Fabrication and welding engineering: National Technical Certificate

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

1

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

2

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

3

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.

4

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.

5

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 CERTIFICATE

Technical Programme

1. Craft Level National Technical Certificate

2. Advanced Craft Level Advanced National Technical 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.

6

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.

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Curriculum Table (NTC)

NTC FABRICATION AND WELDING ENIGINEERING CRAFT PRACTICE

YEAR 1 YEAR 2 YEAR 3

S/No Subject

Code

Module Term

1

Term

2

Term

3

Term

1

Term

2

Term

3

Term

1

Term

2

Term

3

Total

Hours

for

each

T P T P T P T P T P T P T P T P T P 216

1 CMA 12-

15

Mathematics 2 - 2 - 2 - 2 - 2 - 2 - 2 - 2 - 2 - 288

2 CEN 11-

17

English 2 - 2 - 2 - 3 - 3 - 3 - 3 - 3 - 3 - 288

3 CPH 10-

12

Physics 2 - 2 - 2 - 2 1 2 1 2 1 2 1 2 1 2 1 288

4 CCH 11-

12

Chemistry 2 - 2 - 2 - 2 1 2 1 2 1 2 1 2 1 2 1 288

5 CEC 11-

13

Economics 2 - 2 - 2 - 2 - 2 - 2 - 2 - - - - - 216

6 CBM 11 Entrepreneurship - - - - - - 2 - 2 - 2 - - - - - - - 72

7 CTD 11-

13

Drawing - 3 - 3 - 3 - 3 - 3 - 3 - 2 - 2 - 2 288

8 ICT 11-

15

Computer Studies - - - - - - 1 2 1 2 1 2 1 2 1 2 - - 180

9 CME 11 General Metal Work I 2 5 2 5 - - - - - - - - - - - - - - 168

10 CME 12 General Metal Work

II

- - - - 2 3 - - - - - - - - - - - - 60

11 CFW 11 Sheet Metal Work - - - - - - - - - - - - 3 6 3 6 - - 216

12 CFW 12 Gas Welding and

Cutting

- - - - - - - - - - - - 3 6 3 6 - - 216

13 CFW 13 Metal Arc Welding - - - - - - - - - - - - - - 3 6 3 6 216

14 CFW 14 Structural Steel Work - - - - - - - - - - - - - - 3 6 3 6 216

15 CFW 11 Sheet metal Work - - - - - - - - - - 2 6 2 5 - - - - 180

GRAND TOTAL 12 8 12 8 12 6 14 7 14 7 14 7 18 18 22 30 15 16 2928

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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 P T P T P

1. CMA 21-22 Mathematics 2 - 2 - 2 - 72

2 CEN 21-22 English and Communication 2 - 2 - 2 - 72

3 CTD 21 Engineering Drawing and Design - 3 - 3 - - 72

4 CTD 22 Fabrication Drawing - - - 3 - 3 72

5 CEC 21-23 Economics 2 - 2 - 2 - 72

6 CBM 21 Entrepreneurship 2 - 2 - 2 - 72

7 ICT 21-22 Computer Studies 1 2 2 2 - - 72

8 CFW 21 Welding 2 5 2 6 - - 180

9 CFW 22 Structural Mechanics & Specification - - 2 5 2 6 180

10 CFW 23 Structural Steel work 2 5 2 6 - - 180

11 CFW 24 Sheet metal work - - 2 5 2 6 180

TOTAL 13 15 17 30 12 15 1044

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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 non-

ferrous 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.

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PRACTICAL TASKS

General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the

following abilities:

Week Specific Learning Outcome Teachers Activities Resources

1-3

1.1 Using and handling hand tools,

portable power tools and machine

1.2 Lifting, moving and storing materials or

job

1.3 Demonstrate first aid application in

cases of minor cuts, electric shock, burns.

• Demonstrate safe ways of

handling basic hand tools

• Show a film on industrial

safety

• Demonstrate how to treat

energy cases like artificial

respiration cold compress,

etc

• Assess student

• Hand tools files, hacksaw

• Television, Video

machines

• Posters on artificial

respiration

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General Objective 2.0: Measuring, Marking, Cutting and Striking


4-6

2.1 Describe the essential features

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

on plane surfaces including profiles

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

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,

piercing saw, etc drills and Drilling.

• Demonstrate how to use

micrometer, venier caliper,

vernier height gauge,

combination set

• Demonstrate the maintenance

and care of the instruments

listed above

• Perform marking out for the

students to learn and practice till

they become competent

• Demonstrate how flat surface

can be tested using surface plate

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

clamp, center square, etc.

• Make a simple precision fitting

project like hexagonal mild steel

bar making push fit through a

mild steel plate

• Micrometer, vernier

calipers, vernier height

gauge, combination sets

• Steel rules, dividers,

punches, trammel, scribe

angle plate, vee block

center square

• Flat file, hand file, try

square

• File card, flat file

• Ball pein hammers, mallet

• Hacksaw blade, Hacksaw

frame.

12

General Objective 3.0: Machine Tools


7-9

3.1 Setting up and operate a drilling machine

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

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.

• Demonstrate how to set

up and operate a drilling

machine in given situation

• Students to practice till

competent

• Demonstrate how a twist

drill can be sharpened

correctly

• Demonstrate with the

appropriate facility how to

perform all the drilling

operations



• 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



• Assess the student.

• Bench drill pillar drill, drill

bits

• Bench drill, pillar drill, twist

drill, flat drill, counter sink

drill, counterbore drill, center

drill

• Drills, taps, tap wrench, die

and die stock

• Rivets and sets of drill bits

• Surface table, surface

plate, marking solution,

center/dot punches, scribing

block

13

General Objective 4.0: Lathe and Lathework


10-12

4.1 Sharpen cutting tool for plain turning,

shouldering, parting off and facing

operations

4.2 Set up rough and turned stock in 3-

jaw-chuck

4.3 Select appropriate cutting tool and set

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

specified tolerance and finish

4.5 Produce simple components involving

taper turning using the compound slide

• Guide the students to

sharpen cutting tool for plain

turning shouldering, parting

off and facing operations

and allow students to


• Demonstrate how to set-up

rough and turned stock in a

3-jaw-chuck and operate

lathe. Allow students to


• Guide the students to

select appropriate cutting

tools and set them up to

center height for lathe work

(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

• Point tools, grinding

machine, lathe machine

• 3-jaw chuck and lathe

machine

• Point tools and lathe

machine

• Lathe machine and

accessories

• Centre lathe and

accessories like catch plate,

face plate, dog lathe, lathe

centers fixed steady and

traveling steading

• Round nose turning tool,

fine finishing tool, form tool,

parting off tool, boring tool,

bar of good length and 4mm

diameter, Live/dead centers

catch plates

• Standard exercises or

prepared

Assessment profile: Practical to take 60% of the overall assessment

14

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


1

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

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

• State sources of hazards

in the workshop.

• Through questions and

answer, determine whether

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 a-

e.

• Use questions and

answer to determine

comprehension.

• Assess the students

• Safety posters, common

hard tools like files

hacksaw

• Television, Video

machine.

• Overall, goggles, gloves,

saftyboots, head shield,

fire extinguishers.

15


PRACTICE

Course: General metal Work I Course Code: CME 11 Contact Hours

7hrs/wk


General Objective: 1.0 understand workshop safety rules and application in machine shop


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.

• 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.

16


PRACTICE


7hrs/wk


General Objective 2.0: Know the physical properties, manufacturing process and application of ferrous

and non-ferrous metals in common use


2

2.1 Explain the meaning of the following

general physical properties of metals:

ductility, malleability, strength,

roughness, brittleness, elasticity,

plasticity.

• Give detail notes and explanations to

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.

Examples of steels and cast irons should

include: plain carbon steels, dead mild

steels, mild steel, medium carbon steel,

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

cast iron, malleable cast iron, iron

carbide, alloy cast iron high speed

steels, high tensile steels, tungsten,

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.

17

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

18


PRACTICE


7hrs/wk


General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools.


3

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.

3.3 Describe, the functions and

application of the following

instruments used in metal-work,

steel rule, dividers, calipers

(inside, outside and odd-legs),

trammel, scriber angle plate,

vee-block, centre square.

3.4 Describe the various types

of files, stating their grades and

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

use in metal work and state their

composition of material used for

their manufacture.

3.6 Sketch the bench vise,

explain its clamping power and

demonstrate the technique of

• Prepare notes that will clearly differentiate

between "line" and "end" measurement.

• Prepare notes and examples that will explain

the use of datum points, datum lines, and

datum faces in marking out.

• Give explanations regarding the functions

and application of: steel rule, dividers, calipers

(inside, outside and oddleg) trammel, scriber,

angle plate, vee block, centre square

• 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.

• Prepare detail notes that will classify the

common files used in the metal work as well as

stafing the composition of materials used for

their manufacture.

• Show a bench vice and demonstrate the work

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

operations.

• 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

operations

• Steel rule, dividers

calipers, trammel,

scribe angle plate

vee block, centre

square.

• Micrometer

vernier callipers

vernier height

gauge combination

set

• Flat file, hard file,

round file square,

half round,

triangular warding,

mill file, rasp file.

• Flat file, handfile

engineers square.

• Surface plate try

square (engineers

square)

• File card

• Flat file

• Bench vice.

• Bench vice.

• Ball pein hammers

mallets.

19

holding work in the vise for

filing, tapping and designing

operations.

3.7 Describe the functions of the

various parts of a bench vice, its

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


• Prepare detail notes and demonstrations that

will describe and uses of: cold chisels, centre

punch dot punch, scrapers and power

hacksaw.

20


PRACTICE


7hrs/wk


General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools.


4

3.9 Describe the various parts of a hack saw

and their function.

3.10 Describe the common types of hacksaw

blades, their range of pitches and their

applications.

3.11 State the safety precautions to be

observed when using a hand hacksaw

• Prepare notes that will describe

the various parts of a hacksaw

and their functions.

• Show sample of hacksaw blades

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.


• Cold chisels,

centre punches, dot

punch, scrapers

power hacksaw

blades.

• Hacksaw blade

• Hacksaw frame

• Adjustable

hacksaw junior

hacksaw piercing

saw.

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


5-6

4.1 Identify the various types of drilling

machines.

4.2 Describe, with sketches, the main

features of a bench or pillar drilling machine.

4.4 Describe with sketches and state where

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.

4.5 Explain the effects of the following faults

Show different types of drilling

machines

Make notes and drawings that will

identify the various types of drilling

m/cs.

Prepare detail notes and drawings

that will describe the main

features of a bench or pillar drilling

machine.

Solve many problems for students

to practice.

Prepare notes and drawings that

• Bench drill

• Pillar drill.

• Twist drill, flat drill

counter sink drill,

counter bore drill

combination centre

drill.

Drilling machines

and its accessories.

21

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/π

S = πdN/1000

Where S = cutting speed

(m/min)

N = revolution/minute

D = diameter of drill (mm)

π = 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.


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.

22


PRACTICE


7hrs/wk


General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut

screws by hand.


5.1 Sketch the thread forms below and

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

• Give detailed notes with diagrams that

will show the various forms of trade and

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

Diagrams/charts of

thread forms

Sample of taps and

tap wrenches.

Parallel reamers,

taper reamers, and

twist drills.

23


PRACTICE


7hrs/wk


General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut

screws by hand.


5.4 State precautions to be taken when

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.

• Prepare notes that will state precautions

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.

• Rivet sets,

drills.

General Objective 6.0: Understand the ISO tolerances and fits and its application in engineering

production.


8

6.1 Differentiate between the following:-

a. nominal size

b. limits (upper and

lower)

c. tolerance (unilateral

and bilateral)

d. fit (clearance,

transition interference).

6.2 Explain the importance of tolerance

and fit in engineering production and

describe briefly the ISO system of limits

and fits.

6.3 Determine by calculation the

amount of tolerance and types of fit in

given situations.

• Give detailed notes that will differentiate

between nominal size, limits, tolerance and

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.

• Give notes and explanations that will

guide in calculating the amount of tolerance

and types of fits in given situations.


•

• Charts on

tolerances, limits

and fits.

24


PRACTICE


7hrs/wk


General Objective 7.0: Produce simple Engineering Components on the bench. Production


9

7.1 Explain layout procedures

from working drawing of simple

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

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 to prepare notes and explanations

to guide the students in producing simple

engineering components as in 7.1


• Lesson notes

• Diagrams and

charts.

25

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE


7hrs/wk


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


10

8.1 Describe the essential features of a

centre lathe and state their functions

e.g lathe bed, headstock, tailstock, saddle or

carriage, etc.

8.2 Explain the working principles of the

centre lathe.

8.3 Identify and state the functions of centre

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

centre lathe, capstan lathe, in terms, of their

main features and functions.

8.5 Name types of cutting fluids used for

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.

• With the aid of a diagram explain the

essential features of a lathe machine

• Explain the working principles and basic

operations of a lathe machine

• Demonstrate some basic operations on

lathe machine.

• Prepare detailed notes that will describe

the essential features of center lathe and

their functions.

• Give notes and diagrams that will explain

the working principles of center lathe and

functions of its accessories.

• Give explanations that will show the

difference between center lathe and

capstan lathe in terms of their main features

and functions.

• Prepare notes that will list types of cutting

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.


• Centre lathe

and accessories

like catch plates,

face plates,

centers, fixed

and traveling

steadies.

• Charts of

center lathe and

capstan lathe.

• Round nose

turning tool,

finishing tool,

site finishing,

knife tool, form

tool, parting off

tool, and boring

tool.

26


PRACTICE


7hrs/wk


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


11-12

8.9 Differentiate between various tool shapes

and state their uses e.g. Round nose rougher,

fine finishing, side finishing, knife tool, form

tool, parting off tool, boring tool, etc.

8.10 Explain with sketches the effects of

wrong setting of cutting tool: e.g. vibration and

chatter, tool rubbing against or digging into 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

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

where θ = taper angle

d1 - small and diameter

d2 = large end diameter

L = length of taper

• Give notes and diagrams of

various tool shapes and their

uses.

• Prepare detailed notes and

explanations to cover 8.10 to

8.15

• Solve many problems for the

students practice.


• Charts on tool

height

• Charts and

diagrams of

different machining

operations.

27

General Metalwork II

COURSE: GENERAL METAL WORK

MODULE: 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

28

PRACTICAL TASKS

General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the

following abilities:

Week Specific Learning Outcome: Teachers Activities Resources

1-2

1.1 Carry out the following heat

treatment processes Hardening,

tempering, annealing normalizing,

case hardening on given plain carbon

steel, engineering component or tool

1.2 Anneal copper, brass and

aluminium for various purposes

• Demonstrate heat treatment

processes and explain the

stages

• Demonstrate the annealing

process on brass, copper and

aluminium for various

purposes.


• Furnace, Forge tongs

29

General Objective 2.0: Forging Processes


3-4

5-8

2.1 Select appropriate forging tools

and produce to specification given

engineering components by forging

processes

a. upsetting - drawing

down

b. setting down -

twisting

c. forge welding

(scarf and spice

welds)

d. bending, turning

closed ring

e. forming an eye

• Demonstrate with appropriate

forging tools how to produce

some engineering components

and let the student practice till



• Anvil, swage block, leg vice,

forging hammers, hot set cold

set, sets of hammer, punchers,

drifts, fillers, top swage,

bottom swage, flatter, open

tongs, hallow bit

General Objective 3.0: Welding Processes


9-12

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

electrode. Adjustment for correct gas

pressure/flame or voltage

3.2 Prepare joints for welding in given

situations

3.3 Weld given components by arc or

gas welding methods, and state

safety precautions to be observed

• List and identify gas and

metal arc welding equipment

• Demonstrate the use of both

gas and metal welding

equipment; and all the

students to practice

• Demonstrate to the students

how to prepare joints for

welding purposes

• Guide students to weld

various components using

both gas and arc welding

process and state safety

precautions to students to


• Oxygen, cylinders and

acetylene, regulations arc,

welding set goggles, shield,

electrodes, diagrams and

charts various welding joints

Assessment: Practical - 60% of overall assessment

30


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 Teacher Activities Resources

1-4

1.1 Explain briefly the structural behaviour of

plain carbon steel as it is heated from room

temperature to about 1000oC.

a. hardening

b. tempering

c. annealing

d. normalising

e. case-hardening.

1.2 Explain the meaning of hardening metal

work.

1.3 Outline safety precautions relating to heat

treatment processes apply them in given

situations.

• Prepare detail notes that will

explain the structural

behaviour of plain carbon

steel as it is heated from room

temperature to about 1000oC.


explain the meaning of

hardening in metalwork.

• Prepare notes that will

outline safety precautions

relating to heat treatment

processes.


• Recommended Text

books

• Lesson notes, etc

31


PRACTICE


5hrs/wk


General Objective 2.0: Understand the techniques of producing simple engineering components by

forging.


5-6

7-8

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

common forging tools. e.g anvil, swage block,

leg vice, forging hammers, hot and cold sets,

set hammer, punches and drifts, hardie,

fullers, top and bottom swages flatter, tongs

(open mouth, closed mouth, hollow bit, etc.).

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.


diagrams that will explain the

main features and working

principles of the black smith's

forge.

• Prepare notes and diagrams

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.


Forge and forging tools.

32


PRACTICE


5hrs/wk


General Objective 3.0 Understand the basic principles and techniques of gas and metal are welding

and apply them in fabricating simple metal components.


9 - 12

3.1 Describe the equipment and explain the

basic principles and application of gas and

metal arc welding.


observed and apply them in given welding

situations.


diagrams that will describe the

equipment and explain the

basic principles and

application of gas and metal

arc welding.

• Prepare diagrams of joints

that the students will practice.


state the safety precautions to

be observed during welding.


• Charts

• Oxygen cylinder

acetylene cylinder

regulations arc welding

set goggles, shield

electrode.

• Diagrams and charts

of various welding

joints, and techniques.

Week 13 Examination - Practical 60%, Theory 40%

33

Sheet metal Work

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING

CRAFT PRACTICE

MODULE: CFW 11 - SHEET METALWORK

PRE-

REQUISITE:

CME 12

DURATION: 18 HOURS PER WEEK - 6 HOURS THEORY 12 HOURS PRACTICAL

GOAL: 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


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.

34


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:


Year 3

Term 1

1.1 Mark out the following projects

on sheet metal material applying

appropriate tools, techniques and

safety practices:

a. rectangular

container

b. funnels

c. cylindrical

container

• Demonstrate the marking out of

projects on sheet metal by applying

the appropriate techniques and

safety practices.

• Demonstrate marking out items

listed on sheet of metal

• Lesson plan

• Appropriate Tools and

Equipment

• Steel rule, divider,

scriber, compass and

chalkboard

1.2 Cut sheet metal to given sizes

using appropriate tools/machines

• Demonstrate sheet metal cutting

to given sizes using appropriate

tools and machine

• Lesson Plan


Machines

1-2 1.3 Form sheet metal to given

shapes using appropriate tools,

machines and techniques

• Demonstrate the formation of

sheet metal

• Demonstrate methods of forming

these shapes.

• Lesson plan

• Appropriate Tools,

Machines and Equipment

3

1.4 Calculate allowance for joint

using the formula: grooved seam =

11/2x width of groover.

• Calculate allowance for joint using

the formula: grooved seam = 11/2x

width of groover, panned down and

knock-up joints.

• Lesson plan Chalkboard

3 1.5 Sketch the joint allowances on

the materials and notch the joints

• Sketch joint allowances on the

materials and notch

• Lesson plan Appropriate

Tools and equipment

35


CRAFT PRACTICE


week- L6: P12





4-5

1.6 Make the following joints in

sheet metal:

a. solid corner joint

b. grooved seam

joint

c. panned down

joint

d. knocked up joint

• Demonstrate the process of

making the following joints:

• solid corner

• groove seam

• panned down

• knock-up

• Lesson plan


Equipment

6

1.7 Name common rivets used in

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.

36


CRAFT PRACTICE


week- L6: P12





6

1.8 State common faults in riveting

e.g.

a. overlapping

b. cracked rivet

c. uneven ends,

etc.

• Explain common faults in riveting

• Show the listed defect to student

• Lesson plan

Charts/Posters

7

1.9 Drill and punch holes on joints

for riveting making sure that burrs,

are removed

• Demonstrate drilling and punching

of holes on sheet metal including

removal of burrs.


Tools, Machine and

Equipment

7

1.10 Rivet joints satisfactorily using

correct sets

• Demonstrate riveting by using

appropriate rivet sets

• Lesson plan

Charts/Posters Various

Types of rivet Sets.

General Objective 2.0: Solder and braze various sheet metal projects with maximum safety.


8

2.1 Identify the types of solders

used in sheet metal work and state

their compositions: e.g.

- tinman's solder,

grade

- self-flux solder

- resin-core solder,

etc

• List and identify types of solders

• show various types of solders

used in sheet metal work and state

their composition

• Lesson plan Charts

Various Types of solders

37


CRAFT PRACTICE


week- L6: P12


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


6

3.1 State the meaning of the

following terms:

a. edge-stiffening

b. beading

c. work hardening

d. beating

e. annealing

f. hollowing

g. raising

h. blocking

i. planishing

j. sand blasting

k. picking

l. lacquering

m. galvanizing

n. plating

o. painting

p. other items used

• Explain the meaning of the terms

listed in 3.1 (a - p)

• Give details note on the above.

• Show samples to students

• Lesson plan Posters

Chalkboard

• Finished sheet metal

projects involving terms

listed in 3,1 (a - p)

11 - 12

3.2 Calculate allowances for edge-

stiffening which include:

a. helming

b. wiring, using the

formula for wiring

allowance: 2D + 4T

(where D is the

diameter of wire

and T is the

thickness of metal)

• Solve problems involving

calculations of allowances for edge-

stiffening using the formula for

wiring allowance: 2D+4T (where D

is the diameter of wire and T is

thickness of metal


Chalkboard

38


CRAFT PRACTICE


week- L6: P12





Year 3

Term 2

1 - 2

3.3 Mark out for edge-stiffening

using the calculated allowance

3.4 Produce projects involving

edge-stiffening such as:

a. beading

b. swaging

3.5 Know the mechanical properties

of the following materials used in

beating metal work:

a. brass

b. copper

c. aluminium

d. low carbon steel

3.6 Develop discs for making bowls

using workshop method

• Ask students to demonstrate the

marking out for edge-stiffening

• Ask students to demonstrate

projects involving edge-stiffening

after sample demonstration.

• Explain the mechanical properties

of materials used in beating sheet

metal work


development of discs for making

bowls using workshop method


Tools and Equipment


Tools and Equipment



Tools and Materials

3 - 4

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

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


laying out and cutting out blanks for

raising, sinking or hollowing

• Lesson plan, Chalkboard

Posters.


Compasses Dividers, etc.


Dividers Scribers, etc

39


CRAFT PRACTICE

COURSE: SHEET METAL WORK Course Code: CFW 11 Contact Hours: 18

per week- L6: P12





3 - 7

3.10 Select appropriate tools and equipment and apply

correct procedures to produce to specification by

raising, sinking or hollowing, given metal forming job.

Note: Sheet metal forming procedures should involve:

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

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.

• Demonstrate and

explain process of

producing bowls by

raising, hollowing and

blocking using necessary

tools.

• list the safety precaution.

• Give student

project/assignment to

produce bowl.

• Explain and demonstrate

removal of dents from

metal surface.

• Give student assignment

on dent removal

• Ask students to

demonstrate removal of

dents using appropriate

tools and equipment

• Lesson plan

• Chalkboard

• Lesson plan,

Chalkboard

Appropriate Tools

and Equipment

Such as wheeling

machine,

planishing harmer,

dollies dent eraser

etc.

• Lesson plan,

Appropriate Tools

and Equipment.

40


CRAFT PRACTICE


week- L6: P12





8 - 9

3.13 Prepare surfaces for finishing

by applying the following

processes:

a. sand blasting the

surface

b. pickling with acid

c. sanding

3.14 Finish sheet metal projects by

using the following techniques:

a. lacquering

b. galvanizing

c. plating

d. painting


preparation of surfaces for finishing

using appropriate tools and

equipment.


finishing of sheet metal project by:

i. laquiring

ii. galvanizing

iii. plating

iv. painting etc.

• Lesson plan, Related

Tools and Equipment.

• Lesson plan Related

Tools and Equipment

41


CRAFT PRACTICE


week- L6: P12


General Objective 4.0: Draw, develop and produce templates for the production of projects


10 - 12

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,

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

• Explain materials used for

making templates

• Demonstrate the production

and reading of blue-prints of

sheet metal projects

• Develop templates using the

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

• Lesson plan

Chalkboard related

Materials

• Lesson plan

chalkboard Charts

Appropriate Tools and

Equipment

• Lesson plan

Chalkboard Instrument

• Lesson plan Related

Tools, Equipment and

Materials

• Lesson plan

• Tool, Equipment and

materials

42

Gas Welding and cutting

Programme: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice

Module: CFW 12 Gas Welding and Cutting

Prerequisite CFW 11

Duration 18 hours/Week 6 theory, 12 Practical

Goal: 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

43


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 Teachers Activities Resources

Year 3

Term 1

1

1.1 Carry, transport and store full and

empty gas cylinders safety using

appropriate equipment

• 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


or Posters and

appropriate equipment

2

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

liquids.

b. Gas welding near

containers with inflammable

materials, e.g. petrol tank;

and

c. Gas welding in confined

spaces.

• List and explain safety

precautions involved in gas

welding operations

• List and explain the use of

protective wears for carrying

out gas welding operations


appropriate safety precaution

while carrying out items 1.2 (a-

c)


etc.

3

1.3 Select, use and care for protective

wears for carrying out gas welding

operations. E.g.

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

44


CRAFT PRACTICE



12 practicals


General Objective 2.0: Know and apply successfully various gas welding processes/operations

including the acetylene and oxy-fuel gas cutting processes.


4

5

6

2.1 Identify the following gas welding

equipment, describing their features, functions,

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

2.2 Differentiate between the following types of

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.

2.4 Distinguish between high and low pressure

systems of welding

2.5 State the composition of calcium carbide

2.6 Generate acetylene using 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

• Show the students items

listed in 2.1

• Identify and explain the

features and functions and

applications listed in 2.1

• Explain the difference

between the two types of

generators stating advantages

and disadvantages

• Explain the main part of

generator

e.g. hydraulic back pressure

valves, purifiers, carbide trays

etc.

• State the difference between

low and high pressure

systems of gas welding

• Explain the composition of

calcium carbide

• Demonstrate how to

generate acetylene using

calcium carbide

• Show and explain the types

of welding rods to students

stating their properties,

composition and uses.

• With the aid of torches

explain the difference between

welding and cutting torches.

• Chalkboard and

Lesson plan

• Chalkboard,

Lesson plan,

sketches/Charts

• Chalkboard

Lesson plans

leveled drawings.

• Lesson plan, low

and high pressure

gas welding sets.

• Lesson plan,

Chalkboard and

calcium carbide

• Lesson plan,

calcium carbide

motor and generator

• Lesson plan

Chalkboard and

different types of

welding rods.

• Lesson plan,

chalkboard Welding

and Cutting torches.

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


7 8 9 10

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 down-hand 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.

• 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

46


COURSE: GAS WELDING AND CUTTING Course Code: CFW 12

Contact Hours: 18 per/week 6 Tutorials 12 practicals


General Objective 3.0: Know and weld together different types of non-ferrous and ferrous metals


11 12

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

• 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 non-ferrous 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

47






Year 3 Term 2 1 - 2 3

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

3.8 Prepare cast-iron for welding by:

a. chamfering or beveling of edges to specification b. pre-heating to specification

3.9 Fusion weld cast iron components 3.10 Identify suitable flux for bronze welding and state its composition 3.11 Prepare bronze to specifications3.12 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

• Explain two function of fluxes used in the welding of ferrous and non-ferrous metals using appropriate fluxes • Demonstrate the welding of ferrous and non-ferrous metals using appropriate fluxes • Show students the different types of cast iron • Explain their composition and properties • Demonstrate preparation of cast iron 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 • Ask the student to demonstrate above • Explain the purpose for post-heating 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

• Lesson plan, Charts, Appropriate Tools and Equipment • Lesson plan, Chalkboard and Sample of Cast Irons • Lesson plan, Charts, Pieces of Cast iron, Related Tools and Equipment

- do - • Lesson plan, Chalkboard • Lesson plan, chalkboard bronze related tools and equipment • Lesson plan, charts, Pieces of Bronze, Related Tools and Equipment. • Lesson plan Chalkboard

- do - • Lesson plan, Chalkboard Stainless Steel, Tools and Equipment

48


CRAFT PRACTICE



12 practicals




4 - 6

3.16 Weld stainless steel using appropriate

welding rods and techniques and observing

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

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

using correct techniques and observing the

correct safety practice.

• Demonstrate the welding of

stainless steel using

appropriate welding rods and

observing safety practices

• Demonstrate the appropriate

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

the above

• Students should be asked to

carryout projects involving all

of the above

• Lesson plan, Charts

Pieces of Stainless

Steel, related Tools

and Equipment

• Soapy cold water,

Worm Water Wire

brushes

• Lesson plan,

Chalkboard and

sketches/Charts

• Lesson plan

Chalkboard

- do -

- do -

• Lesson plan,

materials tools and

equipment.

• Sample of metals

49


CRAFT PRACTICE



12 practicals


General Objective 4.0: Understand the process of building up worn metallic shafts or surfaces


7

4.1 Identify the composition of given worn

metallic shafts or other worn metallic

objects

4.2 Discuss the properties of the metal used

for given worn metallic shafts or other

objects

4.3 Build up given worn metallic surfaces to

specifications using suitable filler rods and

applying the correct technique/sequence of

operation


given worn metallic shaft or

objects

• Describe the properties of

the metal used for given worn

metallic shaft or other objects

• Demonstrate how to built up

worn metallic surfaces to

specification, using suitable

techniques and filler rods

• Lesson plan,

Chalkboard, Worn out

Metallic Part or Shaft

- do -

• Lesson plan and

Appropriate materials,

related tool and

equipment

50




General Objective 5.0: Know the various welding defects and rectify them


8 9 10 - 12

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

• List and identify various welding defects to students • Explain the defects in gas welded joint as listed in 5.1 (i-vi) • Give detailed notes on all of the above • Explain how the weld defects in (5.1) above can be avoided in oxy-acetylene welding • Explain the use of test to detect defect in welded joint a non-destructive test • Give detailed notes • Explain and Demonstrate how to use of test to detect defects in welded joints: destructive and non-destructive test • Ask students to demonstrate correction of welding defects enumerated in (5.1) above • Test and evaluate the students in production process

• Lesson plan Chalkboard Sketches/charts • Lesson plan, Chalkboard, Sketches/Charts • Lesson plan • Films • Video taper • Industrial visit/execution etc. • Lesson plan, Test piece Related Tools and Equipment • do - • Lesson plan • Tools, equipment and materials


51

Metal Arc Welding

Programme: National Technical Certificate in Fabrication AND Welding Engineering Craft Practice

Module: CFW 13 Metal Arc Welding

Prerequisite CFW 12

Duration 18 hours/Week 6 theory, 12 Practical

Goal: 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



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

52


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


Year 3

Term 2

1

1.1 List and explain the hazards related to

metal arc welding, e.g.

a. arc eye

b. burning

c. radiation

d. electric shock

e. toxic fumes, etc

• Explain the hazard related to

metal arc welding as listed in 1.1

• Discuss how these listed

hazards can be avoided

• Give detailed notes

• Lesson plan

• Chalkboard and

Charts

2

1.2 Select, use and care for protective

wears required while carrying out metal

arc welding operations, e.g.

a. head and hand shield

b. hand gloves

c. apron

d. spats

e. boots and leggings, etc.

• List and Describe the use and

care for protective wears while

metal arc welding as listed in 1.2

• Show these items to students

and give detailed notes

- do -

• items listed in 2.1

• chalkboard, charts

3

1.3 Apply appropriate safety precautions

while carrying out:

a. arc welding in confined

spaces

b. arc welding empty

vessels or drums that had

contained inflammable or

toxic materials

c. arc welding near

inflammable materials

• Discus Safety precautions while

carrying out a - c


appropriate safety precaution

while carrying out arc welding as

listed in 1.3

• Lesson plan Arc

Welding Equipment

53


CRAFT PRACTICE



12 practicals


General Objective 2.0: Understand the construction, features and working principles of arc welding

machines and accessories


4

5

2.1 Differentiate between A.C and D.C arc

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

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

machines for specified voltage/amperage

operation, observing safety precaution

2.6 Explain the following processes of

electrode manufacture:

a. solid extrusion process

b. extruded with re-

enforcing coating

c. dipped process

Show students the different

features in the construction of the

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.

welding machines for specified

voltage and amperage observing

safety precautions

• Describe the processes of

electrode manufacturing as listed

in 2.6

6. Chalkboard Lesson

plan Arc Welding

Equipment

7. Lesson plan

Chalkboard Chart

• Chalkboard Arc

Welding Accessories

etc.

• Chalkboard Lesson

plan ac/dc welding

machine etc.

- do -

- do -

54


CRAFT PRACTICE



12 practicals


General Objective 2.0: Understand the construction, features and working principles of arc welding



6

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

2.10 State the basic methods of electrode

care, e.g.

a. dry storage

b. oven storage

c. safe handling

2.11 Strike metal arc and maintain the arc

• Explain with sketches, material

composition of different types of

electrode

• Explain the conventional

electrode classification system

• Explain the selection of

electrode materials according to

parent metals

• 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

• 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

7

2.12 Carry out with proficiency the

following arc welding

techniques/operations:

a. weaving

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 multi-

runs etc

observing safety

regulations as

required

• Lesson Plan,

Welding Machine

Tools and

Accessories

55


CRAFT PRACTICE



12 practicals


General Objective 3.0: Make different types of welded joints in all positions


8

9

3.1 Describe with sketches the application

of the following joints in metal fabrication:

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

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.

• Explain with sketches the

application of the following joints

in metal fabrication:

i. square butt

ii. single vee

iii. double vee

iv. single U

v. fillet and

vi. open corner

etc

• Describe the factors that govern

the selection of joint to be used

for a project with reference to 3.2

(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 (e-

f)

• 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

• Chalkboard,

Sketches/Charts

lesson Plan

• Lesson plan

Chalkboard

• Lesson plan and

Chalkboard

• Lesson plan,

Process of metals,


Equipment

• Lesson plan

Appropriate tools and

Related Materials

56


CRAFT PRACTICE



12 practicals


10

11 - 12

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

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


pipes and flanges in rotated

positions


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

57


CRAFT PRACTICE



12 practicals


General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and

weld them together


Year 3

Term 3

1

2 - 3

4.1 Identify by inspection various types of

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

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

• Explain by inspection various

types of ferrous metals: cast iron,

steel, stainless steel, etc

• Discuss four physical properties

of cast iron

• Describe the behaviour of the

following types of cast iron when

welding as in 4.3 (a-c) above

• Explain the uses and

demonstrate the following

procedures as in 4.4 (a-d).

• Demonstrate the preparation of

cast iron pieces by chamfering

and pre-heating and weld

satisfactorily as listed in 4.5 (a-d)

• Lesson plan,

Chalkboard and

Various Type of

Ferrous Metals

• Lesson plan,

Chalkboard

• Samples of grey cast

iron, white cast iron,

and malleable cast

iron

• Lesson plan Welding

Equipment and

Appropriate Tools.

58


CRAFT PRACTICE



12 practicals



weld them together


4

4.6 Identify various types of non-ferrous

metals, e.g.

a. copper

b. aluminium

c. brass

d. iconel

e. monel

• State various types of non-

ferrous metals as in 4.6 (a-e)

• Show samples of the listed

above to students

• Lesson plan

Chalkboard Different

Types of non-ferrous

metal

5

4.7 Describe the composition and state

the mechanical properties of the non-

ferrous metals named in 4.6 above,

mechanical properties to include:

a. ductility

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.

59


CRAFT PRACTICE



12 practicals



weld them together


4.8 Select suitable electrodes and

machines for welding various types of

given non-ferrous metals

• Explain the selection of suitable

electrode and mechanics for

welding various type given non-

ferrous metals

• Lesson plan

Different sizes of

Electrode and

Welding Machine

4.9 Outline appropriate heat treatment

method for a finished welding of non-

ferrous metal

• Discuss through demonstration,

the appropriate heat treatment

method for finished weld of non

ferrous metals

• Lesson plan

• Furnace

• Samples of non

furnace 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

• Demonstrate the welding of non-

ferrous metals and apply the

appropriate heat treatment

method as in 4.10 (a-e)

• Lesson plan, welding

equipment and

appropriate tools

60


CRAFT PRACTICE



12 practicals



weld them together


General Objective 5.0: Build up worn metallic shafts; air surfaces using metal arc welding


7

5.1 Identify the composition of given worn

metallic shafts or other worn metallic

parts. e.g. gear teeth that can be restored

by arc welding.

5.2 Discuss the properties of the given

worn metallic parts to be restored by arc

welding

5.3 Build-up given worn metallic parts to

specification using appropriate techniques

including controls against distortion

• Describe the composition of a

given worn metal shafts or parts

e.g. gear teeth that can be

restored by arc welding

• State the properties of given

worn metal parts to be restored

by arc welding

• Demonstrate the building up of

worn metal parts to specification,

using appropriate techniques and

control against distortion

• Lesson plan

Chalkboard, and Worn

metal shaft and gear

teeth

• Lesson plan,

Welding Machine and


Equipment

General Objective 6.0: Cut Metals to various specifications using metal Arc Cutting process.


6.1 Know the principles and application of the following arc cutting methods in metal fabrication:

a. air arc method b. carbon arc method c. oxy arc method

• Explain the principles and application of the following arc cutting methods in metal fabrication:

i. air arc method ii. carbon arc method and iii. oxy arc method

• Lesson plan Chalkboard Sketches/Charts • Welding equipment and accessories

8

6.2 Identify arc cutting electrodes and state their compositions and uses

• Explain arc cutting electrode stating their composition and uses

• Lesson plan chalkboard various arc cutting electrode

6.3 Cut metals with facility using the different cutting methods named in 6.1 above.

• Demonstrate the cutting of metals using the different cutting method named in 6.1 above

• Lesson plan Arc Cutting Electrode and Welding Equipment

61

General Objective 7.0: Know various welding defects and rectify them


9

7.1 Describe major defects in arc welded

joints including undercut; lack of fusion

(side, root, inter-run); porosity; slag

inclusion (oxide entrenchment); unequal

leg length (uneven alignment); and lack of

reinforcement.

• Explain major defects in arc

welded joint as in 7.1

• Show students samples of these

defects


• Lesson plan

Chalkboard,

Sketches/charts

• Samples of defects

10 7.2 Know how the weld defects in 7.1

above can be avoided

• Explain how weld defects in 7.1

above can be avoided.

• Lesson plan,

Chalkboard

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

penetrant;

b. destructive tests such

as bend test, macro and

micro examinations

sulphur print, izod and

fatigue


the following test to detect defects

in arc welded joints as shown in

7.3 (a-b)

• Lesson plan,

Chalkboard, Testing

Apparatus

11

7.4 Rectify welded joint defects named 7.1

above

• Explain how to correct defects in

welded joints named in 7.1 above

- Do -

12

7.5 Produce project involving the

application of:

a. General safety

precaution

b. Using both AC and DE

machines

c. Ferrous and non-

ferrous metals

d. Different type of joints

in all positions and defect

etc

• Test, evaluate the students in

the production process

• Lesson plan

• Material, tool and

equipment


62

Structural Steel Work

PROGRAMME: National Technical Certificate In Fabrication And Welding Engineering Craft

MODULE: CFW 14- Structural Steel Work

DURATION: 18 Hours/week 6 Tutorial; 12 Practical

GOAL: 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:


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.



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

63


CRAFT PRACTICE

COURSE: STRUCTURAL STEEL WORK Course Code: CFW 14 Contact Hours: 18 hrs

per week 6 tutorials; 12

practicals


General Objective 1.0 Understand the safety rules as applicable to structural steel work


Year 3

Term 2

1

1.1 Select, use and care for the

following protective wears used in

structural steel work:

a. gloves

b. aprons

c. boots

d. goggles, etc

• Explain the use and care for

protective wears used in

structural steel work

• Show students items listed in 11

• Demonstrate how to take care

of these items


• Lesson plan

Chalkboard

• Posters

• Related Protective

Wears

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

structure

c. rules for transporting

of structures, etc.

• Explain the safety for operations

in structural steel work and give

detailed notes

• Lesson plan

Chalkboard

• Posters

• Necessary Tools and

Equipment

2

1.3 Apply the safety rules in carrying out

operations named in 1.2 above.


safety rules in carrying out

operations mentioned in 1.2

above

- do -

64


CRAFT PRACTICE



practicals


General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work


3

2.1 Select and use common hand tools

used in structural steel work: e.g.

a. hammers (assorted)

sheers

b. spanners (assorted)

dog

c. drills (assorted) dice

d. punches dollies, etc

e. chisels

f. screw drivers

g. pliers

h. strips

List common hand tools used in


Explain their uses

Show students these tools

Give detailed notes

Ask student to sketch these tools

Lesson plan,

Chalkboard Appropriate

Tools and Equipment

2.2 Identify and use with facility the

following power tools used in structural

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

power tools used in structural

steel work

• Show the student these tools

• Demonstrate using these tools


• Lesson plan


Equipment

65


CRAFT PRACTICE



practicals


General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work


4

5

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

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

• 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


• Lesson plan

Chalkboard, charts


Equipment

6

2.4 Maintain tools, machines and

equipment used in structural steel work

e.g. by:

a. cleaning

b. oiling

c. greasing

d. regrinding, etc

• Demonstrate how to maintain

tools, machine and equipment

used in structural steel work

• Lesson plan

Appropriate Tools,

Equipment and

Materials

• Oil and grease cans.

• Grinding machine

66


CRAFT PRACTICE



practicals


General Objective 3.0: Know the structural properties of materials used in structural steel work and

make simple calculations related to their strength.


7


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)

h. Bridge beams, etc.


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.

• Sketch and explain forms of

structural steel materials

• Give detailed notes on each of

the equipments

• Asked students to sketch these

equipment

• Lesson plan,

Chalkboard,

Posters/Charts.

• Samples of equipment

where available

67


CRAFT PRACTICE



practicals


General Objective 3.0: Know the structural properties of materials used in structural steel work and

make simple calculations related to their strength.


8

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

structural steel work design.

3.4 State the use and limitations of the

structural steel materials named in 3.1

above

3.5 Apply Hooke's Law in the design of

given simple structural elements.

• Ask students to sketch and

explain conventional symbols 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

3.1

• Explain and apply Hooke's Law

in the design of simple structural

elements

• Lesson plan

Chalkboard Charts.

• Lesson plan

Chalkboard, Charts

• Lesson plan

Chalkboard

• Lesson plan

Chalkboard

3.6 Distinguish between the following

stresses in structural steel-work:

a. tensile stress

b. compressive stress

c. shear stress

• Explain and state the

differences of stresses in


• Lesson plan

Chalkboard Charts

3.7 Know simple calculations involving

practical applications of tensile,

compressive and shear stresses, e.g. in

riveted and welded joints

• Explain simple calculations

involving practical application of

stresses in riveted joint, welded

joints etc.

• Give student some problems to

solve

• Lesson plan

Chalkboard 9

3.8 Read structural steel work drawing

and sketch simple structural steel work

details.

• Draw and interpret structural

steel work drawing and sketches

of simple structural steel work

details

• Lesson plan

Chalkboard Sample

drawings and sketches

68


CRAFT PRACTICE



practicals


General Objective 4.0: Produce simple structural steel projects on the shop floor


10

4.1 Calculate allowances for forming

thick metal or angle bar rings using the

following methods:

a. meanline method

b. neutral line method

• Explain calculations of

allowances for forming thick metal

or angle bar rings using meanline

and neutral line method

• Solve some problems

• Lesson plan

Chalkboard sketches

11

4.2 Produce simple projects in structural

steel work e.g. stanchion bar plate rafter

hunches, etc.

• Give students projects to

demonstrate the production of

simple projects in structural steel

work

• Lesson plan

Appropriate tools

equipment and

materials

12 4.3 Develop templates with regular

surfaces

• Demonstrate how to develop

templates with regular surfaces

• Lesson plan Drawing

instruments

Year 3

Term 3

1

4.4 cut out templates from the following

materials:

a. wood

b. cardboard

c. any other suitable

materials

• Demonstrate how to cut

templates from various materials

• Ask student to cut out template

on wood, cardboard etc

• Lesson plan

Appropriate Materials

Tools and Equipment

2

4.5 Reproduce simple jobs on structural

steel materials using templates cut in

4.4 above

• Give student Project to

demonstrate how to reproduce

simple jobs on structural steel

materials using templates in 4.4

above

• Lesson plan

Appropriate Materials

Tools and Equipment

3

4.6 sketch and produce simple working

jigs, e.g. jig for mass production of

stanchions, rafters, etc., on the shop

floor

• Demonstrate how to sketch and

produce simple working jigs.

• Ask students to do the same

• Lesson plan


Equipment.

69


CRAFT PRACTICE



practicals


General Objective 5.0: Understand the process of manufacture of iron and steel


5.1 Sketch a blast furnace and describe

its working principles

• Sketch and label a blast furnace

and explain the working principles

• Note: Student should visit

industry/factory to see a typical

blast furnace.

• Students are asked to sketch

and label blast furnace

• Lesson plan

Chalkboard

Posters/Chart Industrial

Visit

5.2 Give the name of fuel and state the

composition of charge used in blast

furnace

• Ask students to state the type of

fuel and the composition of

charge used in blast furnace

Lesson plan

chalkboard, charts

5.3 Explain the working principles of

Bessemer process with the aid of a

sketch

• Ask students to state the

working principles of a Bessemer

process with the aid of a sketch.

• Students are asked to sketch

Bessemer converter

- do -

4

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

70


CRAFT PRACTICE



practicals


General Objective 6.0: Assemble simple structural steel components


6.1 Know the uses of fixtures and bolts

in the assembly of structural

components

• Explain the uses of fixtures and

bolts in the assembly of structural

components


• Lesson plan

Chalkboard, bolts and

fixtures

5 6.2 Assemble simple structural

components such as rafter bracing,

simple canopy simple roof trusses, etc.

Note: Assembly should

involve basic jointing

operations, e.g. bolting,

riveting and welding

• Demonstrate how to assemble

simple structural components,

using bolts, rivets and welding

operation

• Show samples of some of these

assemblies

• Lesson plan


Equipment

General Objective 7.0: Know the effect of corrosion on structural steel materials and apply

protective coating against corrosion.


6

7.1 Name some common causes of

corrosion on steel e.g.

a. atmospheric

b. chemical such as

electrolytic action.etc

Ask students to list some

common causes of corrosion on

steel

Show student samples of

corroded steel.

Lesson plan Chalkboard

Sample of corroded

steel

7

7.2 Describe the effect of corrosion on

structural steel, e.g.

a. weakening of

structure

b. defacing of steel

• Ask students to explain the

effects of corrosion on structural

steel

- do -

8

7.3 Know the purposes for applying

undercoat to structural steel

components

• Explain the purposes for

applying undercoat to structural

steel components

- do -

71


CRAFT PRACTICE



practicals


General Objective 7.0: Know the effect of corrosion on structural steel materials and apply

protective coating against corrosion.


9

7.4 Prepare the surfaces of structural

steel components for finishing with the

following methods:

b. brushing

c. de-greasing

d. de-scaling

• Demonstrate how to prepare the

surface of structural steel

components for finishing

• Ask the student to perform the

operation above

• Lesson plan


Equipment

10

7.5 State the composition of common

undercoat used for structural steel work

• List and explain the composition

of common undercoat used for

structural steel work.

• Lesson plan

Chalkboard, Charts,

and samples of under

coat

11

7.6 Apply suitable undercoat to

structural steel components. E.g. red

oxide, metalization

Note: Observe safety precautions in the

use of the undercoats.


suitable undercoat to structural

steel components and observe

safety precautions.

• Lesson plan


Equipment

12

7.7 Produce project involving the

application of safety rules in structural

steel work

• Test, evaluate the student in the

process of the production

• Lesson plan


equipment


72

Advanced National Technical Certificate

Welding

PROGRAMME: Advanced National Technical Certificate In Fabrication And Welding Engineering Craft

MODULE: CFW 21-Welding


GOAL: 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


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.



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

73

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


General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded

arc and ancillary welding processes


1

1.1 Know the importance of a safe working

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

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.

• Explain the importance of a

safe working environment

with respect to safety to self

and others as per 1.1 (a-d)

• Welding tools, lesson

plan chalkboard goggle

and appropriate

equipment

74





Practicals


General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded

arc and ancillary welding processes


1.2 List and explain the hazards related to

gas shielded arc welding. e.g.

a. arc eye

b. burning

c. radiation

d. electric shock

e. toxic fumes, etc.

• Describe the hazard related

to gas shielded arc welding

as listed in 1.2 (a-e)

• Lesson plan

• Chalkboard. And chart

1.3 Select, use and care for the protective

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.

• Explain the use and care for

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

• Lesson plan and

protective wears

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

• 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

75

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


General Objective 2.0: Understand the constructional features and the working principles of TIG and MIG welding machines and accessories


2.1 Explain the constructional features and 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

a. State the constructional 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

e. Lesson plan, chalkboard, sketches and charts and some accessories

2.2 State the advantages and disadvantages of AC and DC welding systems 2.3 Identify the electrodes and filler wires for TIG process and state their composition2.4 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 disadvantages of AC and DC welding system g. Describe the electrode and filler wires for TIG process 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 (a-e) 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

l. Lesson plan, chalkboardm. Lesson plan, chalkboard and TIG accessories n. Lesson plan and chalkboard

76





Practicals


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


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

applications.

e. Shielding Gases

f. Pure and mixed,

functions and applications

g. d) Filler materials and

their composition

• Ask students to describe the

major process variables and

characteristics as listed in 3.1

(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


• Sketches/Charts

accessories and materials

3

3.2 Appreciate the applications of TIG

welding process and select suitable

operating characteristics for the welding of

the following: low carbon steels, high yield

steels, stainless alloys, nimonic alloys,

titanium alloy, cooper alloys and aluminum

alloys.

• Explain the application of

TIG welding process and

state operating characteristics

for the welding listed in 3-2

and give detailed notes

• Lesson plan,

• Chalkboard

• Charts

77





Practicals





3.3 Compare backing materials, purging

and under-bead shielding as a means of

producing acceptable welds.

• Explain backing materials

purging and under-bead

shielding as mean of

producing acceptable welds.

• Lesson plan and

chalkboard

3.4 Explain the effects of joint preparation

on the production of acceptable and

economical welds by the TIG welding

processes

• State the effect of joint

preparation on the production

of acceptable and economical

welds by TIG welding

processes and give notes.

- do -

4

3.5 Explain the importance of adhering to

specifications, codes and standards for

TIG welding processes.

• State the importance of

adhering to specification

codes and standards for TIG

welding processes and give

notes

- do -

78





Practicals





5

3.6 List and state the functions of TIG

welding accessories, e.g. electrode holder,

earth lead, welding lead, etc.

3.7 Describe with sketches the materials

composition of different types of electrodes

used for TIG welding.

3.8 Set and use the TIG welding machines

to weld the following metals - aluminum,

copper and stainless steel at specified

voltage observing safety precautions

3.9 Explain the difference between TIG

and MIG processes.

• Explain the functions of TIG

welding accessories as listed

in 3.6

• With the aid of sketch or

diagram, ask student to

sketch each of the items

• Ask students to explain with

sketches the materials

composition of different types

of electrodes use for TIG

welding.


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


and

• TIG welding accessories

• do -

• Lesson plan

• TIG welding machine

equipment and materials.


and Charts

79





Practicals





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

• State the factors that govern

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



• TIG welding equipment

and accessories and

materials.

3.11 Sketch and explain the meaning of

the various arc welding

symbols/conventions, e.g. symbol of a

single V butt weld with sealing run, symbol

of weld on both sides etc.

• Sketch and state the

meaning of the various arc

welding symbols/conventions

as out line in 3.11


and

• Sketch/chart

80





Practicals





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


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

6

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

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

and MIG welding techniques

on the listed items in 3.14 (a -

f)



fixed cluster in a gearbox

• Lesson plan

Ancilliary/welding

equipment, tools and

materials

- do -

• Lesson plan, TIG and

MIG welding equipment,

accessories and materials

- do -

81





Practicals





3.16 Explain the principles of MIG welding

and state the techniques of consumable

and non-consumable electrodes and wires

and their composition.

3.17 Explain the details of equipment used

and describe the setting of their controls

3.18 state the effects of wrong setting, type

of defects, causes and elimination

• State the principles of MIG

welding and explain the

techniques of consumable

and non-consumable

electrode and wires and their

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.


Appropriate electrodes

and wires

- do -


Sketches/Chart

82





Practicals





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.

• State the major process

variables and characteristics,

listed in 3.19 (a-c)

- do -

83

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


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


3.20 Apply the MIG welding process and select suitable operating characteristics for 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.

• Demonstrate the MIG welding process and show suitable operating characteristics for welding of items listed in 3.20 and give detailed notes

• Lesson plan • MIG equipment & Accessories/Materials

7

3.21 Explain the principles of spot welding 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 cooling on welds 3.26 Discriminate between the types of welds e.g. plasma arc or sub-merge arc and spot welding

• Ask students to state the principle of spot welding and explain the size and shape of 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, sub-merged arc and spot welding • Give detailed notes on all of the above

• Lesson plan • Chalkboard • Spot welding machine - do -

84





Practicals


General Objective 4.0: Apply appropriate workshop processes and techniques to mark out and form

projects for welding


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

• Demonstrate the marking

out of project in welding as

listed in 4.1 (a-d) applying

appropriate tools, techniques

and safety practices

• Give students projects

involving items listed in 4.1

• Lesson plan Spot

Welding, Appropriate

Equipment, Tools,

Materials and Protective

Wear

4.2 Prepare bronze components for

welding avoiding sharp edges and weld to

specification.


preparation and welding of

bronze component for

avoiding sharp edges and

welding to specifications and

give notes

• Lesson plan, Welding

Equipment Tools and

Materials

4.3 Prepare stainless steel components for

welding using welding rods and techniques

and observing safety precautions.

• Demonstrate preparation

and welding of stainless steel

components using welding

rods and techniques and

observing safety precautions.

• - do -

4.4 Identify and state the type, composition

and properties of common stainless steels

used in metal work

• List types of stainless steel

• Explain their composition

• Discus their properties and

uses

• Lesson plan,

Chalkboard, Sketches

Chart and Different pieces

of stainless steel.

85





Practicals


General Objective 5.0: Make different types of welded joints in all positions


5.1 Describe with sketches the application

of the following joints in metal fabrication:

a. Square butt

b. Single vee

c. Double vee

d. Single U

e. Open corner, etc.

• Explain with sketches the

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.

• Lesson plan

• Chalkboard and

• Charts

9

5.2 Prepare edges for welding the joints in

5.1 observing safety rules.

• Demonstrate how to prepare

edge for welding the joints in

5.1 observing safety rules

• Ask the student to prepare

edges for welding joints in 5.1

• Lesson plan, Necessary

Tools, Equipment and

Materials

5.3 Weld pipes and flanges in various

positions e.g:

a) fixed position

b) rotated position

• Demonstrate how to weld

pipes and flanges in various

position - both fix and rotated

- do -

5.4 Prepare metal surfaces and make

multi-run and weaving welds


metal processes and make

multi run and weaving

- do -

10 5.5 Weld joints in vertical, horizontal and

overhead positions

• 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 -

86





Practicals


General Objective 6.0: Understand and apply the fuel-gas cutting process in cutting metals to given

specification.


6.1 State the principles and applications of

fuel-gas cutting process, e.g.:

a. Manual

b. Machine

• Explain the principles and

applications of fuel-gas

cutting as listed in item 6.1 (a-

b)

• Give the students, projects

involving the two processes

Lesson plan, Chalkboard

11 6.2 Describe various fuel-gas used in oxy-

fuel cutting e.g:

a. acetylene

b. propane

c. butane

d. coal-gas, etc

• Ask students to state

various fuel-gases used in

oxy-fuel cutting gas listed in

6.2 (a-d)

- do -

6.3 State the advantages and disadvantages of using the above-named fuel-gas for oxy-fuel cutting operations

• Explain the advantages and disadvantages of using above named fuel gases for oxy-fuel cutting operation.

- do -

6.4 Prepare templates for the mass production of given objects of regular or irregular shapes by profile cutting

• Demonstrate how to prepare templates for mass production of given object by profile cutting

• Lesson plan, Equipment Tools and Materials

6.5 Cut smooth, curved, circular and straight objects using the hand cutting torch including oxy-lance and flame gauging

• Demonstrate and explain how to cut smooth, curved circular and straight objects using hand flame gauging.

• Lesson plan Appropriate Equipment Tools and Materials

12

6.6 Produce project involving Arc and Ancillary welding process

Assist student to design and produce projects involving Arc and ancillary welding. Test and evaluate the studentGive detailed notes on all of the above

Arc and ancillary welding equipment.


87

Structural Mechanics and Specification


MODULE: CFW 22-Structural Mechanics and Specification


GOAL: 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



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


88



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.


1.1 Apply with facility standard

specifications for structural steel

construction using America or British

Standards and their Nigerian counter-

parts.


standard specifications for structural

steel construction. And give detailed

notes

• Lesson plan

• Chalkboard

• Charts.

1-2

1.2 Calculate weight of given structural

steel components using appropriate table

of specifications.

• Explain and calculate the weight of a

given structural steel components

using appropriate specifications

• Give the students problems to solve

• Lesson plan

• Chalkboard.

1.3 Draw diagrams to show the

applications of the following in structural

steel work:

a. tensile forces and

stresses

b. compressive forces

and stresses

c. shear forces and

stresses

• Sketch diagrams to show the

application of structural steel work

forces and stresses and ask the

students to do same.

• Lesson plan

• Chalkboard

• Charts

3

1.4 Calculate the reaction at the supports

of cantilever and simply supported

beams having points and uniform loading

e.g. simple shed frame with flat roof.

• Explain and calculate the reaction at

the support of cantilever and simple

supported beam having points and

uniform loading.

• Lesson plan

• Chalkboard, etc.

89




SPECIFICATION


per week - 4

tutorials; 11

practicals



steel work design.


1.5 Calculate bending moments and

moment of resistance of simply

supported beam with point and uniform

loading.

• Explain the calculation of bending

moments and moment of resistance of

simply supported with point and

uniform loading.


• Lesson plan

• Chalkboard

• Charts.

1.6 Determine sizes of materials or

sections required for columns, rafters,

etc.

• Explain how to determine sizes of

materials required for columns, rafters,

etc.

• Lesson plan

• Chalkboard

• Charts

4

1.7 Sketch bending moment diagram for

cantilever with uniform load and calculate

the bending moment.

• Sketch and explain bending moment

diagram for cantilever with uniform load

and calculation on the bending

moment.

• Lesson plan

• Chalkboard

• Charts

1.8 Apply 1.4 in determining reaction at

support of actual frames. e.g.

b. canopy

c. riveted angle stiffered

for crane beams

• Demonstrate how to apply 1.4 in

determining reaction at support of

actual frames.

• Lesson plan

• Appropriate tools

and equipment.

1.9 Apply stress diagrams to determine

load on member of structural frames. e.g.

trusses.

• Explain how to apply stress diagrams

to determine load on member of

structural frames.

• Lesson plan

• Chalkboard

• Charts

• Appropriate tools

and equipment

5

1.10 Calculate bending stress due to web

or flange connections. E.g. floor beams

multistory frame building.

• Explain the calculation of bending

stress due to web or flange

connections

• Lesson plana

• Chalkboard

90




SPECIFICATION


per week - 4

tutorials; 11

practicals



steel work design.


6

1.11 Explain the purpose of the following

in structural steel assembly:

b. rag bolt

c. gusset plate

d. base plate

• Enumerate the purpose of the

following in structural steel assembly:

• rag bolt

• gusset plate

• base plate

• Lesson plan

• Chalkboard

• Posters

• Samples

1.12 Calculate the deflections on a

column or other members using standard

specifications/formulae.

• Solve some problems involving

calculations on deflections on a column

or other members using standard

specifications/formulae.


• Lesson plan

• Chalkboard

• Charts.

General Objective 2.0: Interpret and produce structural steel working drawings


2.1 Read and interpret working drawings

of structural steel work

• Explain how to read and interpret

working drawings of structural steel

work

• Lesson plan

• Chalkboard

• Relevant work

drawings.

2.2 Design and produce simple structural

drawings observing conventional

standards, symbols and notations.

• Demonstrate how to design and

produce simple structural drawings

observing conventional standards,

symbols and notations.

• Lesson plan

• Chalkboard

• Relevant work

drawings

2.3 Produce project applying simple

structural mechanics and standard

specification to structural steel work

• Ask student to produce project

applying simple structural mechanics

and standard specification to structural

steel work.

• Test and evaluate the students

-do-


91

Structural Steel Work


MODULE: CFW 23-Structural Steel Work


GOAL: 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



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

92



COURSE: STRUCTURAL STEEL WORK Course Code: CFW 23 Contact Hours: 15 per

week - 4 Tutorials, 11

practicals


General Objective 1.0 Develop and Produce Templates for Structural Steel Work


1.1 Calculate areas of irregular surfaces

using the following rules:

a. mid-ordinates rule

b. Simpson's rule

• Solve problems involving

calculation on areas of irregular

surfaces using various methods

• Lesson plan

• Chalkboard

1.2 Develop given templates having:

a. regular surfaces

b. irregular surfaces


templates having:

• regular surfaces

• irregular surfaces

• Lesson plan

• Chalkboard.

• Drawing instruments

1.3 Cut out the developed templates

from the following materials:

a. wood

b. card-board

c. other suitable

materials

• show students how to how to

cut out developed templates from

various materials.

• Lesson plan

• Template materials

Relevant tools and

equipment. 4

1.4 Reproduce the cut templates in 1.3

above from structural steel materials

using the following workshop processes:

a. cutting - using oxy-

fuel gas, profile cutting

and power saw

b. punching - using

punching machine

c. chamfering - using

oxy-fuel gases

• Demonstrate how to reproduce

cut templates in 1.3 from

structural steel materials using

various workshop processes.

• Ask students to perform the

above functions

• Lesson plan

• Materials, Relevant


93





practicals


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.


2.1 Explain the functions of jigs and

fixtures in structural steel works

• State the functions of jigs and

fixtures in structural steel works.

• Give notes

• Lesson plan

• Chalkboard, Sample of

jigs and fixtures

2.2 Make simple jigs, fixtures and

manipulators for assembling structural

steel members.

• Demonstrate how to make

simple jigs, fixtures and

manipulators for assembling

structural steel members.

• Lesson plan

• Appropriate tools and

Equipment.

2.3 Assemble structural components

using the following jointing methods:

a. welding (arc and gas)

b. riveting

c. bolting

• Demonstrate how to assemble

structural components using

various jointing methods

• Students asked to perform the

above function


Tools and Equipment and

Structural Components

2.4 Explain the purpose of metal

finishing e.g.

a) protection from the

weather and corrosion

b) decoration

• State the purpose of metal

finishing

• Lesson plan

• Chalkboard

2.5 Describe the composition of various

materials used for finishing structural

steel work


various materials used for

finishing structural steel work

• Lesson plan

• Chalkboard

• Samples of materials for

finishing

5-7

2.6 Prepare the surfaces of structural

steel components for finishing using the

following techniques:

a. brushing - using wire

brush

b. de-greasing, using

suitable degreasing

agent

c. de-scaling


the surfaces of structural steel

components for finishing using

various techniques

• Ask student to perform above

operations

• Lesson plan

• Samples of Structural

Components, Appropriate

tools and equipment

94





practicals


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.


2.7 Apply suitable undercoat to

structural steel components e.g. red

oxide by brushing or spray methods.

• Demonstrate how to apply

undercoat to structural steel

components

• Lesson plan


Equipment 8

2.8 Store and maintain structural steel

materials and equipment

• Explain methods of storing and

maintaining structural steel

components

• Lesson plan

• Chalkboard

• Visit Relevant Stores.

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

necessary


9-12

3.1 Identify common defects in structural

steel assembly e.g.

a. distortion

b. undercutting

c. lack of reinforcement

d. lack of penetration of

weld, etc. and state their

causes.

3.2 Carry out visual inspection to detect

defects on finished structural steel

assembly

3.3 Rectify defects in assembled

structural steel components

3.4 Produce and develop templates for


3.5 Fabricate and assemble various

structural steel component

• State common defects in

structural steel assembly as

listed in 3.1

• Show student sample of defects



how to carry out visual inspection

to detect defects on finished

structural steel assembly


how to rectify defects in

assembled structural steel

components



• Lesson plan

• Chalkboard

• Any Relevant Materials

• Lesson plan

• Sample of defects

• Sample of finished weld

Components, Relevant


• Lesson plan

• Samples of

Components with weld

defects,

• Relevant Tools and

Equipment.


95

Sheet metal work


MODULE: CFW 24-Sheet Metal Work


GOAL: 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.



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

96




week-4 theory: Practical

11


General Objective 1.0: Understand the Principles of Pantograph System and pattern forming

attachment


1.1 State the principles, functions and

the constructional details of pattern

forming machines and attachments

• Explain the principles, functions

and the constructional details of

pattern forming machines

• Lesson plan

• Chalkboard

• Posters/charts.

1.2 Explain the types and

characteristics of the machines in 1.1

above

• Explain the types and

characteristics of the machines in

1.1

• Lesson plan

• Chalkboard

• Posters 1-3

1.3 Apply the machines for the

production of sheet metal work

• Demonstrate how to apply the

machines for the production of

sheet metal work. Give note on

all of above

• Lesson plan

• Relevant tools and

equipment

General Objective 2.0: Understand the construction of patterns and masters of irregular trinket box

shapes using pattern forming machine/attachment.


4-6

2.1 Explain the methods of box and

tray construction, using beadings and

joints.

• Sate the methods of box and

tray construction, using beadings

and joints. Give detailed note.

• Lesson plan

• Chalkboard


2.2 Explain the making of articles such

as oblique tee with branch, lobster back

bend, and similar utensils which involve

the development of a pattern.

• Demonstrate how to produce

articles such as oblique tee with

branch, lobster back bend, and

similar utensils which involve the

development of a pattern.

• Lesson plan

• Chalkboard


appropriate tools and

equipment

2.3 Design, construct and decorate

articles combing ornament with utility.

• Demonstrate how to design,

construct and decorate articles

combining ornament with utility.

• Relevant materials for

demonstration

97





11


General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes


a. 3.1 Review of sheet metal materials

and their preparation for industrial use

of the following metals: Tin, Lead, Zinc,

Copper, and Aluminium

• Explain and review non-ferrous

sheet metal material and their

preparation for industrial use.

Give detailed note

• Lesson plan

• Chalkboard

• Materials

3.2 State the composition of more

important brasses and bronzes, inconel

and monel; their properties and chief

uses, the composition and properties of

wrought aluminium alloys, magnesium

and titanium alloys in common use.


more important alloy metals and

alloy elements; their properties

and uses.

• Lesson plan

• Chalkboard

• Samples of materials 7-8

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

98





11


General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes


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

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.


and produce sheet metal projects

involving the use of more

advanced machines.

• Give student project on the

above to produce some of the

items listed in 3.4

• Lesson plan

• Drawing instruments,

appropriate materials,

tools and equipment.

9

3.5 Explain the methods of producing

more difficult work in hollowing, raising

and planishing, hand flattening and

setting.

• State the methods of producing

more difficult beating sheet metal

work.

• Discuss and demonstrate

processes involved

• Lesson plan

• Chalkboard.

99





11


General Objective 4.0: Understand the processes of planning and layout of engineering

workshops/industry.


10-12

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

sections in the workshops.

4.4 Describe and lay out plan for single,

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

• 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.

• Explain lay out plan for single,

batch and quantity production of

engineering components.

• Explain how to arrange

workshops according to the lay

out plans


• Take student on excursion to

industries

• Lesson plan

• Chalkboard, Charts visit

factory

• Lesson plan

• Visit

workshops/industries

• Lesson plan

• Visit

workshops/industries

• Lesson plan

• Chars

• Visit factory/industry.

• Lesson plan

• Charts.

• Lesson plan


equipment


100

List of tools and equipment for welding and fabrication

engineering

S/NO MINIMUM

QUANTITY

REQUIRED

QUANTITY

AVAILABLE

ADDITIONAL

QUANTITY REQUIRED

1. Power guillotine of capacity

10swg x 36 in length

2

2. Treadle guillotine of capacity

20swg x 36 length

2

3. Swing beam folder 10swg x 3'-6'

capacity

2

4. Bending roller capacity 40"x2"

dia

2

5. Bending roller capacity 18"x11/4

dia

2

6. Bench mounted cone roller 5

7. Hand-operated copper capacity

3/32 in mild steel

5

8. Power bench grinding machine 2

9. Double-ended buffer and polisher 2

10. Universal beading and swaging

machine

2

11. Power-operated drilling machine

maximum capacity 3/8"

2

12. Wheeling machine 2

13. Fly Press 1

14. Hand nibbling Machine 2

15. Left and right hand snips 5 each

16. Straight snips 5

17. A "kit" of tools consisting of

hammer, mallet, steel rule,

scriber and wing compass, etc.

5

18. Bench shears 2

19. Power saw cutting machine

10mm

2

101

S/NO MINIMUM

QUANTITY

REQUIRED

QUANTITY

AVAILABLE

ADDITIONAL

QUANTITY REQUIRED

20. Disc cutting machine 2

21. Profile cutting machine with gas

cutting nozzles

2

22. Piller drilling machine 2

23. Louver shearing machine

(manual)

2

24. Overhead crane 1

25. Straightening machine 2

26. Cropping machine 2

27. Straight edge 10

28. Trammels dividers (set) 10

29. Hammers 10

30. Chisels 10

31. Punches 10

32. Try-squares 10

33. Steel rules 10

34. Smith open forge 2

35. Vee blocks 10

36. Electrode holders 10

37. Electrode drying oven 2

38. Heavy duty grinding machine 2

39. Bench-type grinding machine 2

40. CO2 cylinders 5

41. Transformers With rectifiers (with

all Instruments)

10

42. Aprons (assorted 20

43. Hand gloves 20

44. Hand shields and head caps 10

45. Wire brushes 10

46. Electrical beaters 2

47. Pliers – assorted 10

48 Gas welding goggles 5

102

S/NO MINIMUM QUANTITY REQUIRED

QUANTITY AVAILABLE

ADDITIONAL QUANTITY REQUIRED

49 Double cylinder trolley 2

50 Oxygen regulators 5

51 Acetylene regulators 5

52 Hoses and clips and all attachments set

53 Blowpipes (low and high pressure

5

54. Tongs 5

55. Combined set of cutting welding outfit

5

56. Power operated profile cutter with turntable

2

57. D.C generators with all connections

5

58. A.C transformer (Argon) with all the connections

5

59. Argon cylinders 5

60. Regulators with flow meters 5

61. Hacksaw and blades 24

62. Water to carbide generators 4

63. Carbide to water generators 4

64. Overhead projector 1

65. Computer set 1

66. ANVIL 2

67. Swage block 2

68. Chipping hammers 20

69. Plain goggles 20

70. First aid box 2

71. Sledge Hammer 2

72. G. Clamps - assorted 26

73. Self grip pliers - assorted 6

74. Magnetic clamp 3

75 Flatters 6

76 Molegrip 6

103

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.

104

• 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.

105

Recommended books for fabrication and welding

engineering craft practice

S/NO BOOKS AUTHORS

1. BASIC WELDING AND FABRICATION W. KENYON

2. BASIC ENGINEERING CRAFT STUDENTS: FABRICATION AND

WELDING 05

BOURBOUSSON &

ASHWORTH

3. THE TECHNOLOGY OF SHEET METAL WORK FOR STUDENTS

AND CRAFTSMEN

A. DICKSON

4. THE GEOMETRY OF SHEET METAL WORK FOR STUDENTS AND

CRAFTSMEN

A. DICKSON

5. THE CALCULATION OF SHEET METAL WORK FOR STUDENTS

AND CRAFTSMEN

A. DICKSON

6. METAL: DESIGN AND CONSTRUCTION A.C. DAVIS - Tenth Edition

7. (a) THE SCIENCE AND PRACTICE OF WELDING Vol. I Cambridge

V. Press, 1992

A. C. DAVIS

(b) Volume II above

8. WELDING SCIENCE AND METALLURGY J. CARDENER

9. WELDING TECHNOLOGY KOENISBERGE

10. FABRICATION AND WELDING TECHNOLOGY A. SMITH

11. BASIC WELDING - Macmillian Publisher Ltd London, 1986 P. SOMSKY

12. WELDING CRAFT PRACTICE - Part 1 Volume I Oxy-acetylene Gas

Welding and Related Studies

N. PARKIN & C.R. FLOOD

13. WELDING CRAFT PRACTICE - Part 1. Volume 2: Electrical Arc

Welding and Related Studies

N. PARKIN & C.R. FLOOD

106

List of Participants UNESCO-NIGERIA PROJECT IN SUPPORT OF REVITALIUSATION OF TECHNICAL AND VOCATIONAL

EDUCATION(TVE) IN NIGERIA

PROJECT TEAM MEMBERS

S/No. NAME DESIGNATION

1 Engr. Dr. Nuru A. Yakubu National Project Coordinator & Executive Secretary, NBTE

2 Dr. M.S. Abubakar Technical Coordinator

3 Engr. S.C. Odumah Curriculum Development Coordinator

4 Mr. B.N. Niriyus Staff Development Coordinator

5 Engr. Dr. S.N. Mumah Information & Communication Technology Coordinator

6 Isa Alhaji Sulaimanu Project Accountant

7 Engr. A.D.K. Muhammad Project Officer

S/No Name Address

1. Omotorsho Isaac

Bamidele

Ondo State Board for Tech. & Voc. Education or P.O. Box 975, Akure.

2. Y.A. Alimi Government Technical College P.M.B.5377, Ado-Ekiti

3. G.G. Idris Government Technical College K/Namoda Zamfara State

4. J.I. Ortserga Dept. of Voc. & Tech. Faculty of Education Benue State University, Makurdi

5. F.M. Alega Fest Development Department, National Business & Technical Exams Board

(NABTEB) P.M.B. 1747, Benin City, Edo State.

6. Olubode Daniel

Majiyagbe

National Board for Technical Education Kaduna

Documents

Fabrication and welding engineering: National Technical Certificate