COURSE OUTLINE
IRON BENDER AND WELDING OPERATIONS.
The IEDC has been set up by IWA group with the objective among others to provide training to the building industry work force, having discovered a gap in the operation of the existing work force.
IWA group had put up an excellent infrastructure consisting of the art training facilities such as; classrooms, studio, workshop with modern machines and audio visual have been created to impact quality training.
We have selected experience team of qualified lecturers and technologist, Many of them have gained experienced both in the industrial and academic areas
The course outline has been so designed to provide the students with the basic knowledge along with specialized and specific requirements keeping in view the prevalent industrial workings and standards. The short come of the existing work force is equally considered. To support the lectures, case studies are presented to the students, to understand the craft fully. Group discussions are encouraged to solve problems through interaction among themselves and with industrial experts.
Industrial visits are also arranged for students for much needed industrial exposure where the need arises.
COURSES CONTENTS
- Introduction to tools/ equipment
- Marking out cutting and forming of sheet metals
- Iron and steel manufacturing
- Corrosion
- Soldering and brazing
- Non ferrous and ferrous metals
- Sheet metal operation
- Structural steel project
- Gas welding process
- Building of worn out parts.
Methodology/ mode of study: Lectures, Discussion, Practical demonstrations, Practices and Industrial visits.
Duration: 2weeks of general studies, 3 ½ month of theory and practices; 2 months of practicals and 3 months of industrial training (Field site works)
Entry qualifications: OND, OND, HND and B.Sc.
Topic/Objective: 1.0 Tools and Equipment
1.1 Classification of the tools and their uses.
Activities/Remarks
Through simple practical demonstrations show how the tools are used in workshop.
Topic/Objective: 2.0Marking, Cutting and Forming of Sheet Metals
Contents
2.1 Mark out of projects on sheet metal materials e.g.
Activities/Remarks
Use tools to mark out on a rectangular piece of metal, an object consisting of flat and semi-circular ends.
Topic/Objective: 3.0Iron and Steel Manufacturing
Contents
3.1 Sketching of blast furnace and its working principles.
3.4 uses of timber.
Topic/Objective: 4.0 Corrosion
Contents
4.1 Some causes of corrosion on steel e.g.
4.2 Methods/ways to avoid corrosion
Activities/Remarks
Using simple materials, explain what is corrosion.
Topic/Objective: 5.0Soldering and Brazing
Contents
5.1 Types of solders used in sheet metal work.
5.2 Composition, e.g. Tinman solder self flux solder resin oore solder etc.
Activities/Remarks
Melt tin and lead together to form soft solder.
Topic/Objective: 6.0 Non-Ferrous and Ferrous Metal
Contents
6.1 Types of non-ferrous metals e.g. Tin, Copper, Zinc etc.
6.2 Use of metals
Activities/Remarks
Using small pieces, how the differences in colour, between copper, aluminum and brass.
Topic/Objective: 7.0Sheet Metal Operation
Contents
7.1 Explanation of terms.
Activities/Remarks
Demonstrate the operations of hollowing, raising and blocking. Necessary precaution should be emphasized.
Topic/Objective: 8.0 Steel Project
Contents
Calculation of allowances forming.
Activities/Remarks
Demonstrate and explain the determination of the actual diameter for calculating the circumference of an angle bar ring. Take any inner diameter using angle bar of any given thickness and work out the circumference for the Metal to form the ring.
Topic/Objective: 9.0 Gas Welding Process
Contents
9.1 Identification of gas welding equipments e.g. generators, regulators, regulators, blow pipes etc, nozzles, hoses, gas cylinders and their colours, economizers check valves etc.
9.2 Handling of welding Equipment.
Activities/Remarks
Demonstrate the connection of a welding unit given necessary apparatus.
Topic/Objective: 10.0 Building up of Worn Mechanic Parts
Contents
10.1 Identifications:
Activities/Remarks
Using gas welding process
Topic/Objective: 11.0 Welding Machines and Accessories
Contents
11.1 Differences between AC and DC
Machines.
Activities/Remarks
Demonstrate the function
of the various parts of the
machines (AC and DC)
Topic/Objective: 12.0 Welding Joints in all positions
Contents
12.1 Sketches and application of joint in metal fabrication e.g. single vee, square butt etc.
Activities/Remarks
Sketch and weld the various joint show weld and where applicable.
Topic/Objective: 13.0Arc Welding Ferrous and Non-Ferrous Metal
Contents
13.1 Identification and inspection of ferrous metals e.g. cast iron, steel etc
13.2 Arc cutting of metal
Activities/Remarks
Weld piece of grey cast iron, white and malleable cast iron. Watch and explain their behaviour in the process and after welding.
Demonstrate the cutting of metal by the different arc cutting methods.
Topic/Objective: 14.0 Welded Joints, Defects and Rectification
Contents
14.1 Some defects in gas welded joints. Causes:
14.2 Major defects in arc welding joints e.g. porosity etc.
Activities/Remarks
Weld a double vee joint and cut for inspection of defects. Demonstrate and explain how non-destructive testing can be carried out in detecting defects in arc welding joints. methods.
Topic/Objective: 15.0 Building up worn metallic parts
Contents
15.1 Composition of worn metallic shafts and other parts – gear teeth, shaft etc.
Activities/Remarks
Following normal welding processes and observing safety precautions weld the worn out parts.