Welding

Below is this year’s WAEC syllabus for Welding And Fabrication Engineering Craft Practice. Note that this syllabus is for both internal and external candidates.

 SCHEME OF EXAMINATION

There will be three papers, Papers 1, 2 and 3, all of which must be taken.

Papers 1 and 2 will be composite papers to be taken in one sitting.

Paper 1:

This will consist of forty multiple-choice objective questions, all of which are to be answered in 1 hour for 40 marks.

Paper 2:

The second paper (Paper 2) will consist of five questions, out of which candidates will be required to answer any four in 1½ hours for 60 marks.

Paper 3:

This will be a practical test of 3 hours, 10 minutes in duration.  It will consist of one compulsory question for 100 marks.

A list of materials for the test shall be made available to schools not less than two weeks before the paper is taken for material procurement and relevant preparations.

 ALTERNATIVE TO PRACTICAL TEST

The Council may consider testing candidates’ ability in practical work as prescribed in the syllabus in the event that materials for the actual practical test cannot be acquired.  For this alternative test, there will be one question to be answered in 3 hours for 100 marks

DETAILED WAEC Syllabus for Welding

1. Workshop and standard workshop practices

Content:

1.1.           Introduction to fabrication and welding practice.

1.2.           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.

1.3.      Workshop layout (fabrication and welding).

1.4 .     Standard welding codes and symbols.

1.5.       First-Aid administration in the workshop.

Practical:

1.2.1.   Demonstration of the use of protective wear in welding and fabrication.

1.5.1.    Demonstration of the use of first aid in the workshop.

2. Properties of metals and selection.

Content:

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

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

2.3.      Sheet metal (aluminum, mild steel, brass)

• – the concept of sheet metal
• –    gauges of sheet metal

2.4.    Selection of suitable metals for specific jobs.

2.5      Heat treatment of metals (hardening, annealing, normalizing, tempering and case-hardening, etc.)

Practical:

2.1.1     Identification of ferrous and non-ferrous metals.

2.5.1.   Annealing, Hardening and Normalizing of Metals

3. Tools and Equipment in Fabrication and Welding

Content:

3.1.     Identification of tools and equipment for fabrication and welding.

3.2.     Equipment set-up for gas, arc welding and fabrication.

3.3.     Job holding devices for fabrication and welding.

3.4.     Measuring instruments, marking out and cutting tools.

3.5.     Identification of parts and accessories for gas and arc welding.

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

3.7.     Preparation of acetylene gas from carbide.

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

3.9.      Equipment for fault detection and troubleshooting in fabrication and welding.

Practical:

3.1.1.   Student to set up oxy-acetylene equipment

3.4.1.   Demonstration of the use of measuring, marking out and cutting tools.

3.5.1.   Demonstration of the preparation of acetylene gas from carbide.

4. Operations and Techniques in Welding and Fabrication.

Content:

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

4.2.     Description of a typical fabrication process.

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

4.4.     Classification of marking-out techniques in welding and fabrications.

4.5.     Description of the use of templates for fabricated and welded assemblies.

4.6.     Welding techniques and application.

4.7.     Techniques in fabrication work

• –   Description of folding techniques and their importance in fabrication work.

Practical:

4.3.1.   Demonstration of various job-cutting techniques.

4.6.1.   Students weld using both leftward and rightward methods.

4.7.1.   Students to work on wire-edge projects.

5. Fasteners

(a)    Classification of fasteners.

(b)    Rivet and its        application

(c)    Bolt and nuts

(d)    Screws

Content:

5.1.    Permanent fasteners.

5.2.    Temporary fasteners.

5.3.     Types of rivets.

5.4.      Uses of rivets.

5.5.      Description of bolts and nuts.

5.6.      Uses of bolts and nuts

5.7.      Classes of rivets and screws.

Practical:

5.4.1.   Students to produce rivets joints.

5.5.1.    Students to produce bolts and nuts.

6. Forging Process

– Introduction to forging

Content:

6.1.      Definition of forging

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

6.3.    Forging process

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

Practical:

6.3.1.   Students to form an eye.

7. Preparation of welding surfaces and environment.

Contents:

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

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

7.3. Post-surface preparation

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

7.4.       Defect in welding surfaces (causes and remedies).

7.5.      Definition of the welding environment

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

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

Practical:

7.2.1.    Preparation of single V surface for welding.

8. Practical Work/Project

Content:

8.1.    Marking of shapes (triangle,           square and rectangle).

8.2.    Cutting and bending of triangles, squares and rectangles.

8.3.    Soldering of sheet metals

8.4.    Welding of steel using arc welding.

8.5.    Welding of steel using gas welding.

8.6.    Fabrication of ferrous and non-ferrous metals into required shapes.

8.7     Suggested projects (students to produce the following):

• –  named plate
• –  trinket box
• –  funnel
• –  kitchen stool
• –  car stopper
• –  metal rake
•  –  scoop
• –  hinges
• –  charcoal stove, etc.

9. Business Entrepreneurship Opportunity

Content:

9.1.    Definition of

• –  entrepreneurship
• –  employer
• –  employee.

9.2     Enterprises

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

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

Practical:

9.3.1.   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

S/NO.	BOOKS	AUTHOR
1 2 3 4 5 6 7	Welding and Fabrication The Science and Practice of Welding Fabrication and Welding Basic Welding The Theory and Practice of Metalwork Metal Craft Theory and Practice Metalwork Motivate Series	W. Kenyon A. C. Davis F. J. M. Smith P. Somsky George Love John R. Bedford J. K. N. Sackey & S. K. Amoakohene
8 9 10	Metalwork Technology Workshop Processes and Materials Ilesanmi Metalwork for Senior Secondary School Books 1 – 3	G. H. Thomas J. V. Courtney Adejuyigbe S. B. and S. K. Akinlosose
11	Practical Welding  Motivate Series	S. W. Gibson and B. K. Amoako-Awuah

Additional Reading: awajis.com/category/waec

Related:

Mining

Auto Body Repairs

Refrigeration And Air-Conditioning

GSM Phones