iti 17 April 2025

ITI Welder (GMAW & GTAW) Syllabus (English)

Course Overview

Trade Name: Welder (GMAW & GTAW)
Duration: 1 Year (2 Semesters)
NSQF Level: Level 4
Eligibility: 10th Grade Pass with Science and Mathematics
Objective: To train candidates in Gas Metal Arc Welding (GMAW) and Gas Tungsten Arc Welding (GTAW) techniques for joining metals, preparing them for roles as welders, fabricators, or self-employment in welding services across industries like manufacturing, construction, and automotive.
Certification: National Trade Certificate (NTC) by NCVT

Trade Theory

Introduction to Welding: Types of welding processes (GMAW, GTAW, SMAW), applications in industries.
Safety Practices: PPE (welding helmets, gloves, aprons), fire prevention, ventilation, electrical safety.
Welding Materials: Metals (steel, aluminum, stainless steel), filler wires, shielding gases (argon, CO2).
GMAW Basics: Equipment (MIG welding machine, wire feeder), process parameters (voltage, wire speed).
Welding Joints: Butt, lap, fillet, corner; joint preparation techniques (beveling, cleaning).
Welding Imperfections: Porosity, cracks, incomplete fusion; causes and prevention.
Basic Metallurgy: Effects of heat on metals, weldability, distortion control.

Trade Practical

Safety Drills: Wearing PPE, handling gas cylinders safely, practicing emergency shutdowns.
GMAW Setup: Assembling MIG welding machine, setting voltage (18-24V), wire speed (±0.5 m/min).
Bead Welding: Depositing straight beads on mild steel plates (3-6 mm thick), ensuring uniform width.
Joint Welding: Performing butt and fillet welds in flat position, achieving penetration (±1 mm).
Cleaning Tasks: Removing slag, grinding welds, preparing surfaces with wire brushes.
Inspection: Checking welds for porosity, cracks using visual inspection techniques.
Project Work: Weld a mild steel T-joint (200x100 mm) using GMAW, ensuring defect-free fillet welds.

Hours: Theory: 160 hours | Practical: 240 hours

Trade Theory

GTAW Basics: Equipment (TIG welding machine, tungsten electrodes), process parameters (current, gas flow).
Advanced GMAW: Multi-pass welding, welding in vertical/horizontal positions, pulse MIG techniques.
Welding Positions: 1G, 2G, 3G, 4G; challenges and techniques for out-of-position welding.
Welding of Alloys: Aluminum, stainless steel; selecting appropriate filler wires and gases.
Quality Control: Non-destructive testing (dye penetrant, magnetic particle), weld acceptance standards.
Maintenance: Servicing welding machines, replacing nozzles, sharpening tungsten electrodes.
Entrepreneurship: Starting a welding workshop, market trends (e.g., robotic welding).

Trade Practical

GTAW Setup: Preparing TIG machine, selecting tungsten (1.6-2.4 mm), setting argon flow (6-10 L/min).
GTAW Welding: Welding beads on stainless steel (2-4 mm), ensuring clean fusion.
Multi-Position Welding: Performing GMAW fillet welds in vertical (3G) position, maintaining arc stability.
Alloy Welding: Welding aluminum butt joints using GTAW, achieving smooth bead appearance.
Testing Welds: Conducting dye penetrant tests, identifying surface defects.
Machine Maintenance: Cleaning contact tips, replacing liners, calibrating gas regulators.
Project Work: Fabricate a stainless steel box frame (300x200x100 mm) using GTAW, ensuring precise joints.

Hours: Theory: 160 hours | Practical: 240 hours

Workshop Calculation and Science
- Calculations: Welding current, electrode consumption, gas flow rate, heat input.
- Science: Thermal conductivity, arc physics, gas shielding principles.
- Hours: 80 hours/year
Engineering Drawing
- Drawings: Weld symbols, joint designs, fabrication blueprints.
- Hours: 80 hours/year
Employability Skills
- Communication: Coordinating with supervisors, reading welding procedures, client interaction.
- IT Literacy: Using welding software, digital weld inspection tools, online material catalogs.
- Soft Skills: Time management, teamwork, resume writing, interview preparation.
- Hours: 60 hours/year