Welding Waec Syllabus

Workshop and standard workshop practices

1. Introduction to fabrication and welding practice
2. Safety precautions in welding and fabrication workshops
   • Types and causes of accidents in the workshop (fire, explosion, sharp objects, hazardous gases, etc.).
   • Accident prevention measures.
   • Types and causes of environmental pollution.
   • Methods of preventing environmental pollution.
   • Safety facilities and protective wear.
3. Workshop layout (fabrication and welding)
4. Standard welding codes and symbols
5. First-Aid administration in the workshop
6. Practical
   • Demonstration of the use of protective wear in welding and fabrication
   • Demonstration of the use of first aid in the workshop

Properties of metals and selection

1. Ferrous and non-ferrous metals (steel, aluminum, cast iron, copper and zinc, tin, alloy steel)
2. Properties of metals (ductility, hardness, toughness, malleability, fusion and tenacity, brittleness, elasticity and plasticity)
3. Sheet metal (aluminum, mild steel, brass)
   • the concept of sheet metal
   • gauges of sheet metal
4. Selection of suitable metals for specific jobs
5. Heat treatment of metals (hardening, annealing, normalizing, tempering and case-hardening, etc.)
   • Identification of ferrous and non-ferrous metals
   • Annealing, Hardening and Normalizing of Metals

Tools and Equipment in Fabrication and Welding

1. Identification of tools and equipment for fabrication and welding
2. Equipment set-up for gas, arc welding and fabrication
3. Job holding devices for fabrication and welding
4. Measuring instruments, marking out and cutting tools
5. Identification of parts and accessories for gas and arc welding
6. Maintenance procedure for arc and gas (oxy-acetylene) welding equipment
7. Preparation of acetylene gas from carbide
8. Types of electrodes and their composition, their application, gauges of electrodes, and selection of appropriate electrodes for a specific job
9. Equipment for fault detection and troubleshooting in fabrication and welding
10. Practical
    • Student to set up oxy-acetylene equipment
    • Demonstration of the use of measuring, marking out and cutting tools
    • Demonstration of the use of measuring, marking out and cutting tools

Operations and Techniques in Welding and Fabrication

1. Types of welding (Gas and Arc welding), explanation of the principles of gas and arc welding and their differences
2. Description of a typical fabrication process
3. Types of joints, joint methods and application in welding and fabrication
4. Classification of marking-out techniques in welding and fabrications
5. Description of the use of templates for fabricated and welded assemblies
6. Welding techniques and application
7. Techniques in fabrication work
   • Description of folding techniques and their importance in fabrication work
8. Practical
   • Demonstration of various job-cutting techniques
   • Students weld using both leftward and rightward methods
   • Students to work on wire-edge projects

Fasteners

1. Classification of fasteners
2. Rivet and its application
3. Bolt and nuts
4. Screws
5. Practical
   • Students to produce rivets joints
   • Students to produce bolts and nuts

Forging Process

1. Definition of forging
2. Forging tools and equipment (furnace, swages, fullers, flatters and tongs)
3. Forging process
   • upsetting.
   • drawing down
   • twisting
   • bending
   • forging an eye.
4. Practical
   • Students to form an eye

Preparation of welding surfaces and environment

1. Preparation of welding surfaces by cleaning with a wire brush, emery cloth, files, scrappers and grinding machine
2. Preparation of edges for welding, e.g., single V, double V, fillets
3. Post-surface preparation
   • cleaning the surface with a wire brush
   • oiling surface to protect from corrosion or rusting
4. Defect in welding surfaces (causes and remedies).
5. Definition of the welding environment
   • awkward, unventilated, flammable material
   • slippery floor (oil/grease on the floor)
6. Surface furnishing for fabrication and welding (painting, metal spraying,  galvanizing and oiling)
7. Practical
   • Preparation of single V surface for welding

Practical Work/Project

1. Marking of shapes (triangle, square and rectangle)
2. Cutting and bending of triangles, squares and rectangles
3. Soldering of sheet metals
4. Welding of steel using arc welding
5. Welding of steel using gas welding
6. Fabrication of ferrous and non-ferrous metals into required shapes
7. Suggested projects (students to produce the following)named plate -  trinket box -  funnel -  kitchen stool -  car stopper -  metal rake  -  scoop -  hinges -  charcoal stove, etc.
   • named plate
   • trinket box
   • funnel
   • kitchen stool
   • car stopper
   • metal rake
   • scoop
   • hinges
   • charcoal stove, etc.

Business Entrepreneurship Opportunity

1. Definition of
   • entrepreneurship
   • employer
   • employee
2. Enterprises
   • small-scale enterprise
   • medium-scale enterprise
   • large-scale enterprise
3. Factors for setting up a workshop (cost, site, weather, material, manpower, market, source of power, transportation)
4. Practical
   • Site visitations to existing enterprises (small, medium or large scale)

LIST OF FACILITIES AND MAJOR EQUIPMENT/MATERIALS REQUIRED

1. 1. Hammers (various types)
   2. Try squares
   3. Chisels
   4. Bending rollers
   5. The combined set of cutting
   6. welding outfits
   7. Bench Grinding Machine
   8. Bench-mounted cone roller
   9. Regulators with flow meters
   10. Electrode Holders
   11. Bench shares
   12. Water to carbide generator
   13. Electrode drying oven
   14. Power Hacksaw
   15. Pillar Drilling Machine
   16. Hand gloves
   17. Vee blocks
   18. Anvil
   19. Smith open forge
   20. Straight edges
   21. Aprons
   22. Swage block
   23. Vice (bench)
   24. Trammel drivers
   25. O2 Cylinders
   26. Chipping hammers
   27. Bench-type Grinding Machine
   28. Left and right snips
   29. Transformers with rectifiers
   30. Flatters
   31. Double-ended buffer and polisher
   32. Straight snips
   33. Hand shield and Head caps
   34. Mole grip
   35. Blowpipes (low and high pressure)
   36. Rule, Scriber and dividers
   37. Gas welding goggles
   38. Sledge Hammers
   39. Files assorted
   40. Hand nibbling machine
   41. Double cylinder Trolley
   42. Plain goggles
   43. Acetylene Cylinder
   44. Wire brushes
   45. Oxygen regulators
   46. G – clamp
   47. Parallel Clamp
   48. Pliers-assorted
   49. Acetylene regulators
   50. First-aid box
   51. Toolmakers clamp
   52. Tongs Assorted
   53. Hoses, Clips and all attachments accessories
   54. Magnetic clamp
   55. Mallets
   56. Hacksaws and blades
   57. DC generators with all connections
   58. Self grip pliers
   59. Workbench
   60. Guillotine
   61. AC Transformers
   62. Folding bars
   63. Fire Extinguisher
   64. Sand bucket
   65. Cramp Folding Machine
   66. Riveting Pliers
   67. Riveting set

RECOMMENDED BOOKS

1. Welding and Fabrication by W. Kenyon
2. The Science and Practice of Welding by A. C. Davis
3. Fabrication and Welding by F. J. M. Smith
4. Basic Welding by P. Somsky
5. The Theory and Practice of Metalwork by George Love
6. Metal Craft Theory and Practice by John R. Bedford
7. Metalwork Motivate Series by J. K. N. Sackey & S. K. Amoakohene
8. Metalwork Technology by G. H. Thomas
9. Workshop Processes and Materials by J. V. Courtney
10. Ilesanmi Metalwork for Senior Secondary School Books 1 – 3 by Adejuyigbe S. B. and S. K. Akinlosose
11. Practical Welding  Motivate Series S. W. Gibson and B. K. Amoako-Awuah