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

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

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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

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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.

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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.

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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.

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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 S/No Subject

Module

YEAR 2

YEAR 3

Term Term Term Term Term Term Term Term Term

Code

1

2

3

1

2

3

1

2

3

Total Hours for each

1

CMA 12- Mathematics

T P T P T P T P T P T P T P T P T P

216

2

-

2

-

2

-

2

-

2

-

2

- 2

-

2

-

2

-

288

2

-

2

-

2

-

3

-

3

-

3

- 3

-

3

-

3

-

288

2

-

2

-

2

-

2

1

2

1

2

1 2

1

2

1

2

1

288

2

-

2

-

2

-

2

1

2

1

2

1 2

1

2

1

2

1

288

2

-

2

-

2

-

2

-

2

-

2

- 2

-

-

-

-

-

216

15 2

CEN 11- English 17

3

CPH 10- Physics 12

4

CCH 11- Chemistry 12

5

CEC 11- Economics 13

6

CBM 11 Entrepreneurship

-

-

-

-

-

-

2

-

2

-

2

-

-

-

-

-

-

-

72

7

CTD 11- Drawing

-

3

-

3

-

3

-

3

-

3

-

3 -

2

-

2

-

2

288

-

-

-

-

-

-

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

13 8

ICT 11- Computer Studies 15

-

-

-

-

2

3

-

-

-

-

-

-

-

-

-

-

-

-

60

II 11

CFW 11 Sheet Metal Work

-

-

-

-

-

-

-

-

-

-

-

- 3

6

3

6

-

-

216

12

CFW 12 Gas Welding and

-

-

-

-

-

-

-

-

-

-

-

- 3

6

3

6

-

-

216

Cutting 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

7

2928

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

13 15 17 30 12 15

1044

TOTAL

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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 nonferrous metals in common use 2. Select and use common measuring, marking out, cutting and striking tools. 3. Understand the basic working principles of drilling machine and be able to use it for various types of screws treads rivets, and be able to rivet and cut screws by hand. 4. Understand the application of various types of screw threads and rivets, and be able to rivet and cut screws by hand. 5. Understand the ISO system of tolerances and fits, and their application in engineering production. 6. Produce simple engineering components on the bench. 7. Understand the essential features and working principles of the center lathe and carry out basic operations such as turning, stepped turning facing, taper turning., knurling, chamfering and undercutting. Practical Competence: On completion of this module, the student will be able to: 1. Use all tools correctly ensuring the machinery guards and protective eye shields are used at all times. 2. Comply with the general rules for safe practice in the work environment at all this. 3. Use and select handtools for carrying out various bench fitting and assembly tasks 4. Tools: hacksaws, taps, reamers, drills, dividers, surface gauge 5. Produce threads using taps and dies 6. Correctly grind drill point angles: Drills: Twist and flat drills 7. Select and set drilling machine speeds to carryout a range of operations using the appropriate coolants. Drilling, reaming, counter sinking, counterboring 8. Perform metal joining by a range of processes. Cut through the joints and investigate the depth of penetration of the metals at the interface. Processes: Soldering, brazing, and fusion welding. 9. Mark out on metals and other materials, datum lines, angles, radii/circles and hole positions using a range of tools.

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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

1.1 Using and handling hand tools,

• Demonstrate safe ways of • Hand tools files, hacksaw

portable power tools and machine

handling basic hand tools

1.2 Lifting, moving and storing materials or • Show a film on industrial 1-3

Resources • Television, Video machines

job

safety

• Posters on artificial

1.3 Demonstrate first aid application in

• Demonstrate how to treat

respiration

cases of minor cuts, electric shock, burns. energy cases like artificial respiration cold compress, etc • Assess student

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General Objective 2.0: Measuring, Marking, Cutting and Striking Week Specific Learning Outcome

Teachers Activities

2.1 Describe the essential features • Demonstrate how to use

Resources • Micrometer, vernier

micrometer, venier caliper,

calipers, vernier height

a. micrometer

vernier height gauge,

gauge, combination sets

b. vernier caliper

combination set

• Steel rules, dividers,

c. Venier height

• Demonstrate the maintenance punches, trammel, scribe

gauge

and care of the instruments

angle plate, vee block

d. combination set

listed above

center square

• Perform marking out for the

• Flat file, hand file, try

and use of the following

2.2 Maintain and care for the

students to learn and practice till square

instruments listed above

they become competent

• File card, flat file

2.3 Perform marking out exercise

• Demonstrate how flat surface

• Ball pein hammers, mallet

on plane surfaces including profiles can be tested using surface plate • Hacksaw blade, Hacksaw

4-6

2.4 File a piece of metal to given

and try square

specifications using any of the

• Demonstrate how files are

following: Cross filing, draw filing,

cleaned and state the

filing square and flat surfaces

precautions to be taken against

2.5 Test surface for flatness using

pinning. Students to practice till

surface plate and try square and

competent

state precautions to be taken to

• Demonstrate the application of

avoid pinning

hammers and mallets for

2.6 Maintain files in good working

engineering purposes

conditions

• Demonstrate how a hacksaw

2.7 Apply various hammers and

blade can be inserted correctly

mallets e.g ball pein, rubber

• Demonstrate how to use

mallets, etc for engineering

adjustable hacksaw, junior

purposes

hacksaw piercing

2.8 Select and insert hacksaw

• Students should be allowed to

blade correctly

practice till competent

2.9 Cut metal and other

• Guide students to produce

engineering materials to given

simple engineering components

specification using the adjustable

like open ended spanner,

hacksaws, junior hacksaws,

engineers square, tool makers

piercing saw, etc drills and Drilling. clamp, center square, etc. • Make a simple precision fitting project like hexagonal mild steel bar making push fit through a mild steel plate

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frame.

General Objective 3.0: Machine Tools Week Specific Learning Outcome

Teachers Activities

Resources

3.1 Setting up and operate a drilling machine • Demonstrate how to set • Bench drill pillar drill, drill bits

in given situations

up and operate a drilling

Note Setting up drilling machine should

machine in given situation • Bench drill, pillar drill, twist

include

• Students to practice till

drill, flat drill, counter sink

competent

drill, counterbore drill, center

a. change of spindle speed

• Demonstrate how a twist drill b. adjustment of drilling table

drill can be sharpened

• Drills, taps, tap wrench, die

to required height and angle,

correctly

and die stock

holding of work on drilling

• Demonstrate with the

• Rivets and sets of drill bits

table to required height and

appropriate facility how to • Surface table, surface

angle, holding of work on

perform all the drilling

plate, marking solution,

drilling table using

operations

center/dot punches, scribing

appropriate clamping device


block

they become competent c. Install the drill bit in chuck

7-9

• Give notes as well as

3.2 Sharpen a twist drill correctly to

demonstrate the operation

manufactures' specification

sequence in cutting

3.3 Perform with facility the following

internal (through and

operations:

blind) and external

a. drilling blind holes

threads by hand method

b. drilling round stock

• Demonstrate how

c. counterboring and

riveting can be done and

counter-sinking

let the students practice

d. drilling large diameter

same till they become

holes

competent • Demonstrate the

3.4 List the operation sequence and cut

marking out procedures

internal (through and blind) and external

on bench working using

threads by hand method and state

datum lines datum faces,

precautions to be taken when taping on the

etc

bench


3.5 Rivet metals together in any given


situations

• Assess the student.

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.

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General Objective 4.0: Lathe and Lathework Week Specific Learning Outcome

Teachers Activities

Resources

4.1 Sharpen cutting tool for plain turning,

• Guide the students to

• Point tools, grinding

shouldering, parting off and facing

sharpen cutting tool for plain machine, lathe machine

operations

turning shouldering, parting • 3-jaw chuck and lathe

4.2 Set up rough and turned stock in 3-

off and facing operations

machine

jaw-chuck

and allow students to

• Point tools and lathe

4.3 Select appropriate cutting tool and set practice till competent

machine

them up to center height for turning or

• Demonstrate how to set-up • Lathe machine and

facing operations

rough and turned stock in a accessories

4.4 Carryout chuck work involving facing,

3-jaw-chuck and operate

• Centre lathe and

step turning, undercutting radiusing,

lathe. Allow students to

accessories like catch plate,

chamfering, parting off and knuring

practice till competent

face plate, dog lathe, lathe

Note Components should be produced to

• Guide the students to

centers fixed steady and

select appropriate cutting

traveling steading

10-12 specified tolerance and finish

4.5 Produce simple components involving tools and set them up to taper turning using the compound slide

• Round nose turning tool,

center height for lathe work fine finishing tool, form tool, (turning or facing)

parting off tool, boring tool,

• Students should be

bar of good length and 4mm

allowed to practice till they

diameter, Live/dead centers

become competent

catch plates

• Prepare simple exercises

• Standard exercises or

that will guide students to

prepared

produce components involving taper turning using the compound slide. Assess the students Assessment profile: Practical to take 60% of the overall assessment

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PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE Course: General metal Work I

Course Code: CME 11


Course Specification: Knowledge Requirement General Objective: 1.0 understand workshop safety rules and application in machine shop Week Specific Learning Outcome

Teachers Activities

Resources

On completion of this module, the trainee

• State sources of hazards • Safety posters, common

should be able to:

in the workshop.

hard tools like files

Workshop safety rules and

• Through questions and

hacksaw

practice

answer, determine whether • Television, Video

1.1 State sources of hazards in the workshop

the students grasped the

machine.

and how to prevent them.

topic

• Overall, goggles, gloves,

e.g.

• Show a film on industrial

saftyboots, head shield,

a. handling and using hand

safety.

fire extinguishers.

tools, portable power tools and

• Through question and

machines;

answer determine comprehension.

b. stepping on or striking

• Demonstrate how to treat

obstructions left on floors or

emergency cases

benches;

• like artifical respiration, cold compress etc.

1

c. lifting, moving and storing

• List the safety equipment

materials or jobs;

and wears that are essential in the workshop.

d. using inflammable or

• Give detail notes and

corrosive liquids and gases;

explanation in each topic ae.

e. inhaling vapours or fumes;

• Use questions and

1.2 Explain the application of factory safety

answer to determine

regulations in the machine shop.

comprehension.

1.3 Name safety equipment and wears

• Assess the students

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

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Course Code: CME 11


Course Specification: Knowledge Requirement General Objective: 1.0 understand workshop safety rules and application in machine shop Week Specific Learning Outcome

Teachers Activities

1.4 Outline safety rules and

• Explain safety rules and regulation in the

regulations relating to:-

workshop, highlighting a - g in 1.4.

a. clothing and health

• Explain appropriate procedures to be

hazards;

taken in the event of workshop accident.

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.

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Resources


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 2.0: Know the physical properties, manufacturing process and application of ferrous and non-ferrous metals in common use Week Specific Learning Outcome

Teachers Activities

Resources

2.1 Explain the meaning of the following • Give detail notes and explanations to

2

general physical properties of metals:

explain the meaning of the following

ductility, malleability, strength,

general physical properties of metals:

roughness, brittleness, elasticity,

ductility, malleability, strength,

plasticity.

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

• Give notes and specific examples of

• Video and

properties of plain carbon steels, cast

tools and equipment made from the

television including

iron and alloy steel and state their

various steels and cast iron.

cassettes on

application in the engineering industry.

• Examples of steels and cast irons

production

Note: Specific examples of tools and

should include plain carbon steels,

processes.

equipment made from the various steel

dead mild steels, mild steel, medium

and cast iron should be mentioned.

carbon steel high carbon steel, gray

Examples of steels and cast irons should cast iron, malleable cast iron, iron include: plain carbon steels, dead mild

carbide, alloy cast iron high speed

steels, mild steel, medium carbon steel, steels, high tensile steels, tungsten, high carbon steel.

stainless steels.

Cast Irons - gray cast

• Give notes and explanation on the

iron malleable cast iron,

cupola process, the blast furnace and

iron carbide, alloy cast

the direct reduction process of

irons (spheroidal and

manufacture of steel.

acicular)

• This can be preceded by film show

Alloy Steels - High

and a visit to be manufacturing plant.

speed steels, high

• Give detail notes and explanations

tensile steels, tungsten,

describing the physical properties and

stainless steels, stellite

applications of the following non-ferrous

2.4 Outline:

metals: copper, tin, zinc, aluminium,

a. the copula process of

aluminium alloys, brass, (muntzmetal,

manufacture of cast iron;

cartridge brass, gilding metal) etc.

16

b. the blast furnace

bronze, manganese bronze bell metal,

process of manufacture

aluminium bronze phosphor bronze and

of pig iron;

lead. Assess the students

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:

17


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools. Week Specific Learning Outcome

Teachers Activities

Resources

3.1 Explain with examples the

• Prepare notes that will clearly differentiate

• Steel rule, dividers

difference between "line" and

between "line" and "end" measurement.

calipers, trammel,

"end" measurement.

• Prepare notes and examples that will explain scribe angle plate

3.2 Explain the use of datum

the use of datum points, datum lines, and

vee block, centre

points, datum lines and datum

datum faces in marking out.

square.

faces in marking out.

• Give explanations regarding the functions

• Micrometer

3.3 Describe, the functions and and application of: steel rule, dividers, calipers vernier callipers application of the following

(inside, outside and oddleg) trammel, scriber,

instruments used in metal-work, angle plate, vee block, centre square

gauge combination

steel rule, dividers, calipers

• Prepare notes that will describe the various

set

(inside, outside and odd-legs),

types of files, stating their grades and

• Flat file, hard file,

trammel, scriber angle plate,

applications. By type it means: flat, square

round file square,

vee-block, centre square.

round, halfround, three square, warding, mill

half round,

3.4 Describe the various types

and rasp.

triangular warding,

of files, stating their grades and • Prepare detail notes that will classify the 3

vernier height

mill file, rasp file.

applications.

common files used in the metal work as well as • Flat file, handfile

Note:

stafing the composition of materials used for

engineers square.

Types of files

their manufacture.

• Surface plate try

should include:

• Show a bench vice and demonstrate the work square (engineers

flat, square,

ithe vice for

square)

round, half

• Show a bench vice and demonstrate the

• File card

round, three

technique of holding work in the vice for filing,

• Flat file

square, warding

tapping and designing operations.

• Bench vice.

pollar, mill and

• Prepare detail notes that will describe the

• Bench vice.

rasp.

functions of the various parts of a bench vice,

• Ball pein hammers

its holding power while performing various

mallets.

3.5 Classify the common files

use in metal work and state their operations. composition of material used for • filing, tapping and designing operations their manufacture.

• Prepare detail notes that will describe the

3.6 Sketch the bench vise,

functions of the various parts of a bench vice,

explain its clamping power and

its holding power while performing various

demonstrate the technique of

operations

18

holding work in the vise for


filing, tapping and designing

• Prepare detail notes and demonstrations that

operations.

will describe and uses of: cold chisels, centre

3.7 Describe the functions of the punch dot punch, scrapers and power various parts of a bench vice, its hacksaw. holding power while performing various operations on its, such as filing, tapping sawing etc. 3.8 Describe and use the following tools: a. cold chisels (flat, cross, cut half round, diamond-point) b. centre punch and dot punch c. scrappers (flat, triangular, half round) d. power hack saw

19


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 3.0: Select and use common measuring, marking out, cutting and striking tools. Week Specific Learning Outcome

Teachers Activities

Resources

3.9 Describe the various parts of a hack saw • Prepare notes that will describe • Cold chisels, and their function.

the various parts of a hacksaw

3.10 Describe the common types of hacksaw and their functions.

centre punches, dot punch, scrapers

blades, their range of pitches and their

• Show sample of hacksaw blades power hacksaw

applications.

as well as prepare notes that will

blades.

3.11 State the safety precautions to be

describe the common types of

• Hacksaw blade

observed when using a hand hacksaw

hacksaw blades, their range of

• Hacksaw frame

pitches and their applications.

• Adjustable

• Prepare notes that will show

hacksaw junior

correct way of inserting blades.

hacksaw piercing

• Prepare detail notes and

saw.

4

explanation, stating the safety precautions to be observed when using a hand hacksaw. • Prepare notes that will describe the uses of various hacksaws. • Assess the students General Objective 4.0: Understand the working principles of a drilling machine, use it to drill and ream holes on metals and other engineering materials Week Specific Learning Outcome

Teachers Activities

Resources

4.1 Identify the various types of drilling

Show different types of drilling

• Bench drill

machines.

machines

• Pillar drill.

4.2 Describe, with sketches, the main

Make notes and drawings that will • Twist drill, flat drill

features of a bench or pillar drilling machine. identify the various types of drilling counter sink drill, 4.4 Describe with sketches and state where m/cs. 5-6

counter bore drill

each of the following types of drills are best

Prepare detail notes and drawings combination centre

suited.

that will describe the main

e.g. twist drill (taper shank, parallel shank

features of a bench or pillar drilling Drilling machines

and jobbers drill, and their relative merits),

machine.

flat drill, countersink drill, counter bore drill,

Solve many problems for students

combination centre drill.

to practice.

4.5 Explain the effects of the following faults Prepare notes and drawings that

20

drill. and its accessories.

in a ground twist drill bit:

will describe where each of the

a. point angle too acute;

following drills are best suited

b. point angle too obtuse;

Twist drill (taper shank, parallel

c. cutting edges at unequal

shank, jobber drill and their

angles;

relative merits), flat drill,

d. insufficient lip clearance;

counterbore drill and combination

e. excessive lip clearance.

center drill.

4.6 Calculate spindle revolution or cutting

Assess the students.

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. 4.9 State the safety precautions to be observed when using a drilling machine. 4.10 Explain the purpose of reaming and describe different types of hand and machine reamers. 4.11 Ream to given specification by hand and machine method.

21


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. Week Specific Learning Outcome

Teachers Activities

Resources

5.1 Sketch the thread forms below and • Give detailed notes with diagrams that Diagrams/charts of state their applications:-

will show the various forms of trade and thread forms

- the ISO metric thread

their uses.

Sample of taps and

- the unified thread

• State the functions of taps, tap

tap wrenches.

- Whitworth and British

wrench, die and die stock.

Parallel reamers,

fine threads

• Demonstrate how to produce

taper reamers, and

- British Association

internaland external threach.

twist drills.

(BA) thread

• Give detailed notes that will explain

- British Standard pipe

the meaning of tapping size or tapping

- Square thread

drill and estimate its values using the

- Acme thread

formula:

- Buttress thread.

T=D-P Where

5.2 Sketch and state the functions of:a. taps (taper tap,

T=

second tap, plug)

tapping

b. tap wrench

diamet

c. die and die stock.

er

5.3 Explain the meaning of tapping size

D=

or tapping drill and estimate its value in

thread

given situations using formulae such

top

as:-

diamet

T=D-P

er and

Where T = tapping

P=

diameter

Pitch

D = thread top diameter P = pitch

22


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 5.0: Understand the applications of various types of screw threads, rivet and cut screws by hand. Week Specific Learning Outcome

Teachers Activities

5.4 State precautions to be taken when • Prepare notes that will state precautions taping on the bench.

to be taken when tapping on bench.

5.5 Describe and differentiate types of

• Give notes and diagrams that will describe

rivets.

and differentiate types of rivets, rivet sets,

e.g. Snap and pan head, mushroom

and its uses and guide to calculate the

and counter-sunk head, flat head, dod

diameter of rivet and riveting allowance.

rivet, etc.

• Assess the students.

Resources • Rivet sets, drills.

5.6 Sketch the rivet set and state its use. 5.7 Calculate the diameter of rivet and riveting allowance in given situations. General Objective 6.0: Understand the ISO tolerances and fits and its application in engineering production. Week Specific Learning Outcome

Teachers Activities

6.1 Differentiate between the following:- • Give detailed notes that will differentiate

8

Resources •

a. nominal size

between nominal size, limits, tolerance and • Charts on

b. limits (upper and

fits.

tolerances, limits

lower)

• Prepare detailed note and diagrams that

and fits.

c. tolerance (unilateral

will explain the important of tolerance and

and bilateral)

fits in engineering production as well as

d. fit (clearance,

describing the ISO systems of limits and

transition interference).

fits.

6.2 Explain the importance of tolerance • Give notes and explanations that will and fit in engineering production and

guide in calculating the amount of tolerance

describe briefly the ISO system of limits and types of fits in given situations. and fits.


6.3 Determine by calculation the amount of tolerance and types of fit in given situations.

23


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 7.0: Produce simple Engineering Components on the bench. Production Week Specific Learning Outcome 7.1 Explain layout procedures

Teachers Activities

Resources

• Teachers to prepare notes and explanations

• Lesson notes

from working drawing of simple to guide the students in producing simple engineering components or

engineering components as in 7.1

tools such as:-


a. open ended spanner b. engineer's try square c. tool maker's clamp d. plate bracket or gusset (involving 9

rounds, angles, holes) e. centre square. 7.2 Explain how to produce any simple engineering component to given specifications including dimensions, tolerance and finish 7.3 Explain how to carry out simple precision fitting project. e.g. hexagonal mild steel bar making push fit through a mild steel plate.

24

• Diagrams and charts.


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 8.0 Understand the essential features and working principles of the centre lathe and use it to carry out basic operations such as plain turning, stepped turning, facing taper turning, chamfering, and under-cutting Week Specific Learning Outcome

Teachers Activities

Resources

8.1 Describe the essential features of a

• With the aid of a diagram explain the

• Centre lathe

centre lathe and state their functions

essential features of a lathe machine

and accessories

e.g lathe bed, headstock, tailstock, saddle or • Explain the working principles and basic carriage, etc.

operations of a lathe machine

face plates,

8.2 Explain the working principles of the

• Demonstrate some basic operations on

centers, fixed

centre lathe.

lathe machine.

and traveling

8.3 Identify and state the functions of centre • Prepare detailed notes that will describe

steadies.

lathe accessories such as: catch or driving

the essential features of center lathe and

• Charts of

plate, face plate, lathe dog or carrier, lathe

their functions.

center lathe and

centres, fixed and travelling steadies.

• Give notes and diagrams that will explain capstan lathe.

8.4 Explain the difference between the

the working principles of center lathe and

centre lathe, capstan lathe, in terms, of their functions of its accessories.

10

like catch plates,

• Round nose turning tool,

main features and functions.

• Give explanations that will show the

finishing tool,

8.5 Name types of cutting fluids used for

difference between center lathe and

site finishing,

lathe turning operations and state their

capstan lathe in terms of their main features knife tool, form

composition and purposes.

and functions.

8.6 Outline safety precautions to be

• Prepare notes that will list types of cutting tool, and boring

observed when working on the lathe

fluid use for lathe turning operations and

8.7 Sketch and describe common tools:

their composition and purposes.

e.g butt-brazed tool, tipped tool, bit and

• Prepare detailed notes and explanation

holder.

that will outlines safety precautions,

Note:

common tools and materials used in Tool description should

marking them.

include tool materials e.g

• Give detailed notes and diagrams that will

plain carbon steel, high

explain the functions of too angles (rake,

speed steel, stellite,

clearance) stating their values for different

cemented carbide, diamond.

metals to be machined.

8.8 Explain with sketches the functions of


tool angles rake, clearance, and state their values for different metals to be machined.

25

tool, parting off tool.


Course Code: CME 11


Course Specification: Knowledge Requirement General Objective 8.0 Understand the essential features and working principles of the centre lathe and use it to carry out basic operations such as plain turning, stepped turning, facing taper turning, chamfering, and under-cutting Week Specific Learning Outcome

Teachers Activities

Resources

8.9 Differentiate between various tool shapes • Give notes and diagrams of

• Charts on tool

and state their uses e.g. Round nose rougher, various tool shapes and their

height

fine finishing, side finishing, knife tool, form

uses.

• Charts and

tool, parting off tool, boring tool, etc.

• Prepare detailed notes and

diagrams of

8.10 Explain with sketches the effects of

explanations to cover 8.10 to

different machining

wrong setting of cutting tool: e.g. vibration and 8.15 chatter, tool rubbing against or digging into the • Solve many problems for the job.

students practice.

8.11 Define cutting speed and feed with


respect to lathe operation. 8.12 Calculate the cutting speed and feed for given turning operation. 8.13 Estimate the rate of metal removal and time required for carrying out specified turning 11-12 operations 8.14 State precautions to be observed when turning between centres. 8.15 Set up the lathe for and carry out basic turning operations between centres. 8.16 Compute required taper dimensions from given data using taper ratic angle formulae i.e. 8.17 Taper Ratio = [d2 - d1]/L OR

where θ = taper angle d1 - small and diameter d2 = large end diameter L = length of taper

26

operations.

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

27

PRACTICAL TASKS General Objective 1.0: On completion of the following practical task, the trainee will demonstrate the following abilities: Week Specific Learning Outcome:

1-2

Teachers Activities

Resources

1.1 Carry out the following heat

• Demonstrate heat treatment • Furnace, Forge tongs

treatment processes Hardening,

processes and explain the

tempering, annealing normalizing,

stages

case hardening on given plain carbon • Demonstrate the annealing steel, engineering component or tool process on brass, copper and 1.2 Anneal copper, brass and

aluminium for various

aluminium for various purposes

purposes. • Assess the students.

28

General Objective 2.0: Forging Processes Week Specific Learning Outcome:

Teachers Activities

Resources

2.1 Select appropriate forging tools

• Demonstrate with appropriate • Anvil, swage block, leg vice,

and produce to specification given

forging tools how to produce

engineering components by forging

some engineering components set, sets of hammer, punchers,

processes

and let the student practice till drifts, fillers, top swage,

forging hammers, hot set cold

a. upsetting - drawing


bottom swage, flatter, open

down


tongs, hallow bit

3-4

b. setting down -

5-8

twisting c. forge welding (scarf and spice welds) d. bending, turning closed ring e. forming an eye General Objective 3.0: Welding Processes

Week Specific Learning Outcome:

Teachers Activities

Resources

3.1 Set up and operate gas or metal

• List and identify gas and

• Oxygen, cylinders and

arc welding equipment in given

metal arc welding equipment

acetylene, regulations arc,

situations.

• Demonstrate the use of both welding set goggles, shield,

Note: Equipment operation should

gas and metal welding

electrodes, diagrams and

include choice of correct nozzles or

equipment; and all the

charts various welding joints

electrode. Adjustment for correct gas students to practice pressure/flame or voltage 9-12

• Demonstrate to the students

3.2 Prepare joints for welding in given how to prepare joints for situations

welding purposes

3.3 Weld given components by arc or • Guide students to weld gas welding methods, and state

various components using

safety precautions to be observed

both gas and arc welding process and state safety precautions to students to practice till competent

Assessment: Practical - 60% of overall assessment

29

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN MECHANICAL ENGINEERING CRAFT PRACTICE MODULE: GENERAL METAL WORK II

MODULE CODE: CME 12

CONTACT HOURS: 5hrs/wk

MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective:1.0 Understand the basic principles and processes of heat treatment of metal in the workshop. Week Specific Learning Outcome

Teacher Activities

Resources

1.1 Explain briefly the structural behaviour of • Prepare detail notes that will • Recommended Text plain carbon steel as it is heated from room temperature to about

1-4

1000oC.

explain the structural

books

behaviour of plain carbon

• Lesson notes, etc

a. hardening

steel as it is heated from room

b. tempering

temperature to about 1000oC.

c. annealing

• Prepare detail notes that will

d. normalising

explain the meaning of

e. case-hardening.

hardening in metalwork.

1.2 Explain the meaning of hardening metal

• Prepare notes that will

work.

outline safety precautions

1.3 Outline safety precautions relating to heat relating to heat treatment treatment processes apply them in given

processes.

situations.


30


MODULE CODE: CME 12


MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective 2.0: Understand the techniques of producing simple engineering components by forging. Week Specific Learning Outcome

Teacher Activities

Resources

2.1 Explain with outline sketch the main


Forge and forging tools.

features and working principles of the black

diagrams that will explain the

smith's forge.

main features and working

2.2 Describe and state the functions of

principles of the black smith's

common forging tools. e.g anvil, swage block, forge. leg vice, forging hammers, hot and cold sets, • Prepare notes and diagrams set hammer, punches and drifts, hardie,

that will describe the functions

fullers, top and bottom swages flatter, tongs

of common forging tools.

(open mouth, closed mouth, hollow bit, etc.). • Prepare detail notes that will 5-6

2.3 Describe with sketches the following

describe the following forging

7-8

forging operations:

operations: upsetting, drawing

a. upsetting

down, setting down, twisting,

b. drawing down

forge welding, bending,

c. setting down

forming closed ring, forming

d. twisting

an eye.

e. forge welding (scarf and


splice welds) f. bending g. forming closed ring h. forming an eye.

31


MODULE CODE: CME 12


MODULE SPECIFICATION: KNOWLEDGE REQUIREMENTS General Objective 3.0 Understand the basic principles and techniques of gas and metal are welding and apply them in fabricating simple metal components. Week Specific Learning Outcome

9 - 12

Teacher Activities

Resources

3.1 Describe the equipment and explain the


• Charts

basic principles and application of gas and

diagrams that will describe the • Oxygen cylinder

metal arc welding.

equipment and explain the

acetylene cylinder

3.2 State the safety precautions to be

basic principles and

regulations arc welding

observed and apply them in given welding

application of gas and metal

set goggles, shield

situations.

arc welding.

electrode.

• Prepare diagrams of joints

• Diagrams and charts

that the students will practice. of various welding • Prepare detail notes that will joints, and techniques. state the safety precautions to be observed during welding. • Assess the students. Week 13 Examination - Practical 60%, Theory 40%

32

Sheet metal Work PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE MODULE:

CFW 11 - SHEET METALWORK

PRE-

CME 12

REQUISITE: 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 On completion of this module, the trainee should be able to: 1. Apply appropriate workshop processes, techniques and tools to mark out and form projects in sheet metal work 2. Solder and braze various sheet metal projects with maximum safety. 3. Produce finished sheet metal project involving: edge stiffening, beading, finished, either as part of the corporate production process or as an independent process. 4. Draw, develop and produce templates for production of sheet metal projects. PRACTICAL COMPETENCE On completion of this module the student will be able to 1. Mark out and form projects in sheet metal work 2. Solder and braze various sheet metal project with maximum safety 3. Produce finished sheet metal projects involving various production processes 4. Draw, develop and produce templates for production of sheet metal projects.

33

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK

Course Code: CFW 11

Contact Hours: 18 per week- L6: P12

Course Specification: Practical/theoretical content General Objective: 1.0 Apply Appropriate Workshop Processes, Techniques And Tools To Mark Out, And Form Pojects In Sheet Metal Work: Week

Year 3 Term 1

Specific Learning Outcome

Teachers Activities

Resources

1.1 Mark out the following projects

• Demonstrate the marking out of

• Lesson plan

on sheet metal material applying

projects on sheet metal by applying • Appropriate Tools and

appropriate tools, techniques and

the appropriate techniques and

Equipment

safety practices:

safety practices.

• Steel rule, divider,

a. rectangular

• Demonstrate marking out items

scriber, compass and

container

listed on sheet of metal

chalkboard

1.2 Cut sheet metal to given sizes

• Demonstrate sheet metal cutting

• Lesson Plan

using appropriate tools/machines

to given sizes using appropriate

• Appropriate Tools and

tools and machine

Machines

1.3 Form sheet metal to given

• Demonstrate the formation of

• Lesson plan

shapes using appropriate tools,

sheet metal

• Appropriate Tools,

machines and techniques

• Demonstrate methods of forming

Machines and Equipment

b. funnels c. cylindrical container

1-2

these shapes. 1.4 Calculate allowance for joint 3

• Calculate allowance for joint using • Lesson plan Chalkboard

using the formula: grooved seam = the formula: grooved seam = 11/2x 11/2x width of groover.

width of groover, panned down and knock-up joints.

3

1.5 Sketch the joint allowances on

• Sketch joint allowances on the

• Lesson plan Appropriate

the materials and notch the joints

materials and notch

Tools and equipment

34


Course Code: CFW 11



4-5


Teachers Activities

Resources

1.6 Make the following joints in

• Demonstrate the process of

• Lesson plan

sheet metal:

making the following joints:


a. solid corner joint

• solid corner

b. grooved seam

• groove seam

joint

• panned down

c. panned down

• knock-up

Equipment

joint d. knocked up joint 6

1.7 Name common rivets used in

• List and explain types of rivets

Lesson plan Chalkboard

metal work and state their

used in sheet metal and their

Samples of rivets.

properties

properties

35


Course Code: CFW 11




Teachers Activities

1.8 State common faults in riveting • Explain common faults in riveting • Show the listed defect to student

e.g. 6

Resources • Lesson plan Charts/Posters

a. overlapping b. cracked rivet c. uneven ends, etc.

7

7

1.9 Drill and punch holes on joints

• Demonstrate drilling and punching • Lesson plan Appropriate

for riveting making sure that burrs,

of holes on sheet metal including

Tools, Machine and

are removed

removal of burrs.

Equipment

1.10 Rivet joints satisfactorily using • Demonstrate riveting by using

• Lesson plan

correct sets

Charts/Posters Various

appropriate rivet sets

Types of rivet Sets. General Objective 2.0: Solder and braze various sheet metal projects with maximum safety. Week


Teachers Activities

Resources

2.1 Identify the types of solders

• List and identify types of solders

• Lesson plan Charts

used in sheet metal work and state • show various types of solders their compositions: e.g. 8

- tinman's solder,

used in sheet metal work and state their composition

grade - self-flux solder - resin-core solder, etc

36

Various Types of solders


Course Code: CFW 11


Course Specification: Practical/theoretical content General Objective 3.0: Produce finished sheet metal projects involving edge stiffening, beating finishing, either as part of the corporate production process or as an independent process Week


Teachers Activities

Resources

3.1 State the meaning of the

• Explain the meaning of the terms

• Lesson plan Posters

following terms:

listed in 3.1 (a - p)

Chalkboard

a. edge-stiffening

• Give details note on the above.

• Finished sheet metal

b. beading

• Show samples to students

projects involving terms listed in 3,1 (a - p)

c. work hardening d. beating e. annealing f. hollowing 6

g. raising h. blocking i. planishing j. sand blasting k. picking l. lacquering m. galvanizing n. plating o. painting p. other items used 3.2 Calculate allowances for edge- • Solve problems involving stiffening which include:

11 - 12


calculations of allowances for edge- Chalkboard

a. helming

stiffening using the formula for

b. wiring, using the

wiring allowance: 2D+4T (where D

formula for wiring

is the diameter of wire and T is

allowance: 2D + 4T

thickness of metal

(where D is the diameter of wire and T is the thickness of metal)

37


Course Code: CFW 11




Teachers Activities

Resources

3.3 Mark out for edge-stiffening

• Ask students to demonstrate the


using the calculated allowance

marking out for edge-stiffening

Tools and Equipment

3.4 Produce projects involving

• Ask students to demonstrate


edge-stiffening such as:

projects involving edge-stiffening

Tools and Equipment

a. beading

after sample demonstration.

• Lesson plan Chalkboard

b. swaging

• Explain the mechanical properties • Lesson plan Appropriate

Year 3 3.5 Know the mechanical properties of materials used in beating sheet Term 2 of the following materials used in 1-2

beating metal work:

Tools and Materials

metal work • Ask students to demonstrate the

a. brass

development of discs for making

b. copper

bowls using workshop method

c. aluminium d. low carbon steel 3.6 Develop discs for making bowls using workshop method

3-4

3.7 Describe the processes of

• Ask students to explain the

• Lesson plan, Chalkboard

raising, sinking, hollowing,

process of raising, sinking,

Posters.

planishing and polishing sheet

hollowing planishing and polishing


metal work in copper or brass.

sheet metal work in copper or

Compasses Dividers, etc.

3.8 Estimate size of blank for

brass.


raising and polishing sheet metal

• Ask students to draw the size of

Dividers Scribers, etc

work in copper or brass.

blank for raising and polishing sheet

3.9 Layout and cut out blanks for

metal work in copper or brass

raising, sinking or hollowing


process.

laying out and cutting out blanks for raising, sinking or hollowing

38


Course Code: CFW 11




Teachers Activities

3.10 Select appropriate tools and equipment and apply • Demonstrate and

• Lesson plan

correct procedures to produce to specification by

explain process of

• Chalkboard

raising, sinking or hollowing, given metal forming job.

producing bowls by

• Lesson plan,

Note: Sheet metal forming procedures should involve: raising, hollowing and

Chalkboard

a. blank size estimation

blocking using necessary Appropriate Tools

b. blank preparation

tools.

c. heat treatment (annealing)

• list the safety precaution. Such as wheeling

d. application of appropriate forming

• Give student

machine,

process

project/assignment to

planishing harmer,

e. cleaning

produce bowl.

dollies dent eraser

f. polishing; and

• Explain and demonstrate etc.

g. edge trueing

removal of dents from

• Lesson plan,

metal surface.

Appropriate Tools

3.11 Produce bowls by the following process:

3-7

Resources

and Equipment

a. raising, using oval head wooden

• Give student assignment and Equipment.

mallet and repeated beating and

on dent removal

annealing;

• Ask students to

b. hollowing, using a hollowed pipe or

demonstrate removal of

cylinder, hollowing hammer and a

dents using appropriate

bossing mallet

tools and equipment

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.

39


Course Code: CFW 11



8-9


Teachers Activities

Resources

3.13 Prepare surfaces for finishing


• Lesson plan, Related

by applying the following

preparation of surfaces for finishing Tools and Equipment.

processes:

using appropriate tools and

• Lesson plan Related

a. sand blasting the

equipment.

Tools and Equipment

surface


b. pickling with acid

finishing of sheet metal project by:

c. sanding

i. laquiring

3.14 Finish sheet metal projects by

ii. galvanizing

using the following techniques:

iii. plating

a. lacquering

iv. painting etc.

b. galvanizing c. plating d. painting

40


Course Code: CFW 11


Course Specification: Practical/theoretical content General Objective 4.0: Draw, develop and produce templates for the production of projects Week

10 - 12


Teachers Activities

Resources

4.1 State materials used for templates

• Explain materials used for

• Lesson plan

a. Wood

making templates

Chalkboard related

b. Cardboard, etc

• Demonstrate the production Materials

4.2 Produce and read blue-prints (which

and reading of blue-prints of

• Lesson plan

include working drawings) of sheet metal

sheet metal projects

chalkboard Charts

projects

• Develop templates using the Appropriate Tools and

4.3 Develop templates by using the

methords listed for indicated

Equipment

following methods for the indicated items:

items in 4.3 (a - e)

• Lesson plan

a. Parallel line method - for

• Ask students to produce

Chalkboard Instrument

elbows and T-pieces,

various sheet metal project

• Lesson plan Related

square and rectangular

using templates methods

Tools, Equipment and

trays etc.

• Ask students to demonstrate Materials

b. Radial line method - for

the production of various

• Lesson plan

right cone, oblique cone,

sheet metal projects

• Tool, Equipment and

etc

• Test and evaluate the

materials

c. Triangulation method -

trainee in production

for transition piece and

processes

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

41

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

42

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: GAS WELDING AND CUTTING

Course Code: CFW 12

Contact Hours: 18 per/week 6 Tutorials 12 practicals

Course Specification: THEORETICAL CONTENT General Objective: 1.0 Understand and apply the general safety precautions related to gas welding WEEK

Year 3


Teachers Activities

Resources

1.1 Carry, transport and store full and

• Explain how to carry


empty gas cylinders safety using

transport and store full and

or Posters and

appropriate equipment

empty gas cylinders

appropriate equipment

Term 1

• Explain how to carry,

1

transport and store full and empty gas cylinder safety using appropriate equipment

2

1.2 Apply appropriate safety precautions

• List and explain safety


while carrying out the following:

precautions involved in gas

etc.

a. Gas welding operations

welding operations

on containers which have

• List and explain the use of

been emptied of chemicals,

protective wears for carrying

inflammable or explosive

out gas welding operations

liquids.


b. Gas welding near

appropriate safety precaution

containers with inflammable

while carrying out items 1.2 (a-

materials, e.g. petrol tank;

c)

and c. Gas welding in confined spaces.

3

1.3 Select, use and care for protective

• Ask students to identify the

• Chalkboard, Lesson

wears for carrying out gas welding

use and care for protective

plan and Protective

operations. E.g.

wears for carrying out gas

wears

a. welding goggles

welding operations e.g.

b. welding shields

welding goggles, welding

c. gloves

shield, globes and boots etc.

d. boots etc.

43


Course Code: CFW 12


Course Specification: THEORETICAL CONTENT General Objective 2.0: Know and apply successfully various gas welding processes/operations including the acetylene and oxy-fuel gas cutting processes. WEEK


Teachers Activities

Resources

2.1 Identify the following gas welding

• Show the students items

• Chalkboard and

equipment, describing their features, functions, listed in 2.1

Lesson plan

• Identify and explain the

• Chalkboard,

a. generators

features and functions and

Lesson plan,

b. regulators

applications listed in 2.1

sketches/Charts

c. blow pipes

• Explain the difference

• Chalkboard

d. nozzles

between the two types of

Lesson plans

e. hoses

generators stating advantages leveled drawings.

f. gas cylinders and their

and disadvantages

• Lesson plan, low

colours

• Explain the main part of

and high pressure

g. economizers

generator

gas welding sets.

h. check valves

e.g. hydraulic back pressure

• Lesson plan,

applications and care:

2.2 Differentiate between the following types of valves, purifiers, carbide trays Chalkboard and 4

generators, stating their merits and demerits

etc.

calcium carbide

a. water-to-carbide generator

• State the difference between • Lesson plan,

5

b. carbide-to-carbide

low and high pressure

calcium carbide

6

generator

systems of gas welding

motor and generator

2.3 Identify the main parts of the generator

• Explain the composition of

• Lesson plan

e.g. hydraulic back pressure valve purifiers,

calcium carbide

Chalkboard and

carbide trays etc.

• Demonstrate how to

different types of

2.4 Distinguish between high and low pressure generate acetylene using

welding rods.

systems of welding

calcium carbide

• Lesson plan,

2.5 State the composition of calcium carbide

• Show and explain the types

chalkboard Welding

2.6 Generate acetylene using calcium carbide of welding rods to students guiding against danger of over-charge

stating their properties,

2.7 Identify types of welding rods stating their

composition and uses.

properties, compositions, and uses.

• With the aid of torches

2.8 Differentiate between welding and cutting

explain the difference between

torches

welding and cutting torches.

44

and Cutting torches.


Course Code: CFW 12


Course Specification: THEORETICAL CONTENT

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 downhand or flat position 2.16 State the functions of backing bars and strips 2.17 Apply backing bars and strips according to instructions on the side of a weld to control penetration.

• Explain the three types of flame in gas welding:- oxidizing, carbonizing and neutral • Describe uses of the types of flame named in 2.9 above • Demonstrate the lighting and setting up of the flames named in 2.9 above • Demonstrate plate surface preparation for running beds, with and without filler rods • Draw neat labeled sketches showing the conventional symbols for welded joints: i. butt ii. fillet iii. lap. etc • demonstrate running of beads with and without filler rods on plate surfaces • show students sketches of weld joints listed in 2.13 • give students detailed notes on the above and work to practice • Demonstrate tack welding and joints listed in 2.1 • Explain the preparation of plate surfaces for i. butt ii. fillet and iii. lap joints • Set up and tack weld the prepared pieces • Give detailed notes • Ask students to demonstrate how to weld metal together in down-hand or flat position • Explain the function of backing bars and strips • Demonstrate the use of backing bars and strips for controlling penetration.

45

• Lesson plan, chalkboard, Sketches/charts. - do - do • Lesson pla, plates and related equipment/tools • Lesson plan, Sketches/charts and Chalkboard • Lesson plan, materials and appropriate tools and equipment • Sample of weld jionts


Course Code: CFW 12


Course Specification: THEORETICAL CONTENT General Objective 3.0: Know and weld together different types of non-ferrous and ferrous metals WEEK


Teachers Activities Resources

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 nonferrous metals

46

• 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


Course Code: CFW 12




Teachers Activities

Resources

3.5 Enumerate two functions of

• Explain two function of fluxes used in • Lesson plan,

fluxes in the welding of non-ferrous

the welding of ferrous and non-ferrous Charts, Appropriate

metals

metals using appropriate fluxes

Tools and

3.6 Prepare and weld non-ferrous

• Demonstrate the welding of ferrous

Equipment

metals using appropriate fluxes.

and non-ferrous metals using

• Lesson plan,

3.7 Identify cast-iron in terms of:

appropriate fluxes

Chalkboard and

a. types

• Show students the different types of Sample of Cast

b. its composition

cast iron

Irons

c. its properties

• Explain their composition and

• Lesson plan,

properties

Charts, Pieces of

3.8 Prepare cast-iron for welding by: • Demonstrate preparation of cast iron Cast iron, Related

Year 3 Term 2 1-2 3

a. chamfering or

for welding

Tools and

beveling of edges to

• Demonstrate the fusion welding of

Equipment

specification

cast iron components

b. pre-heating to

• Explain the composition of suitable

• Lesson plan,

specification

flux for bronze welding

Chalkboard

• Demonstrate preparation of bronze

• Lesson plan,

3.9 Fusion weld cast iron

components for welding, avoiding

chalkboard bronze

components

sharp edges

related tools and

3.10 Identify suitable flux for bronze

• Demonstrate the welding of bronze

equipment

welding and state its composition

to specification

• Lesson plan,

3.11 Prepare bronze to specifications • Ask the student to demonstrate

- do -

charts, Pieces of Bronze, Related

3.12 Weld bronze to specifications

above

3.13 State reasons for post-heating

• Explain the purpose for post-heating Tools and

bronze welds

bronze welds

Equipment.

3.14 Identify and state the type,

• Explain and state the types of

• Lesson plan

composition and properties of

composition and properties of

Chalkboard

common stainless steels used in

common stainless steels

metal work.

• Demonstrate the preparation of

• Lesson plan,

3.15 Prepare stainless steel

stainless steel components for

Chalkboard

components for welding

welding

Stainless Steel,

• Ask students to practice above

Tools and

- do -

Equipment

47


Course Code: CFW 12




Teachers Activities

Resources

3.16 Weld stainless steel using appropriate • Demonstrate the welding of • Lesson plan, Charts welding rods and techniques and observing stainless steel using

4-6

Pieces of Stainless

safety practice.

appropriate welding rods and Steel, related Tools

3.17 Apply appropriate treatment to the

observing safety practices

welded joint e.g. washing in soapy water,

• Demonstrate the appropriate • Soapy cold water,

brushing off lux residue, etc. to avoid weld

treatment to the welded joint

Worm Water Wire

decay

to avoid weld decay

brushes

3.18 Explain the effect of welding together

• State the effects of welding

• Lesson plan,

two different metals

together two different metals

Chalkboard and

3.19 Identify dis-similar metals such as:

• Explain dissimilar metal

sketches/Charts

a. copper and brass

listed in 3.19 (a-c)

• Lesson plan

b. steel and cast-iron

• Describe the effect of

Chalkboard

c. aluminium and steel, etc

dilusion in welding

- do -

3.20 State the effect of dilusion in welding

• State the principles of the

- do -

3.21 Explain the principles of the following

following welding process in

• Lesson plan,

welding processes:

3.21 (a-d) giving examples

materials tools and

and Equipment

a. cladding

• Demonstrate the welding of equipment.

b. stelliting

dissimilar metals observing

c. hard surfacing

correct techniques and safety

d. brazing

practices

3.22 Prepare and weld dis-similar metals

• Give detailed notes on all of

using correct techniques and observing the the above correct safety practice.

• Students should be asked to carryout projects involving all of the above

48

• Sample of metals


Course Code: CFW 12


Course Specification: THEORETICAL CONTENT General Objective 4.0: Understand the process of building up worn metallic shafts or surfaces WEEK


Teachers Activities

Resources

4.1 Identify the composition of given worn


• Lesson plan,

metallic shafts or other worn metallic

given worn metallic shaft or

Chalkboard, Worn out

objects

objects

Metallic Part or Shaft

4.2 Discuss the properties of the metal used • Describe the properties of 7

- do -

for given worn metallic shafts or other

the metal used for given worn • Lesson plan and

objects

metallic shaft or other objects Appropriate materials,

4.3 Build up given worn metallic surfaces to • Demonstrate how to built up related tool and specifications using suitable filler rods and

worn metallic surfaces to

applying the correct technique/sequence of specification, using suitable operation

techniques and filler rods

49

equipment


Course Code: CFW 12


Course Specification: THEORETICAL CONTENT General Objective 5.0: Know the various welding defects and rectify them WEEK

8 9 10 - 12


Teachers Activities

Resources

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

• Lesson plan

welding defects to students

Chalkboard

• Explain the defects in gas

Sketches/charts

welded joint as listed in 5.1 (i- • Lesson plan, vi)

Chalkboard,


Sketches/Charts

the above

• Lesson plan

• Explain how the weld defects • Films in (5.1) above can be avoided • Video taper in oxy-acetylene welding

• Industrial

• Explain the use of test to

visit/execution etc.

detect defect in welded joint a • Lesson plan, Test non-destructive test

piece Related Tools

• Give detailed notes

and Equipment

• Explain and Demonstrate

• do -

how to use of test to detect

• Lesson plan

defects in welded joints:

• Tools, equipment

destructive and non-

and materials

destructive test • Ask students to demonstrate correction of welding defects enumerated in (5.1) above • Test and evaluate the students in production process

Week 13 Examination - Practical 60%, Theory 40%

50

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 Practical Competence On completion of this module, the student will be able to: 1. Apply general safety precaution related to arc welding 2. Use the Arc welding machine in fabricating simple engineering projects involving different types of joints and position involving different welding techniques 3. cut metals to various specification using metal arc cutting processes 4. identify and rectify various welding defects

51

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: METAL ARC WELDING

Course Code: CFW 13

Contact Hours: 18 hrs per week - 6 tutorials; 12 practicals

Course Specification: Theoretical/Practical contents General Objective 1.0: Understand And Apply Safety Precautions Related To Metal Arc Welding Week


Teachers Activities

1.1 List and explain the hazards related to • Explain the hazard related to metal arc welding, e.g.

Resources • Lesson plan

metal arc welding as listed in 1.1 • Chalkboard and

Year 3

a. arc eye

• Discuss how these listed

Term 2

b. burning

hazards can be avoided

1

c. radiation


Charts

d. electric shock e. toxic fumes, etc

2

- do -

1.2 Select, use and care for protective

• List and Describe the use and

wears required while carrying out metal

care for protective wears while

arc welding operations, e.g.

metal arc welding as listed in 1.2 • chalkboard, charts

a. head and hand shield

• Show these items to students

b. hand gloves

and give detailed notes

• items listed in 2.1

c. apron d. spats e. boots and leggings, etc.

3

1.3 Apply appropriate safety precautions

• Discus Safety precautions while • Lesson plan Arc

while carrying out:

carrying out a - c

a. arc welding in confined


spaces

appropriate safety precaution

b. arc welding empty

while carrying out arc welding as

vessels or drums that had

listed in 1.3

contained inflammable or toxic materials c. arc welding near inflammable materials

52

Welding Equipment


Course Code: CFW 13


Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the construction, features and working principles of arc welding machines and accessories Week


Teachers Activities

2.1 Differentiate between A.C and D.C arc Show students the different

4 5

Resources 6. Chalkboard Lesson

welding machine

features in the construction of the plan Arc Welding

2.2 Know the working principles of a.c.

arc welding machine

Equipment

and d.c. welding machines

Explain the differences between

7. Lesson plan

2.3 List and state the functions of the

a.c. and d.c. arc welding

Chalkboard Chart

welding accessories, e.g.

machines

• Chalkboard Arc

1. welding load

State the working principles of

Welding Accessories

2. earth load

a.c. and d.c. welding machines

etc.

3. electrode holder

• Explain the function of welding

• Chalkboard Lesson

4. chipping hammer

accessories as listed in 2.3

plan ac/dc welding

5. wire brush, etc.

• Show students these items

machine etc.

2.4 Know the advantages and

• List and explain the advantages

- do -

disadvantages of a.c. and d.c. welding

and disadvantages of a.c. and

- do -

systems

d.c. welding machines

2.5 set and use the a.c. and d.c. welding

• Demonstrate the use of a.c. d.c.

machines for specified voltage/amperage welding machines for specified operation, observing safety precaution

voltage and amperage observing

2.6 Explain the following processes of

safety precautions

electrode manufacture:

• Describe the processes of

a. solid extrusion process

electrode manufacturing as listed

b. extruded with re-

in 2.6

enforcing coating c. dipped process

53


Course Code: CFW 13


Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the construction, features and working principles of arc welding machines and accessories Week


Teachers Activities

Resources

2.7 Describe with sketches the material

• Explain with sketches, material

• Lesson plan,

composition of different types of

composition of different types of

Chalkboard

electrodes

electrode

Sketches/Charts

2.8 State the conventional electrode

• Explain the conventional

classification system

electrode classification system

• Lesson plan,

2.9 Select electrode materials according

• Explain the selection of

Appropriate Electrode

to parent system

electrode materials according to

etc.

2.10 State the basic methods of electrode parent metals 6

care, e.g. a. dry storage

- do -

• Electrode drying

• Explain the basic method of

oven, lesson plan etc.

electrode care with reference to

• Lesson plan,

b. oven storage

i. dry storage

Appropriate Arc

c. safe handling

ii. oven storage

Welding Equipment

iii. safe handling

and tools

2.11 Strike metal arc and maintain the arc

• Demonstrate how to strike and maintain the arc • Ask students to practice striking metal arc and maintaining the arc

7

2.12 Carry out with proficiency the

• Demonstrate with proficiency

• Lesson Plan,

following arc welding

the following arc welding

Welding Machine

techniques/operations:

techniques/operations:

Tools and

a. weaving

i. weaving

b. laying of multi-runs, etc.

ii. laying of multi-

Note: Safety regulations and requirements

runs etc

must be observed.

observing safety regulations as required

54

Accessories


Course Code: CFW 13


Course Specification: Theoretical/Practical contents General Objective 3.0: Make different types of welded joints in all positions Week


9

Resources

3.1 Describe with sketches the application • Explain with sketches the

• Chalkboard,

of the following joints in metal fabrication: application of the following joints

Sketches/Charts

a. square butt

8

Teachers Activities

in metal fabrication:

lesson Plan

b. single vee

i. square butt

• Lesson plan

c. double vee

ii. single vee

Chalkboard

d. single U Fillet

iii. double vee

• Lesson plan and

e. open corner, etc.

iv. single U

Chalkboard

3.2 Know the factors that govern the

v. fillet and

• Lesson plan,

selection of joints to be used for a project

vi. open corner

Process of metals,

e.g.

etc

Appropriate Tools and

a. type of metal

• Describe the factors that govern Equipment

b. thickness of metal

the selection of joint to be used

c. shape of plate

for a project with reference to 3.2 Appropriate tools and

d. position of joint

(a-d)

3.3 Interpret the various arc welding

• Show and explain the various

symbols and conventions used in

arc welding symbols use in

engineering working drawings

engineering working drawing

3.4 Prepare edges for welding the

• Demonstrate preparation of

following joints:

edges for welding joints in 3.4 (e-

a. square butt

f)

b. single vee

• Give students projects that

c. double vee

require the joints listed in 3.4 (a-f)

d. single U

• Demonstrate welding of joint in

e. double U

3.4 above in flat position

f. open corner

observing necessary safety

3.5 Weld the prepared joints in (3.4)

precautions

above in flat positions observing

• Ask students to practice the

necessary safety precautions.

above

55

• Lesson plan Related Materials


Course Code: CFW 13


Course Specification: Theoretical/Practical contents 3.6 Prepare metal surfaces for: a. multi-run welds

11 - 12

surfaces for

Materials Welding machine

b. weaving welds

i. multi-run welds

Flat bars and other

3.7 Make multi-run welds

ii. weaving welds

related materials

3.8 Make weaving welds

• Demonstrate the making of

3.9 Weld joints in the following positions:

multi-run welds

a. vertical position

• Demonstrate making weaving

b. horizontal position

welds

c. overhead position

• Explain the welding of joint in

3.10 Weld pipes and flanges in various 10

Demonstrate preparation of metal

the following position:

fixed positions

i. vertical

3.11 Weld pipes and flanges in rotated

ii. horizontal and

position

iii. overhead

3.12 Weld pipes using the store pipe

• Discuss the welding pipes and

method

flanges in various fixed position • Demonstrate the welding of pipes and flanges in rotated positions • Demonstrate the welding of pipes using the store pipe methods • Give students projects involving the welding processes above

56

required for welding


Course Code: CFW 13


Course Specification: Theoretical/Practical contents General Objective 4.0: Know the properties of various types of ferrous and non-ferrous metals and weld them together Week


Teachers Activities

4.1 Identify by inspection various types of • Explain by inspection various

Year 3 Term 3 1 2-3

Resources • Lesson plan,

ferrous metals. e.g. cast iron, steel, etc.

types of ferrous metals: cast iron, Chalkboard and

4.2 List four physical properties of cast

steel, stainless steel, etc

iron

• Discuss four physical properties Ferrous Metals

4.3 Know the behaviour of the following

of cast iron

• Lesson plan,

types of cast iron when welded:

• Describe the behaviour of the

Chalkboard

Various Type of

a. grey cast iron

following types of cast iron when • Samples of grey cast

b. white cast iron

welding as in 4.3 (a-c) above

iron, white cast iron,

c. malleable cast iron

• Explain the uses and

and malleable cast

4.4 State the use and carry out the

demonstrate the following

iron

following procedures:

procedures as in 4.4 (a-d).

• Lesson plan Welding

a. pre-heating

• Demonstrate the preparation of Equipment and

b. post-heating

cast iron pieces by chamfering

c. preing

and pre-heating and weld

d. fixed - -free - -end

satisfactorily as listed in 4.5 (a-d)

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

57

Appropriate Tools.


Course Code: CFW 13



4


Teachers Activities

Resources

4.6 Identify various types of non-ferrous

• State various types of non-

• Lesson plan

metals, e.g.

ferrous metals as in 4.6 (a-e)

Chalkboard Different

a. copper

• Show samples of the listed

Types of non-ferrous

b. aluminium

above to students

metal

4.7 Describe the composition and state

• Explain the composition and

• Lesson plan

the mechanical properties of the non-

state mechanical properties of

Chalkboard and

ferrous metals named in 4.6 above,

non-ferrous metals in 4.6 above

Charts.

mechanical properties to include:

as listed in 4.7

c. brass d. iconel e. monel

a. ductility 5

b. malleability c. hardness d. tenacity e. fusion f. fatigue g. effect of heat h. distortion

58


Course Code: CFW 13



6


Teachers Activities

Resources

4.8 Select suitable electrodes and

• Explain the selection of suitable • Lesson plan

machines for welding various types of

electrode and mechanics for

Different sizes of

given non-ferrous metals

welding various type given non-

Electrode and

ferrous metals

Welding Machine

4.9 Outline appropriate heat treatment

• Discuss through demonstration, • Lesson plan

method for a finished welding of non-

the appropriate heat treatment

• Furnace

ferrous metal

method for finished weld of non

• Samples of non

ferrous metals

furnace

4.10 Weld the following non-ferrous

• Demonstrate the welding of non- • Lesson plan, welding

metals and apply the appropriate heat

ferrous metals and apply the

equipment and

treatment:

appropriate heat treatment

appropriate tools

a. copper

method as in 4.10 (a-e)

b. bronze c. aluminium d. brass e. iconelmonel

59


Course Code: CFW 13




Teachers Activities

Resources

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


Teachers Activities

5.1 Identify the composition of given worn • Describe the composition of a metallic shafts or other worn metallic

given worn metal shafts or parts

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

7

Resources • Lesson plan Chalkboard, and Worn metal shaft and gear

by arc welding.

restored by arc welding

teeth

5.2 Discuss the properties of the given

• State the properties of given

• Lesson plan,

worn metallic parts to be restored by arc

worn metal parts to be restored

Welding Machine and

welding

by arc welding


5.3 Build-up given worn metallic parts to

• Demonstrate the building up of

Equipment

specification using appropriate techniques worn metal parts to specification, including controls against distortion

using appropriate techniques and control against distortion

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


Teachers Activities

Resources

6.1 Know the principles and application of • Explain the principles and

• Lesson plan

the following arc cutting methods in metal application of the following arc

Chalkboard

fabrication:

cutting methods in metal

Sketches/Charts

fabrication:

• Welding equipment

a. air arc method

8

b. carbon arc method

i. air arc method

c. oxy arc method

ii. carbon arc

and accessories

method and iii. oxy arc method 6.2 Identify arc cutting electrodes and

• Explain arc cutting electrode

• Lesson plan

state their compositions and uses

stating their composition and

chalkboard various

uses

arc cutting electrode

6.3 Cut metals with facility using the

• Demonstrate the cutting of

• Lesson plan Arc

different cutting methods named in 6.1

metals using the different cutting Cutting Electrode and

above.

method named in 6.1 above

60

Welding Equipment

General Objective 7.0: Know various welding defects and rectify them Week

9


Teachers Activities

Resources

7.1 Describe major defects in arc welded

• Explain major defects in arc

• Lesson plan

joints including undercut; lack of fusion

welded joint as in 7.1

Chalkboard,

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

• Show students samples of these Sketches/charts

inclusion (oxide entrenchment); unequal

defects

• Samples of defects

leg length (uneven alignment); and lack of • Give detailed notes reinforcement. 10

7.2 Know how the weld defects in 7.1

• Explain how weld defects in 7.1 • Lesson plan,

above can be avoided

above can be avoided.

Chalkboard

7.3 Apply the following tests to detect


• Lesson plan,

defects in arc welded joints:

the following test to detect defects Chalkboard, Testing

a. non-destructive tests

in arc welded joints as shown in

such as visual inspection,

7.3 (a-b)

Apparatus

x-ray test, gamma, ray test, ultrasonic test, magnetic track detector penetrant;

11

b. destructive tests such as bend test, macro and micro examinations sulphur print, izod and fatigue 7.4 Rectify welded joint defects named 7.1 • Explain how to correct defects in above

welded joints named in 7.1 above

7.5 Produce project involving the

• Test, evaluate the students in

• Lesson plan

application of:

the production process

• Material, tool and equipment

a. General safety precaution b. Using both AC and DE 12

- Do -

machines c. Ferrous and nonferrous metals d. Different type of joints in all positions and defect etc Week 13 Examination - Practical 60%, Theory 40%

61

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: On completion of this module, the trainee should be able to: 1. Understand the safety rules as applicable to structural steel work 2. Use and Care for Tools and Equipment used in Structural Steel Work 3. Know the structural properties of materials used in structural steel work and make simple calculations related to their strength. 4. Produce simple structural steel projects on the shop floor 5. Understand the process of manufacture of iron and steel 6. Assemble simple structural steel components 7. Know the effect of corrosion on structural steel materials and apply protective coating against corrosion. Practical Competence On completion of this module, the student will be able to: 1. Comply with general safety related to structural steel work 2. Use tools and equipment correctly 3. Identify properties of structural steel working materials 4. Produce structural steel projects 5. Assemble structural steel components 6. Apply protective coating against corrosion

62

PROGRAMME: NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK

Course Code: CFW 14

Contact Hours: 18 hrs per week 6 tutorials; 12 practicals

Course Specification: Theoretical/Practical contents General Objective 1.0 Understand the safety rules as applicable to structural steel work Week


Teachers Activities

Resources

1.1 Select, use and care for the

• Explain the use and care for

• Lesson plan

following protective wears used in

protective wears used in

Chalkboard

structural steel work

• Posters

Year 3 structural steel work: Term 2

a. gloves

• Show students items listed in 11 • Related Protective

1

b. aprons

• Demonstrate how to take care

c. boots

of these items

d. goggles, etc


Wears

1.2 Know safety rules for the following

• Explain the safety for operations • Lesson plan

operations in structural steel work:

in structural steel work and give

Chalkboard

detailed notes

• Posters

a. rules for storage of full and empty gas

• Necessary Tools and

cylinders

Equipment

b. rules for lifting of 2

structure c. rules for transporting of structures, etc. 1.3 Apply the safety rules in carrying out • Demonstrate the application of operations named in 1.2 above.

safety rules in carrying out operations mentioned in 1.2 above

63

- do -


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work Week


Teachers Activities

2.1 Select and use common hand tools List common hand tools used in

Lesson plan,


Chalkboard Appropriate

a. hammers (assorted)

Explain their uses

Tools and Equipment

sheers

Show students these tools

b. spanners (assorted)

Give detailed notes

dog

Ask student to sketch these tools

used in structural steel work: e.g.

3

Resources

c. drills (assorted) dice d. punches dollies, etc e. chisels f. screw drivers g. pliers h. strips 2.2 Identify and use with facility the

• List and explain the use of

following power tools used in structural power tools used in structural steel work: e.g.

steel work

a. riveting hammer

• Show the student these tools

(assorted)

• Demonstrate using these tools

b. holder on


c. impact wrenches d. grinder e. torque spanners f. straight edge etc.

64

• Lesson plan Appropriate Tools and Equipment


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 2.0: Use and Care for Tools and Equipment used in Structural Steel Work Week


Teachers Activities

Resources

2.3 Identify, use and care for the

• List the equipment in 2.3

• Lesson plan

following structural steel working

• Explain the use of each

Chalkboard, charts

equipment: e.g.

• Explain the care of each


a. cranes (assorted)

equipment

Equipment

b. straightening

• Show the students each of

machine

these equipment physically where

c. circular sewing

available. If not show them the

machine

picture

d. loafty platform

• Ask student to produce diagram

4

e. cropper

of each equipment

5

f. shearing machine


g. punching machines h. drilling machine i. guillotine j. bending machine k. rolling machine l. brake pens m. tape, twine and chalk n. trammel 2.4 Maintain tools, machines and

• Demonstrate how to maintain

equipment used in structural steel work tools, machine and equipment used in structural steel work

e.g. by: 6

• Lesson plan Appropriate Tools, Equipment and

a. cleaning

Materials

b. oiling

• Oil and grease cans.

c. greasing

• Grinding machine

d. regrinding, etc

65


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 3.0: Know the structural properties of materials used in structural steel work and make simple calculations related to their strength. Week


Teachers Activities

3.1 Describe with sketches the following • Sketch and explain forms of

• Lesson plan,

structural steel materials

Chalkboard,

a. plates (various

• Give detailed notes on each of

Posters/Charts.

thicknesses)

the equipments

• Samples of equipment

b. universal channel

• Asked students to sketch these where available

c. universal beams

equipment

forms of structural steel materials e.g.

d. rolled steel joist e. T-bar f. Angle bar g. Check plates (assorted) 7

Resources

h. Bridge beams, etc. 3.1 Describe with sketches the following forms of structural steel materials: i. e.g. plates (various thicknesses) j. universal channel k. universal beams l. rolled steel joist m. T-bar n. Angle bar o. Check plates (assorted) p. Bridge beams, etc.

66


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 3.0: Know the structural properties of materials used in structural steel work and make simple calculations related to their strength. Week

8


Teachers Activities

Resources

3.2 Intepret conventional symbols and

• Ask students to sketch and

• Lesson plan

abbreviations used for representing

explain conventional symbols and Chalkboard Charts.

structural steel sections

abbreviations used in

• Lesson plan

3.3 Apply standard specifications, e.g.

representing structural steel

Chalkboard, Charts

Nigerian standard (where available) -

section

• Lesson plan

American or British standards to

• Explain and apply standard

Chalkboard

structural steel work design.

specifications used in structural

• Lesson plan

3.4 State the use and limitations of the

steel work design

Chalkboard

structural steel materials named in 3.1

• Explain the use and limitations

above

of the structural steel materials in

3.5 Apply Hooke's Law in the design of 3.1 given simple structural elements.

• Explain and apply Hooke's Law in the design of simple structural elements

3.6 Distinguish between the following

• Explain and state the

• Lesson plan

stresses in structural steel-work:

differences of stresses in

Chalkboard Charts

a. tensile stress


b. compressive stress c. shear stress

9

3.7 Know simple calculations involving

• Explain simple calculations

• Lesson plan

practical applications of tensile,

involving practical application of

Chalkboard

compressive and shear stresses, e.g. in stresses in riveted joint, welded riveted and welded joints

joints etc. • Give student some problems to solve

3.8 Read structural steel work drawing

• Draw and interpret structural

• Lesson plan

and sketch simple structural steel work steel work drawing and sketches Chalkboard Sample details.

of simple structural steel work details

67

drawings and sketches


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 4.0: Produce simple structural steel projects on the shop floor Week


Teachers Activities

Resources

4.1 Calculate allowances for forming

• Explain calculations of

• Lesson plan

thick metal or angle bar rings using the allowances for forming thick metal Chalkboard sketches 10

11

12

following methods:

or angle bar rings using meanline

a. meanline method

and neutral line method

b. neutral line method

• Solve some problems

4.2 Produce simple projects in structural • Give students projects to

• Lesson plan

steel work e.g. stanchion bar plate rafter demonstrate the production of

Appropriate tools

hunches, etc.

simple projects in structural steel equipment and work

materials

4.3 Develop templates with regular

• Demonstrate how to develop

• Lesson plan Drawing

surfaces

templates with regular surfaces

instruments

4.4 cut out templates from the following • Demonstrate how to cut Year 3

materials:

Term 3 1

• Lesson plan

templates from various materials Appropriate Materials

a. wood

• Ask student to cut out template

b. cardboard

on wood, cardboard etc

Tools and Equipment

c. any other suitable materials 4.5 Reproduce simple jobs on structural • Give student Project to

2

• Lesson plan

steel materials using templates cut in

demonstrate how to reproduce

Appropriate Materials

4.4 above

simple jobs on structural steel

Tools and Equipment

materials using templates in 4.4 above 4.6 sketch and produce simple working • Demonstrate how to sketch and • Lesson plan 3

jigs, e.g. jig for mass production of

produce simple working jigs.


stanchions, rafters, etc., on the shop

• Ask students to do the same

Equipment.

floor

68


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 5.0: Understand the process of manufacture of iron and steel Week


Teachers Activities

Resources

5.1 Sketch a blast furnace and describe • Sketch and label a blast furnace • Lesson plan its working principles

and explain the working principles Chalkboard • Note: Student should visit

Posters/Chart Industrial

industry/factory to see a typical

Visit

blast furnace. • Students are asked to sketch and label blast furnace 5.2 Give the name of fuel and state the • Ask students to state the type of Lesson plan 4

composition of charge used in blast

fuel and the composition of

furnace

charge used in blast furnace

5.3 Explain the working principles of

• Ask students to state the

Bessemer process with the aid of a

working principles of a Bessemer

sketch

process with the aid of a sketch.

chalkboard, charts - do -

• Students are asked to sketch Bessemer converter 5.4 Outline the characteristics of pig

• List the characteristics of pig

iron, cast iron and low carbon steel

iron, cast iron and low carbon steel

69

- Charts


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 6.0: Assemble simple structural steel components Week


Teachers Activities

Resources

6.1 Know the uses of fixtures and bolts • Explain the uses of fixtures and • Lesson plan in the assembly of structural

bolts in the assembly of structural Chalkboard, bolts and

components

components

fixtures

• Give detailed notes • Lesson plan

6.2 Assemble simple structural 5

components such as rafter bracing,

• Demonstrate how to assemble

simple canopy simple roof trusses, etc. simple structural components, Note: Assembly should

using bolts, rivets and welding

involve basic jointing

operation

operations, e.g. bolting,

• Show samples of some of these

riveting and welding

assemblies

Appropriate Tools and Equipment

General Objective 7.0: Know the effect of corrosion on structural steel materials and apply protective coating against corrosion. Week

6

7


Teachers Activities

Resources

7.1 Name some common causes of

Ask students to list some

Lesson plan Chalkboard

corrosion on steel e.g.

common causes of corrosion on

Sample of corroded

a. atmospheric

steel

steel

b. chemical such as

Show student samples of

electrolytic action.etc

corroded steel.

7.2 Describe the effect of corrosion on

• Ask students to explain the

structural steel, e.g.

effects of corrosion on structural

a. weakening of

- do -

steel

structure b. defacing of steel 8

7.3 Know the purposes for applying

• Explain the purposes for

undercoat to structural steel

applying undercoat to structural

components

steel components

70

- do -


Course Code: CFW 14


Course Specification: Theoretical/Practical contents General Objective 7.0: Know the effect of corrosion on structural steel materials and apply protective coating against corrosion. Week

9


Teachers Activities

7.4 Prepare the surfaces of structural

• Demonstrate how to prepare the • Lesson plan

steel components for finishing with the

surface of structural steel


following methods:

components for finishing

Equipment

b. brushing

• Ask the student to perform the

c. de-greasing

operation above

Resources

d. de-scaling 7.5 State the composition of common 10

• List and explain the composition • Lesson plan

undercoat used for structural steel work of common undercoat used for structural steel work.

Chalkboard, Charts, and samples of under coat

11

7.6 Apply suitable undercoat to


• Lesson plan

structural steel components. E.g. red

suitable undercoat to structural


oxide, metalization

steel components and observe

Equipment

Note: Observe safety precautions in the safety precautions. use of the undercoats. 12

7.7 Produce project involving the

• Test, evaluate the student in the • Lesson plan

application of safety rules in structural

process of the production

steel work

• Material, tool and equipment


71

Advanced National Technical Certificate Welding PROGRAMME:

Advanced National Technical Certificate In Fabrication And Welding Engineering Craft

MODULE:

CFW 21-Welding

DURATION:


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 machines and accessories 3. Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts 4. Apply appropriate workshop processes and techniques to mark out and form projects for welding 5. Make different types of welded joints in all positions 6. Understand and apply the fuel-gas cutting process in cutting metals to given specification. Practical Competence On completion of this module, the student will be able to: 7. Comply with general safety related to gas shielded arc and ancillary welding process 8. Apply basic principles and techniques of TIG and MIG welding in fabricating simple machine component parts 9. Use workshop process techniques and tools to mark out and form projects in welding 10. perform welding operations in all position involving different types of joints

72

11. Cut metals to given specification using the fuel gas cutting process PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING

Course Code: CFW 21

Contact Hours: 15 per week 4 Tutorials; 11 Practicals

Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes Week Specific Learning Outcome

Teachers Activities

Resources

1.1 Know the importance of a safe working • Explain the importance of a • Welding tools, lesson environment with particular reference to

safe working environment

plan chalkboard goggle

personal safety, and the student's

with respect to safety to self

and appropriate

responsibility to others.

and others as per 1.1 (a-d)

equipment

a. State the reasons for the use of face protection and the wearing of protective clothing. b. Describe the dangers inherent in the following: grinding, oxy-acetylene 1

welding, metal arc welding, shearing, bending, folding, compressed air, lifting tackle. c. State the correct methods for handling, storing and using compressed gas cylinders. d. State the dangers of electric shock and describe user precautions.

73

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: WELDING

Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 1.0: Understand and Apply the general safety precautions related to gas shielded arc and ancillary welding processes Week Specific Learning Outcome

Teachers Activities

Resources

1.2 List and explain the hazards related to • Describe the hazard related • Lesson plan gas shielded arc welding. e.g. a. arc eye

to gas shielded arc welding

• Chalkboard. And chart

as listed in 1.2 (a-e)

b. burning c. radiation d. electric shock e. toxic fumes, etc. 1.3 Select, use and care for the protective • Explain the use and care for • Lesson plan and wears used in gas shielded arc welding

the protective wears used in

operations: e.g.

gas shielded arc welding

a. head and pan shields

operations as in 1.3 (a-e)

b. hand gloves

• Show students items listed

c. apron

in 1.3 (a-e)

d. spats

• Ask student to sketch the

e. boots, etc.

items

protective wears

1.4 Apply with facility, appropriate safety

• Demonstrate with facilities

• Lesson plan and

precautions required in carrying out TIG

appropriate safety

protective wears

and MIG welding operations:

precautions required in

• Welding Equipment

a. in confined spaces

carrying out TIG and MIG

b. on empty vessels or

welding operation as listed in

drums that had contained

1.4 (a-c)

inflammable or toxic materials near inflammable materials, e.g. petrol tanker, etc

74


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 2.0: Understand the constructional features and the working principles of TIG and MIG welding machines and accessories Week Specific Learning Outcome

Teachers Activities

2.1 Explain the constructional features and a. State the constructional

Resources e. Lesson plan,

functions of the following equipment and

features and functions of

chalkboard, sketches and

accessories:

equipment and accessories

charts and some

a. DC and AC machines

listed in 2.1 (a-k)

accessories

b. High frequency unit

b. Show students items listed

c. Gas economizer

in 2.1 (A-K)

d. Regulator

c. Ask students to sketch the

e. Air and water cooled

items

torches

d. Give student short notes on

f. Pedal switch

each

g. Gas nozzles h. Suppressor unit i. Flow meter j. Contactor k. Nylon hoses, etc 2.2 State the advantages and

f. Explain the advantages and l. Lesson plan, chalkboard

disadvantages of AC and DC welding

disadvantages of AC and DC m. Lesson plan,

systems

welding system

2.3 Identify the electrodes and filler wires

g. Describe the electrode and accessories

for TIG process and state their composition filler wires for TIG process 2.4 Identify the following gas cylinders by

and state their composition

their colour codes:

and show students samples

a. argon

of electrode and filler wire

b. helium

h. Ask students to explain and

c. carbon dioxide

show gas cylinders by their

d. hydrogen

colour code as listed in 2.4 (a-

e. nitrogen

e)

2.5 State the main advantage of the TIG

i. Call on students to identify

process over other welding processes.

them j. Give detailed notes k. Ask students to explain the main advantage of TIG process over other welding processes

75

chalkboard and TIG n. Lesson plan and chalkboard


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome

Teachers Activities

Resources

3.1 Explain the following major process

• Ask students to describe the • Lesson plan, Chalkboard

variables and characteristics.

major process variables and

3

• Sketches/Charts

a. Electrical

characteristics as listed in 3.1 accessories and materials

b. Direct current, pulsed

(a-d)

current alternating current

• Demonstrate TIG welding to

rectification and

students, emphasizing types

modulation volt,/ampere

of current rectification and

characteristics arc

modulation

initiation.

• Show students the different

c. Electrodes

types of electrodes and the

d. Types, shapes, current

profiles

carrying capacities and

• Explain the importance of

applications.

shielding glasses

e. Shielding Gases


f. Pure and mixed,

the above

functions and applications g. d) Filler materials and their composition 3.2 Appreciate the applications of TIG

• Explain the application of

• Lesson plan,

welding process and select suitable

TIG welding process and

• Chalkboard

operating characteristics for the welding of state operating characteristics • Charts the following: low carbon steels, high yield for the welding listed in 3-2 steels, stainless alloys, nimonic alloys,

and give detailed notes

titanium alloy, cooper alloys and aluminum alloys.

76


Course Code: CFW 21



Teachers Activities

Resources

3.3 Compare backing materials, purging

• Explain backing materials

• Lesson plan and

and under-bead shielding as a means of

purging and under-bead

chalkboard

producing acceptable welds.

shielding as mean of producing acceptable welds.

4

3.4 Explain the effects of joint preparation

• State the effect of joint

on the production of acceptable and

preparation on the production

economical welds by the TIG welding

of acceptable and economical

processes

welds by TIG welding

- do -

processes and give notes. 3.5 Explain the importance of adhering to

• State the importance of

specifications, codes and standards for

adhering to specification

TIG welding processes.

codes and standards for TIG welding processes and give notes

77

- do -


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.6 List and state the functions of TIG

Teachers Activities

Resources

• Explain the functions of TIG • Lesson plan, Chalkboard

welding accessories, e.g. electrode holder, welding accessories as listed and earth lead, welding lead, etc.

in 3.6

• TIG welding accessories

3.7 Describe with sketches the materials

• With the aid of sketch or

• do -

composition of different types of electrodes diagram, ask student to used for TIG welding.

sketch each of the items

• Lesson plan • TIG welding machine

3.8 Set and use the TIG welding machines • Ask students to explain with equipment and materials.

5


to weld the following metals - aluminum,

sketches the materials

copper and stainless steel at specified

composition of different types and Charts

voltage observing safety precautions

of electrodes use for TIG

3.9 Explain the difference between TIG

welding.

and MIG processes.

• Ask students to demonstrate the setting up and use of TIG welding machines for welding metals as listed in 3.8 observing all safety precautions • Call on students to perform above. • Ask students to state the differences between TIG and MIG processes

78


Course Code: CFW 21



Teachers Activities

Resources

3.10 Explain the factors that govern the

• State the factors that govern • Lesson plan Chalkboard

design of joints requiring MIG and TIG

the design of joints requiring

• TIG welding equipment

processes e.g.

MIG and TIG processes as

and accessories and

a) type of metal

listed in 3.10 (a0c) and

materials.

b) thickness of metal

demonstrate the welding of

c) shape of material

metal joints using TIG and

d) position of joint; and

MIG processes in positions

welding various metal

listed in 3.10

joints using TIG and MIG

• Ask the students to practice

processes in the following

the process

positions:


a) flat positions b) confined space c) other positions 3.11 Sketch and explain the meaning of

• Sketch and state the


the various arc welding

meaning of the various arc

and

symbols/conventions, e.g. symbol of a

welding symbols/conventions • Sketch/chart

single V butt weld with sealing run, symbol as out line in 3.11 of weld on both sides etc.

79


Course Code: CFW 21



Teachers Activities

3.12 Weld metals using at least six of the

• Demonstrate the welding of

following ancilliary welding processes:

metals using at least six of

a. resistance

the ancillary welding

b. spot

processes listed in 3.12 (a-l)

c. seam

• Prepare and give detailed

d. projection

notes

e. submerged arc

• Explain the factors

f. flash butt

governing the choice of any of

g. fire cracker

the ancillary processes

h. stud

named in 3.12 above

Resources

i. atomic hydrogen, etc. j. Thermit k. Helectrode l. plasma arc

6

3.13 Outline the factors governing the

• Demonstrate the use of TIG • Lesson plan

choice of any of the ancilliary processes

and MIG welding techniques

named in 3.12 above

on the listed items in 3.14 (a - equipment, tools and

3.14 Produce using TIG and MIG welding

f)

techniques the following items:


Ancilliary/welding materials - do -

a. pressure vessels

• Demonstrate the welding of • Lesson plan, TIG and

b. pipe flanges

fixed cluster in a gearbox

MIG welding equipment, accessories and materials

c. boiler drums

- do -

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.

80


Course Code: CFW 21



Teachers Activities

3.16 Explain the principles of MIG welding • State the principles of MIG and state the techniques of consumable

welding and explain the

and non-consumable electrodes and wires techniques of consumable and their composition.

and non-consumable

Resources • Lesson plan Chalkboard Appropriate electrodes and wires - do -

3.17 Explain the details of equipment used electrode and wires and their • Lesson plan, Chalkboard and describe the setting of their controls

composition.

3.18 state the effects of wrong setting, type • Give detailed notes of defects, causes and elimination

• 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.

81

Sketches/Chart


Course Code: CFW 21



Teachers Activities

3.19 Explain the following major process

• State the major process

variable and characteristics:

variables and characteristics,

a. Modes of metal transfer

listed in 3.19 (a-c)

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.

82

Resources - do -


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the basic principles and techniques of TIG and MIG welding and be able to apply them in fabricating simple machine component parts Week Specific Learning Outcome 3.20 Apply the MIG welding process and

Teachers Activities

Resources

• Demonstrate the MIG

• Lesson plan

select suitable operating characteristics for welding process and show welding:

suitable operating

a. M.S (Mild Steel) in

characteristics for welding of

different welding position

items listed in 3.20 and give

b. S.S (Stainless Steel)

detailed notes

• MIG equipment & Accessories/Materials

c. Aluminium d. Pipes and pipe joints e. Titanium alloys f. Copper alloys, etc. 3.21 Explain the principles of spot welding • Ask students to state the

7

• Lesson plan • Chalkboard

and describe the size and shape of

principle of spot welding and

electrode in relation to metal thickness

explain the size and shape of • Spot welding machine

3.22 State the purpose of spot welding in

electrode in relation to

machine shop or industry

thickness

3.23 State the effects of current, time and

• Explain the purpose of spot

force in spot welding process

welding in machine shop or

3.24 Evaluate the effect of heat balance

industry

and heat shrinkage in welding

• Explain the effect of current

3.25 Describe the methods of external

time and force in spot welding

cooling on welds

process

3.26 Discriminate between the types of

• Explain the effect of heat

welds e.g. plasma arc or sub-merge arc

balance and heat shrinkage in

and spot welding

spot welding • Explain the method of external cooling on welds • Explain the difference between the types of welds produced by plasma arc, submerged arc and spot welding • Give detailed notes on all of the above

83

- do -


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 4.0: Apply appropriate workshop processes and techniques to mark out and form projects for welding Week Specific Learning Outcome

Teachers Activities

Resources

4.1 Mark out the following projects in

• Demonstrate the marking

• Lesson plan Spot

welding - applying appropriate tools,

out of project in welding as

Welding, Appropriate

techniques and safety practice:

listed in 4.1 (a-d) applying

Equipment, Tools,

a. Rectangular container

appropriate tools, techniques Materials and Protective

b. Cylindrical shaped

and safety practices

objects

• Give students projects

c. Solid corner joints

involving items listed in 4.1

Wear

d. Butt joint 4.2 Prepare bronze components for

• Ask students to demonstrate • Lesson plan, Welding

welding avoiding sharp edges and weld to preparation and welding of specification.

bronze component for

Equipment Tools and Materials

avoiding sharp edges and welding to specifications and give notes 4.3 Prepare stainless steel components for • Demonstrate preparation

• - do -

welding using welding rods and techniques and welding of stainless steel and observing safety precautions.

components using welding rods and techniques and observing safety precautions.

4.4 Identify and state the type, composition • List types of stainless steel

• Lesson plan,

and properties of common stainless steels • Explain their composition

Chalkboard, Sketches

used in metal work

• Discus their properties and

Chart and Different pieces

uses

of stainless steel.

84


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 5.0: Make different types of welded joints in all positions Week Specific Learning Outcome

Teachers Activities

5.1 Describe with sketches the application • Explain with sketches the

• Lesson plan

application of the following

• Chalkboard and

a. Square butt

joint in metal fabrication as

• Charts

b. Single vee

listed in 5.1 (a-e)

c. Double vee

• Ask students to sketch the

d. Single U

joints

e. Open corner, etc.

• Give detailed notes on each.

of the following joints in metal fabrication:

9

Resources

5.2 Prepare edges for welding the joints in • Demonstrate how to prepare • Lesson plan, Necessary 5.1 observing safety rules.

edge for welding the joints in Tools, Equipment and 5.1 observing safety rules

Materials

• Ask the student to prepare edges for welding joints in 5.1 5.3 Weld pipes and flanges in various

• Demonstrate how to weld

positions e.g:

pipes and flanges in various

a) fixed position

- do -

position - both fix and rotated

b) rotated position

10

5.4 Prepare metal surfaces and make

• Demonstrate how to prepare - do -

multi-run and weaving welds

metal processes and make multi run and weaving

5.5 Weld joints in vertical, horizontal and

• Demonstrate how to weld

overhead positions

joint in vertical, horizontal and overhead positions. • Ask the student to carry out the above operations and give detailed notes

85

- do -


Course Code: CFW 21


Course Specification: Theoretical/Practical contents General Objective 6.0: Understand and apply the fuel-gas cutting process in cutting metals to given specification. Week Specific Learning Outcome

Teachers Activities

6.1 State the principles and applications of • Explain the principles and fuel-gas cutting process, e.g.:

Resources Lesson plan, Chalkboard

applications of fuel-gas

a. Manual

cutting as listed in item 6.1 (a-

b. Machine

b) • Give the students, projects

11

involving the two processes 6.2 Describe various fuel-gas used in oxy- • Ask students to state fuel cutting e.g:

- do -

various fuel-gases used in

a. acetylene

oxy-fuel cutting gas listed in

b. propane

6.2 (a-d)

c. butane d. coal-gas, etc 6.3 State the advantages and

• Explain the advantages and - do -

disadvantages of using the above-named

disadvantages of using above

fuel-gas for oxy-fuel cutting operations

named fuel gases for oxy-fuel cutting operation.

6.4 Prepare templates for the mass

• Demonstrate how to prepare • Lesson plan, Equipment

production of given objects of regular or

templates for mass

irregular shapes by profile cutting

production of given object by

Tools and Materials

profile cutting 12

6.5 Cut smooth, curved, circular and

• Demonstrate and explain


straight objects using the hand cutting

how to cut smooth, curved

Equipment Tools and

torch including oxy-lance and flame

circular and straight objects

Materials

gauging

using hand flame gauging.

6.6 Produce project involving Arc and

Assist student to design and

Ancillary welding process

produce projects involving Arc equipment. and ancillary welding. Test and evaluate the student Give detailed notes on all of the above


86

Arc and ancillary welding

Structural Mechanics and Specification PROGRAMME:


MODULE:

CFW 22-Structural Mechanics and Specification

DURATION:


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 Practical Competence On completion of this module, the student will be able to: 12. Apply with facilities, standard specification for structural steel construction 13. perform simple calculation on structural steel construction 14. interpret and produce simple structural steel working drawings 15. produce projects applying simple structural mechanics and standard specification to structural steel work

87

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL MECHANICS AND

Course Code: CFW 22

SPECIFICATION

Contact Hours: 15 per week - 4 tutorials; 11 practicals

Course Specification Theoretical/Practical contents General Objective 1.0: Apply simple structural mechanics and standard specifications to structural steel work design. Week Specific Learning Outcome

1-2

Teachers Activities

Resources

1.1 Apply with facility standard


• Lesson plan

specifications for structural steel

standard specifications for structural

• Chalkboard

construction using America or British

steel construction. And give detailed

• Charts.

Standards and their Nigerian counter-

notes

parts. 1.2 Calculate weight of given structural

• Explain and calculate the weight of a • Lesson plan

steel components using appropriate table given structural steel components of specifications.

• Chalkboard.

using appropriate specifications • Give the students problems to solve

1.3 Draw diagrams to show the

• Sketch diagrams to show the

applications of the following in structural application of structural steel work steel work: a. tensile forces and

forces and stresses and ask the

• Lesson plan • Chalkboard • Charts

students to do same.

stresses b. compressive forces 3

and stresses c. shear forces and stresses 1.4 Calculate the reaction at the supports • Explain and calculate the reaction at of cantilever and simply supported

the support of cantilever and simple

beams having points and uniform loading supported beam having points and e.g. simple shed frame with flat roof.

uniform loading.

88

• Lesson plan • Chalkboard, etc.


Course Code: CFW 22

SPECIFICATION



Teachers Activities

Resources

1.5 Calculate bending moments and

• Explain the calculation of bending

• Lesson plan

moment of resistance of simply

moments and moment of resistance of • Chalkboard

supported beam with point and uniform

simply supported with point and

loading.

uniform loading.

• Charts.

• Give the students problems to solve 4

1.6 Determine sizes of materials or

• Explain how to determine sizes of

• Lesson plan

sections required for columns, rafters,

materials required for columns, rafters, • Chalkboard

etc.

etc.

• Charts

1.7 Sketch bending moment diagram for • Sketch and explain bending moment • Lesson plan cantilever with uniform load and calculate diagram for cantilever with uniform load • Chalkboard the bending moment.

and calculation on the bending

• Charts

moment. 1.8 Apply 1.4 in determining reaction at

• Demonstrate how to apply 1.4 in

• Lesson plan

support of actual frames. e.g.

determining reaction at support of

• Appropriate tools

actual frames.

and equipment.

b. canopy c. riveted angle stiffered for crane beams 1.9 Apply stress diagrams to determine 5

• Explain how to apply stress diagrams • Lesson plan

load on member of structural frames. e.g. to determine load on member of

• Chalkboard

trusses.

• Charts

structural frames.

• Appropriate tools and equipment 1.10 Calculate bending stress due to web • Explain the calculation of bending

• Lesson plana

or flange connections. E.g. floor beams

stress due to web or flange

• Chalkboard

multistory frame building.

connections

89


Course Code: CFW 22

SPECIFICATION



Teachers Activities

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

• Lesson plan

following in structural steel assembly:

• Chalkboard

b. rag bolt

• rag bolt

• Posters

c. gusset plate

• gusset plate

• Samples

d. base plate

• base plate

in structural steel assembly: 6

Resources

1.12 Calculate the deflections on a

• Solve some problems involving

• Lesson plan

column or other members using standard calculations on deflections on a column • Chalkboard specifications/formulae.

or other members using standard

• Charts.

specifications/formulae. • Give the students problems to solve General Objective 2.0: Interpret and produce structural steel working drawings Week Specific Learning Outcome

Teachers Activities

Resources

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

• Lesson plan

of structural steel work

working drawings of structural steel

• Chalkboard

work

• Relevant work drawings.

2.2 Design and produce simple structural • Demonstrate how to design and

• Lesson plan

drawings observing conventional

produce simple structural drawings

• Chalkboard

standards, symbols and notations.

observing conventional standards,

• Relevant work

symbols and notations.

drawings

2.3 Produce project applying simple

• Ask student to produce project

structural mechanics and standard

applying simple structural mechanics

specification to structural steel work

and standard specification to structural steel work. • Test and evaluate the students


90

-do-

Structural Steel Work PROGRAMME:


MODULE:

CFW 23-Structural Steel Work

DURATION:


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 Practical Competence On completion of this module, the student will be able to: 1. Develop and produce template for structural steel work 2. Fabricate and assemble various structural steel component 3. carry out inspection on structural steel project 4. Rectify defects in structural steel project 5. provide and develop temperature for structural steel work

91

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: STRUCTURAL STEEL WORK

Course Code: CFW 23

Contact Hours: 15 per week - 4 Tutorials, 11 practicals

Course Specification Theoretical/Practical contents General Objective 1.0 Develop and Produce Templates for Structural Steel Work Week Specific Learning Outcome

Teachers Activities

1.1 Calculate areas of irregular surfaces • Solve problems involving using the following rules: a. mid-ordinates rule

calculation on areas of irregular

Resources • Lesson plan • Chalkboard

surfaces using various methods

b. Simpson's rule • Demonstrate how to develop

• Lesson plan

a. regular surfaces

templates having:

• Chalkboard.

b. irregular surfaces

• regular surfaces

• Drawing instruments

1.2 Develop given templates having:

• irregular surfaces • show students how to how to

from the following materials:

cut out developed templates from • Template materials

a. wood 4

• Lesson plan

1.3 Cut out the developed templates

various materials.

Relevant tools and equipment.

b. card-board c. other suitable materials 1.4 Reproduce the cut templates in 1.3

• Demonstrate how to reproduce • Lesson plan

above from structural steel materials

cut templates in 1.3 from

using the following workshop processes: structural steel materials using a. cutting - using oxy-

various workshop processes.

fuel gas, profile cutting

• Ask students to perform the

and power saw

above functions

b. punching - using punching machine c. chamfering - using oxy-fuel gases

92

• Materials, Relevant Tools and Equipment.


Course Code: CFW 23


Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. Week Specific Learning Outcome

Teachers Activities

Resources

2.1 Explain the functions of jigs and

• State the functions of jigs and

• Lesson plan

fixtures in structural steel works

fixtures in structural steel works. • Chalkboard, Sample of • Give notes

jigs and fixtures

2.2 Make simple jigs, fixtures and

• Demonstrate how to make

• Lesson plan

manipulators for assembling structural

simple jigs, fixtures and

• Appropriate tools and

steel members.

manipulators for assembling

Equipment.

structural steel members.

5-7

2.3 Assemble structural components

• Demonstrate how to assemble • Lesson plan Appropriate

using the following jointing methods:

structural components using

Tools and Equipment and

a. welding (arc and gas)

various jointing methods

Structural Components

b. riveting

• Students asked to perform the

c. bolting

above function

2.4 Explain the purpose of metal

• State the purpose of metal

• Lesson plan

finishing e.g.

finishing

• Chalkboard

a) protection from the weather and corrosion b) decoration 2.5 Describe the composition of various • Explain the composition of

• Lesson plan

materials used for finishing structural

various materials used for

• Chalkboard

steel work

finishing structural steel work

• Samples of materials for finishing

2.6 Prepare the surfaces of structural

• Demonstrate how to prepare

steel components for finishing using the the surfaces of structural steel

• Lesson plan • Samples of Structural

components for finishing using

Components, Appropriate

a. brushing - using wire

various techniques

tools and equipment

brush

• Ask student to perform above

b. de-greasing, using

operations

following techniques:

suitable degreasing agent c. de-scaling

93


Course Code: CFW 23


Course Specification Theoretical/Practical contents General Objective 2.0: Fabricate and Assemble various structural steel components for and products such as roof trusses, stanchions, girders, slop-plating, bridges, tanks, etc. Week Specific Learning Outcome

8

Teachers Activities

Resources

2.7 Apply suitable undercoat to

• Demonstrate how to apply

• Lesson plan

structural steel components e.g. red

undercoat to structural steel


oxide by brushing or spray methods.

components

Equipment

2.8 Store and maintain structural steel

• Explain methods of storing and • Lesson plan

materials and equipment

maintaining structural steel

• Chalkboard

components

• Visit Relevant Stores.

General Objective 3.0: Inspect finished structural steel work for defects and rectify the defects as necessary Week Specific Learning Outcome

Teachers Activities

3.1 Identify common defects in structural • State common defects in

• Lesson plan

structural steel assembly as

• Chalkboard

a. distortion

listed in 3.1

• Any Relevant Materials

b. undercutting

• Show student sample of defects • Lesson plan

c. lack of reinforcement


• Sample of defects

d. lack of penetration of


• Sample of finished weld

weld, etc. and state their

how to carry out visual inspection Components, Relevant

causes.

to detect defects on finished

steel assembly e.g.

9-12

Resources

3.2 Carry out visual inspection to detect structural steel assembly

Tools and Equipment. • Lesson plan

defects on finished structural steel


• Samples of

assembly

how to rectify defects in

Components with weld

3.3 Rectify defects in assembled

assembled structural steel

defects,

structural steel components

components

• Relevant Tools and

3.4 Produce and develop templates for


Equipment.


• Test and evaluate the students

3.5 Fabricate and assemble various structural steel component Week 13 Examination - Practical 60%, Theory 40%

94

Sheet metal work PROGRAMME:


MODULE:

CFW 24-Sheet Metal Work

DURATION:


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. Practical Competence On completion of this module, the student will be able to: 1. Apply machines for the production of sheet metals work 2. Design, Construct and decorate articles 3. Construct patterns of irregular shapes using pattern forming attachment 4. Participate in the planning and laying out engineering workshop/industry

95

PROGRAMME: ADVANCED NATIONAL TECHNICAL CERTIFICATE IN FABRICATION AND WELDING ENGINEERING CRAFT PRACTICE COURSE: SHEET METAL WORK

Course Code: CFW 24

Contact Hours: 15 per week-4 theory: Practical 11

Course Specification: Theoretical/Practical contents General Objective 1.0: Understand the Principles of Pantograph System and pattern forming attachment Week Specific Learning Outcome

1-3

Teachers Activities

Resources

1.1 State the principles, functions and

• Explain the principles, functions • Lesson plan

the constructional details of pattern

and the constructional details of

• Chalkboard

forming machines and attachments

pattern forming machines

• Posters/charts.

1.2 Explain the types and

• Explain the types and

• Lesson plan

characteristics of the machines in 1.1

characteristics of the machines in • Chalkboard

above

1.1

• Posters

1.3 Apply the machines for the

• Demonstrate how to apply the

• Lesson plan

production of sheet metal work

machines for the production of

• Relevant tools and

sheet metal work. Give note on

equipment

all of above General Objective 2.0: Understand the construction of patterns and masters of irregular trinket box shapes using pattern forming machine/attachment. Week Specific Learning Outcome 4-6

Teachers Activities

Resources

2.1 Explain the methods of box and

• Sate the methods of box and

• Lesson plan

tray construction, using beadings and

tray construction, using beadings • Chalkboard

joints.

and joints. Give detailed note.


2.2 Explain the making of articles such • Demonstrate how to produce

• Lesson plan

as oblique tee with branch, lobster back articles such as oblique tee with

• Chalkboard

bend, and similar utensils which involve branch, lobster back bend, and


the development of a pattern.

similar utensils which involve the appropriate tools and development of a pattern.

equipment

2.3 Design, construct and decorate

• Demonstrate how to design,

• Relevant materials for

articles combing ornament with utility.

construct and decorate articles

demonstration

combining ornament with utility.

96


Course Code: CFW 24


Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes Week Specific Learning Outcome

Teachers Activities

Resources

a. 3.1 Review of sheet metal materials • Explain and review non-ferrous • Lesson plan and their preparation for industrial use sheet metal material and their

• Chalkboard

of the following metals: Tin, Lead, Zinc, preparation for industrial use.

• Materials

Copper, and Aluminium

Give detailed note

3.2 State the composition of more


• Lesson plan

important brasses and bronzes, inconel more important alloy metals and • Chalkboard and monel; their properties and chief 7-8

alloy elements; their properties

• Samples of materials

uses, the composition and properties of and uses. wrought aluminium alloys, magnesium and titanium alloys in common use. 3.3 Describe the process of

• Explain the process of

• Lesson plan

manufacture of mild steel sheets of

manufacture of coated sheet

• Chalkboard

various tempers, the manufacture of

metals, listed in 3.3. Give

• Samples of materials

coated sheets such as tinned sheets,

detailed notes.

templates and galvanized iron.

97


Course Code: CFW 24


Course Specification: Theoretical/Practical contents General Objective 3.0: Understand the mechanical cutting of basic geometrical shapes Week Specific Learning Outcome

Teachers Activities

Resources

3.4 Develop and produce at least two

• Demonstrate how to develop

• Lesson plan

sheet metal projects involving the use

and produce sheet metal projects • Drawing instruments,

of more advanced machines and the

involving the use of more

appropriate materials,

application of advanced pattern

advanced machines.

tools and equipment.

development covered in fabrication

• Give student project on the

drawing.

above to produce some of the

Note: Some of the sheet metal project

items listed in 3.4

should include: a. trinket box of all types b. lobster back bend c. oblique tee with branch d. small bait can

9

e. petrol or oil measure f. oval container with lid or with loose lid g. oiled bottle h. conical jug i. scoop j. funnel k. ornamental bowls and vases. Etc. 3.5 Explain the methods of producing

• State the methods of producing • Lesson plan

more difficult work in hollowing, raising more difficult beating sheet metal • Chalkboard. and planishing, hand flattening and

work.

setting.

• Discuss and demonstrate processes involved

98


Course Code: CFW 24


Course Specification: Theoretical/Practical contents General Objective 4.0: Understand the processes of planning and layout of engineering workshops/industry. Week Specific Learning Outcome

10-12

Teachers Activities

Resources

4.1 Demonstrate the methods of

• State the methods of planning

• Lesson plan

planning and the layout of shops in

and layout of shops in

• Chalkboard, Charts visit

engineering workshops/factory

engineering workshops/factory

factory

regulations.

regulations. Give detailed note

• Lesson plan

4.2 Know the types of

• Explain different types

• Visit

workshops/industry, e.g. mechanical,

workshops/industry. Give

workshops/industries

electrical, welding, carpentry, etc.

detailed notes.

• Lesson plan

4.3 State the types and function of

• Explain the types and function

• Visit

sections in the workshops.

of sections in the workshop.

workshops/industries

4.4 Describe and lay out plan for single, • Explain lay out plan for single,

• Lesson plan

batch and quantity production of

batch and quantity production of • Chars

engineering components.

engineering components.

• Visit factory/industry.

4.5 Arrange workshops according to

• Explain how to arrange

• Lesson plan

the lay out plans

workshops according to the lay

• Charts.

4.6 Produce project involving pattern

out plans

• Lesson plan

forming machines

• Test and evaluate the students • Material, tool and • Take student on excursion to industries


99

equipment

List of tools and equipment for welding and fabrication engineering S/NO

MINIMUM

QUANTITY

ADDITIONAL

QUANTITY

AVAILABLE

QUANTITY REQUIRED

REQUIRED 1.

Power guillotine of capacity

2

10swg x 36 in length 2.

Treadle guillotine of capacity

2

20swg x 36 length 3.

Swing beam folder 10swg x 3'-6'

2

capacity 4.

Bending roller capacity 40"x2"

2

dia 5.

Bending roller capacity 18"x11/4

2

dia 6.

Bench mounted cone roller

5

7.

Hand-operated copper capacity

5

3/32 in mild steel 8.

Power bench grinding machine

2

9.

Double-ended buffer and polisher

2

10.

Universal beading and swaging

2

machine 11.

Power-operated drilling machine

2

maximum capacity 3/8" 12.

Wheeling machine

2

13.

Fly Press

1

14.

Hand nibbling Machine

2

15.

Left and right hand snips

16.

Straight snips

5

17.

A "kit" of tools consisting of

5

5 each

hammer, mallet, steel rule, scriber and wing compass, etc. 18.

Bench shears

2

19.

Power saw cutting machine

2

10mm

100

S/NO

MINIMUM

QUANTITY

ADDITIONAL

QUANTITY

AVAILABLE

QUANTITY REQUIRED

REQUIRED 20.

Disc cutting machine

2

21.

Profile cutting machine with gas

2

cutting nozzles 22.

Piller drilling machine

2

23.

Louver shearing machine

2

(manual) 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

10

all Instruments) 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

101

S/NO

MINIMUM

QUANTITY

ADDITIONAL

QUANTITY

AVAILABLE

QUANTITY REQUIRED

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

5

pressure 54.

Tongs

5

55.

Combined set of cutting welding

5

outfit 56.

Power operated profile cutter

2

with turntable 57.

D.C generators with all

5

connections 58.

A.C transformer (Argon) with all

5

the connections 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

102

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

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

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Recommended books for fabrication and welding engineering craft practice S/NO BOOKS

AUTHORS

1.

BASIC WELDING AND FABRICATION

W. KENYON

2.

BASIC ENGINEERING CRAFT STUDENTS: FABRICATION AND

BOURBOUSSON &

WELDING 05

ASHWORTH

THE TECHNOLOGY OF SHEET METAL WORK FOR STUDENTS

A. DICKSON

3.

AND CRAFTSMEN 4.

THE GEOMETRY OF SHEET METAL WORK FOR STUDENTS AND A. DICKSON CRAFTSMEN

5.

THE CALCULATION OF SHEET METAL WORK FOR STUDENTS

A. DICKSON

AND CRAFTSMEN 6. 7.

METAL: DESIGN AND CONSTRUCTION

A.C. DAVIS - Tenth Edition

(a) THE SCIENCE AND PRACTICE OF WELDING Vol. I Cambridge A. C. DAVIS V. Press, 1992 (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

N. PARKIN & C.R. FLOOD

Welding and Related Studies 13.

WELDING CRAFT PRACTICE - Part 1. Volume 2: Electrical Arc Welding and Related Studies

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N. PARKIN & C.R. FLOOD

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.

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

Omotorsho Isaac Bamidele

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

National Board for Technical Education Kaduna

Majiyagbe

106