iti 15 April 2025

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

Trade Theory

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

Trade Practical

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

Hours: Theory: 160 hours | Practical: 240 hours

Trade Theory

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

Trade Practical

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

Hours: Theory: 160 hours | Practical: 240 hours

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

Welder (Fabrication & Fitting)

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