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

National Technical Certificate

General Metalwork I ................................................................................................................................... 2 General Metalwork II ................................................................................................................................ 20 Sheet metal Work ..................................................................................................................................... 26 Gas Welding and cutting .......................................................................................................................... 35 Metal Arc Welding .................................................................................................................................... 44 Structural Steel Work................................................................................................................................ 55

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.

PRACTICAL TASKS General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the following abilities: Week Specific Learning Outcome 1.1 Using and handling hand tools, portable power tools and machine job 1-3 1.3 Demonstrate first aid application in Teachers Activities handling basic hand tools safety Demonstrate how to treat respiration cold compress, etc Assess student Resources Television, Video machines Posters on artificial respiration

Demonstrate safe ways of Hand tools files, hacksaw

1.2 Lifting, moving and storing materials or Show a film on industrial

cases of minor cuts, electric shock, burns. energy cases like artificial

General Objective 2.0: Measuring, Marking, Cutting and Striking Week Specific Learning Outcome 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 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 4-6 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, Teachers Activities micrometer, venier caliper, vernier height gauge, combination set and care of the instruments listed above Perform marking out for the they become competent Demonstrate how flat surface and try square 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 Make a simple precision fitting project like hexagonal mild steel bar making push fit through a mild steel plate Resources Micrometer, vernier calipers, vernier height gauge, combination sets Steel rules, dividers, angle plate, vee block center square Flat file, hand file, try File card, flat file Ball pein hammers, mallet frame.

2.1 Describe the essential features Demonstrate how to use

Demonstrate the maintenance punches, trammel, scribe

students to learn and practice till square

on plane surfaces including profiles can be tested using surface plate Hacksaw blade, Hacksaw

piercing saw, etc drills and Drilling. clamp, center square, etc.

General Objective 3.0: Machine Tools Week Specific Learning Outcome 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 7-9 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. Teachers Activities up and operate a drilling Students to practice till competent drill can be sharpened correctly Demonstrate with the perform all the drilling operations Students to practice till 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. Resources bits drill, flat drill, counter sink drill, counterbore drill, center Drills, taps, tap wrench, die and die stock Rivets and sets of drill bits plate, marking solution, center/dot punches, scribing block

3.1 Setting up and operate a drilling machine Demonstrate how to set Bench drill pillar drill, drill machine in given situation Bench drill, pillar drill, twist

Demonstrate how a twist drill

appropriate facility how to Surface table, surface

General Objective 4.0: Lathe and Lathework Week Specific Learning Outcome 4.1 Sharpen cutting tool for plain turning, shouldering, parting off and facing operations 4.2 Set up rough and turned stock in 3jaw-chuck 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 10-12 specified tolerance and finish taper turning using the compound slide Teachers Activities Guide the students to Resources Point tools, grinding

sharpen cutting tool for plain machine, lathe machine turning shouldering, parting 3-jaw chuck and lathe off and facing operations and allow students to machine Point tools and lathe machine

4.3 Select appropriate cutting tool and set practice till competent

Demonstrate how to set-up Lathe machine and rough and turned stock in a accessories 3-jaw-chuck and operate lathe. Allow students to practice till competent Guide the students to select appropriate cutting Centre lathe and accessories like catch plate, face plate, dog lathe, lathe centers fixed steady and traveling steading Round nose turning tool, parting off tool, boring tool, bar of good length and 4mm diameter, Live/dead centers catch plates Standard exercises or prepared

4.5 Produce simple components involving tools and set them up to (turning or facing) Students should be allowed to practice till they become competent Prepare simple exercises that will guide students to produce components involving taper turning using the compound slide. Assess the students Assessment profile: Practical to take 60% of the overall assessment

center height for lathe work fine finishing tool, form tool,

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Specification: Knowledge Requirement General Objective: 1.0 understand workshop safety rules and application in machine shop Week Specific Learning Outcome 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 1 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 Teachers Activities in the workshop. Through questions and the students grasped the topic Show a film on industrial safety. 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 ae. Use questions and answer to determine comprehension. Assess the students Resources hard tools like files hacksaw machine. Overall, goggles, gloves, saftyboots, head shield, fire extinguishers. Course Code: CME 11 Contact Hours 7hrs/wk

State sources of hazards Safety posters, common

answer, determine whether Television, Video

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 Week Specific Learning Outcome 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. 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. Teachers Activities 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. Resources

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I 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 Week Specific Learning Outcome general physical properties of metals: ductility, malleability, strength, 2 roughness, brittleness, elasticity, plasticity. Teachers Activities 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 2.1 2.3 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. include: plain carbon steels, dead mild 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; 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 carbide, alloy cast iron high speed 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. Video and television including cassettes on production processes. Resources Course Code: CME 11 Contact Hours 7hrs/wk

2.1 Explain the meaning of the following Give detail notes and explanations to

Examples of steels and cast irons should cast iron, malleable cast iron, iron steels, mild steel, medium carbon steel, steels, high tensile steels, tungsten,

b. the blast furnace process of manufacture of pig iron; c. the direct reduction process of manufacture of steel. 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:

bronze, manganese bronze bell metal, aluminium bronze phosphor bronze and lead. Assess the students

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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. Week Specific Learning Outcome 3.1 Explain with examples the difference between "line" and "end" measurement. 3.2 Explain the use of datum points, datum lines and datum faces in marking out. application of the following steel rule, dividers, calipers (inside, outside and odd-legs), trammel, scriber angle plate, vee-block, centre square. 3.4 Describe the various types applications. Note: Types of files should include: flat, square, round, half round, three square, warding pollar, mill and rasp. 3.5 Classify the common files Teachers Activities Prepare notes that will clearly differentiate between "line" and "end" measurement. the use of datum points, datum lines, and datum faces in marking out. Give explanations regarding the functions (inside, outside and oddleg) trammel, scriber, 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. Resources Steel rule, dividers calipers, trammel, vee block, centre square. Micrometer vernier height gauge combination set Flat file, hard file, round file square, half round, triangular warding, mill file, rasp file. engineers square. Surface plate try square) File card Flat file Bench vice. Bench vice. Ball pein hammers mallets.

Prepare notes and examples that will explain scribe angle plate

3.3 Describe, the functions and and application of: steel rule, dividers, calipers vernier callipers instruments used in metal-work, angle plate, vee block, centre square

of files, stating their grades and Prepare detail notes that will classify the 3 stafing the composition of materials used for their manufacture. 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

common files used in the metal work as well as Flat file, handfile

Show a bench vice and demonstrate the work square (engineers

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

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holding work in the vise for filing, tapping and designing operations.

Assess the students Prepare detail notes and demonstrations that 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

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Specification: Knowledge Requirement General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools. Week Specific Learning Outcome and their function. blades, their range of pitches and their applications. 3.11 State the safety precautions to be observed when using a hand hacksaw 4 Teachers Activities the various parts of a hacksaw Resources centre punches, dot punch, scrapers blades. Hacksaw blade Hacksaw frame Adjustable hacksaw junior hacksaw piercing saw. Course Code: CME 11 Contact Hours 7hrs/wk

3.9 Describe the various parts of a hack saw Prepare notes that will describe Cold chisels, 3.10 Describe the common types of hacksaw and their functions. as well as prepare notes that will describe the common types of 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 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 Week Specific Learning Outcome 4.1 Identify the various types of drilling machines. 4.2 Describe, with sketches, the main Teachers Activities Show different types of drilling machines Resources Bench drill Pillar drill.

Show sample of hacksaw blades power hacksaw

Make notes and drawings that will Twist drill, flat drill counter bore drill drill. and its accessories.

features of a bench or pillar drilling machine. identify the various types of drilling counter sink drill, 4.4 Describe with sketches and state where m/cs. 5-6 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. that will describe the main machine. Solve many problems for students to practice. Prepare detail notes and drawings combination centre features of a bench or pillar drilling Drilling machines

4.5 Explain the effects of the following faults Prepare notes and drawings that

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in a ground twist drill bit: a. point angle too acute; b. point angle too obtuse; c. cutting edges at unequal angles; d. insufficient lip clearance; e. excessive lip clearance. 4.6 Calculate spindle revolution or cutting speed for specified size of drill using the formulae:N = 1000S/ S = dN/1000 Where S = cutting speed (m/min) N = revolution/minute D = diameter of drill (mm) = 3.142 4.8 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. 4.10 Explain the purpose of reaming and describe different types of hand and machine reamers. 4.11 Ream to given specification by hand and machine method.

will describe where each of the following drills are best suited Twist drill (taper shank, parallel shank, jobber drill and their relative merits), flat drill, counterbore drill and combination center drill. Assess the students.

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. Week Specific Learning Outcome 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 Teachers Activities Resources Course Code: CME 11 Contact Hours 7hrs/wk

5.1 Sketch the thread forms below and 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.

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. Week Specific Learning Outcome 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. General Objective 6.0: Understand the ISO tolerances and fits and its application in engineering production. Week Specific Learning Outcome a. nominal size b. limits (upper and lower) c. tolerance (unilateral and bilateral) d. fit (clearance, 8 transition interference). and fit in engineering production and and fits. 6.3 Determine by calculation the amount of tolerance and types of fit in given situations. Teachers Activities Resources tolerances, limits and fits. Teachers Activities to be taken when tapping on bench. 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. Resources Rivet sets, drills. Course Code: CME 11 Contact Hours 7hrs/wk

5.4 State precautions to be taken when Prepare notes that will state precautions

6.1 Differentiate between the following:- Give detailed notes that will differentiate 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. guide in calculating the amount of tolerance Assess the students.

between nominal size, limits, tolerance and Charts on

6.2 Explain the importance of tolerance Give notes and explanations that will describe briefly the ISO system of limits and types of fits in given situations.

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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 Week Specific Learning Outcome 7.1 Explain layout procedures 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 9 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 Activities Teachers to prepare notes and explanations engineering components as in 7.1 Assess the students. Resources Lesson notes Diagrams and charts.

from working drawing of simple to guide the students in producing simple

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I 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 Week Specific Learning Outcome 8.1 Describe the essential features of a centre lathe and state their functions carriage, etc. 8.2 Explain the working principles of the centre lathe. 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 main features and functions. 8.5 Name types of cutting fluids used for 10 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. Teachers Activities With the aid of a diagram explain the essential features of a lathe machine operations of a lathe machine Demonstrate some basic operations on lathe machine. the essential features of center lathe and their functions. the working principles of center lathe and Give explanations that will show the difference between center lathe and and functions. fluid use for lathe turning operations and 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 Resources Centre lathe and accessories like catch plates, face plates, centers, fixed and traveling steadies. Charts of center lathe and Round nose turning tool, finishing tool, site finishing, tool, parting off tool. Course Code: CME 11 Contact Hours 7hrs/wk

e.g lathe bed, headstock, tailstock, saddle or Explain the working principles and basic

8.3 Identify and state the functions of centre Prepare detailed notes that will describe

Give notes and diagrams that will explain capstan lathe.

centre lathe, capstan lathe, in terms, of their functions of its accessories.

capstan lathe in terms of their main features knife tool, form Prepare notes that will list types of cutting tool, and boring

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I 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 Week Specific Learning Outcome Teachers Activities Resources Charts on tool height Charts and diagrams of different machining operations. Course Code: CME 11 Contact Hours 7hrs/wk

8.9 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 tool, parting off tool, boring tool, etc. 8.10 Explain with sketches the effects of uses. Prepare detailed notes and 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. 8.11 Define cutting speed and feed with respect to lathe operation. 8.12 Calculate the cutting speed and feed for given turning operation. 8.13 Estimate the rate of metal removal and time required for carrying out specified turning 11-12 operations 8.14 State precautions to be observed when turning between centres. 8.15 Set up the lathe for and carry out basic turning operations between centres. 8.16 Compute required taper dimensions from given data using taper ratic angle formulae i.e. 8.17 Taper Ratio = [d2 - d1]/L OR students practice. Assess the students

where = taper angle d1 - small and diameter d2 = large end diameter L = length of taper

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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

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PRACTICAL TASKS General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the following abilities: Week Specific Learning Outcome: 1.1 Carry out the following heat treatment processes Hardening, tempering, annealing normalizing, 1-2 Teachers Activities processes and explain the stages Resources

Demonstrate heat treatment Furnace, Forge tongs

case hardening on given plain carbon Demonstrate the annealing steel, engineering component or tool process on brass, copper and 1.2 Anneal copper, brass and aluminium for various purposes aluminium for various purposes. Assess the students.

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General Objective 2.0: Forging Processes Week Specific Learning Outcome: 2.1 Select appropriate forging tools and produce to specification given engineering components by forging processes a. upsetting - drawing down 3-4 5-8 b. setting down twisting c. forge welding (scarf and spice welds) d. bending, turning closed ring e. forming an eye General Objective 3.0: Welding Processes Week Specific Learning Outcome: 3.1 Set up and operate gas or metal arc welding equipment in given situations. Note: Equipment operation should include choice of correct nozzles or pressure/flame or voltage 9-12 situations gas welding methods, and state safety precautions to be observed Teachers Activities List and identify gas and metal arc welding equipment gas and metal welding equipment; and all the Demonstrate to the students welding purposes various components using both gas and arc welding process and state safety precautions to students to practice till competent Assessment: Practical - 60% of overall assessment Resources Oxygen, cylinders and acetylene, regulations arc, electrodes, diagrams and charts various welding joints Teachers Activities forging tools how to produce Resources forging hammers, hot set cold

Demonstrate with appropriate Anvil, swage block, leg vice, some engineering components set, sets of hammer, punchers, and let the student practice till drifts, fillers, top swage, they become competent Assess the students bottom swage, flatter, open tongs, hallow bit

Demonstrate the use of both welding set goggles, shield,

electrode. Adjustment for correct gas students to practice 3.2 Prepare joints for welding in given how to prepare joints for 3.3 Weld given components by arc or Guide students to weld

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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 plain carbon steel as it is heated from room temperature to about a. hardening b. tempering c. annealing 1-4 d. normalising e. case-hardening. 1.2 Explain the meaning of hardening metal work. treatment processes apply them in given situations. 1000oC. Teacher Activities explain the structural behaviour of plain carbon steel as it is heated from room temperature to about 1000oC. Prepare detail notes that will explain the meaning of hardening in metalwork. Prepare notes that will outline safety precautions processes. Assess the students Resources books Lesson notes, etc

1.1 Explain briefly the structural behaviour of Prepare detail notes that will Recommended Text

1.3 Outline safety precautions relating to heat relating to heat treatment

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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 2.1 Explain with outline sketch the main features and working principles of the black smith's forge. 2.2 Describe and state the functions of Teacher Activities Prepare detail notes and diagrams that will explain the main features and working principles of the black smith's Resources 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 5-6 7-8 2.3 Describe with sketches the following forging operations: a. upsetting b. drawing down c. setting down d. twisting e. forge welding (scarf and splice welds) f. bending g. forming closed ring h. forming an eye. that will describe the functions of common forging tools. describe the following forging operations: upsetting, drawing down, setting down, twisting, forge welding, bending, forming closed ring, forming an eye. Assess the students.

(open mouth, closed mouth, hollow bit, etc.). Prepare detail notes that will

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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 3.1 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 9 - 12 situations. Teacher Activities Prepare detail notes and equipment and explain the basic principles and application of gas and metal arc welding. Prepare diagrams of joints Resources Charts acetylene cylinder regulations arc welding set goggles, shield electrode. Diagrams and charts

diagrams that will describe the Oxygen cylinder

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%

25

Sheet metal Work

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE MODULE: PREREQUISITE: DURATION: GOAL: 18 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. CFW 11 - SHEET METALWORK CME 12

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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: Week Specific Learning Outcome 1.1 Mark out the following projects on sheet metal material applying appropriate tools, techniques and Year 3 Term 1 safety practices: a. rectangular container b. funnels c. cylindrical container 1.2 Cut sheet metal to given sizes using appropriate tools/machines 1-2 1.3 Form sheet metal to given shapes using appropriate tools, machines and techniques 1.4 Calculate allowance for joint 3 11/2x width of groover. 1.5 Sketch the joint allowances on the materials and notch the joints Demonstrate sheet metal cutting to given sizes using appropriate tools and machine Demonstrate the formation of sheet metal Demonstrate methods of forming these shapes. Calculate allowance for joint using Lesson plan Chalkboard width of groover, panned down and knock-up joints. 3 Sketch joint allowances on the materials and notch Lesson plan Appropriate Tools and equipment using the formula: grooved seam = the formula: grooved seam = 11/2x Lesson Plan Appropriate Tools and Machines Lesson plan Appropriate Tools, Machines and Equipment Teachers Activities Demonstrate the marking out of the appropriate techniques and safety practices. Demonstrate marking out items listed on sheet of metal Resources Lesson plan Equipment Steel rule, divider, scriber, compass and chalkboard

projects on sheet metal by applying Appropriate Tools and

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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: Week Specific Learning Outcome 1.6 Make the following joints in sheet metal: a. solid corner joint 4-5 b. grooved seam joint c. panned down joint d. knocked up joint 1.7 Name common rivets used in 6 metal work and state their properties List and explain types of rivets used in sheet metal and their properties Lesson plan Chalkboard Samples of rivets. Teachers Activities Demonstrate the process of making the following joints: solid corner groove seam panned down knock-up Resources Lesson plan Appropriate Tools and Equipment

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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: Week Specific Learning Outcome e.g. 6 a. overlapping b. cracked rivet c. uneven ends, etc. 1.9 Drill and punch holes on joints 7 for riveting making sure that burrs, are removed 7 correct sets Demonstrate drilling and punching Lesson plan Appropriate of holes on sheet metal including removal of burrs. appropriate rivet sets Tools, Machine and Equipment Lesson plan Charts/Posters Various Types of rivet Sets. General Objective 2.0: Solder and braze various sheet metal projects with maximum safety. Week Specific Learning Outcome 2.1 Identify the types of solders their compositions: e.g. 8 - tinman's solder, grade - self-flux solder - resin-core solder, etc Teachers Activities List and identify types of solders used in sheet metal work and state their composition Resources Lesson plan Charts Various Types of solders Teachers Activities Show the listed defect to student Resources Lesson plan Charts/Posters

1.8 State common faults in riveting Explain common faults in riveting

1.10 Rivet joints satisfactorily using Demonstrate riveting by using

used in sheet metal work and state show various types of solders

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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 Week Specific Learning Outcome 3.1 State the meaning of the following terms: a. edge-stiffening b. beading c. work hardening d. beating e. annealing f. hollowing 6 g. raising h. blocking i. planishing j. sand blasting k. picking l. lacquering m. galvanizing n. plating o. painting p. other items used 3.2 Calculate allowances for edge- Solve problems involving stiffening which include: a. helming b. wiring, using the 11 - 12 formula for wiring allowance: 2D + 4T (where D is the diameter of wire and T is the thickness of metal) stiffening using the formula for wiring allowance: 2D+4T (where D is the diameter of wire and T is thickness of metal Lesson plan Charts calculations of allowances for edge- Chalkboard Teachers Activities Explain the meaning of the terms listed in 3.1 (a - p) Give details note on the above. Show samples to students Resources Lesson plan Posters Chalkboard Finished sheet metal projects involving terms listed in 3,1 (a - p)

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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 Week Specific Learning Outcome 3.3 Mark out for edge-stiffening using the calculated allowance 3.4 Produce projects involving edge-stiffening such as: a. beading b. swaging Term 2 of the following materials used in 1-2 beating metal work: a. brass b. copper c. aluminium d. low carbon steel 3.6 Develop discs for making bowls using workshop method 3.7 Describe the processes of raising, sinking, hollowing, planishing and polishing sheet metal work in copper or brass. 3.8 Estimate size of blank for 3-4 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 process of raising, sinking, hollowing planishing and polishing sheet metal work in copper or brass. Ask students to draw the size of 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 Lesson plan, Chalkboard Posters. Lesson plan Chalkboard Compasses Dividers, etc. Lesson plan Chalkboard Dividers Scribers, etc Teachers Activities Ask students to demonstrate the marking out for edge-stiffening Ask students to demonstrate projects involving edge-stiffening after sample demonstration. Resources Lesson plan Appropriate Tools and Equipment Lesson plan Appropriate Tools and Equipment Lesson plan Chalkboard Tools and Materials

Explain the mechanical properties Lesson plan Appropriate metal work Ask students to demonstrate the development of discs for making bowls using workshop method

Year 3 3.5 Know the mechanical properties of materials used in beating sheet

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK 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 Week Specific Learning Outcome correct procedures to produce to specification by raising, sinking or hollowing, given metal forming job. 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 3-7 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. Teachers Activities explain process of producing bowls by Resources Lesson plan Chalkboard Lesson plan, Chalkboard and Equipment machine, planishing harmer, dollies dent eraser Lesson plan, Appropriate Tools Course Code: CFW 11 Contact Hours: 18 per week- L6: P12

3.10 Select appropriate tools and equipment and apply Demonstrate and

Note: Sheet metal forming procedures should involve: raising, hollowing and tools. Give student project/assignment to produce bowl. removal of dents from metal surface. on dent removal Ask students to demonstrate removal of dents using appropriate tools and equipment

blocking using necessary Appropriate Tools list the safety precaution. Such as wheeling

Explain and demonstrate etc.

Give student assignment and Equipment.

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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 Week Specific Learning Outcome 3.13 Prepare surfaces for finishing by applying the following processes: a. sand blasting the surface b. pickling with acid 8-9 c. sanding 3.14 Finish sheet metal projects by using the following techniques: a. lacquering b. galvanizing c. plating d. painting Teachers Activities Ask students to demonstrate using appropriate tools and equipment. Ask students to demonstrate finishing of sheet metal project by: i. laquiring ii. galvanizing iii. plating iv. painting etc. Resources Lesson plan, Related Lesson plan Related Tools and Equipment

preparation of surfaces for finishing Tools and Equipment.

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Specification: Practical/theoretical content General Objective 4.0: Draw, develop and produce templates for the production of projects Week Specific Learning Outcome 4.1 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, 10 - 12 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 Teachers Activities Explain materials used for making templates and reading of blue-prints of sheet metal projects methords listed for indicated items in 4.3 (a - e) Ask students to produce various sheet metal project using templates methods the production of various sheet metal projects Test and evaluate the trainee in production processes Resources Lesson plan Chalkboard related Lesson plan chalkboard Charts Equipment Lesson plan Chalkboard Instrument Lesson plan Related Tools, Equipment and Lesson plan Tool, Equipment and materials Course Code: CFW 11 Contact Hours: 18 per week- L6: P12

Demonstrate the production Materials

Develop templates using the Appropriate Tools and

Ask students to demonstrate Materials

34

Gas Welding and cutting

Programme: Module: Prerequisite Duration Goal: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice CFW 12 Gas Welding and Cutting CFW 11 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

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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 1.1 Carry, transport and store full and empty gas cylinders safety using Year 3 Term 1 1 appropriate equipment Teachers Activities Explain how to carry transport and store full and empty gas cylinders Explain how to carry, transport and store full and empty gas cylinder safety using appropriate equipment 1.2 Apply appropriate safety precautions while carrying out the following: a. Gas welding operations on containers which have been emptied of chemicals, inflammable or explosive 2 liquids. b. Gas welding near containers with inflammable materials, e.g. petrol tank; and c. Gas welding in confined spaces. 1.3 Select, use and care for protective wears for carrying out gas welding operations. E.g. 3 a. welding goggles b. welding shields c. gloves d. boots etc. Ask students to identify the use and care for protective wears for carrying out gas welding operations e.g. welding goggles, welding shield, globes and boots etc. Chalkboard, Lesson plan and Protective wears List and explain safety precautions involved in gas 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) Lesson plan Charts etc. Resources Lesson plan Charts or Posters and appropriate equipment

36

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 2.1 Identify the following gas welding applications and care: a. generators b. regulators c. blow pipes d. nozzles e. hoses f. gas cylinders and their colours g. economizers h. check valves 4 5 6 generators, stating their merits and demerits a. water-to-carbide generator b. carbide-to-carbide generator 2.3 Identify the main parts of the generator e.g. hydraulic back pressure valve purifiers, carbide trays etc. systems of welding 2.5 State the composition of calcium carbide 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 Teachers Activities Show the students items Identify and explain the features and functions and applications listed in 2.1 Explain the difference between the two types of and disadvantages Explain the main part of generator e.g. hydraulic back pressure etc. low and high pressure systems of gas welding Explain the composition of calcium carbide Demonstrate how to calcium carbide Show and explain the types stating their properties, composition and uses. With the aid of torches explain the difference between welding and cutting torches. Resources Chalkboard and Lesson plan Chalkboard, Lesson plan, sketches/Charts Chalkboard Lesson plans Lesson plan, low and high pressure gas welding sets. Lesson plan, calcium carbide calcium carbide motor and generator Lesson plan Chalkboard and different types of welding rods. Lesson plan, chalkboard Welding and Cutting torches.

equipment, describing their features, functions, listed in 2.1

generators stating advantages leveled drawings.

2.2 Differentiate between the following types of valves, purifiers, carbide trays Chalkboard and State the difference between Lesson plan,

2.4 Distinguish between high and low pressure generate acetylene using

2.6 Generate acetylene using calcium carbide of welding rods to students

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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 Lesson plan, chalkboard, Sketches/charts. - do - do Lesson pla, plates and related equipment/tools Lesson plan, Sketches/charts and Chalkboard Lesson plan, materials and appropriate tools and equipment Sample of weld jionts

Course Specification: THEORETICAL CONTENT 2.9 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 neutral Describe uses of the types of flame named in 2.9 above Demonstrate the lighting and setting up of the flames named in 2.9 above Demonstrate plate surface preparation for running beds, with and without filler rods Draw neat labeled sketches showing the conventional symbols for welded joints: i. butt ii. fillet iii. lap. etc demonstrate running of beads with and 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.

7 8 9 10

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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 3.1 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 Teachers Activities Resources Show students samples of metals listed in 3.1 Explain the different types of non-ferrous and ferrous metals and their composition, as listed in 3.1 Explain the characteristics listed in 3.2 Ask students to explain the general 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 Lesson plan, Chalkboard Samples Ferrous and Non-ferrous Metals listed in 3.1 Lesson plan, Chalkboard and Charts Fabricated samples of items listed in 3.3

11 12

39

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 3.5 Enumerate two functions of fluxes in the welding of non-ferrous 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 Teachers Activities Resources Explain two function of fluxes used in Lesson plan, the welding of ferrous and non-ferrous Charts, Appropriate metals using appropriate fluxes Demonstrate the welding of ferrous and non-ferrous metals using appropriate fluxes cast iron Explain their composition and properties a. chamfering or beveling of edges to specification Year 3 Term 2 1-2 3 b. pre-heating to specification 3.9 Fusion weld cast iron components 3.10 Identify suitable flux for bronze welding and state its composition 3.12 Weld bronze to specifications 3.13 State reasons for post-heating bronze welds 3.14 Identify and state the type, composition and properties of common stainless steels used in metal work. 3.15 Prepare stainless steel components for welding for welding Demonstrate the fusion welding of cast iron components Explain the composition of suitable flux for bronze welding Demonstrate preparation of bronze components for welding, avoiding sharp edges Demonstrate the welding of bronze to specification above 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 Tools and Equipment Lesson plan, Chalkboard and Irons Lesson plan, Charts, Pieces of Tools and Equipment - do Lesson plan, Chalkboard Lesson plan, chalkboard bronze related tools and equipment Lesson plan, charts, Pieces of Bronze, Related Equipment. Lesson plan Chalkboard - do Lesson plan, Chalkboard Stainless Steel, Tools and Equipment

Show students the different types of Sample of Cast

3.8 Prepare cast-iron for welding by: Demonstrate preparation of cast iron Cast iron, Related

3.11 Prepare bronze to specifications Ask the student to demonstrate

Explain the purpose for post-heating Tools and

40

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 Pieces of Stainless and Equipment Worm Water Wire brushes Lesson plan, Chalkboard and sketches/Charts Lesson plan Chalkboard - do - do Lesson plan, materials tools and Sample of metals

3.16 Weld stainless steel using appropriate Demonstrate the welding of Lesson plan, Charts welding rods and techniques and observing stainless steel using safety practice. 3.17 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 4-6 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 correct safety practice. observing safety practices treatment to the welded joint to avoid weld decay State the effects of welding together two different metals Explain dissimilar metal listed in 3.19 (a-c) Describe the effect of dilusion in welding State the principles of the following welding process in 3.21 (a-d) giving examples dissimilar metals observing correct techniques and safety practices Give detailed notes on all of Students should be asked to carryout projects involving all of the above appropriate welding rods and Steel, related Tools Demonstrate the appropriate Soapy cold water,

Demonstrate the welding of equipment.

using correct techniques and observing the the above

41

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 4.1 Identify the composition of given worn metallic shafts or other worn metallic objects for given worn metallic shafts or other objects specifications using suitable filler rods and operation Teachers Activities Explain the composition of given worn metallic shaft or objects Resources Lesson plan, Chalkboard, Worn out Metallic Part or Shaft - do -

4.2 Discuss the properties of the metal used Describe the properties of 7

the metal used for given worn Lesson plan and metallic shaft or other objects Appropriate materials, worn metallic surfaces to techniques and filler rods equipment

4.3 Build up given worn metallic surfaces to Demonstrate how to built up related tool and applying the correct technique/sequence of specification, using suitable

42

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 5.1 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 Teachers Activities List and identify various welding defects to students Explain the defects in gas vi) Give detailed notes on all of the above Resources Lesson plan Chalkboard Sketches/charts Chalkboard, Sketches/Charts Lesson plan

welded joint as listed in 5.1 (i- Lesson plan,

Explain how the weld defects Films in (5.1) above can be avoided Video taper in oxy-acetylene welding Explain the use of test to 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 Industrial visit/execution etc. piece Related Tools and Equipment do Lesson plan Tools, equipment and materials

detect defect in welded joint a Lesson plan, Test

8 9 10 - 12

Week 13 Examination - Practical 60%, Theory 40%

43

Metal Arc Welding

Programme: Module: Prerequisite Duration Goal: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice CFW 13 Metal Arc Welding CFW 12 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

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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 Week Specific Learning Outcome metal arc welding, e.g. Year 3 Term 2 1 a. arc eye b. burning c. radiation d. electric shock e. toxic fumes, etc 1.2 Select, use and care for protective wears required while carrying out metal arc welding operations, e.g. 2 a. head and hand shield b. hand gloves c. apron d. spats e. boots and leggings, etc. 1.3 Apply appropriate safety precautions while carrying out: a. arc welding in confined spaces 3 b. arc welding empty vessels or drums that had contained inflammable or toxic materials c. arc welding near inflammable materials Discus Safety precautions while Lesson plan Arc carrying out a - c Ask students to demonstrate the appropriate safety precaution while carrying out arc welding as listed in 1.3 Welding Equipment List and Describe the use and care for protective wears while Show these items to students and give detailed notes - do items listed in 2.1 Teachers Activities Resources Lesson plan Charts

1.1 List and explain the hazards related to Explain the hazard related to Discuss how these listed hazards can be avoided Give detailed notes

metal arc welding as listed in 1.1 Chalkboard and

metal arc welding as listed in 1.2 chalkboard, charts

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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 Week Specific Learning Outcome welding machine 2.2 Know the working principles of a.c. and d.c. welding machines 2.3 List and state the functions of the welding accessories, e.g. 1. welding load 2. earth load 3. electrode holder 4. chipping hammer 4 5 5. wire brush, etc. 2.4 Know the advantages and disadvantages of a.c. and d.c. welding systems 2.5 set and use the a.c. and d.c. welding operation, observing safety precaution 2.6 Explain the following processes of electrode manufacture: a. solid extrusion process b. extruded with reenforcing coating c. dipped process Teachers Activities Resources 6. Chalkboard Lesson Equipment 7. Lesson plan Chalkboard Chart Chalkboard Arc Welding Accessories etc. Chalkboard Lesson plan ac/dc welding machine etc. - do - do -

2.1 Differentiate between A.C and D.C arc Show students the different arc welding machine Explain the differences between a.c. and d.c. arc welding machines State the working principles of a.c. and d.c. welding machines Explain the function of welding accessories as listed in 2.3 Show students these items List and explain the advantages and disadvantages of a.c. and d.c. welding machines Demonstrate the use of a.c. d.c. voltage and amperage observing safety precautions Describe the processes of electrode manufacturing as listed in 2.6

features in the construction of the plan Arc Welding

machines for specified voltage/amperage welding machines for specified

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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 Week Specific Learning Outcome 2.7 Describe with sketches the material composition of different types of electrodes 2.8 State the conventional electrode classification system 2.9 Select electrode materials according to parent system 6 care, e.g. a. dry storage b. oven storage c. safe handling 2.11 Strike metal arc and maintain the arc Teachers Activities Explain with sketches, material composition of different types of electrode Explain the conventional electrode classification system Explain the selection of electrode materials according to Explain the basic method of electrode care with reference to i. dry storage ii. oven storage iii. safe handling 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 following arc welding techniques/operations: a. weaving 7 b. laying of multi-runs, etc. Note: Safety regulations and requirements must be observed. Demonstrate with proficiency the following arc welding techniques/operations: i. weaving ii. laying of multiruns etc observing safety regulations as required Lesson Plan, Welding Machine Tools and Accessories Resources Lesson plan, Chalkboard Sketches/Charts - do Lesson plan, Appropriate Electrode etc. Electrode drying oven, lesson plan etc. Lesson plan, Appropriate Arc Welding Equipment and tools

2.10 State the basic methods of electrode parent metals

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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 Week Specific Learning Outcome Teachers Activities Resources Chalkboard, Sketches/Charts lesson Plan Lesson plan Chalkboard Lesson plan and Chalkboard Lesson plan, Process of metals, Appropriate Tools and Lesson plan Related Materials

3.1 Describe with sketches the application Explain with sketches the of the following joints in metal fabrication: application of the following joints 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 8 9 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. in metal fabrication: i. square butt ii. single vee iii. double vee iv. single U v. fillet and vi. open corner etc the selection of joint to be used (a-d) 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

Describe the factors that govern Equipment for a project with reference to 3.2 Appropriate tools and

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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 3.6 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 10 11 - 12 fixed positions 3.11 Weld pipes and flanges in rotated position 3.12 Weld pipes using the store pipe method Demonstrate preparation of metal surfaces for i. multi-run welds ii. weaving welds Demonstrate the making of 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 Materials Welding machine Flat bars and other related materials required for welding

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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 Week Specific Learning Outcome 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 Year 3 Term 3 1 2-3 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 Teachers Activities Resources Lesson plan, Various Type of Lesson plan, Chalkboard iron, white cast iron, and malleable cast iron Lesson plan Welding Appropriate Tools.

4.1 Identify by inspection various types of Explain by inspection various steel, stainless steel, etc of cast iron Describe the behaviour of the welding as in 4.3 (a-c) above Explain the uses and demonstrate the following procedures as in 4.4 (a-d). cast iron pieces by chamfering and pre-heating and weld satisfactorily as listed in 4.5 (a-d)

types of ferrous metals: cast iron, Chalkboard and Discuss four physical properties Ferrous Metals

following types of cast iron when Samples of grey cast

Demonstrate the preparation of Equipment and

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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 Week Specific Learning Outcome 4.6 Identify various types of non-ferrous metals, e.g. a. copper 4 b. aluminium c. brass d. iconel e. monel 4.7 Describe the composition and state the mechanical properties of the nonferrous metals named in 4.6 above, mechanical properties to include: a. ductility 5 b. malleability c. hardness d. tenacity e. fusion f. fatigue g. effect of heat h. distortion Explain the composition and state mechanical properties of non-ferrous metals in 4.6 above as listed in 4.7 Lesson plan Chalkboard and Charts. Teachers Activities State various types of nonferrous metals as in 4.6 (a-e) Show samples of the listed above to students Resources Lesson plan Chalkboard Different Types of non-ferrous metal

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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 Week Specific Learning Outcome 4.8 Select suitable electrodes and machines for welding various types of given non-ferrous metals 4.9 Outline appropriate heat treatment method for a finished welding of nonferrous metal 6 4.10 Weld the following non-ferrous metals and apply the appropriate heat treatment: a. copper b. bronze c. aluminium d. brass e. iconelmonel Teachers Activities electrode and mechanics for welding various type given nonferrous metals the appropriate heat treatment method for finished weld of non ferrous metals ferrous metals and apply the appropriate heat treatment method as in 4.10 (a-e) Resources Different sizes of Electrode and Welding Machine Furnace Samples of non furnace equipment and appropriate tools

Explain the selection of suitable Lesson plan

Discuss through demonstration, Lesson plan

Demonstrate the welding of non- Lesson plan, welding

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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 Week Specific Learning Outcome Teachers Activities Resources

General Objective 5.0: Build up worn metallic shafts; air surfaces using metal arc welding Week Specific Learning Outcome metallic shafts or other worn metallic by arc welding. 5.2 Discuss the properties of the given 7 worn metallic parts to be restored by arc welding 5.3 Build-up given worn metallic parts to including controls against distortion Teachers Activities given worn metal shafts or parts restored by arc welding State the properties of given worn metal parts to be restored by arc welding Demonstrate the building up of using appropriate techniques and control against distortion General Objective 6.0: Cut Metals to various specifications using metal Arc Cutting process. Week Specific Learning Outcome Teachers Activities Resources Lesson plan Chalkboard Sketches/Charts Welding equipment and accessories Resources Lesson plan Chalkboard, and Worn metal shaft and gear teeth Lesson plan, Welding Machine and Appropriate Tools and Equipment

5.1 Identify the composition of given worn Describe the composition of a parts. e.g. gear teeth that can be restored e.g. gear teeth that can be

specification using appropriate techniques worn metal parts to specification,

6.1 Know the principles and application of Explain the principles and the following arc cutting methods in metal application of the following arc fabrication: a. air arc method b. carbon arc method 8 c. oxy arc method cutting methods in metal fabrication: i. air arc method ii. carbon arc method and iii. oxy arc method 6.2 Identify arc cutting electrodes and state their compositions and uses 6.3 Cut metals with facility using the different cutting methods named in 6.1 above. Explain arc cutting electrode stating their composition and uses Demonstrate the cutting of method named in 6.1 above

Lesson plan chalkboard various arc cutting electrode Lesson plan Arc Welding Equipment

metals using the different cutting Cutting Electrode and

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General Objective 7.0: Know various welding defects and rectify them Week Specific Learning Outcome 7.1 Describe major defects in arc welded joints including undercut; lack of fusion 9 (side, root, inter-run); porosity; slag inclusion (oxide entrenchment); unequal reinforcement. 10 7.2 Know how the weld defects in 7.1 above can be avoided 7.3 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 11 penetrant; b. destructive tests such as bend test, macro and micro examinations sulphur print, izod and fatigue 7.4 Rectify welded joint defects named 7.1 Explain how to correct defects in above 7.5 Produce project involving the application of: a. General safety 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% welded joints named in 7.1 above Test, evaluate the students in the production process Lesson plan Material, tool and equipment - Do Explain how weld defects in 7.1 Lesson plan, above can be avoided. Demonstrate the application of in arc welded joints as shown in 7.3 (a-b) Chalkboard Lesson plan, Apparatus Teachers Activities Explain major defects in arc welded joint as in 7.1 defects Resources Lesson plan Chalkboard, Samples of defects

Show students samples of these Sketches/charts

leg length (uneven alignment); and lack of Give detailed notes

the following test to detect defects Chalkboard, Testing

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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

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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 Week Specific Learning Outcome 1.1 Select, use and care for the following protective wears used in Year 3 structural steel work: Term 2 1 a. gloves b. aprons c. boots d. goggles, etc 1.2 Know safety rules for the following operations in structural steel work: a. rules for storage of full and empty gas cylinders 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 Teachers Activities Explain the use and care for protective wears used in structural steel work Demonstrate how to take care of these items Give detailed notes Explain the safety for operations Lesson plan in structural steel work and give detailed notes Chalkboard Posters Necessary Tools and Equipment Resources Lesson plan Chalkboard Posters Wears

Show students items listed in 11 Related Protective

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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 Week Specific Learning Outcome used in structural steel work: e.g. a. hammers (assorted) sheers b. spanners (assorted) 3 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 steel work: e.g. a. riveting hammer (assorted) b. holder on c. impact wrenches d. grinder e. torque spanners f. straight edge etc. List and explain the use of steel work Show the student these tools Demonstrate using these tools Give detailed notes Lesson plan Appropriate Tools and Equipment following power tools used in structural power tools used in structural Teachers Activities structural steel work Explain their uses Show students these tools Give detailed notes Ask student to sketch these tools Resources Lesson plan, Chalkboard Appropriate Tools and Equipment

2.1 Select and use common hand tools List common hand tools used in

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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 Week Specific Learning Outcome 2.3 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 4 5 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 2.4 Maintain tools, machines and e.g. by: 6 a. cleaning b. oiling c. greasing d. regrinding, etc Demonstrate how to maintain used in structural steel work Lesson plan Appropriate Tools, Equipment and Materials Oil and grease cans. Grinding machine equipment used in structural steel work tools, machine and equipment Teachers Activities List the equipment in 2.3 Explain the use of each Explain the care of each 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 Resources Lesson plan Chalkboard, charts Appropriate Tools and Equipment

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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. Week Specific Learning Outcome 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) 7 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. Teachers Activities structural steel materials Give detailed notes on each of the equipments equipment Resources Lesson plan, Chalkboard, Posters/Charts. Samples of equipment

3.1 Describe with sketches the following Sketch and explain forms of

Asked students to sketch these where available

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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. Week Specific Learning Outcome 3.2 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 8 structural steel work design. 3.4 State the use and limitations of the structural steel materials named in 3.1 above given simple structural elements. Teachers Activities Ask students to sketch and abbreviations used in representing structural steel section Explain and apply standard specifications used in structural steel work design Explain the use and limitations of the structural steel materials in Explain and apply Hooke's Law in the design of simple structural elements 3.6 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, 9 riveted and welded joints Explain simple calculations involving practical application of joints etc. Give student some problems to solve 3.8 Read structural steel work drawing details. Draw and interpret structural of simple structural steel work details Lesson plan drawings and sketches and sketch simple structural steel work steel work drawing and sketches Chalkboard Sample Lesson plan Chalkboard Explain and state the differences of stresses in structural steel work Lesson plan Chalkboard Charts Resources Lesson plan Lesson plan Chalkboard, Charts Lesson plan Chalkboard Lesson plan Chalkboard

explain conventional symbols and Chalkboard Charts.

3.5 Apply Hooke's Law in the design of 3.1

compressive and shear stresses, e.g. in stresses in riveted joint, welded

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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 Week Specific Learning Outcome 4.1 Calculate allowances for forming 10 following methods: a. meanline method b. neutral line method Teachers Activities Explain calculations of or angle bar rings using meanline and neutral line method Solve some problems Lesson plan Appropriate tools materials Lesson plan Drawing instruments Lesson plan Tools and Equipment Resources Lesson plan

thick metal or angle bar rings using the allowances for forming thick metal Chalkboard sketches

4.2 Produce simple projects in structural Give students projects to 11 steel work e.g. stanchion bar plate rafter demonstrate the production of hunches, etc. 4.3 Develop templates with regular surfaces materials: a. wood b. cardboard c. any other suitable materials 4.5 Reproduce simple jobs on structural Give student Project to steel materials using templates cut in 2 4.4 above demonstrate how to reproduce simple jobs on structural steel materials using templates in 4.4 above work 12 Demonstrate how to develop templates with regular surfaces

simple projects in structural steel equipment and

4.4 cut out templates from the following Demonstrate how to cut Year 3 Term 3 1 Ask student to cut out template on wood, cardboard etc

templates from various materials Appropriate Materials

Lesson plan Appropriate Materials Tools and Equipment

4.6 sketch and produce simple working Demonstrate how to sketch and Lesson plan 3 jigs, e.g. jig for mass production of stanchions, rafters, etc., on the shop floor produce simple working jigs. Ask students to do the same Appropriate Tools and Equipment.

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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 Week Specific Learning Outcome its working principles Teachers Activities Resources

5.1 Sketch a blast furnace and describe Sketch and label a blast furnace Lesson plan and explain the working principles Chalkboard Note: Student should visit industry/factory to see a typical 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 5.3 Explain the working principles of Bessemer process with the aid of a sketch fuel and the composition of charge used in blast furnace Ask students to state the working principles of a Bessemer process with the aid of a sketch. Students are asked to sketch Bessemer converter 5.4 Outline the characteristics of pig iron, cast iron and low carbon steel List the characteristics of pig iron, cast iron and low carbon steel - Charts - do chalkboard, charts Posters/Chart Industrial Visit

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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 Week Specific Learning Outcome in the assembly of structural components 6.2 Assemble simple structural 5 components such as rafter bracing, Note: Assembly should involve basic jointing operations, e.g. bolting, riveting and welding protective coating against corrosion. Week Specific Learning Outcome 7.1 Name some common causes of corrosion on steel e.g. 6 a. atmospheric b. chemical such as electrolytic action.etc 7.2 Describe the effect of corrosion on structural steel, e.g. 7 a. weakening of structure b. defacing of steel 7.3 Know the purposes for applying 8 undercoat to structural steel components Explain the purposes for applying undercoat to structural steel components - do Teachers Activities Ask students to list some common causes of corrosion on steel Show student samples of corroded steel. Ask students to explain the effects of corrosion on structural steel - do Resources Lesson plan Chalkboard Sample of corroded steel Demonstrate how to assemble using bolts, rivets and welding operation Show samples of some of these assemblies simple canopy simple roof trusses, etc. simple structural components, Teachers Activities Resources

6.1 Know the uses of fixtures and bolts Explain the uses of fixtures and Lesson plan bolts in the assembly of structural Chalkboard, bolts and components Give detailed notes Lesson plan Appropriate Tools and Equipment fixtures

General Objective 7.0: Know the effect of corrosion on structural steel materials and apply

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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. Week Specific Learning Outcome 7.4 Prepare the surfaces of structural steel components for finishing with the 9 following methods: b. brushing c. de-greasing d. de-scaling 7.5 State the composition of common 10 List and explain the composition Lesson plan Chalkboard, Charts, and samples of under coat 7.6 Apply suitable undercoat to structural steel components. E.g. red 11 oxide, metalization use of the undercoats. 7.7 Produce project involving the 12 application of safety rules in structural steel work Week 13 Examination - Practical 60%, Theory 40% Test, evaluate the student in the Lesson plan process of the production Material, tool and equipment Demonstrate the application of suitable undercoat to structural steel components and observe Lesson plan Appropriate Tools and Equipment structural steel work. undercoat used for structural steel work of common undercoat used for Teachers Activities surface of structural steel components for finishing Ask the student to perform the operation above Resources Appropriate Tools and Equipment

Demonstrate how to prepare the Lesson plan

Note: Observe safety precautions in the safety precautions.

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