Welding Waec Syllabus

Workshop and standard workshop practices

Introduction to fabrication and welding practice

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.

Workshop layout (fabrication and welding)

Standard welding codes and symbols

First-Aid administration in the workshop

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

Ferrous and non-ferrous metals (steel, aluminum, cast iron, copper and zinc, tin, alloy steel)

Properties of metals (ductility, hardness, toughness, malleability, fusion and tenacity, brittleness, elasticity and plasticity)

Sheet metal (aluminum, mild steel, brass)

• the concept of sheet metal
• gauges of sheet metal

Selection of suitable metals for specific jobs

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

Identification of tools and equipment for fabrication and welding

Equipment set-up for gas, arc welding and fabrication

Job holding devices for fabrication and welding

Measuring instruments, marking out and cutting tools

Identification of parts and accessories for gas and arc welding

Maintenance procedure for arc and gas (oxy-acetylene) welding equipment

Preparation of acetylene gas from carbide

Types of electrodes and their composition, their application, gauges of electrodes, and selection of appropriate electrodes for a specific job

Equipment for fault detection and troubleshooting in fabrication and welding

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

Types of welding (Gas and Arc welding), explanation of the principles of gas and arc welding and their differences

Description of a typical fabrication process

Types of joints, joint methods and application in welding and fabrication

Classification of marking-out techniques in welding and fabrications

Description of the use of templates for fabricated and welded assemblies

Welding techniques and application

Techniques in fabrication work

• Description of folding techniques and their importance in fabrication work

Practical

• Demonstration of various job-cutting techniques
• Students weld using both leftward and rightward methods
• Students to work on wire-edge projects

Fasteners

Classification of fasteners

Rivet and its application

Bolt and nuts

Screws

Practical

• Students to produce rivets joints
• Students to produce bolts and nuts

Forging Process

Definition of forging

Forging tools and equipment (furnace, swages, fullers, flatters and tongs)

Forging process

• upsetting.
• drawing down
• twisting
• bending
• forging an eye.

Practical

• Students to form an eye

Preparation of welding surfaces and environment

Preparation of welding surfaces by cleaning with a wire brush, emery cloth, files, scrappers and grinding machine

Preparation of edges for welding, e.g., single V, double V, fillets

Post-surface preparation

• cleaning the surface with a wire brush
• oiling surface to protect from corrosion or rusting

Defect in welding surfaces (causes and remedies).

Definition of the welding environment

• awkward, unventilated, flammable material
• slippery floor (oil/grease on the floor)

Surface furnishing for fabrication and welding (painting, metal spraying,  galvanizing and oiling)

Practical

• Preparation of single V surface for welding

Practical Work/Project

Marking of shapes (triangle, square and rectangle)

Cutting and bending of triangles, squares and rectangles

Soldering of sheet metals

Welding of steel using arc welding

Welding of steel using gas welding

Fabrication of ferrous and non-ferrous metals into required shapes

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

Definition of

• entrepreneurship
• employer
• employee

Enterprises

• small-scale enterprise
• medium-scale enterprise
• large-scale enterprise

Factors for setting up a workshop (cost, site, weather, material, manpower, market, source of power, transportation)

Practical

• Site visitations to existing enterprises (small, medium or large scale)

LIST OF FACILITIES AND MAJOR EQUIPMENT/MATERIALS REQUIRED

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

Welding and Fabrication by W. Kenyon

The Science and Practice of Welding by A. C. Davis

Fabrication and Welding by F. J. M. Smith

Basic Welding by P. Somsky

The Theory and Practice of Metalwork by George Love

Metal Craft Theory and Practice by John R. Bedford

Metalwork Motivate Series by J. K. N. Sackey & S. K. Amoakohene

Metalwork Technology by G. H. Thomas

Workshop Processes and Materials by J. V. Courtney

Ilesanmi Metalwork for Senior Secondary School Books 1 – 3 by Adejuyigbe S. B. and S. K. Akinlosose

Practical Welding  Motivate Series S. W. Gibson and B. K. Amoako-Awuah