ED/STV/2001/PI/10

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

Curriculum and Course Specifications

NATIONAL BOARD FOR TECHNICAL EDUCATION Federal Republic of Nigeria

UNESCO Nigeria Project

2001

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

Curriculum and Module Specifications OFFICE: PLOT B, BIDA ROAD, P.M.B. 2239, KADUNA

NATIONAL TECHNICAL CERTIFICATE AND ADVANCED NATIONAL TECHNICAL CERTIFICATE PROGRAMMES

Table of Contents
General Information .............................................................................................................3 Curriculum Table (NTC).......................................................................................................7 Curriculum Table (ANTC) ....................................................................................................8 National Technical Certificate ..............................................................................................9 General Metalwork I .........................................................................................................9 General Metalwork II ......................................................................................................27 Sheet metal Work...........................................................................................................33 Gas Welding and cutting ................................................................................................42 Metal Arc Welding ..........................................................................................................51 Structural Steel Work .....................................................................................................62 Advanced National Technical Certificate ...........................................................................72 Welding ..........................................................................................................................72 Structural Mechanics and Specification..........................................................................87 Structural Steel Work .....................................................................................................91 Sheet metal work ...........................................................................................................95 List of tools and equipment for welding and fabrication engineering................................100 Guideline for textbooks development...............................................................................103 Recommended books for fabrication and welding engineering craft practice ..................105 List of Participants ...........................................................................................................106

General Information
AIM To give training and impart the necessary skills leading to the production of craftsmen, technicians and other skilled personnel who will be enterprising and self-reliant. ENTRY QUALIFICATIONS Craft Programme Candidates must not be less than 14 years of age and should have successfully completed three years of Junior Secondary education or its equivalent. Special consideration may be given to sponsored candidates with lower academic qualifications who hold trade test certificates and are capable of benefiting from the programme. Advanced Craft Programme Candidates should possess the National Technical Certificate or its equivalent and should have had a minimum of two years post qualification cognate industrial experience. The Curriculum The Curriculum of each programme is broadly divided into three components: a. General Education, which accounts for 30% of the total hours required for the programme. b. Trade Theory, Trade Practice and Related Studies which account for 65% and c. Supervised Industrial Training/Work Experience, which accounts for about 5% of the total hours required for the programme. This component of the course which may be taken in industry or in college production unit is compulsory for the full-time students. Included in the curriculum is the teacher's activity and learning resources required for the guidance of the teacher. Unit Course/Modules A Course/Module is defined as a body of knowledge and skills capable of being utilized on its own or as a foundation or pre-requisite knowledge for more advanced work in the same or other fields of study. Each trade when successfully completed can be used for employment purposes.

Behavioural Objectives These are educational objectives, which identify precisely the type of behaviour a student should exhibit at the end of a course/module or programme. Two types of behavioural objectives have been used as the curriculum. They are: a. General Objectives b. Specific learning outcomes General objectives are concise but general statements of the behaviour of the students on completion of a unit of week such as understanding the principles and application in: a. Orthographic projection in engineering/technical drawing; b. Loci in Mathematics c. Basic concepts of politics and government in Political Science d. Demand and supply in Economics Specific learning outcomes are concise statements of the specific behaviour expressed in units of discrete practical tasks and related knowledge the students should demonstrate as a result of the educational process to ascertain that the general objectives of course/programme have been achieved. They are more discrete and quantitative expressions of the scope of the tasks contained in a teaching unit. General Education In Technical Colleges The General Education component of the curriculum aims at providing the trainee with complete secondary education in critical subjects like English Language, Economics, Physics, Chemistry, Biology, Entrepreneurial Studies and Mathematics to enhance the understanding of machines, tools and materials of their trades and their application and as a foundation for post-secondary technical education for the above average trainee. Hence, it is hoped that trainees who successfully complete their trade and general education may be able to compete with their secondary school counterparts for direct entry into the polytechnics or colleges of education (technical) for ND or NCE courses respectively. The Social Studies component is designed to broaden the trainee's social skills and his understanding or his environment. For the purpose of certification, only the first three courses in mathematics will be required. The remaining modules are optional and are designed for the above average students. National Certification The NTC and ANTC programmes are run by Technical Colleges accredited by NBTE. NABTEB conducts the final National examination and awards certificates.

Trainees who successfully complete all the courses/modules specified in the curriculum table and passed the national examinations in the trade will be awarded one of the following certificates: S/NO LEVEL Technical Programme 1. 2. Craft Level Advanced Craft Level National Technical Certificate Advanced National Technical Certificate CERTIFICATE

Guidance Notes For Teachers Teaching The Curriculum The number of hours stated in the curriculum table may be increased or decreased to suit individual institutions' timetable provided the entire course content is properly covered and the goals and objectives of each module are achieved at the end of the term. The maximum duration of any module in the new scheme is 300 hours. This means that for a term of 15 weeks, the course should be offered for 20 hours a week. This can be scheduled in sessions of 4 hours in a day leaving the remaining hours for general education. However, (properly organized and if there are adequate resources), most of these courses can be offered in two sessions a day, one in the morning and the other one in the afternoon. In so doing, some of these programmes may be completed in lesser number of years than at present. The sessions of 4 hours include the trade theory and practice. It is left to the teacher to decide when the class should e held in the workshop or in a lecture room. Integrated Approach In The Teacher Of Trade Theory, Trade Science And Trade Calculation The traditional approach of teaching trade science and trade calculation as separate and distinct subjects in technical college programmes is not relevant to the new programme as it will amount to a duplication of the teaching of mathematics and physical science subjects in the course. The basic concepts and principles in mathematics and physical science are the same as in the trade calculation and trade science. In the new scheme therefore, qualified persons in these fields will teach mathematics and physical science and the instructors will apply the principles and concepts in solving trade science and calculation problems in the trade theory classes. To this end, efforts have been made to ensure that mathematics and science modules required to be able to solve technical problems were taken as pre-requisite to the trade module.

Evaluation Of Programme/Module For the programme to achieve its objectives, any course started at the beginning of a term must terminate at the end of the term. Instructors should therefore device methods of accurately assessing the trainees to enable them give the student's final grades at the end of the term. A national examination will be taken by all students who have successfully completed their modules. The final award will be based on the aggregate of the scores attained in the course work and the national examination.

Curriculum Table (NTC)

NTC FABRICATION AND WELDING ENIGINEERING CRAFT PRACTICE YEAR 1 S/No Subject Code Module 1 2 3 1 YEAR 2 2 3 1 YEAR 3 Total Hours for each T P T P T P T P T P T P T P T P T P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CMA 12- Mathematics 15 CEN 11- English 17 CPH 10- Physics 12 CCH 11- Chemistry 12 CEC 11- Economics 13 CBM 11 Entrepreneurship CTD 11- Drawing 13 ICT 11- Computer Studies 15 CME 11 General Metal Work I 2 5 2 CME 12 General Metal Work II CFW 11 Sheet Metal Work CFW 12 Gas Welding and Cutting CFW 13 Metal Arc Welding CFW 14 Structural Steel Work CFW 11 Sheet metal Work GRAND TOTAL 2 5 3 3 6 6 3 3 6 6 216 216 180 2928 - 3 - 3 6 6 3 3 6 6 216 216 5 2 3 168 60 1 2 1 2 1 2 1 2 1 2 180 3 3 3 2 3 2 3 2 2 2 2 72 288 2 2 2 2 2 2 - 2 216 2 2 2 2 1 2 1 2 1 2 1 2 1 2 1 288 2 2 2 2 1 2 1 2 1 2 1 2 1 2 1 288 2 2 2 3 3 3 - 3 3 3 288 2 2 2 2 2 2 - 2 2 2 216 288 2 3

Term Term Term Term Term Term Term Term Term

3 -

6 2

12 8 12 8 12 6 14 7 14 7 14 7 18 18 22 30 15 16

Curriculum Table (ANTC)

ANTC FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE YEAR 1 S/No Subject Code Module Term 1 Term 2 Term 3 Total Hours for each T 1. 2 3 4 5 6 7 8 9 10 11 CMA 21-22 CEN 21-22 CTD 21 CTD 22 CEC 21-23 CBM 21 ICT 21-22 CFW 21 CFW 22 CFW 23 CFW 24 Mathematics English and Communication Engineering Drawing and Design Fabrication Drawing Economics Entrepreneurship Computer Studies Welding Structural Mechanics & Specification Structural Steel work Sheet metal work TOTAL 2 2 2 2 1 2 2 P 3 2 5 5 T 2 2 2 2 2 2 2 2 2 P 3 3 2 6 5 6 5 T 2 2 2 2 2 2 P 3 6 6 72 72 72 72 72 72 72 180 180 180 180 1044

13 15 17 30 12 15

National Technical Certificate

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

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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.

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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

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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,

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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

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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: 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

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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,

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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

25

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

26

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

27

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.

28

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

29

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

30

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

31

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%

32

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

33

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

34

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

35

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

36

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)

37

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

38

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.

39

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.

40

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

41

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

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: 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

43

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

44

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

45

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

46

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

47

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

48

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

49

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%

50

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

51

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

52

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

53

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

54

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

55

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

56

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

57

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

58

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

59

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

60

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

61

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

62

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

63

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

64

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

65

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

66

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

67

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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Advanced National Technical Certificate

Welding
PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 21-Welding 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to equip the trainee with advanced skills and knowledge required to carry out gas shielded arc and ancillary welding process with proficiency General Objectives: 1. Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes 2. Understand the constructional features and the working principles of TIG and MIG welding machines and accessories 3. Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 4. Apply appropriate workshop processes and techniques to mark out and form projects for welding 5. Make different types of welded joints in all positions 6. Understand and apply the fuel-gas cutting process in cutting metals to given specification. Practical Competence On completion of this module, the student will be able to: 7. Comply with general safety related to gas shielded arc and ancillary welding process 8. Apply basic principles and techniques of TIG and MIG welding in fabricating simple machine component parts 9. Use workshop process techniques and tools to mark out and form projects in welding 10. perform welding operations in all position involving different types of joints

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11. Cut metals to given specification using the fuel gas cutting process PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes Week Specific Learning Outcome environment with particular reference to personal safety, and the student's responsibility to others. a. State the reasons for the use of face protection and the wearing of protective clothing. b. Describe the dangers inherent in the following: grinding, oxy-acetylene 1 welding, metal arc welding, shearing, bending, folding, compressed air, lifting tackle. c. State the correct methods for handling, storing and using compressed gas cylinders. d. State the dangers of electric shock and describe user precautions. Teachers Activities safe working environment with respect to safety to self and others as per 1.1 (a-d) Resources plan chalkboard goggle and appropriate equipment

1.1 Know the importance of a safe working Explain the importance of a Welding tools, lesson

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes Week Specific Learning Outcome gas shielded arc welding. e.g. a. arc eye b. burning c. radiation d. electric shock e. toxic fumes, etc. 1.3 Select, use and care for the protective Explain the use and care for Lesson plan and wears used in gas shielded arc welding operations: e.g. a. head and pan shields b. hand gloves c. apron d. spats e. boots, etc. 1.4 Apply with facility, appropriate safety precautions required in carrying out TIG and MIG welding operations: a. in confined spaces b. on empty vessels or drums that had contained inflammable or toxic materials near inflammable materials, e.g. petrol tanker, etc the protective wears used in gas shielded arc welding operations as in 1.3 (a-e) Show students items listed in 1.3 (a-e) Ask student to sketch the items Demonstrate with facilities appropriate safety precautions required in carrying out TIG and MIG welding operation as listed in 1.4 (a-c) Lesson plan and protective wears Welding Equipment protective wears Teachers Activities to gas shielded arc welding as listed in 1.2 (a-e) Resources Chalkboard. And chart

1.2 List and explain the hazards related to Describe the hazard related Lesson plan

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the constructional features and the working principles of TIG and MIG welding machines and accessories Week Specific Learning Outcome functions of the following equipment and accessories: a. DC and AC machines b. High frequency unit c. Gas economizer d. Regulator e. Air and water cooled torches f. Pedal switch g. Gas nozzles h. Suppressor unit i. Flow meter j. Contactor k. Nylon hoses, etc 2.2 State the advantages and disadvantages of AC and DC welding systems 2.3 Identify the electrodes and filler wires 2.4 Identify the following gas cylinders by their colour codes: a. argon b. helium c. carbon dioxide d. hydrogen e. nitrogen 2.5 State the main advantage of the TIG process over other welding processes. f. Explain the advantages and l. Lesson plan, chalkboard disadvantages of AC and DC m. Lesson plan, welding system chalkboard and TIG n. Lesson plan and chalkboard g. Describe the electrode and accessories and state their composition and show students samples of electrode and filler wire h. Ask students to explain and show gas cylinders by their colour code as listed in 2.4 (ae) i. Call on students to identify them j. Give detailed notes k. Ask students to explain the main advantage of TIG process over other welding processes Teachers Activities features and functions of equipment and accessories listed in 2.1 (a-k) b. Show students items listed in 2.1 (A-K) c. Ask students to sketch the items d. Give student short notes on each Resources e. Lesson plan, chalkboard, sketches and charts and some accessories 2.1 Explain the constructional features and a. State the constructional

for TIG process and state their composition filler wires for TIG process

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.1 Explain the following major process variables and characteristics. a. Electrical b. Direct current, pulsed current alternating current rectification and modulation volt,/ampere characteristics arc initiation. c. Electrodes d. Types, shapes, current carrying capacities and 3 applications. e. Shielding Gases f. Pure and mixed, functions and applications g. d) Filler materials and their composition 3.2 Appreciate the applications of TIG welding process and select suitable Explain the application of TIG welding process and Lesson plan, Chalkboard Teachers Activities major process variables and (a-d) Demonstrate TIG welding to students, emphasizing types of current rectification and modulation Show students the different types of electrodes and the profiles Explain the importance of shielding glasses Give detailed notes on all of the above Resources Sketches/Charts

Ask students to describe the Lesson plan, Chalkboard characteristics as listed in 3.1 accessories and materials

operating characteristics for the welding of state operating characteristics Charts the following: low carbon steels, high yield for the welding listed in 3-2 steels, stainless alloys, nimonic alloys, titanium alloy, cooper alloys and aluminum alloys. and give detailed notes

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.3 Compare backing materials, purging and under-bead shielding as a means of producing acceptable welds. 3.4 Explain the effects of joint preparation on the production of acceptable and 4 economical welds by the TIG welding processes 3.5 Explain the importance of adhering to specifications, codes and standards for TIG welding processes. Teachers Activities Explain backing materials purging and under-bead shielding as mean of producing acceptable welds. State the effect of joint preparation on the production of acceptable and economical welds by TIG welding processes and give notes. State the importance of adhering to specification codes and standards for TIG welding processes and give notes - do - do Resources Lesson plan and chalkboard

77

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.6 List and state the functions of TIG earth lead, welding lead, etc. 3.7 Describe with sketches the materials used for TIG welding. to weld the following metals - aluminum, copper and stainless steel at specified voltage observing safety precautions 5 3.9 Explain the difference between TIG and MIG processes. Teachers Activities Resources

Explain the functions of TIG Lesson plan, Chalkboard in 3.6 With the aid of sketch or sketch each of the items sketches the materials of electrodes use for TIG welding. Ask students to demonstrate the setting up and use of TIG welding machines for welding metals as listed in 3.8 observing all safety precautions Call on students to perform above. Ask students to state the differences between TIG and MIG processes TIG welding accessories do Lesson plan TIG welding machine Lesson plan Chalkboard

welding accessories, e.g. electrode holder, welding accessories as listed and

composition of different types of electrodes diagram, ask student to

3.8 Set and use the TIG welding machines Ask students to explain with equipment and materials. composition of different types and Charts

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.10 Explain the factors that govern the design of joints requiring MIG and TIG processes e.g. a) type of metal b) thickness of metal c) shape of material d) position of joint; and welding various metal joints using TIG and MIG processes in the following positions: a) flat positions b) confined space c) other positions 3.11 Sketch and explain the meaning of the various arc welding symbols/conventions, e.g. symbol of a of weld on both sides etc. Sketch and state the meaning of the various arc Lesson plan Chalkboard and Teachers Activities the design of joints requiring MIG and TIG processes as listed in 3.10 (a0c) and demonstrate the welding of metal joints using TIG and MIG processes in positions listed in 3.10 Ask the students to practice the process Give detailed notes Resources TIG welding equipment and accessories and materials.

State the factors that govern Lesson plan Chalkboard

welding symbols/conventions Sketch/chart

single V butt weld with sealing run, symbol as out line in 3.11

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.12 Weld metals using at least six of the following ancilliary welding processes: a. resistance b. spot c. seam d. projection e. submerged arc f. flash butt g. fire cracker h. stud i. atomic hydrogen, etc. j. Thermit k. Helectrode l. plasma arc 3.13 Outline the factors governing the choice of any of the ancilliary processes named in 3.12 above 3.14 Produce using TIG and MIG welding techniques the following items: a. pressure vessels 6 b. pipe flanges c. boiler drums d. box section chassis e. tool post guides on a lathe machine f. fixed clusters, etc. 3.15 Weld the fixed cluster in a gearbox. Demonstrate the use of TIG Lesson plan and MIG welding techniques f) Give detailed notes fixed cluster in a gearbox Ancilliary/welding materials - do MIG welding equipment, accessories and materials - do on the listed items in 3.14 (a - equipment, tools and Teachers Activities Demonstrate the welding of metals using at least six of the ancillary welding processes listed in 3.12 (a-l) Prepare and give detailed notes Explain the factors governing the choice of any of the ancillary processes named in 3.12 above Resources

Demonstrate the welding of Lesson plan, TIG and

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome and state the techniques of consumable and their composition. and describe the setting of their controls of defects, causes and elimination Teachers Activities welding and explain the and non-consumable composition. State the details of equipment used and explain the setting of their controls Explain the effect of wrong setting, type of defects, causes and elimination. Resources Lesson plan Chalkboard Appropriate electrodes and wires - do Sketches/Chart

3.16 Explain the principles of MIG welding State the principles of MIG and non-consumable electrodes and wires techniques of consumable

3.17 Explain the details of equipment used electrode and wires and their Lesson plan, Chalkboard 3.18 state the effects of wrong setting, type Give detailed notes

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.19 Explain the following major process variable and characteristics: a. Modes of metal transfer b. Electrical - power supply characteristics characteri stics relative to modes of metal transfer - current density, speed, feed, voltage and inductanc e. c. Shielding gases - pure and mixed, functions and Applications. Teachers Activities State the major process variables and characteristics, listed in 3.19 (a-c) Resources - do -

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.20 Apply the MIG welding process and welding: a. M.S (Mild Steel) in different welding position b. S.S (Stainless Steel) c. Aluminium d. Pipes and pipe joints e. Titanium alloys f. Copper alloys, etc. 3.21 Explain the principles of spot welding Ask students to state the and describe the size and shape of electrode in relation to metal thickness 3.22 State the purpose of spot welding in machine shop or industry 3.23 State the effects of current, time and force in spot welding process 3.24 Evaluate the effect of heat balance and heat shrinkage in welding 3.25 Describe the methods of external 7 cooling on welds 3.26 Discriminate between the types of welds e.g. plasma arc or sub-merge arc and spot welding principle of spot welding and electrode in relation to thickness Explain the purpose of spot welding in machine shop or industry Explain the effect of current time and force in spot welding process Explain the effect of heat balance and heat shrinkage in spot welding Explain the method of external cooling on welds Explain the difference between the types of welds produced by plasma arc, submerged arc and spot welding Give detailed notes on all of the above Lesson plan Chalkboard - do Teachers Activities Demonstrate the MIG suitable operating characteristics for welding of items listed in 3.20 and give detailed notes Resources Lesson plan MIG equipment & Accessories/Materials

select suitable operating characteristics for welding process and show

explain the size and shape of Spot welding machine

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 4.0: Apply appropriate workshop processes and techniques to mark out and form projects for welding Week Specific Learning Outcome 4.1 Mark out the following projects in welding - applying appropriate tools, techniques and safety practice: a. Rectangular container b. Cylindrical shaped objects c. Solid corner joints d. Butt joint 4.2 Prepare bronze components for specification. Ask students to demonstrate Lesson plan, Welding Equipment Tools and Materials bronze component for avoiding sharp edges and welding to specifications and give notes 4.3 Prepare stainless steel components for Demonstrate preparation welding using welding rods and techniques and welding of stainless steel and observing safety precautions. components using welding rods and techniques and observing safety precautions. 4.4 Identify and state the type, composition List types of stainless steel and properties of common stainless steels Explain their composition used in metal work Discus their properties and uses Lesson plan, Chalkboard, Sketches Chart and Different pieces of stainless steel. - do welding avoiding sharp edges and weld to preparation and welding of Teachers Activities Demonstrate the marking out of project in welding as listed in 4.1 (a-d) applying and safety practices Give students projects involving items listed in 4.1 Resources Lesson plan Spot Welding, Appropriate Equipment, Tools, Wear

appropriate tools, techniques Materials and Protective

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 5.0: Make different types of welded joints in all positions Week Specific Learning Outcome of the following joints in metal fabrication: a. Square butt b. Single vee c. Double vee 9 d. Single U e. Open corner, etc. 5.1 observing safety rules. Teachers Activities application of the following joint in metal fabrication as listed in 5.1 (a-e) Ask students to sketch the joints Give detailed notes on each. edge for welding the joints in Tools, Equipment and 5.1 observing safety rules Ask the student to prepare edges for welding joints in 5.1 5.3 Weld pipes and flanges in various positions e.g: a) fixed position b) rotated position 5.4 Prepare metal surfaces and make multi-run and weaving welds 10 5.5 Weld joints in vertical, horizontal and overhead positions Demonstrate how to prepare - do metal processes and make multi run and weaving Demonstrate how to weld joint in vertical, horizontal and overhead positions. Ask the student to carry out the above operations and give detailed notes - do Demonstrate how to weld pipes and flanges in various position - both fix and rotated - do Materials Resources Lesson plan Chalkboard and Charts

5.1 Describe with sketches the application Explain with sketches the

5.2 Prepare edges for welding the joints in Demonstrate how to prepare Lesson plan, Necessary

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING Course Code: CFW 21 Contact Hours: 15 per week 4 Tutorials; 11 Practicals Course Specification: Theoretical/Practical contents General Objective 6.0: Understand and apply the fuel-gas cutting process in cutting metals to given specification. Week Specific Learning Outcome fuel-gas cutting process, e.g.: a. Manual b. Machine Teachers Activities applications of fuel-gas cutting as listed in item 6.1 (ab) Give the students, projects 11 involving the two processes 6.2 Describe various fuel-gas used in oxy- Ask students to state fuel cutting e.g: a. acetylene b. propane c. butane d. coal-gas, etc 6.3 State the advantages and disadvantages of using the above-named fuel-gas for oxy-fuel cutting operations 6.4 Prepare templates for the mass production of given objects of regular or irregular shapes by profile cutting 6.5 Cut smooth, curved, circular and straight objects using the hand cutting torch including oxy-lance and flame gauging 6.6 Produce project involving Arc and Ancillary welding process Explain the advantages and - do disadvantages of using above named fuel gases for oxy-fuel cutting operation. Demonstrate how to prepare Lesson plan, Equipment templates for mass production of given object by profile cutting 12 Demonstrate and explain how to cut smooth, curved circular and straight objects using hand flame gauging. Assist student to design and and ancillary welding. Test and evaluate the student Give detailed notes on all of the above Week 13 Examination - Practical 60%, Theory 40% Arc and ancillary welding produce projects involving Arc equipment. Lesson plan Appropriate Equipment Tools and Materials Tools and Materials various fuel-gases used in oxy-fuel cutting gas listed in 6.2 (a-d) - do Resources Lesson plan, Chalkboard

6.1 State the principles and applications of Explain the principles and

86

Structural Mechanics and Specification

PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 22-Structural Mechanics and Specification 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to provide the trainee with the knowledge of simple structural Mechanics and standard specifications required to appreciate steel designs and working drawings General Objectives: 1. Apply simple structural mechanics and standard specifications to structural steel work design. 2. Interpret and produce structural steel working drawings Practical Competence On completion of this module, the student will be able to: 12. Apply with facilities, standard specification for structural steel construction 13. perform simple calculation on structural steel construction 14. interpret and produce simple structural steel working drawings 15. produce projects applying simple structural mechanics and standard specification to structural steel work

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design. Week Specific Learning Outcome 1.1 Apply with facility standard specifications for structural steel construction using America or British Standards and their Nigerian counter1-2 parts. 1.2 Calculate weight of given structural of specifications. 1.3 Draw diagrams to show the steel work: a. tensile forces and stresses b. compressive forces 3 and stresses c. shear forces and stresses 1.4 Calculate the reaction at the supports Explain and calculate the reaction at of cantilever and simply supported e.g. simple shed frame with flat roof. the support of cantilever and simple uniform loading. beams having points and uniform loading supported beam having points and Lesson plan Chalkboard, etc. Explain and calculate the weight of a Lesson plan Chalkboard. using appropriate specifications Give the students problems to solve Sketch diagrams to show the forces and stresses and ask the students to do same. Lesson plan Chalkboard Charts applications of the following in structural application of structural steel work steel components using appropriate table given structural steel components Teachers Activities Demonstrate the application of standard specifications for structural steel construction. And give detailed notes Resources Lesson plan Chalkboard Charts.

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design. Week Specific Learning Outcome 1.5 Calculate bending moments and moment of resistance of simply supported beam with point and uniform loading. 1.6 Determine sizes of materials or sections required for columns, rafters, etc. Teachers Activities Explain the calculation of bending simply supported with point and uniform loading. Give the students problems to solve 4 Explain how to determine sizes of etc. Lesson plan Charts materials required for columns, rafters, Chalkboard Resources Lesson plan Charts.

moments and moment of resistance of Chalkboard

1.7 Sketch bending moment diagram for Sketch and explain bending moment Lesson plan cantilever with uniform load and calculate diagram for cantilever with uniform load Chalkboard the bending moment. 1.8 Apply 1.4 in determining reaction at support of actual frames. e.g. b. canopy c. riveted angle stiffered for crane beams 1.9 Apply stress diagrams to determine 5 trusses. Explain how to apply stress diagrams Lesson plan Chalkboard Charts Appropriate tools and equipment 1.10 Calculate bending stress due to web Explain the calculation of bending or flange connections. E.g. floor beams multistory frame building. stress due to web or flange connections Lesson plana Chalkboard structural frames. load on member of structural frames. e.g. to determine load on member of and calculation on the bending moment. Demonstrate how to apply 1.4 in determining reaction at support of actual frames. Lesson plan Appropriate tools and equipment. Charts

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND SPECIFICATION Course Code: CFW 22 Contact Hours: 15 per week - 4 tutorials; 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design. Week Specific Learning Outcome in structural steel assembly: 6 b. rag bolt c. gusset plate d. base plate 1.12 Calculate the deflections on a specifications/formulae. Teachers Activities following in structural steel assembly: rag bolt gusset plate base plate Solve some problems involving or other members using standard specifications/formulae. Give the students problems to solve General Objective 2.0: Interpret and produce structural steel working drawings Week Specific Learning Outcome of structural steel work Teachers Activities working drawings of structural steel work 2.2 Design and produce simple structural Demonstrate how to design and drawings observing conventional standards, symbols and notations. 2.3 Produce project applying simple structural mechanics and standard specification to structural steel work produce simple structural drawings observing conventional standards, symbols and notations. Ask student to produce project applying simple structural mechanics and standard specification to structural steel work. Test and evaluate the students Week 13 Examination - Practical 60%, Theory 40% Resources Lesson plan Chalkboard Relevant work drawings. Lesson plan Chalkboard Relevant work drawings -do Lesson plan Charts. Resources Lesson plan Chalkboard Posters Samples

1.11 Explain the purpose of the following Enumerate the purpose of the

column or other members using standard calculations on deflections on a column Chalkboard

2.1 Read and interpret working drawings Explain how to read and interpret

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Structural Steel Work

PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 23-Structural Steel Work 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to provide the trainee with further knowledge and skills to carry out simple design, fabrication and erection of structural steel work General Objectives: 1. Develop and Produce Templates for Structural Steel Work 2. Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. 3. Inspect finished structural steel work for defects and rectify the defects as necessary Practical Competence On completion of this module, the student will be able to: 1. Develop and produce template for structural steel work 2. Fabricate and assemble various structural steel component 3. carry out inspection on structural steel project 4. Rectify defects in structural steel project 5. provide and develop temperature for structural steel work

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 1.0 Develop and Produce Templates for Structural Steel Work Week Specific Learning Outcome using the following rules: a. mid-ordinates rule b. Simpson's rule 1.2 Develop given templates having: a. regular surfaces b. irregular surfaces 1.3 Cut out the developed templates from the following materials: a. wood 4 b. card-board c. other suitable materials 1.4 Reproduce the cut templates in 1.3 above from structural steel materials a. cutting - using oxyfuel gas, profile cutting and power saw b. punching - using punching machine c. chamfering - using oxy-fuel gases Demonstrate how to reproduce Lesson plan cut templates in 1.3 from various workshop processes. Ask students to perform the above functions Materials, Relevant Tools and Equipment. Demonstrate how to develop templates having: regular surfaces irregular surfaces show students how to how to various materials. Lesson plan Relevant tools and equipment. cut out developed templates from Template materials Lesson plan Chalkboard. Drawing instruments Teachers Activities calculation on areas of irregular surfaces using various methods Resources Lesson plan Chalkboard

1.1 Calculate areas of irregular surfaces Solve problems involving

using the following workshop processes: structural steel materials using

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. Week Specific Learning Outcome 2.1 Explain the functions of jigs and fixtures in structural steel works 2.2 Make simple jigs, fixtures and manipulators for assembling structural steel members. 2.3 Assemble structural components using the following jointing methods: a. welding (arc and gas) b. riveting c. bolting 2.4 Explain the purpose of metal finishing e.g. 5-7 a) protection from the weather and corrosion b) decoration 2.5 Describe the composition of various Explain the composition of materials used for finishing structural steel work 2.6 Prepare the surfaces of structural following techniques: a. brushing - using wire brush b. de-greasing, using suitable degreasing agent c. de-scaling various materials used for finishing structural steel work Demonstrate how to prepare components for finishing using various techniques Ask student to perform above operations Lesson plan Chalkboard Samples of materials for finishing Lesson plan Samples of Structural Components, Appropriate tools and equipment steel components for finishing using the the surfaces of structural steel Teachers Activities State the functions of jigs and Give notes Demonstrate how to make simple jigs, fixtures and manipulators for assembling structural steel members. Demonstrate how to assemble Lesson plan Appropriate structural components using various jointing methods Students asked to perform the above function State the purpose of metal finishing Lesson plan Chalkboard Tools and Equipment and Structural Components Resources Lesson plan jigs and fixtures Lesson plan Appropriate tools and Equipment.

fixtures in structural steel works. Chalkboard, Sample of

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per week - 4 Tutorials, 11 practicals Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. Week Specific Learning Outcome 2.7 Apply suitable undercoat to structural steel components e.g. red 8 oxide by brushing or spray methods. 2.8 Store and maintain structural steel materials and equipment Teachers Activities Demonstrate how to apply undercoat to structural steel components maintaining structural steel components necessary Week Specific Learning Outcome steel assembly e.g. a. distortion b. undercutting c. lack of reinforcement d. lack of penetration of weld, etc. and state their causes. 9-12 defects on finished structural steel assembly 3.3 Rectify defects in assembled structural steel components 3.4 Produce and develop templates for structural steel work 3.5 Fabricate and assemble various structural steel component Week 13 Examination - Practical 60%, Theory 40% Teachers Activities structural steel assembly as listed in 3.1 Give detailed notes Ask students to demonstrate to detect defects on finished Ask students to demonstrate how to rectify defects in assembled structural steel components Give detailed notes Test and evaluate the students Resources Lesson plan Chalkboard Any Relevant Materials Sample of defects Sample of finished weld Tools and Equipment. Lesson plan Samples of Components with weld defects, Relevant Tools and Equipment. Resources Lesson plan Appropriate Tools and Equipment Chalkboard Visit Relevant Stores.

Explain methods of storing and Lesson plan

General Objective 3.0: Inspect finished structural steel work for defects and rectify the defects as

3.1 Identify common defects in structural State common defects in

Show student sample of defects Lesson plan

how to carry out visual inspection Components, Relevant

3.2 Carry out visual inspection to detect structural steel assembly

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Sheet metal work

PROGRAMME: MODULE: DURATION: GOAL: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft CFW 24-Sheet Metal Work 15 Hours/week 4 Tutorial; 11 Practical The Module is designed to upgrade the professional competence of operators who has good knowledge of the use and application of sheet metal working equipment, materials, processes, techniques and safety precautions General Objectives: 1. Understand the Principles of Pantograph System and pattern forming attachment 2. Understand the construction of patterns and masters of irregular trinket box shapes using pattern forming machine/attachment. 3. Understand the mechanical cutting of basic geometrical shapes 4. Understand the processes of planning and layout of engineering workshops/industry. Practical Competence On completion of this module, the student will be able to: 1. Apply machines for the production of sheet metals work 2. Design, Construct and decorate articles 3. Construct patterns of irregular shapes using pattern forming attachment 4. Participate in the planning and laying out engineering workshop/industry

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 1.0: Understand the Principles of Pantograph System and pattern forming attachment Week Specific Learning Outcome 1.1 State the principles, functions and the constructional details of pattern forming machines and attachments 1.2 Explain the types and 1-3 characteristics of the machines in 1.1 above 1.3 Apply the machines for the production of sheet metal work Teachers Activities and the constructional details of pattern forming machines Explain the types and 1.1 Demonstrate how to apply the machines for the production of sheet metal work. Give note on all of above General Objective 2.0: Understand the construction of patterns and masters of irregular trinket box shapes using pattern forming machine/attachment. Week Specific Learning Outcome 2.1 Explain the methods of box and 4-6 tray construction, using beadings and joints. Teachers Activities Sate the methods of box and and joints. Give detailed note. Resources Lesson plan Drawing instruments Lesson plan Chalkboard Drawing instruments equipment Relevant materials for demonstration Resources Chalkboard Posters/charts. Lesson plan Posters Lesson plan Relevant tools and equipment

Explain the principles, functions Lesson plan

characteristics of the machines in Chalkboard

tray construction, using beadings Chalkboard

2.2 Explain the making of articles such Demonstrate how to produce as oblique tee with branch, lobster back articles such as oblique tee with bend, and similar utensils which involve branch, lobster back bend, and the development of a pattern. 2.3 Design, construct and decorate articles combing ornament with utility. development of a pattern. Demonstrate how to design, construct and decorate articles combining ornament with utility.

similar utensils which involve the appropriate tools and

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes Week Specific Learning Outcome Teachers Activities Resources Chalkboard Materials Lesson plan Samples of materials

a. 3.1 Review of sheet metal materials Explain and review non-ferrous Lesson plan and their preparation for industrial use sheet metal material and their of the following metals: Tin, Lead, Zinc, preparation for industrial use. Copper, and Aluminium 3.2 State the composition of more and monel; their properties and chief 7-8 wrought aluminium alloys, magnesium and titanium alloys in common use. 3.3 Describe the process of manufacture of mild steel sheets of various tempers, the manufacture of coated sheets such as tinned sheets, templates and galvanized iron. Explain the process of manufacture of coated sheet metals, listed in 3.3. Give detailed notes. Lesson plan Chalkboard Samples of materials Give detailed note Explain the composition of alloy elements; their properties

important brasses and bronzes, inconel more important alloy metals and Chalkboard uses, the composition and properties of and uses.

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes Week Specific Learning Outcome 3.4 Develop and produce at least two sheet metal projects involving the use of more advanced machines and the application of advanced pattern development covered in fabrication drawing. Note: Some of the sheet metal project should include: a. trinket box of all types b. lobster back bend c. oblique tee with branch 9 d. small bait can e. petrol or oil measure f. oval container with lid or with loose lid g. oiled bottle h. conical jug i. scoop j. funnel k. ornamental bowls and vases. Etc. 3.5 Explain the methods of producing and planishing, hand flattening and setting. State the methods of producing Lesson plan work. Discuss and demonstrate processes involved more difficult work in hollowing, raising more difficult beating sheet metal Chalkboard. Teachers Activities Demonstrate how to develop involving the use of more advanced machines. Give student project on the above to produce some of the items listed in 3.4 Resources Lesson plan appropriate materials, tools and equipment.

and produce sheet metal projects Drawing instruments,

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PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK Course Code: CFW 24 Contact Hours: 15 per week-4 theory: Practical 11 Course Specification: Theoretical/Practical contents General Objective 4.0: Understand the processes of planning and layout of engineering workshops/industry. Week Specific Learning Outcome 4.1 Demonstrate the methods of planning and the layout of shops in engineering workshops/factory regulations. 4.2 Know the types of workshops/industry, e.g. mechanical, electrical, welding, carpentry, etc. 4.3 State the types and function of 10-12 sections in the workshops. batch and quantity production of engineering components. 4.5 Arrange workshops according to the lay out plans 4.6 Produce project involving pattern forming machines Teachers Activities State the methods of planning and layout of shops in engineering workshops/factory regulations. Give detailed note Explain different types workshops/industry. Give detailed notes. Explain the types and function of sections in the workshop. Resources Lesson plan Chalkboard, Charts visit factory Lesson plan Visit workshops/industries Lesson plan Visit workshops/industries Lesson plan Visit factory/industry. Lesson plan Charts. Lesson plan equipment

4.4 Describe and lay out plan for single, Explain lay out plan for single, engineering components. Explain how to arrange workshops according to the lay out plans Take student on excursion to industries Week 13 Examination - Practical 60%, Theory 40%

batch and quantity production of Chars

Test and evaluate the students Material, tool and

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List of tools and equipment for welding and fabrication engineering

S/NO MINIMUM QUANTITY REQUIRED 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Power guillotine of capacity 10swg x 36 in length Treadle guillotine of capacity 20swg x 36 length Swing beam folder 10swg x 3'-6' capacity Bending roller capacity 40"x2" dia Bending roller capacity 18"x11/4 dia Bench mounted cone roller Hand-operated copper capacity 3/32 in mild steel Power bench grinding machine Double-ended buffer and polisher Universal beading and swaging machine Power-operated drilling machine maximum capacity 3/8" Wheeling machine Fly Press Hand nibbling Machine Left and right hand snips Straight snips A "kit" of tools consisting of hammer, mallet, steel rule, scriber and wing compass, etc. 18. 19. Bench shears Power saw cutting machine 10mm 2 2 2 1 2 5 each 5 5 2 2 2 2 5 5 2 2 2 2 2 QUANTITY AVAILABLE ADDITIONAL QUANTITY REQUIRED

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S/NO

MINIMUM QUANTITY REQUIRED

QUANTITY AVAILABLE

ADDITIONAL QUANTITY REQUIRED

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48

Disc cutting machine Profile cutting machine with gas cutting nozzles Piller drilling machine Louver shearing machine (manual) Overhead crane Straightening machine Cropping machine Straight edge Trammels dividers (set) Hammers Chisels Punches Try-squares Steel rules Smith open forge Vee blocks Electrode holders Electrode drying oven Heavy duty grinding machine Bench-type grinding machine CO2 cylinders Transformers With rectifiers (with all Instruments) Aprons (assorted Hand gloves Hand shields and head caps Wire brushes Electrical beaters Pliers assorted Gas welding goggles

2 2 2 2 1 2 2 10 10 10 10 10 10 10 2 10 10 2 2 2 5 10 20 20 10 10 2 10 5

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S/NO

MINIMUM QUANTITY REQUIRED

QUANTITY AVAILABLE

ADDITIONAL QUANTITY REQUIRED

49 50 51 52 53 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75 76

Double cylinder trolley Oxygen regulators Acetylene regulators Hoses and clips and all attachments set Blowpipes (low and high pressure Tongs Combined set of cutting welding outfit Power operated profile cutter with turntable D.C generators with all connections A.C transformer (Argon) with all the connections Argon cylinders Regulators with flow meters Hacksaw and blades Water to carbide generators Carbide to water generators Overhead projector Computer set ANVIL Swage block Chipping hammers Plain goggles First aid box Sledge Hammer G. Clamps - assorted Self grip pliers - assorted Magnetic clamp Flatters Molegrip

2 5 5

5 5 5 2 5 5 5 5 24 4 4 1 1 2 2 20 20 2 2 26 6 3 6 6

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Guideline for textbooks development

NATIONAL/ADVANCE TECHNICAL CERTIFICATE IN REFRIGERATION AND AIR CONDITIONING WORK The following guidelines are suggestions from the Engineering Committees to the writers of the textbooks for the new curricula. They are intended to supplement the detailed syllabuses which have been produced, and which define the content and level of the courses. Authors should bear in mind that the curriculum has been designed to give the students a broad understanding of applications in industry and commerce, and this is reflected in the curriculum objectives. One book should be produced for each syllabus Page size should be A4 The front size should be 12 points for normal text and 14 point where emphasis is needed. Line spacing should be set to 1.5 lines Headings and subheadings should be emboldened Photographs, diagrams and charts should used extensively throughout the book, and these items must be up-to-date In all cases the material must be related to industry and commerce, using real life examples wherever possible so that the book is not just a theory book. It must help the students to see the subject in the context of the 'real word' The philosophy of the courses is one of an integrated approach to theory and practice, and as such the books should reflect this by not making an artificial divide between theory and practice. Examples should drawn from Nigeria wherever possible, so that the information is set in a country text. Each chapter should end with student self-assessment questions (SAG) so that students can check their own master of the subject. Accurate instructions should be given for any practical work having first conducted the practical to check that the instructions do indeed work.

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 The books must have a proper index or table of contents, a list of references and an introduction based on the overall course philosophy an aims of the syllabus. Symbols and units must be listed and a unified approach used throughout the book. In case of queries regarding the contents o the books and the depth of information, the author must contact the relevant curriculum committee via the National Board for Technical Education. The final draft version of the books should be submitted to Nigerian members of the curriculum working groups for their comments regarding the content in relation to the desired syllabus.

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Recommended books for fabrication and welding engineering craft practice

S/NO BOOKS 1. 2. 3. 4. 5. 6. 7. BASIC WELDING AND FABRICATION BASIC ENGINEERING CRAFT STUDENTS: FABRICATION AND WELDING 05 THE TECHNOLOGY OF SHEET METAL WORK FOR STUDENTS AND CRAFTSMEN THE GEOMETRY OF SHEET METAL WORK FOR STUDENTS AND A. DICKSON CRAFTSMEN THE CALCULATION OF SHEET METAL WORK FOR STUDENTS AND CRAFTSMEN METAL: DESIGN AND CONSTRUCTION V. Press, 1992 (b) Volume II above 8. 9. 10. 11. 12. 13. WELDING SCIENCE AND METALLURGY WELDING TECHNOLOGY FABRICATION AND WELDING TECHNOLOGY BASIC WELDING - Macmillian Publisher Ltd London, 1986 WELDING CRAFT PRACTICE - Part 1 Volume I Oxy-acetylene Gas Welding and Related Studies WELDING CRAFT PRACTICE - Part 1. Volume 2: Electrical Arc Welding and Related Studies N. PARKIN & C.R. FLOOD J. CARDENER KOENISBERGE A. SMITH P. SOMSKY N. PARKIN & C.R. FLOOD A.C. DAVIS - Tenth Edition A. DICKSON AUTHORS W. KENYON BOURBOUSSON & ASHWORTH A. DICKSON

(a) THE SCIENCE AND PRACTICE OF WELDING Vol. I Cambridge A. C. DAVIS

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List of Participants
UNESCO-NIGERIA PROJECT IN SUPPORT OF REVITALIUSATION OF TECHNICAL AND VOCATIONAL EDUCATION(TVE) IN NIGERIA PROJECT TEAM MEMBERS S/No. NAME 1 2 3 4 5 6 7 Engr. Dr. Nuru A. Yakubu Dr. M.S. Abubakar Engr. S.C. Odumah Mr. B.N. Niriyus Engr. Dr. S.N. Mumah Isa Alhaji Sulaimanu Engr. A.D.K. Muhammad DESIGNATION National Project Coordinator & Executive Secretary, NBTE Technical Coordinator Curriculum Development Coordinator Staff Development Coordinator Information & Communication Technology Coordinator Project Accountant Project Officer

S/No Name 1. 2. 3. 4. 5. 6. Omotorsho Isaac Bamidele Y.A. Alimi G.G. Idris J.I. Ortserga F.M. Alega Olubode Daniel Majiyagbe

Address Ondo State Board for Tech. & Voc. Education or P.O. Box 975, Akure. Government Technical College P.M.B.5377, Ado-Ekiti Government Technical College K/Namoda Zamfara State Dept. of Voc. & Tech. Faculty of Education Benue State University, Makurdi Fest Development Department, National Business & Technical Exams Board (NABTEB) P.M.B. 1747, Benin City, Edo State. National Board for Technical Education Kaduna

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