plate 3.2 Explain the use of datum points, datum lines and datum faces in marking out. the use of datum points, datum lines, and datum faces in marking out. Give explanations regarding the functions vee block, centre square. Micrometer 3.3 Describe, the functions and and application of: steel rule, dividers, calipers vernier callipers application of the following (inside, outside and oddleg) trammel, scriber, vernier height instruments used in metal-work, angle plate, vee block, centre square gauge combination 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 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 set Flat file, hard file, round file square, half round, triangular warding, mill file, rasp file. applications. common files used in the metal work as well as Flat file, handfile Note: stafing the composition of materials used for engineers square. Types of files their manufacture. Surface plate try should include: Show a bench vice and demonstrate the work square (engineers flat, square, round, half round, three square, warding pollar, mill and rasp. 3.5 Classify the common files 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 square) File card Flat file Bench vice. Bench vice. Ball pein hammers mallets. use in metal work and state their operations. composition of material used for filing, tapping and designing operations their manufacture. 3.6 Sketch the bench vise, explain its clamping power and demonstrate the technique of Prepare detail notes that will describe the functions of the various parts of a bench vice, its holding power while performing various operations 18

20 holding work in the vise for Assess the students filing, tapping and designing Prepare detail notes and demonstrations that operations. will describe and uses of: cold chisels, centre 3.7 Describe the functions of the punch dot punch, scrapers and power various parts of a bench vice, its hacksaw. 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 19

21 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools Describe the various parts of a hack saw Prepare notes that will describe and their function. the various parts of a hacksaw 3.10 Describe the common types of hacksaw and their functions. blades, their range of pitches and their Show sample of hacksaw blades applications. as well as prepare notes that will 3.11 State the safety precautions to be describe the common types of observed when using a hand hacksaw 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. General Objective 4.0: Understand the working principles of a drilling machine, use it to drill and ream holes on metals and other engineering materials 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 Bench drill machines Pillar drill. Make notes and drawings that will Twist drill, flat drill identify the various types of drilling counter sink drill, m/cs. counter bore drill Prepare detail notes and drawings combination centre that will describe the main drill. features of a bench or pillar drilling Drilling machines machine. and its accessories. Solve many problems for students to practice. Prepare notes and drawings that 20

22 in a ground twist drill bit: will describe where each of the a. point angle too acute; following drills are best suited b. point angle too obtuse; Twist drill (taper shank, parallel c. cutting edges at unequal shank, jobber drill and their angles; relative merits), flat drill, d. insufficient lip clearance; counterbore drill and combination e. excessive lip clearance. center drill. 4.6 Calculate spindle revolution or cutting Assess the students. speed for specified size of drill using the formulae:- N = 1000S/π S = πdn/1000 Where S = cutting speed (m/min) N = revolution/minute D = diameter of drill (mm) π = 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 Explain the purpose of reaming and describe different types of hand and machine reamers Ream to given specification by hand and machine method. 21

23 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. 5.1 Sketch the thread forms below and state their applications:- - the ISO metric thread - the unified thread - Whitworth and British fine threads - British Association (BA) thread - British Standard pipe - Square thread - Acme thread - Buttress thread. 5.2 Sketch and state the functions of:- a. taps (taper tap, second tap, plug) b. tap wrench c. die and die stock. 5.3 Explain the meaning of tapping size or tapping drill and estimate its value in given situations using formulae such as:- T = D - P Where T = tapping diameter D = thread top diameter P = pitch Give detailed notes with diagrams that Diagrams/charts of will show the various forms of trade and thread forms their uses. State the functions of taps, tap wrench, die and die stock. Demonstrate how to produce internaland external threach. Give detailed notes that will explain the meaning of tapping size or tapping drill and estimate its values using the formula: T = D - P Where T = tapping diamet er D = thread top diamet er and P = Pitch Sample of taps and tap wrenches. Parallel reamers, taper reamers, and twist drills. 22

24 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. 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 Rivet sets, to be taken when tapping on bench. drills. 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. Assess the students. General Objective 6.0: Understand the ISO tolerances and fits and its application in engineering production Differentiate between the following:- Give detailed notes that will differentiate a. nominal size between nominal size, limits, tolerance and Charts on b. limits (upper and lower) c. tolerance (unilateral and bilateral) d. fit (clearance, transition interference). 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. tolerances, limits and fits. 6.2 Explain the importance of tolerance Give notes and explanations that will and fit in engineering production and guide in calculating the amount of tolerance describe briefly the ISO system of limits and types of fits in given situations. and fits. Assess the students. 6.3 Determine by calculation the amount of tolerance and types of fit in given situations. 23

25 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 7.0: Produce simple Engineering Components on the bench. Production Explain layout procedures from working drawing of simple engineering components or tools such as:- a. open ended spanner 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 Assess the students. Lesson notes Diagrams and charts. 24

26 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 8.0 Understand the essential features and working principles of the centre lathe and use it to carry out basic operations such as plain turning, stepped turning, facing taper turning, chamfering, and under-cutting 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 Centre lathe essential features of a lathe machine and accessories Explain the working principles and basic like catch plates, operations of a lathe machine face plates, Demonstrate some basic operations on centers, fixed lathe machine. and traveling Prepare detailed notes that will describe steadies. the essential features of center lathe and Charts of their functions. center lathe and Give notes and diagrams that will explain capstan lathe. the working principles of center lathe and Round nose functions of its accessories. turning tool, Give explanations that will show the finishing tool, difference between center lathe and site finishing, capstan lathe in terms of their main features knife tool, form and functions. tool, parting off Prepare notes that will list types of cutting tool, and boring fluid use for lathe turning operations and tool. 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 25

27 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Code: CME 11 Contact Hours 7hrs/wk Course Specification: Knowledge Requirement General Objective 8.0 Understand the essential features and working principles of the centre lathe and use it to carry out basic operations such as plain turning, stepped turning, facing taper turning, chamfering, and under-cutting Differentiate between various tool shapes Give notes and diagrams of and state their uses e.g. Round nose rougher, various tool shapes and their fine finishing, side finishing, knife tool, form uses. tool, parting off tool, boring tool, etc. Prepare detailed notes and 8.10 Explain with sketches the effects of explanations to cover 8.10 to wrong setting of cutting tool: e.g. vibration and 8.15 chatter, tool rubbing against or digging into the Solve many problems for the job. students practice Define cutting speed and feed with Assess the students respect to lathe operation Calculate the cutting speed and feed for given turning operation 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 Set up the lathe for and carry out basic turning operations between centres Compute required taper dimensions from given data using taper ratic angle formulae i.e Taper Ratio = [d2 - d1]/l OR Charts on tool height Charts and diagrams of different machining operations. where θ = taper angle d1 - small and diameter d2 = large end diameter L = length of taper 26

28 General Metalwork II COURSE: MODULE: GENERAL METAL WORK CME 12 GENERAL METAL WORK II PRE-REQUISITE: CME 11 CONTACT HOUR: 2 HRS THEORY 3 HRS PRACTICAL GOAL: The module is designed to introduce the trainee to basic processes in mechanical engineering such as forging, sheet-metal work and welding. General Objectives: 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. PRACTICAL COMPETENCE: 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 27

29 PRACTICAL TASKS General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the following abilities: Week Specific Learning Outcome: Teachers Activities Resources 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. Assess the students. Furnace, Forge tongs 28

30 General Objective 2.0: Forging Processes Week Specific Learning Outcome: Teachers Activities Resources Select appropriate forging tools and produce to specification given engineering 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 Anvil, swage block, leg vice, forging tools how to produce forging hammers, hot set cold some engineering components set, sets of hammer, punchers, and let the student practice till drifts, fillers, top swage, they become competent bottom swage, flatter, open Assess the students tongs, hallow bit General Objective 3.0: Welding Processes Week Specific Learning Outcome: Teachers Activities Resources 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 practice till competent Oxygen, cylinders and acetylene, regulations arc, welding set goggles, shield, electrodes, diagrams and charts various welding joints Assessment: Practical - 60% of overall assessment 29

31 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE MODULE: GENERAL METAL WORK II MODULE CODE: CME 12 CONTACT HOURS: 5hrs/wk MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective:1.0 Understand the basic principles and processes of heat treatment of metal in the workshop. Week Specific Learning Outcome Teacher Activities Resources Explain briefly the structural behaviour of Prepare detail notes that will Recommended Text plain carbon steel as it is heated from room temperature to about 1000 o C. a. hardening b. tempering c. annealing d. normalising e. case-hardening. 1.2 Explain the meaning of hardening metal work. explain the structural behaviour of plain carbon steel as it is heated from room temperature to about 1000 o C. Prepare detail notes that will explain the meaning of hardening in metalwork. Prepare notes that will outline safety precautions books Lesson notes, etc 1.3 Outline safety precautions relating to heat relating to heat treatment treatment processes apply them in given situations. processes. Assess the students 30

32 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE MODULE: GENERAL METAL WORK II MODULE CODE: CME 12 CONTACT HOURS: 5hrs/wk MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective 2.0: Understand the techniques of producing simple engineering components by forging. Week Specific Learning Outcome Teacher Activities Resources Explain with outline sketch the main features and working principles of the black smith's forge. 2.2 Describe and state the functions of Prepare detail notes and diagrams that will explain the main features and working principles of the black smith's Forge and forging tools. common forging tools. e.g anvil, swage block, forge. leg vice, forging hammers, hot and cold sets, Prepare notes and diagrams 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 that will describe the functions of common forging tools. Prepare detail notes that will describe the following forging operations: upsetting, drawing down, setting down, twisting, forge welding, bending, forming closed ring, forming an eye. Assess the students. splice welds) f. bending g. forming closed ring h. forming an eye. 31

33 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE MODULE: GENERAL METAL WORK II MODULE CODE: CME 12 CONTACT HOURS: 5hrs/wk MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective 3.0 Understand the basic principles and techniques of gas and metal are welding and apply them in fabricating simple metal components. Week Specific Learning Outcome Teacher Activities Resources Describe the equipment and explain the basic principles and application of gas and metal arc welding. 3.2 State the safety precautions to be observed and apply them in given welding situations. Prepare detail notes and Charts diagrams that will describe the Oxygen cylinder equipment and explain the acetylene cylinder basic principles and regulations arc welding application of gas and metal set goggles, shield arc welding. electrode. Prepare diagrams of joints Diagrams and charts that the students will practice. of various welding Prepare detail notes that will joints, and techniques. state the safety precautions to be observed during welding. Assess the students. Week 13 Examination - Practical 60%, Theory 40% 32

34 Sheet metal Work PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE MODULE: PRE- REQUISITE: DURATION: GOAL: CFW 11 - SHEET METALWORK CME HOURS PER WEEK - 6 HOURS THEORY 12 HOURS PRACTICAL 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. GENERAL OBJECTIVES 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. PRACTICAL COMPETENCE 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. 33

35 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective: 1.0 Apply Appropriate Workshop Processes, Techniques And Tools To Mark Out, And Form Pojects In Sheet Metal Work: 1.1 Mark out the following projects Demonstrate the marking out of on sheet metal material applying projects on sheet metal by applying Appropriate Tools and appropriate tools, techniques and the appropriate techniques and Equipment Year 3 Term 1 safety practices: a. rectangular container safety practices. Demonstrate marking out items listed on sheet of metal Steel rule, divider, scriber, compass and chalkboard b. funnels c. cylindrical container 1.2 Cut sheet metal to given sizes Demonstrate sheet metal cutting Lesson Plan using appropriate tools/machines to given sizes using appropriate Appropriate Tools and tools and machine Machines Form sheet metal to given shapes using appropriate tools, machines and techniques Demonstrate the formation of sheet metal Demonstrate methods of forming these shapes. Appropriate Tools, Machines and Equipment 1.4 Calculate allowance for joint Calculate allowance for joint using Chalkboard 3 using the formula: grooved seam = 11/2x width of groover. the formula: grooved seam = 11/2x width of groover, panned down and knock-up joints Sketch the joint allowances on the materials and notch the joints Sketch joint allowances on the materials and notch Appropriate Tools and equipment 34

36 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective: 1.0 Apply Appropriate Workshop Processes, Techniques And Tools To Mark Out, And Form Pojects In Sheet Metal Work: 1.6 Make the following joints in Demonstrate the process of sheet metal: making the following joints: Appropriate Tools and a. solid corner joint solid corner Equipment 4-5 b. grooved seam joint groove seam panned down c. panned down knock-up joint d. knocked up joint 1.7 Name common rivets used in List and explain types of rivets Lesson plan Chalkboard 6 metal work and state their used in sheet metal and their Samples of rivets. properties properties 35

37 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective: 1.0 Apply Appropriate Workshop Processes, Techniques And Tools To Mark Out, And Form Pojects In Sheet Metal Work: 1.8 State common faults in riveting Explain common faults in riveting e.g. Show the listed defect to student Charts/Posters 6 a. overlapping b. cracked rivet c. uneven ends, etc. 1.9 Drill and punch holes on joints Demonstrate drilling and punching Appropriate 7 for riveting making sure that burrs, of holes on sheet metal including Tools, Machine and are removed removal of burrs. Equipment 1.10 Rivet joints satisfactorily using Demonstrate riveting by using 7 correct sets appropriate rivet sets Charts/Posters Various Types of rivet Sets. General Objective 2.0: Solder and braze various sheet metal projects with maximum safety. 2.1 Identify the types of solders List and identify types of solders Charts used in sheet metal work and state show various types of solders Various Types of solders their compositions: e.g. used in sheet metal work and state 8 - tinman's solder, grade their composition - self-flux solder - resin-core solder, etc 36

38 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective 3.0: Produce finished sheet metal projects involving edge stiffening, beating finishing, either as part of the corporate production process or as an independent process State the meaning of the following terms: a. edge-stiffening b. beading c. 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 Posters Chalkboard Finished sheet metal projects involving terms listed in 3,1 (a - p) Calculate allowances for edgestiffening which include: a. helming b. 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 Charts calculations of allowances for edgestiffening using the formula for Chalkboard wiring allowance: 2D+4T (where D is the diameter of wire and T is thickness of metal 37

39 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective 3.0: Produce finished sheet metal projects involving edge stiffening, beating finishing, either as part of the corporate production process or as an independent process Year 3 Term Mark out for edge-stiffening Ask students to demonstrate the using the calculated allowance marking out for edge-stiffening 3.4 Produce projects involving Ask students to demonstrate edge-stiffening such as: projects involving edge-stiffening a. beading after sample demonstration. b. swaging Explain the mechanical properties 3.5 Know the mechanical properties of materials used in beating sheet 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 metal work Ask students to demonstrate the development of discs for making bowls using workshop method Appropriate Tools and Equipment Appropriate Tools and Equipment Chalkboard Appropriate Tools and Materials 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 metal work in copper or brass. 3.9 Layout and cut out blanks for raising, sinking or hollowing process. Ask students to explain the, Chalkboard process of raising, sinking, Posters. hollowing planishing and polishing Chalkboard sheet metal work in copper or Compasses Dividers, etc. brass. Chalkboard Ask students to draw the size of Dividers Scribers, etc blank for raising and polishing sheet metal work in copper or brass Ask students to demonstrate the laying out and cutting out blanks for raising, sinking or hollowing 38

40 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective 3.0: Produce finished sheet metal projects involving edge stiffening, beating finishing, either as part of the corporate production process or as an independent process 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 Chalkboard producing bowls by, raising, hollowing and Chalkboard blocking using necessary Appropriate Tools tools. and Equipment list the safety precaution. Such as wheeling Give student machine, project/assignment to planishing harmer, produce bowl. dollies dent eraser Explain and demonstrate etc. removal of dents from, metal surface. Appropriate Tools Give student assignment and Equipment. on dent removal Ask students to demonstrate removal of dents using appropriate tools and equipment 39

41 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective 3.0: Produce finished sheet metal projects involving edge stiffening, beating finishing, either as part of the corporate production process or as an independent process Prepare surfaces for finishing by applying the following processes: a. sand blasting the surface 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 Ask students to demonstrate 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., Related Tools and Equipment. Related Tools and Equipment 40

42 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18 per week- L6: P12 Course Specification: Practical/theoretical content General Objective 4.0: Draw, develop and produce templates for the production of projects State materials used for templates a. Wood b. Cardboard, etc 4.2 Produce and read blue-prints (which include working drawings) of sheet metal projects 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 Chalkboard related Demonstrate the production Materials and reading of blue-prints of sheet metal projects chalkboard Charts Develop templates using the Appropriate Tools and methords listed for indicated Equipment items in 4.3 (a - e) Ask students to produce Chalkboard Instrument various sheet metal project Related using templates methods Tools, Equipment and Ask students to demonstrate Materials the production of various sheet metal projects Tool, Equipment and Test and evaluate the materials trainee in production processes 41

43 Gas Welding and cutting Programme: Module: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice CFW 12 Gas Welding and Cutting Prerequisite CFW 11 Duration Goal: 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 General Objectives: 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 Practical Competence 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 42

44 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective: 1.0 Understand and apply the general safety precautions related to gas welding WEEK Specific Learning Outcome Teachers Activities Resources 1.1 Carry, transport and store full and Explain how to carry Charts empty gas cylinders safety using transport and store full and or Posters and Year 3 appropriate equipment empty gas cylinders appropriate equipment Term 1 Explain how to carry, 1 transport and store full and empty gas cylinder safety using appropriate equipment 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 Charts precautions involved in gas etc. welding operations List and explain the use of protective wears for carrying out gas welding operations Ask students to demonstrate appropriate safety precaution while carrying out items 1.2 (ac) 1.3 Select, use and care for protective Ask students to identify the Chalkboard, Lesson wears for carrying out gas welding use and care for protective plan and Protective operations. E.g. wears for carrying out gas wears 3 a. welding goggles welding operations e.g. b. welding shields welding goggles, welding c. gloves shield, globes and boots etc. d. boots etc. 43

45 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective 2.0: Know and apply successfully various gas welding processes/operations including the acetylene and oxy-fuel gas cutting processes. WEEK Specific Learning Outcome Teachers Activities Resources Identify the following gas welding Show the students items Chalkboard and equipment, describing their features, functions, listed in 2.1 Lesson plan applications and care: a. generators b. regulators c. blow pipes d. nozzles Identify and explain the features and functions and applications listed in 2.1 Explain the difference between the two types of Chalkboard, Lesson plan, sketches/charts Chalkboard Lesson plans e. hoses generators stating advantages leveled drawings. f. gas cylinders and their colours g. economizers h. check valves and disadvantages Explain the main part of generator e.g. hydraulic back pressure, low and high pressure gas welding sets., 2.2 Differentiate between the following types of valves, purifiers, carbide trays Chalkboard and generators, stating their merits and demerits etc. calcium carbide a. water-to-carbide generator State the difference between, b. carbide-to-carbide generator 2.3 Identify the main parts of the generator e.g. hydraulic back pressure valve purifiers, carbide trays etc. low and high pressure systems of gas welding Explain the composition of calcium carbide Demonstrate how to calcium carbide motor and generator Chalkboard and different types of 2.4 Distinguish between high and low pressure generate acetylene using welding rods. systems of welding 2.5 State the composition of calcium carbide calcium carbide Show and explain the types, chalkboard Welding 2.6 Generate acetylene using calcium carbide of welding rods to students and Cutting torches. 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 stating their properties, composition and uses. With the aid of torches explain the difference between welding and cutting torches. 44

46 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT 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 joint c. lap joint 2.15 Weld metals together in downhand 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 chalkboard, neutral Sketches/charts. Describe uses of the types of flame - do - named in 2.9 above - do - Demonstrate the lighting and setting up Lesson pla, of the flames named in 2.9 above plates and related Demonstrate plate surface preparation equipment/tools for running beds, with and without filler, rods Sketches/charts Draw neat labeled sketches showing and Chalkboard the conventional symbols for welded, joints: materials and i. butt appropriate tools ii. fillet and equipment iii. lap. etc Sample of weld demonstrate running of beads with and jionts 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. butt ii. 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. 45

47 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Specification: THEORETICAL CONTENT Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals General Objective 3.0: Know and weld together different types of non-ferrous and ferrous metals WEEK Specific Learning Outcome Teachers Activities Resources Identify the following types of non-ferrous and ferrous metals Non-ferrous a. copper b. aluminium c. brass d. bronze e. tin f. zinc g. lead h. iconel and monel Ferrous a. wrought iron b. mild steel c. stainless steel d. 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 Chalkboard listed in 3.1 Samples Explain the Ferrous and different types of Non-ferrous non-ferrous and Metals listed in ferrous metals and 3.1 their composition,, as listed in 3.1 Chalkboard Explain the and Charts characteristics Fabricated listed in 3.2 samples of Ask students to items listed in explain the general 3.3 characteristic of metal 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 for welding non ferrous metals Explain the properties and composition of fluxes used for ferrous and nonferrous metals 46

48 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective 3.0: Know and weld together different types of non-ferrous and ferrous metals WEEK Specific Learning Outcome Teachers Activities Resources 3.5 Enumerate two functions of fluxes in the welding of non-ferrous Explain two function of fluxes used in, the welding of ferrous and non-ferrous Charts, Appropriate 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 metals using appropriate fluxes Demonstrate the welding of ferrous and non-ferrous metals using appropriate fluxes Show students the different types of cast iron Explain their composition and properties Tools and Equipment, Chalkboard and Sample of Cast Irons, Charts, Pieces of 3.8 Prepare cast-iron for welding by: Demonstrate preparation of cast iron Cast iron, Related a. chamfering or beveling of edges to specification for welding Demonstrate the fusion welding of cast iron components Tools and Equipment - do - b. pre-heating to Explain the composition of suitable, Year 3 specification flux for bronze welding Chalkboard Term 2 Demonstrate preparation of bronze, Fusion weld cast iron components for welding, avoiding chalkboard bronze 3 components sharp edges related tools and 3.10 Identify suitable flux for bronze welding and state its composition Demonstrate the welding of bronze to specification equipment, 3.11 Prepare bronze to specifications Ask the student to demonstrate charts, Pieces of 3.12 Weld bronze to specifications above Bronze, Related 3.13 State reasons for post-heating Explain the purpose for post-heating Tools and bronze welds 3.14 Identify and state the type, composition and properties of common stainless steels used in metal work Prepare stainless steel components for welding 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 Equipment. Chalkboard - do -, Chalkboard Stainless Steel, Tools and Equipment 47

49 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective 3.0: Know and weld together different types of non-ferrous and ferrous metals WEEK Specific Learning Outcome Teachers Activities Resources Weld stainless steel using appropriate welding rods and techniques and observing safety practice Apply appropriate treatment to the welded 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, Charts stainless steel using Pieces of Stainless appropriate welding rods and Steel, related Tools observing safety practices and Equipment Demonstrate the appropriate Soapy cold water, treatment to the welded joint Worm Water Wire to avoid weld decay brushes State the effects of welding, together two different metals Chalkboard and Explain dissimilar metal sketches/charts listed in 3.19 (a-c) Describe the effect of Chalkboard dilusion in welding - do - State the principles of the - do - following welding process in, 3.21 (a-d) giving examples materials tools and Demonstrate the welding of equipment. dissimilar metals observing Sample of metals 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 48

50 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective 4.0: Understand the process of building up worn metallic shafts or surfaces WEEK Specific Learning Outcome Teachers Activities Resources Identify the composition of given worn Explain the composition of metallic shafts or other worn metallic given worn metallic shaft or objects objects 4.2 Discuss the properties of the metal used Describe the properties of for given worn metallic shafts or other the metal used for given worn objects metallic shaft or other objects 4.3 Build up given worn metallic surfaces to Demonstrate how to built up specifications using suitable filler rods and worn metallic surfaces to applying the correct technique/sequence of specification, using suitable operation techniques and filler rods, Chalkboard, Worn out Metallic Part or Shaft - do - and Appropriate materials, related tool and equipment 49

51 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING Course Code: CFW 12 Contact Hours: 18 per/week 6 Tutorials 12 practicals Course Specification: THEORETICAL CONTENT General Objective 5.0: Know the various welding defects and rectify them WEEK Specific Learning Outcome Teachers Activities Resources 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 (ivi) Give detailed notes on all of the above Explain how the weld defects Films 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 nondestructive test Ask students to demonstrate correction of welding defects enumerated in (5.1) above Test and evaluate the students in production process Chalkboard Sketches/charts, Chalkboard, Sketches/Charts Video taper Industrial visit/execution etc., Test piece Related Tools and Equipment do - Tools, equipment and materials Week 13 Examination - Practical 60%, Theory 40% 50

52 Metal Arc Welding Programme: Module: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice CFW 13 Metal Arc Welding Prerequisite CFW 12 Duration Goal: 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 General Objectives: 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 Practical Competence 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 51

53 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 1.0: Understand And Apply Safety Precautions Related To Metal Arc Welding 1.1 List and explain the hazards related to Explain the hazard related to metal arc welding, e.g. metal arc welding as listed in 1.1 Chalkboard and Year 3 a. arc eye Discuss how these listed Charts Term 2 b. burning hazards can be avoided 1 c. radiation Give detailed notes d. electric shock e. toxic fumes, etc 1.2 Select, use and care for protective List and Describe the use and - do - wears required while carrying out metal care for protective wears while items listed in 2.1 arc welding operations, e.g. metal arc welding as listed in 1.2 chalkboard, charts 2 a. head and hand shield b. hand gloves Show these items to students and give detailed notes c. apron d. spats e. boots and leggings, etc 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 Arc carrying out a - c Welding Equipment Ask students to demonstrate the appropriate safety precaution while carrying out arc welding as listed in

54 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the construction, features and working principles of arc welding machines and accessories 2.1 Differentiate between A.C and D.C arc Show students the different 6. Chalkboard Lesson welding machine features in the construction of the plan Arc Welding 2.2 Know the working principles of a.c. arc welding machine Equipment and d.c. welding machines Explain the differences between 7. Lesson plan 2.3 List and state the functions of the a.c. and d.c. arc welding Chalkboard Chart welding accessories, e.g. machines Chalkboard Arc 1. welding load State the working principles of Welding Accessories 2. earth load a.c. and d.c. welding machines etc. 3. electrode holder Explain the function of welding Chalkboard Lesson 4. chipping hammer accessories as listed in 2.3 plan ac/dc welding wire brush, etc. 2.4 Know the advantages and disadvantages of a.c. and d.c. welding Show students these items List and explain the advantages and disadvantages of a.c. and machine etc. - do - - do - systems d.c. welding machines 2.5 set and use the a.c. and d.c. welding Demonstrate the use of a.c. d.c. machines for specified voltage/amperage welding machines for specified operation, observing safety precaution voltage and amperage observing 2.6 Explain the following processes of safety precautions electrode manufacture: Describe the processes of a. solid extrusion process electrode manufacturing as listed b. extruded with re- in 2.6 enforcing coating c. dipped process 53

55 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the construction, features and working principles of arc welding machines and accessories 2.7 Describe with sketches the material Explain with sketches, material, composition of different types of composition of different types of Chalkboard electrodes electrode Sketches/Charts 2.8 State the conventional electrode Explain the conventional - do - classification system electrode classification system, 2.9 Select electrode materials according Explain the selection of Appropriate Electrode to parent system electrode materials according to etc State the basic methods of electrode parent metals Electrode drying 6 care, e.g. Explain the basic method of oven, lesson plan etc. a. dry storage electrode care with reference to, b. oven storage i. dry storage Appropriate Arc c. safe handling ii. oven storage Welding Equipment 2.11 Strike metal arc and maintain the arc iii. safe handling and tools Demonstrate how to strike and maintain the arc Ask students to practice striking metal arc and maintaining the arc 2.12 Carry out with proficiency the Demonstrate with proficiency Lesson Plan, following arc welding the following arc welding Welding Machine techniques/operations: techniques/operations: Tools and a. weaving i. weaving Accessories 7 b. laying of multi-runs, etc. ii. laying of multi- Note: Safety regulations and requirements runs etc must be observed. observing safety regulations as required 54

56 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Make different types of welded joints in all positions 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 Chalkboard, application of the following joints Sketches/Charts in metal fabrication: lesson Plan i. square butt ii. single vee Chalkboard iii. double vee and iv. single U Chalkboard v. fillet and, vi. open corner Process of metals, etc Appropriate Tools and Describe the factors that govern Equipment the selection of joint to be used for a project with reference to 3.2 Appropriate tools and (a-d) Related Materials Show and explain the various arc welding symbols use in engineering working drawing Demonstrate preparation of edges for welding joints in 3.4 (ef) Give students projects that require the joints listed in 3.4 (a-f) Demonstrate welding of joint in 3.4 above in flat position observing necessary safety precautions Ask students to practice the above 55

57 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents Prepare metal surfaces for: a. multi-run welds b. weaving welds 3.7 Make multi-run welds 3.8 Make weaving welds 3.9 Weld joints in the following positions: a. vertical position b. horizontal position c. overhead position 3.10 Weld pipes and flanges in various fixed positions 3.11 Weld pipes and flanges in rotated position 3.12 Weld pipes using the store pipe method Demonstrate preparation of metal Materials surfaces for Welding machine i. multi-run welds Flat bars and other ii. weaving welds related materials Demonstrate the making of required for welding multi-run welds Demonstrate making weaving welds Explain the welding of joint in the following position: i. vertical ii. horizontal and iii. overhead Discuss the welding pipes and flanges in various fixed position Demonstrate the welding of pipes and flanges in rotated positions Demonstrate the welding of pipes using the store pipe methods Give students projects involving the welding processes above 56

58 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and weld them together Year 3 Term Identify by inspection various types of ferrous metals. e.g. cast iron, steel, etc. 4.2 List four physical properties of cast iron 4.3 Know the behaviour of the following types of cast iron when welded: a. grey cast iron b. white cast iron c. malleable cast iron 4.4 State the use and carry out the following procedures: a. pre-heating b. post-heating c. preing d. fixed - -free - -end welding, etc. 4.5 Prepare cast iron pieces by chamfering and pre-heating, etc. and weld them satisfactorily, using the following techniques: a. fusion b. bronze c. studing d. buttering Explain by inspection various, types of ferrous metals: cast iron, Chalkboard and steel, stainless steel, etc Various Type of Discuss four physical properties Ferrous Metals of cast iron, Describe the behaviour of the Chalkboard following types of cast iron when Samples of grey cast welding as in 4.3 (a-c) above iron, white cast iron, Explain the uses and and malleable cast demonstrate the following iron procedures as in 4.4 (a-d). Welding Demonstrate the preparation of Equipment and cast iron pieces by chamfering Appropriate Tools. and pre-heating and weld satisfactorily as listed in 4.5 (a-d) 57

59 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and weld them together 4.6 Identify various types of non-ferrous State various types of non- metals, e.g. ferrous metals as in 4.6 (a-e) Chalkboard Different a. copper Show samples of the listed Types of non-ferrous 4 b. aluminium above to students metal c. brass d. iconel e. monel 4.7 Describe the composition and state Explain the composition and the mechanical properties of the non- state mechanical properties of Chalkboard and ferrous metals named in 4.6 above, non-ferrous metals in 4.6 above Charts. mechanical properties to include: as listed in 4.7 a. ductility 5 b. malleability c. hardness d. tenacity e. fusion f. fatigue g. effect of heat h. distortion 58

60 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and weld them together 4.8 Select suitable electrodes and machines for welding various types of given non-ferrous metals Explain the selection of suitable electrode and mechanics for welding various type given nonferrous metals Different sizes of Electrode and Welding Machine Outline appropriate heat treatment method for a finished welding of nonferrous metal 4.10 Weld the following non-ferrous metals and apply the appropriate heat treatment: a. copper b. bronze c. aluminium d. brass e. iconelmonel Discuss through demonstration, the appropriate heat treatment Furnace method for finished weld of non Samples of non ferrous metals furnace Demonstrate the welding of nonferrous metals and apply the equipment and, welding appropriate heat treatment appropriate tools method as in 4.10 (a-e) 59

61 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING Course Code: CFW 13 Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and weld them together General Objective 5.0: Build up worn metallic shafts; air surfaces using metal arc welding 5.1 Identify the composition of given worn Describe the composition of a metallic shafts or other worn metallic given worn metal shafts or parts Chalkboard, and Worn parts. e.g. gear teeth that can be restored e.g. gear teeth that can be metal shaft and gear by arc welding. restored by arc welding teeth 5.2 Discuss the properties of the given State the properties of given, 7 worn metallic parts to be restored by arc worn metal parts to be restored Welding Machine and welding by arc welding Appropriate Tools and 5.3 Build-up given worn metallic parts to Demonstrate the building up of Equipment specification using appropriate techniques worn metal parts to specification, including controls against distortion using appropriate techniques and control against distortion General Objective 6.0: Cut Metals to various specifications using metal Arc Cutting process Know the principles and application of the following arc cutting methods in metal fabrication: a. air arc method b. carbon arc method c. oxy arc method Explain the principles and application of the following arc cutting methods in metal fabrication: i. air arc method ii. carbon arc method and iii. oxy arc method Chalkboard Sketches/Charts Welding equipment and accessories 6.2 Identify arc cutting electrodes and state their compositions and uses Explain arc cutting electrode stating their composition and uses chalkboard various arc cutting electrode 6.3 Cut metals with facility using the different cutting methods named in 6.1 above. Demonstrate the cutting of metals using the different cutting method named in 6.1 above Arc Cutting Electrode and Welding Equipment 60

62 General Objective 7.0: Know various welding defects and rectify them Describe major defects in arc welded joints including undercut; lack of fusion (side, root, inter-run); porosity; slag inclusion (oxide entrenchment); unequal leg length (uneven alignment); and lack of reinforcement. Explain major defects in arc welded joint as in 7.1 Chalkboard, Show students samples of these Sketches/charts defects Samples of defects Give detailed notes Know how the weld defects in 7.1 above can be avoided Explain how weld defects in 7.1 above can be avoided., Chalkboard Apply the following tests to detect defects in arc welded joints: a. non-destructive tests such as visual inspection, x-ray test, gamma, ray test, ultrasonic test, magnetic track detector penetrant; b. destructive tests such as bend test, macro and micro examinations sulphur print, izod and fatigue Demonstrate the application of, the following test to detect defects Chalkboard, Testing in arc welded joints as shown in Apparatus 7.3 (a-b) 7.4 Rectify welded joint defects named 7.1 Explain how to correct defects in above welded joints named in 7.1 above - Do Produce project involving the Test, evaluate the students in application of: the production process Material, tool and a. General safety equipment precaution b. Using both AC and DE 12 machines c. Ferrous and nonferrous metals d. Different type of joints in all positions and defect etc Week 13 Examination - Practical 60%, Theory 40% 61

63 Structural Steel Work PROGRAMME: MODULE: DURATION: GOAL: National Technical Certificate In Fabrication And Welding Engineering Craft CFW 14- Structural Steel Work 18 Hours/week 6 Tutorial; 12 Practical The Module is designed to provide the trainee with knowledge and skill to enable him produce simple finished structural steel work projects with safety General Objectives: On completion of this module, the trainee should be able to: 1. Understand the safety rules as applicable to structural steel work 2. Use and Care for Tools and Equipment used in Structural Steel Work 3. Know the structural properties of materials used in structural steel work and make simple calculations related to their strength. 4. Produce simple structural steel projects on the shop floor 5. Understand the process of manufacture of iron and steel 6. Assemble simple structural steel components 7. Know the effect of corrosion on structural steel materials and apply protective coating against corrosion. Practical Competence On completion of this module, the student will be able to: 1. Comply with general safety related to structural steel work 2. Use tools and equipment correctly 3. Identify properties of structural steel working materials 4. Produce structural steel projects 5. Assemble structural steel components 6. Apply protective coating against corrosion 62

64 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 1.0 Understand the safety rules as applicable to structural steel work 1.1 Select, use and care for the Explain the use and care for following protective wears used in protective wears used in Chalkboard Year 3 structural steel work: structural steel work Posters Term 2 a. gloves Show students items listed in 11 Related Protective 1 b. aprons Demonstrate how to take care Wears c. boots of these items d. goggles, etc Give detailed notes 1.2 Know safety rules for the following Explain the safety for operations operations in structural steel work: in structural steel work and give Chalkboard a. rules for storage of detailed notes Posters full and empty gas Necessary Tools and cylinders Equipment b. rules for lifting of 2 structure c. rules for transporting of structures, etc. 1.3 Apply the safety rules in carrying out Demonstrate the application of operations named in 1.2 above. safety rules in carrying out operations mentioned in 1.2 above - do - 63

65 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work Select and use common hand tools used in structural steel work: e.g. a. hammers (assorted) sheers b. spanners (assorted) dog c. drills (assorted) dice d. punches dollies, etc e. chisels f. screw drivers g. pliers h. strips 2.2 Identify and use with facility the following power tools used in structural steel work: e.g. a. riveting hammer (assorted) b. holder on c. impact wrenches d. grinder e. torque spanners f. straight edge etc. List common hand tools used in structural steel work Explain their uses Show students these tools Give detailed notes Ask student to sketch these tools List and explain the use of power tools used in structural steel work Show the student these tools Demonstrate using these tools Give detailed notes Lesson plan, Chalkboard Appropriate Tools and Equipment Appropriate Tools and Equipment 64

66 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work Identify, use and care for the following structural steel working equipment: e.g. a. cranes (assorted) b. straightening machine c. circular sewing machine d. loafty platform e. cropper f. shearing machine g. punching machines h. drilling machine i. guillotine j. bending machine k. rolling machine l. brake pens m. tape, twine and chalk n. trammel List the equipment in 2.3 Explain the use of each Chalkboard, charts Explain the care of each Appropriate Tools and equipment Equipment Show the students each of these equipment physically where available. If not show them the picture Ask student to produce diagram of each equipment Give detailed notes Maintain tools, machines and equipment used in structural steel work e.g. by: a. cleaning b. oiling c. greasing d. regrinding, etc Demonstrate how to maintain tools, machine and equipment used in structural steel work Appropriate Tools, Equipment and Materials Oil and grease cans. Grinding machine 65

67 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Know the structural properties of materials used in structural steel work and make simple calculations related to their strength Describe with sketches the following forms of structural steel materials e.g. a. plates (various thicknesses) b. universal channel c. universal beams d. rolled steel joist e. T-bar f. Angle bar g. Check plates (assorted) h. Bridge beams, etc. 3.1 Describe with sketches the following forms of structural steel materials: i. e.g. plates (various thicknesses) j. universal channel k. universal beams l. rolled steel joist m. T-bar n. Angle bar o. Check plates (assorted) p. Bridge beams, etc. Sketch and explain forms of structural steel materials Give detailed notes on each of the equipments Asked students to sketch these equipment, Chalkboard, Posters/Charts. Samples of equipment where available 66

68 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Know the structural properties of materials used in structural steel work and make simple calculations related to their strength Intepret conventional symbols and abbreviations used for representing structural steel sections 3.3 Apply standard specifications, e.g. Nigerian standard (where available) - American or British standards to structural steel work design. 3.4 State the use and limitations of the structural steel materials named in 3.1 above 3.5 Apply Hooke's Law in the design of given simple structural elements. Ask students to sketch and explain conventional symbols and Chalkboard Charts. abbreviations used in representing structural steel Chalkboard, Charts section Explain and apply standard Chalkboard specifications used in structural steel work design Chalkboard Explain the use and limitations of the structural steel materials in 3.1 Explain and apply Hooke's Law in the design of simple structural elements Distinguish between the following stresses in structural steel-work: a. tensile stress b. compressive stress c. shear stress 3.7 Know simple calculations involving practical applications of tensile, compressive and shear stresses, e.g. in riveted and welded joints 3.8 Read structural steel work drawing and sketch simple structural steel work details. Explain and state the differences of stresses in structural steel work Explain simple calculations involving practical application of stresses in riveted joint, welded joints etc. Give student some problems to solve Draw and interpret structural steel work drawing and sketches of simple structural steel work details Chalkboard Charts Chalkboard Chalkboard Sample drawings and sketches 67

69 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Produce simple structural steel projects on the shop floor Calculate allowances for forming thick metal or angle bar rings using the following methods: a. meanline method b. neutral line method Explain calculations of allowances for forming thick metal Chalkboard sketches or angle bar rings using meanline and neutral line method Solve some problems Produce simple projects in structural Give students projects to steel work e.g. stanchion bar plate rafter demonstrate the production of hunches, etc. simple projects in structural steel work Appropriate tools equipment and materials Develop templates with regular surfaces Demonstrate how to develop templates with regular surfaces Drawing instruments 4.4 cut out templates from the following Demonstrate how to cut Year 3 Term 3 1 materials: a. wood b. cardboard c. any other suitable templates from various materials Ask student to cut out template on wood, cardboard etc Appropriate Materials Tools and Equipment materials 4.5 Reproduce simple jobs on structural Give student Project to steel materials using templates cut in demonstrate how to reproduce Appropriate Materials above simple jobs on structural steel Tools and Equipment materials using templates in 4.4 above 4.6 sketch and produce simple working Demonstrate how to sketch and 3 jigs, e.g. jig for mass production of stanchions, rafters, etc., on the shop produce simple working jigs. Ask students to do the same Appropriate Tools and Equipment. floor 68

70 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 5.0: Understand the process of manufacture of iron and steel 5.1 Sketch a blast furnace and describe its working principles Sketch and label a blast furnace and explain the working principles Chalkboard Note: Student should visit Posters/Chart Industrial industry/factory to see a typical Visit blast furnace. Students are asked to sketch and label blast furnace 5.2 Give the name of fuel and state the Ask students to state the type of Lesson plan 4 composition of charge used in blast furnace fuel and the composition of charge used in blast furnace chalkboard, charts 5.3 Explain the working principles of Ask students to state the - do - Bessemer process with the aid of a working principles of a Bessemer sketch process with the aid of a sketch. Students are asked to sketch Bessemer converter 5.4 Outline the characteristics of pig List the characteristics of pig - Charts iron, cast iron and low carbon steel iron, cast iron and low carbon steel 69

71 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 6.0: Assemble simple structural steel components 6.1 Know the uses of fixtures and bolts Explain the uses of fixtures and in the assembly of structural bolts in the assembly of structural Chalkboard, bolts and components components fixtures Give detailed notes Assemble simple structural components such as rafter bracing, Demonstrate how to assemble Appropriate Tools and simple canopy simple roof trusses, etc. simple structural components, Equipment Note: Assembly should using bolts, rivets and welding involve basic jointing operation operations, e.g. bolting, Show samples of some of these riveting and welding assemblies General Objective 7.0: Know the effect of corrosion on structural steel materials and apply protective coating against corrosion. 7.1 Name some common causes of Ask students to list some Lesson plan Chalkboard corrosion on steel e.g. common causes of corrosion on Sample of corroded 6 a. atmospheric steel steel b. chemical such as Show student samples of electrolytic action.etc corroded steel. 7.2 Describe the effect of corrosion on Ask students to explain the - do - structural steel, e.g. effects of corrosion on structural 7 a. weakening of steel structure b. defacing of steel 7.3 Know the purposes for applying Explain the purposes for - do - 8 undercoat to structural steel applying undercoat to structural components steel components 70

72 PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs per week 6 tutorials; 12 practicals Course Specification: Theoretical/Practical contents General Objective 7.0: Know the effect of corrosion on structural steel materials and apply protective coating against corrosion Prepare the surfaces of structural steel components for finishing with the following methods: b. brushing c. de-greasing d. de-scaling Demonstrate how to prepare the surface of structural steel Appropriate Tools and components for finishing Equipment Ask the student to perform the operation above 7.5 State the composition of common List and explain the composition 10 undercoat used for structural steel work of common undercoat used for structural steel work. Chalkboard, Charts, and samples of under coat 7.6 Apply suitable undercoat to Demonstrate the application of structural steel components. E.g. red suitable undercoat to structural Appropriate Tools and 11 oxide, metalization steel components and observe Equipment Note: Observe safety precautions in the safety precautions. use of the undercoats. 7.7 Produce project involving the Test, evaluate the student in the 12 application of safety rules in structural process of the production Material, tool and steel work equipment Week 13 Examination - Practical 60%, Theory 40% 71

73 Advanced National Technical Certificate Welding PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 21-Welding 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to equip the trainee with advanced skills and knowledge required to carry out gas shielded arc and ancillary welding process with proficiency General Objectives: 1. Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes 2. Understand the constructional features and the working principles of TIG and MIG welding machines and accessories 3. Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 4. Apply appropriate workshop processes and techniques to mark out and form projects for welding 5. Make different types of welded joints in all positions 6. Understand and apply the fuel-gas cutting process in cutting metals to given specification. Practical Competence On completion of this module, the student will be able to: 7. Comply with general safety related to gas shielded arc and ancillary welding process 8. Apply basic principles and techniques of TIG and MIG welding in fabricating simple machine component parts 9. Use workshop process techniques and tools to mark out and form projects in welding 10. perform welding operations in all position involving different types of joints 72

74 11. Cut metals to given specification using the fuel gas cutting process PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes 1.1 Know the importance of a safe working environment with particular reference to personal safety, and the student's responsibility to others. a. State the reasons for the use of face protection and the wearing of protective clothing. Explain the importance of a safe working environment with respect to safety to self and others as per 1.1 (a-d) Welding tools, lesson plan chalkboard goggle and appropriate equipment 1 b. Describe the dangers inherent in the following: grinding, oxy-acetylene welding, metal arc welding, shearing, bending, folding, compressed air, lifting tackle. c. State the correct methods for handling, storing and using compressed gas cylinders. d. State the dangers of electric shock and describe user precautions. 73

75 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes 1.2 List and explain the hazards related to gas shielded arc welding. e.g. a. arc eye b. burning c. radiation d. electric shock e. toxic fumes, etc. 1.3 Select, use and care for the protective wears used in gas shielded arc welding operations: e.g. a. head and pan shields b. hand gloves c. apron d. spats e. boots, etc. 1.4 Apply with facility, appropriate safety precautions required in carrying out TIG and MIG welding operations: a. in confined spaces b. on empty vessels or drums that had contained inflammable or toxic materials near inflammable materials, e.g. petrol tanker, etc Describe the hazard related to gas shielded arc welding as listed in 1.2 (a-e) Explain the use and care for the protective wears used in gas shielded arc welding operations as in 1.3 (a-e) Show students items listed in 1.3 (a-e) Ask student to sketch the items Demonstrate with facilities appropriate safety precautions required in carrying out TIG and MIG welding operation as listed in 1.4 (a-c) Chalkboard. And chart and protective wears and protective wears Welding Equipment 74

76 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the constructional features and the working principles of TIG and MIG welding machines and accessories 2.1 Explain the constructional features and a. State the constructional e. Lesson plan, functions of the following equipment and accessories: a. DC and AC machines features and functions of equipment and accessories listed in 2.1 (a-k) chalkboard, sketches and charts and some accessories b. High frequency unit c. Gas economizer d. Regulator e. Air and water cooled torches f. Pedal switch g. Gas nozzles h. Suppressor unit i. Flow meter j. Contactor k. Nylon hoses, etc b. Show students items listed in 2.1 (A-K) c. Ask students to sketch the items d. Give student short notes on each 2.2 State the advantages and disadvantages of AC and DC welding f. Explain the advantages and l. Lesson plan, chalkboard disadvantages of AC and DC m. Lesson plan, systems welding system chalkboard and TIG 2.3 Identify the electrodes and filler wires g. Describe the electrode and accessories for TIG process and state their composition filler wires for TIG process n. Lesson plan and 2.4 Identify the following gas cylinders by their colour codes: a. argon b. helium c. carbon dioxide d. hydrogen e. nitrogen 2.5 State the main advantage of the TIG process over other welding processes. and state their composition and show students samples of electrode and filler wire h. Ask students to explain and show gas cylinders by their colour code as listed in 2.4 (ae) i. Call on students to identify them j. Give detailed notes k. Ask students to explain the main advantage of TIG process over other welding processes chalkboard 75

77 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Explain the following major process variables and characteristics. a. Electrical b. Direct current, pulsed current alternating current rectification and modulation volt,/ampere characteristics arc initiation. c. Electrodes d. Types, shapes, current carrying capacities and applications. e. Shielding Gases f. Pure and mixed, functions and applications g. d) Filler materials and their composition Ask students to describe the major process variables and characteristics as listed in 3.1 (a-d) Demonstrate TIG welding to students, emphasizing types of current rectification and modulation Show students the different types of electrodes and the profiles Explain the importance of shielding glasses Give detailed notes on all of the above, Chalkboard Sketches/Charts accessories and materials 3.2 Appreciate the applications of TIG welding process and select suitable operating characteristics for the welding of the following: low carbon steels, high yield steels, stainless alloys, nimonic alloys, titanium alloy, cooper alloys and aluminum alloys. Explain the application of TIG welding process and, Chalkboard state operating characteristics Charts for the welding listed in 3-2 and give detailed notes 76

78 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Compare backing materials, purging and under-bead shielding as a means of producing acceptable welds. 3.4 Explain the effects of joint preparation on the production of acceptable and economical welds by the TIG welding processes 3.5 Explain the importance of adhering to specifications, codes and standards for TIG welding processes. Explain backing materials purging and under-bead shielding as mean of producing acceptable welds. State the effect of joint preparation on the production of acceptable and economical welds by TIG welding processes and give notes. State the importance of adhering to specification codes and standards for TIG welding processes and give notes and chalkboard - do - - do - 77

79 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts List and state the functions of TIG welding accessories, e.g. electrode holder, earth lead, welding lead, etc. 3.7 Describe with sketches the materials composition of different types of electrodes used for TIG welding. 3.8 Set and use the TIG welding machines to weld the following metals - aluminum, copper and stainless steel at specified voltage observing safety precautions 3.9 Explain the difference between TIG and MIG processes. Explain the functions of TIG, Chalkboard welding accessories as listed and in 3.6 TIG welding accessories With the aid of sketch or do - diagram, ask student to sketch each of the items TIG welding machine Ask students to explain with equipment and materials. sketches the materials Chalkboard composition of different types and Charts of electrodes use for TIG welding. Ask students to demonstrate the setting up and use of TIG welding machines for welding metals as listed in 3.8 observing all safety precautions Call on students to perform above. Ask students to state the differences between TIG and MIG processes 78

80 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 3.10 Explain the factors that govern the design of joints requiring MIG and TIG processes e.g. a) type of metal b) thickness of metal c) shape of material d) position of joint; and welding various metal joints using TIG and MIG processes in the following positions: a) flat positions b) confined space c) other positions 3.11 Sketch and explain the meaning of the various arc welding symbols/conventions, e.g. symbol of a single V butt weld with sealing run, symbol of weld on both sides etc. State the factors that govern the design of joints requiring MIG and TIG processes as listed in 3.10 (a0c) and demonstrate the welding of metal joints using TIG and MIG processes in positions listed in 3.10 Ask the students to practice the process Give detailed notes Sketch and state the meaning of the various arc welding symbols/conventions as out line in 3.11 Chalkboard TIG welding equipment and accessories and materials. Chalkboard and Sketch/chart 79

81 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 3.12 Weld metals using at least six of the Demonstrate the welding of following ancilliary welding processes: metals using at least six of a. resistance the ancillary welding b. spot processes listed in 3.12 (a-l) c. seam Prepare and give detailed d. projection notes e. submerged arc Explain the factors f. flash butt governing the choice of any of g. fire cracker the ancillary processes h. stud named in 3.12 above i. atomic hydrogen, etc. j. Thermit k. Helectrode l. plasma arc 3.13 Outline the factors governing the Demonstrate the use of TIG choice of any of the ancilliary processes and MIG welding techniques Ancilliary/welding named in 3.12 above on the listed items in 3.14 (a - equipment, tools and 3.14 Produce using TIG and MIG welding f) materials techniques the following items: Give detailed notes - do - a. pressure vessels Demonstrate the welding of, TIG and 6 b. pipe flanges fixed cluster in a gearbox MIG welding equipment, c. boiler drums accessories and materials d. box section chassis - do - e. tool post guides on a lathe machine f. fixed clusters, etc Weld the fixed cluster in a gearbox. 80

82 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 3.16 Explain the principles of MIG welding and state the techniques of consumable and non-consumable electrodes and wires and their composition Explain the details of equipment used and describe the setting of their controls 3.18 state the effects of wrong setting, type of defects, causes and elimination State the principles of MIG welding and explain the techniques of consumable and non-consumable electrode and wires and their composition. Give detailed notes State the details of equipment used and explain the setting of their controls Explain the effect of wrong setting, type of defects, causes and elimination. Chalkboard Appropriate electrodes and wires - do -, Chalkboard Sketches/Chart 81

83 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 3.19 Explain the following major process variable and characteristics: a. Modes of metal transfer State the major process variables and characteristics, listed in 3.19 (a-c) - do - b. Electrical - power supply characteristics - characteri stics relative to modes of metal transfer - current density, speed, feed, voltage and inductanc e. c. Shielding gases - pure and mixed, functions and Applications. 82

84 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 3.20 Apply the MIG welding process and Demonstrate the MIG select suitable operating characteristics for welding process and show MIG equipment & welding: suitable operating Accessories/Materials a. M.S (Mild Steel) in different welding position b. S.S (Stainless Steel) c. Aluminium d. Pipes and pipe joints e. Titanium alloys f. Copper alloys, etc. characteristics for welding of items listed in 3.20 and give detailed notes 3.21 Explain the principles of spot welding and describe the size and shape of Ask students to state the principle of spot welding and Chalkboard electrode in relation to metal thickness explain the size and shape of Spot welding machine 3.22 State the purpose of spot welding in machine shop or industry 3.23 State the effects of current, time and force in spot welding process 3.24 Evaluate the effect of heat balance and heat shrinkage in welding 3.25 Describe the methods of external electrode in relation to thickness Explain the purpose of spot welding in machine shop or industry Explain the effect of current time and force in spot welding - do - 7 cooling on welds process 3.26 Discriminate between the types of Explain the effect of heat welds e.g. plasma arc or sub-merge arc and spot welding balance and heat shrinkage in spot welding Explain the method of external cooling on welds Explain the difference between the types of welds produced by plasma arc, submerged arc and spot welding Give detailed notes on all of the above 83

85 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Apply appropriate workshop processes and techniques to mark out and form projects for welding 4.1 Mark out the following projects in welding - applying appropriate tools, techniques and safety practice: a. Rectangular container b. Cylindrical shaped objects c. Solid corner joints d. Butt joint Demonstrate the marking out of project in welding as listed in 4.1 (a-d) applying appropriate tools, techniques and safety practices Give students projects involving items listed in 4.1 Spot Welding, Appropriate Equipment, Tools, Materials and Protective Wear 4.2 Prepare bronze components for welding avoiding sharp edges and weld to specification. Ask students to demonstrate, Welding preparation and welding of Equipment Tools and bronze component for Materials avoiding sharp edges and welding to specifications and give notes 4.3 Prepare stainless steel components for welding using welding rods and techniques and observing safety precautions. 4.4 Identify and state the type, composition and properties of common stainless steels used in metal work Demonstrate preparation and welding of stainless steel components using welding rods and techniques and observing safety precautions. List types of stainless steel Explain their composition Discus their properties and uses - do -, Chalkboard, Sketches Chart and Different pieces of stainless steel. 84

86 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 5.0: Make different types of welded joints in all positions Describe with sketches the application of the following joints in metal fabrication: a. Square butt b. Single vee c. Double vee d. Single U e. Open corner, etc. 5.2 Prepare edges for welding the joints in 5.1 observing safety rules. Explain with sketches the application of the following Chalkboard and joint in metal fabrication as Charts listed in 5.1 (a-e) Ask students to sketch the joints Give detailed notes on each. Demonstrate how to prepare, Necessary edge for welding the joints in Tools, Equipment and 5.1 observing safety rules Materials Ask the student to prepare edges for welding joints in Weld pipes and flanges in various positions e.g: a) fixed position b) rotated position Demonstrate how to weld pipes and flanges in various position - both fix and rotated - do Prepare metal surfaces and make multi-run and weaving welds 5.5 Weld joints in vertical, horizontal and overhead positions Demonstrate how to prepare - do - metal processes and make multi run and weaving Demonstrate how to weld - do - joint in vertical, horizontal and overhead positions. Ask the student to carry out the above operations and give detailed notes 85

87 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 6.0: Understand and apply the fuel-gas cutting process in cutting metals to given specification State the principles and applications of fuel-gas cutting process, e.g.: a. Manual b. Machine 6.2 Describe various fuel-gas used in oxyfuel cutting e.g: a. acetylene b. propane c. butane d. coal-gas, etc Explain the principles and Lesson plan, Chalkboard applications of fuel-gas cutting as listed in item 6.1 (ab) Give the students, projects involving the two processes Ask students to state - do - various fuel-gases used in oxy-fuel cutting gas listed in 6.2 (a-d) State the advantages and Explain the advantages and - do - disadvantages of using the above-named fuel-gas for oxy-fuel cutting operations disadvantages of using above named fuel gases for oxy-fuel cutting operation. 6.4 Prepare templates for the mass Demonstrate how to prepare, Equipment production of given objects of regular or templates for mass Tools and Materials irregular shapes by profile cutting production of given object by profile cutting 6.5 Cut smooth, curved, circular and straight objects using the hand cutting torch including oxy-lance and flame gauging Demonstrate and explain how to cut smooth, curved circular and straight objects using hand flame gauging. Appropriate Equipment Tools and Materials 6.6 Produce project involving Arc and Assist student to design and Arc and ancillary welding Ancillary welding process produce projects involving Arc equipment. and ancillary welding. Test and evaluate the student Give detailed notes on all of the above Week 13 Examination - Practical 60%, Theory 40% 86

88 Structural Mechanics and Specification PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 22-Structural Mechanics and Specification 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to provide the trainee with the knowledge of simple structural Mechanics and standard specifications required to appreciate steel designs and working drawings General Objectives: 1. Apply simple structural mechanics and standard specifications to structural steel work design. 2. Interpret and produce structural steel working drawings Practical Competence On completion of this module, the student will be able to: 12. Apply with facilities, standard specification for structural steel construction 13. perform simple calculation on structural steel construction 14. interpret and produce simple structural steel working drawings 15. produce projects applying simple structural mechanics and standard specification to structural steel work 87

89 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design Apply with facility standard specifications for structural steel construction using America or British Standards and their Nigerian counterparts. Demonstrate the application of standard specifications for structural steel construction. And give detailed notes Chalkboard Charts. 1.2 Calculate weight of given structural Explain and calculate the weight of a steel components using appropriate table given structural steel components of specifications. using appropriate specifications Give the students problems to solve Chalkboard Draw diagrams to show the applications of the following in structural steel work: a. tensile forces and stresses b. compressive forces and stresses c. shear forces and stresses 1.4 Calculate the reaction at the supports of cantilever and simply supported beams having points and uniform loading e.g. simple shed frame with flat roof. Sketch diagrams to show the application of structural steel work forces and stresses and ask the students to do same. Explain and calculate the reaction at the support of cantilever and simple supported beam having points and uniform loading. Chalkboard Charts Chalkboard, etc. 88

90 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design. 1.5 Calculate bending moments and Explain the calculation of bending moment of resistance of simply moments and moment of resistance of Chalkboard supported beam with point and uniform simply supported with point and Charts. loading. uniform loading. Give the students problems to solve Determine sizes of materials or sections required for columns, rafters, Explain how to determine sizes of materials required for columns, rafters, Chalkboard etc. etc. Charts 1.7 Sketch bending moment diagram for Sketch and explain bending moment cantilever with uniform load and calculate diagram for cantilever with uniform load Chalkboard the bending moment. and calculation on the bending moment. Charts 1.8 Apply 1.4 in determining reaction at support of actual frames. e.g. b. canopy c. riveted angle stiffered for crane beams Demonstrate how to apply 1.4 in determining reaction at support of actual frames. Appropriate tools and equipment Apply stress diagrams to determine Explain how to apply stress diagrams load on member of structural frames. e.g. to determine load on member of trusses. structural frames Calculate bending stress due to web Explain the calculation of bending or flange connections. E.g. floor beams stress due to web or flange multistory frame building. connections Chalkboard Charts Appropriate tools and equipment a Chalkboard 89

91 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design Explain the purpose of the following Enumerate the purpose of the in structural steel assembly: following in structural steel assembly: Chalkboard 6 b. rag bolt rag bolt Posters c. gusset plate gusset plate Samples d. base plate base plate 1.12 Calculate the deflections on a column or other members using standard specifications/formulae. Solve some problems involving calculations on deflections on a column Chalkboard or other members using standard specifications/formulae. Give the students problems to solve Charts. General Objective 2.0: Interpret and produce structural steel working drawings 2.1 Read and interpret working drawings of structural steel work 2.2 Design and produce simple structural drawings observing conventional standards, symbols and notations. 2.3 Produce project applying simple structural mechanics and standard specification to structural steel work Explain how to read and interpret working drawings of structural steel work Demonstrate how to design and produce simple structural drawings observing conventional standards, symbols and notations. Ask student to produce project applying simple structural mechanics and standard specification to structural steel work. Test and evaluate the students Chalkboard Relevant work drawings. Chalkboard Relevant work drawings -do- Week 13 Examination - Practical 60%, Theory 40% 90

92 Structural Steel Work PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 23-Structural Steel Work 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to provide the trainee with further knowledge and skills to carry out simple design, fabrication and erection of structural steel work General Objectives: 1. Develop and Produce Templates for Structural Steel Work 2. Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. 3. Inspect finished structural steel work for defects and rectify the defects as necessary Practical Competence On completion of this module, the student will be able to: 1. Develop and produce template for structural steel work 2. Fabricate and assemble various structural steel component 3. carry out inspection on structural steel project 4. Rectify defects in structural steel project 5. provide and develop temperature for structural steel work 91

93 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0 Develop and Produce Templates for Structural Steel Work 1.1 Calculate areas of irregular surfaces using the following rules: a. mid-ordinates rule b. Simpson's rule 1.2 Develop given templates having: a. regular surfaces b. irregular surfaces Solve problems involving calculation on areas of irregular surfaces using various methods Demonstrate how to develop templates having: regular surfaces irregular surfaces Chalkboard Chalkboard. Drawing instruments Cut out the developed templates from the following materials: a. wood b. card-board c. other suitable materials show students how to how to cut out developed templates from Template materials various materials. Relevant tools and equipment. 1.4 Reproduce the cut templates in 1.3 above from structural steel materials using the following workshop processes: a. cutting - using oxyfuel gas, profile cutting and power saw b. punching - using punching machine c. chamfering - using oxy-fuel gases Demonstrate how to reproduce cut templates in 1.3 from structural steel materials using various workshop processes. Ask students to perform the above functions Materials, Relevant Tools and Equipment. 92

94 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc Explain the functions of jigs and fixtures in structural steel works 2.2 Make simple jigs, fixtures and manipulators for assembling structural steel members. 2.3 Assemble structural components using the following jointing methods: a. welding (arc and gas) b. riveting c. bolting 2.4 Explain the purpose of metal finishing e.g. a) protection from the weather and corrosion b) decoration 2.5 Describe the composition of various materials used for finishing structural steel work 2.6 Prepare the surfaces of structural steel components for finishing using the following techniques: a. brushing - using wire brush b. de-greasing, using suitable degreasing agent c. de-scaling State the functions of jigs and fixtures in structural steel works. Give notes Demonstrate how to make simple jigs, fixtures and manipulators for assembling structural steel members. Demonstrate how to assemble structural components using various jointing methods Students asked to perform the above function State the purpose of metal finishing Explain the composition of various materials used for finishing structural steel work Demonstrate how to prepare the surfaces of structural steel components for finishing using various techniques Ask student to perform above operations Chalkboard, Sample of jigs and fixtures Appropriate tools and Equipment. Appropriate Tools and Equipment and Structural Components Chalkboard Chalkboard Samples of materials for finishing Samples of Structural Components, Appropriate tools and equipment 93

95 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. 2.7 Apply suitable undercoat to Demonstrate how to apply structural steel components e.g. red undercoat to structural steel Appropriate Tools and 8 oxide by brushing or spray methods. 2.8 Store and maintain structural steel components Explain methods of storing and Equipment materials and equipment maintaining structural steel Chalkboard components Visit Relevant Stores. General Objective 3.0: Inspect finished structural steel work for defects and rectify the defects as necessary Identify common defects in structural State common defects in steel assembly e.g. a. distortion structural steel assembly as listed in 3.1 Chalkboard Any Relevant Materials b. undercutting Show student sample of defects c. lack of reinforcement d. lack of penetration of Give detailed notes Ask students to demonstrate Sample of defects Sample of finished weld weld, etc. and state their how to carry out visual inspection Components, Relevant causes. 3.2 Carry out visual inspection to detect defects on finished structural steel assembly 3.3 Rectify defects in assembled structural steel components 3.4 Produce and develop templates for structural steel work 3.5 Fabricate and assemble various structural steel component to detect defects on finished structural steel assembly Ask students to demonstrate how to rectify defects in assembled structural steel components Give detailed notes Test and evaluate the students Tools and Equipment. Samples of Components with weld defects, Relevant Tools and Equipment. Week 13 Examination - Practical 60%, Theory 40% 94

96 Sheet metal work PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 24-Sheet Metal Work 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to upgrade the professional competence of operators who has good knowledge of the use and application of sheet metal working equipment, materials, processes, techniques and safety precautions General Objectives: 1. Understand the Principles of Pantograph System and pattern forming attachment 2. Understand the construction of patterns and masters of irregular trinket box shapes using pattern forming machine/attachment. 3. Understand the mechanical cutting of basic geometrical shapes 4. Understand the processes of planning and layout of engineering workshops/industry. Practical Competence On completion of this module, the student will be able to: 1. Apply machines for the production of sheet metals work 2. Design, Construct and decorate articles 3. Construct patterns of irregular shapes using pattern forming attachment 4. Participate in the planning and laying out engineering workshop/industry 95

97 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 1.0: Understand the Principles of Pantograph System and pattern forming attachment 1.1 State the principles, functions and the constructional details of pattern forming machines and attachments Explain the principles, functions and the constructional details of pattern forming machines Chalkboard Posters/charts Explain the types and characteristics of the machines in 1.1 above Explain the types and characteristics of the machines in Chalkboard 1.1 Posters 1.3 Apply the machines for the production of sheet metal work Demonstrate how to apply the machines for the production of sheet metal work. Give note on all of above Relevant tools and equipment General Objective 2.0: Understand the construction of patterns and masters of irregular trinket box shapes using pattern forming machine/attachment. 2.1 Explain the methods of box and Sate the methods of box and 4-6 tray construction, using beadings and tray construction, using beadings Chalkboard joints. and joints. Give detailed note. Drawing instruments 2.2 Explain the making of articles such Demonstrate how to produce as oblique tee with branch, lobster back articles such as oblique tee with bend, and similar utensils which involve branch, lobster back bend, and the development of a pattern. similar utensils which involve the development of a pattern. Chalkboard Drawing instruments appropriate tools and equipment 2.3 Design, construct and decorate articles combing ornament with utility. Demonstrate how to design, construct and decorate articles combining ornament with utility. Relevant materials for demonstration 96

98 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes a. 3.1 Review of sheet metal materials and their preparation for industrial use of the following metals: Tin, Lead, Zinc, Copper, and Aluminium Explain and review non-ferrous sheet metal material and their preparation for industrial use. Give detailed note Chalkboard Materials State the composition of more Explain the composition of important brasses and bronzes, inconel more important alloy metals and and monel; their properties and chief alloy elements; their properties uses, the composition and properties of and uses. wrought aluminium alloys, magnesium and titanium alloys in common use. Chalkboard Samples of materials 3.3 Describe the process of manufacture of mild steel sheets of various tempers, the manufacture of coated sheets such as tinned sheets, templates and galvanized iron. Explain the process of manufacture of coated sheet metals, listed in 3.3. Give detailed notes. Chalkboard Samples of materials 97

99 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes Develop and produce at least two sheet metal projects involving the use of more advanced machines and the application of advanced pattern development covered in fabrication drawing. Note: Some of the sheet metal project should include: a. trinket box of all types b. lobster back bend c. oblique tee with branch d. small bait can e. petrol or oil measure f. oval container with lid or with loose lid g. oiled bottle h. conical jug i. scoop j. funnel k. ornamental bowls and vases. Etc. 3.5 Explain the methods of producing more difficult work in hollowing, raising and planishing, hand flattening and setting. Demonstrate how to develop and produce sheet metal projects Drawing instruments, involving the use of more appropriate materials, advanced machines. tools and equipment. Give student project on the above to produce some of the items listed in 3.4 State the methods of producing more difficult beating sheet metal Chalkboard. work. Discuss and demonstrate processes involved 98

100 PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 4.0: Understand the processes of planning and layout of engineering workshops/industry Demonstrate the methods of State the methods of planning planning and the layout of shops in and layout of shops in engineering workshops/factory engineering workshops/factory regulations. regulations. Give detailed note 4.2 Know the types of Explain different types workshops/industry, e.g. mechanical, workshops/industry. Give electrical, welding, carpentry, etc. detailed notes. 4.3 State the types and function of Explain the types and function sections in the workshops. of sections in the workshop. 4.4 Describe and lay out plan for single, Explain lay out plan for single, batch and quantity production of batch and quantity production of engineering components. engineering components. 4.5 Arrange workshops according to Explain how to arrange the lay out plans workshops according to the lay 4.6 Produce project involving pattern out plans forming machines Test and evaluate the students Take student on excursion to industries Week 13 Examination - Practical 60%, Theory 40% Chalkboard, Charts visit factory Visit workshops/industries Visit workshops/industries Chars Visit factory/industry. Charts. Material, tool and equipment 99

101 List of tools and equipment for welding and fabrication engineering S/NO MINIMUM QUANTITY ADDITIONAL QUANTITY AVAILABLE QUANTITY REQUIRED REQUIRED 1. Power guillotine of capacity 2 10swg x 36 in length 2. Treadle guillotine of capacity 2 20swg x 36 length 3. Swing beam folder 10swg x 3'-6' 2 capacity 4. Bending roller capacity 40"x2" 2 dia 5. Bending roller capacity 18"x11/4 2 dia 6. Bench mounted cone roller 5 7. Hand-operated copper capacity 3/32 in mild steel 5 8. Power bench grinding machine 2 9. Double-ended buffer and polisher Universal beading and swaging machine 11. Power-operated drilling machine maximum capacity 3/8" Wheeling machine Fly Press Hand nibbling Machine Left and right hand snips 5 each 16. Straight snips A "kit" of tools consisting of hammer, mallet, steel rule, scriber and wing compass, etc Bench shears Power saw cutting machine 10mm 2 100

102 S/NO MINIMUM QUANTITY ADDITIONAL QUANTITY AVAILABLE QUANTITY REQUIRED REQUIRED 20. Disc cutting machine Profile cutting machine with gas cutting nozzles Piller drilling machine Louver shearing machine (manual) Overhead crane Straightening machine Cropping machine Straight edge Trammels dividers (set) Hammers Chisels Punches Try-squares Steel rules Smith open forge Vee blocks Electrode holders Electrode drying oven Heavy duty grinding machine Bench-type grinding machine CO2 cylinders Transformers With rectifiers (with all Instruments) Aprons (assorted Hand gloves Hand shields and head caps Wire brushes Electrical beaters Pliers assorted Gas welding goggles 5 101

103 S/NO MINIMUM QUANTITY REQUIRED 49 Double cylinder trolley 2 50 Oxygen regulators 5 51 Acetylene regulators 5 52 Hoses and clips and all attachments set 53 Blowpipes (low and high 5 pressure 54. Tongs Combined set of cutting welding 5 outfit 56. Power operated profile cutter 2 with turntable 57. D.C generators with all 5 connections 58. A.C transformer (Argon) with all 5 the connections 59. Argon cylinders Regulators with flow meters Hacksaw and blades Water to carbide generators Carbide to water generators Overhead projector Computer set ANVIL Swage block Chipping hammers Plain goggles First aid box Sledge Hammer G. Clamps - assorted Self grip pliers - assorted Magnetic clamp 3 75 Flatters 6 76 Molegrip 6 QUANTITY AVAILABLE ADDITIONAL QUANTITY REQUIRED 102

104 Guideline for textbooks development NATIONAL/ADVANCE TECHNICAL CERTIFICATE IN REFRIGERATION AND AIR CONDITIONING WORK The following guidelines are suggestions from the Engineering Committees to the writers of the textbooks for the new curricula. They are intended to supplement the detailed syllabuses which have been produced, and which define the content and level of the courses. Authors should bear in mind that the curriculum has been designed to give the students a broad understanding of applications in industry and commerce, and this is reflected in the curriculum objectives. One book should be produced for each syllabus Page size should be A4 The front size should be 12 points for normal text and 14 point where emphasis is needed. Line spacing should be set to 1.5 lines Headings and subheadings should be emboldened Photographs, diagrams and charts should used extensively throughout the book, and these items must be up-to-date In all cases the material must be related to industry and commerce, using real life examples wherever possible so that the book is not just a theory book. It must help the students to see the subject in the context of the 'real word' The philosophy of the courses is one of an integrated approach to theory and practice, and as such the books should reflect this by not making an artificial divide between theory and practice. Examples should drawn from Nigeria wherever possible, so that the information is set in a country text. Each chapter should end with student self-assessment questions (SAG) so that students can check their own master of the subject. Accurate instructions should be given for any practical work having first conducted the practical to check that the instructions do indeed work. 103

105 The books must have a proper index or table of contents, a list of references and an introduction based on the overall course philosophy an aims of the syllabus. Symbols and units must be listed and a unified approach used throughout the book. In case of queries regarding the contents o the books and the depth of information, the author must contact the relevant curriculum committee via the National Board for Technical Education. The final draft version of the books should be submitted to Nigerian members of the curriculum working groups for their comments regarding the content in relation to the desired syllabus. 104

106 Recommended books for fabrication and welding engineering craft practice S/NO BOOKS AUTHORS 1. BASIC WELDING AND FABRICATION W. KENYON 2. BASIC ENGINEERING CRAFT STUDENTS: FABRICATION AND WELDING THE TECHNOLOGY OF SHEET METAL WORK FOR STUDENTS AND CRAFTSMEN 4. THE GEOMETRY OF SHEET METAL WORK FOR STUDENTS AND CRAFTSMEN 5. THE CALCULATION OF SHEET METAL WORK FOR STUDENTS AND CRAFTSMEN BOURBOUSSON & ASHWORTH A. DICKSON A. DICKSON A. DICKSON 6. METAL: DESIGN AND CONSTRUCTION A.C. DAVIS - Tenth Edition 7. (a) THE SCIENCE AND PRACTICE OF WELDING Vol. I Cambridge V. Press, 1992 A. C. DAVIS (b) Volume II above 8. WELDING SCIENCE AND METALLURGY J. CARDENER 9. WELDING TECHNOLOGY KOENISBERGE 10. FABRICATION AND WELDING TECHNOLOGY A. SMITH 11. BASIC WELDING - Macmillian Publisher Ltd London, 1986 P. SOMSKY 12. WELDING CRAFT PRACTICE - Part 1 Volume I Oxy-acetylene Gas Welding and Related Studies 13. WELDING CRAFT PRACTICE - Part 1. Volume 2: Electrical Arc Welding and Related Studies N. PARKIN & C.R. FLOOD N. PARKIN & C.R. FLOOD 105

107 List of Participants UNESCO-NIGERIA PROJECT IN SUPPORT OF REVITALIUSATION OF TECHNICAL AND VOCATIONAL EDUCATION(TVE) IN NIGERIA PROJECT TEAM MEMBERS S/No. NAME DESIGNATION 1 Engr. Dr. Nuru A. Yakubu National Project Coordinator & Executive Secretary, NBTE 2 Dr. M.S. Abubakar Technical Coordinator 3 Engr. S.C. Odumah Curriculum Development Coordinator 4 Mr. B.N. Niriyus Staff Development Coordinator 5 Engr. Dr. S.N. Mumah Information & Communication Technology Coordinator 6 Isa Alhaji Sulaimanu Project Accountant 7 Engr. A.D.K. Muhammad Project Officer S/No Name 1. Omotorsho Isaac Bamidele Address Ondo State Board for Tech. & Voc. Education or P.O. Box 975, Akure. 2. Y.A. Alimi Government Technical College P.M.B.5377, Ado-Ekiti 3. G.G. Idris Government Technical College K/Namoda Zamfara State 4. J.I. Ortserga Dept. of Voc. & Tech. Faculty of Education Benue State University, Makurdi 5. F.M. Alega Fest Development Department, National Business & Technical Exams Board (NABTEB) P.M.B. 1747, Benin City, Edo State. 6. Olubode Daniel Majiyagbe National Board for Technical Education Kaduna 106