The Directorate General of Training (DGT) under Ministry of Skill Development & Entrepreneurship offers a range of vocational training courses catering to the need of different sectors of economy/ Labour market. The vocational training programmes are delivered under the aegis of Directorate General of Training (DGT). Craftsman Training Scheme (CTS) with variants and Apprenticeship Training Scheme (ATS) are two pioneer schemes of DGT for strengthening vocational training.

Welder (Structural) trade under CTS is one of the popular courses delivered nationwide through network of ITIs. The course is of one year duration. It mainly consists of Domain area and Core area. The Domain area (Trade Theory & Practical) imparts professional skills and knowledge, while Core area (Workshop Calculation science, Engineering Drawing and Employability Skills) imparts requisite core skills, knowledge and life skills. After passing out of the training program, the trainee is awarded National Trade Certificate (NTC) by DGTwhich is recognized worldwide.

Broadly candidates need to demonstrate that they are able to:

• Read & interpret technical parameters/document, plan and organize work processes, identify necessary materials and tools;
• Perform task with due consideration to safety rules, accident prevention regulations and environmental protection stipulations;
• Apply professional skill, knowledge, core skills & employability skills while performing jobs.
• Check the job/assembly as per drawing for functioning, identify and rectify errors in job/assembly.
• Document the technical parameters related to the task undertaken.

JOB ROLE

Welder (Structural)while gas welding, fuses metal parts viz. M.S, S.S, Brass & Aluminium sheets and Cast Iron plates together using welding rod and oxygen acetylene flame. Examines parts to be welded, cleans portion to be joined, holds them together by some suitable device and if necessary makes narrow groove to direct flow of molten metal to strengthen joint. Selects correct type and size of welding rod, fluxes nozzle etc. and tests welding, torch. Wears dark glasses and other protective devices while welding. Releases and regulates valves of oxygen and acetylene cylinders to control their flow into torch. Ignites torch and regulates flame gradually. Preheats joints as required. Applies flux as required for welding Aluminium and Cast Iron. Guides flame along joint and heats it to melting point, simultaneously melting welding rod and spreading molten metal along joint shape, size etc. Makes Square butt, lap, Tee, Corner and Single Vee but joints by Gas welding. Rectifies defects if any.

Welder (Structural) while gas cutting, cuts metal to required shape and size by gas flame either manually or by machine. Examines material to be cut and marks it according to instruction of specification. Makes necessary connections and fits required size of nozzle in welding torch. Releases and regulates flow of gas in nozzle, ignites and adjusts flame. Guides flame by hand or machine along cutting line at required speed and cuts metal to required size.

Welder (Structural) while gas brazing, joints metal parts by heating using flux and filler rods. Cleans and fastens parts to be joined face to face by wire brush. Apply flux on the joint and heats by Oxy acetylene welding torch to melt filler rods into joint. Allows it to cool down. Clean and examines the joint.

Welder (Structural) while Shielded Metal Arc welding (SMAW) on plates fuses metals using arcwelding power source and electrodes. Examines parts to be welded, cleans them and sets joints together with clamps or any other suitable device. Starts welding power source and regulates current according to material and thickness of welding. Connect one lead to part to be welded, selects required type of electrode and clamps other lead to electrode holder. May join parts first at various points for holding at specified angles, shape, form and dimension by tack welding. Establish arc between electrode and joint and maintain it throughout the length of the joint. . Makes Square butt, lap, Tee, Corner and Single Vee but joints by Shielded Metal Arc Welding. Rectifies defects if any by Arc gouging and re-welding.

Welder (Structural) while fitting and Welding Structural assembles Examines drawings and other specifications, cuts steel plates and angle iron using power shear or flame cutting equipment, checks parts to be fitted together, aligns members in position with suitable fasteners to ensure that members fit together properly preparatory to permanent erection of structures at site and fits together various parts of heavy structures in workshop according to drawings under instructions of structural Engineer. Checks alignment of members to ensure accuracy of fit. Weld the assemblies by specified welding process. May bend or otherwise shape plates and assemble structural members.

Welder (Structural) while welding M.S plates by Gas Metal Arc Welding (GMAW) reads fabrication drawing, examines parts to be welded, cleans them and sets joints with clamps or any other suitable device. Connects work piece with earth cable. Connects the machine with CO2 gas Cylinder, regulator and flow meter. Connects preheater, selects suitable wire electrode, feed it to welding GMA Welding torch through wire feeder. Selects contact tip gas nozzle and fit in to the GMA welding torch. Preheats joints as required. Starts the Constant Voltage GMA welding machine, sets suitable welding voltage & wire feed speed and shielding gas flow, produces arc between work piece and continuously fed wire electrode. Melts the metal and deposit weld beads on the surface of metals or joins Mild steel metal to a requires quality minimizing distortion and avoiding weld defects. Maintains inter pass temperature as required. Makes Lap, T and Corner joint welding in down hand well position. Takes precautionary measures such as wearing hand gloves & leg pads, suitable helmet with correct weld filter glass and protecting eyes from harm full electric arc. Inspects the weld by visual and Liquid Penetrant test and rectifies defects if any. May weld with Flux cored Arc Welding wire also.

Welder (Structural) while welding M.S plates by Gas Metal Arc Welding (GMAW) reads fabrication drawing, examines parts to be welded, cleans them and sets joints with clamps or any other suitable device. Connects work piece with earth cable. Connects the machine with CO2 gas Cylinder, regulator and flow meter. Connects preheater. Selects suitable wire electrode, feed it to welding GMA Welding torch through wire feeder. Selects contact tip gas nozzle and fit in to the GMA welding torch. Preheats joints as required. Starts the Constant Voltage GMA welding machine, sets suitable welding voltage & wire feed speed and shielding gas flow, produces arc between work piece and continuously fed wire electrode. Melts the metal and deposit weld beads on the surface of metals or joins Mild steel metal to a requires quality minimizing distortion and avoiding weld defects. Maintains inter pass temperature as required. Makes Lap, T and Corner joints but joints by Gas Metal Arc Welding on plates in down hand welding. Takes precautionary measures such as wearing hand gloves & leg pads, suitable helmet with correct weld filter glass and protecting eyes from harm full electric arc. Inspects the weld by visual and Liquid Penetrant test and rectifies defects if any.

Welder (Structural) while welding M.S, SS, Aluminium sheets and M.S pipes by Gas Tungsten Arc Welding (GTAW) also known as Tungsten Inert Gas shielded Arc Welder (TIG welder) reads fabrication drawing, examines parts to be welded, cleans them and sets joints with clamps or any other suitable device. Selects suitable tungsten electrode, grinds the edges and fit in to the GTA welding torch. Selects gas nozzle and fit in to the GTA welding torch. Selects suitable filler rods and cleans them. Connects work piece with earth cable, Connects the machine with Inert gas Cylinder, regulator and flow meter. Preheats joints as required. Starts the Constant current GTA welding machine, sets suitable welding current and inert gas flow, produces arc through across a column of highly ionized inert gas between work piece and Tungsten electrode, melts the metal and deposit weld beads on metal surfaces by passing the suitable filler rod in to the weld puddle or joins metal pieces such as Steel, Stainless steel, Aluminiun, to a required quality minimizing distortion and avoiding weld defects Takes precautionary measures such as wearing hand gloves, selecting suitable helmet with correct weld filter glass and protecting eyes from harm full electric arc.

Welder (Structural)while welding M.S plates by Automatic Submerged Arc Welding (SAW) load the electrode wire spool and feed the electrode through the contact tip. Set the welding parameters. Fill the granular flux on the Hooper. Prepare the work pieces and set and align it on the welding table. Start the SAW machine and weld the plates together. Inspect the weld to ensure quality.

LEARNING OUTCOME

• 1. Join MS sheets by Gas welding in different positions following safety precautions.
• 2. Join MS plates by SMAW in different positions.
• 3. Perform straight, bevel & circular cutting on MS plate by Oxy-acetylene cutting process.
• 4. Perform different type of MS pipe joints by Gas welding (OAW).
• 5. Weld different types of MS pipe joints by SMAW.
• 6. Weld Stainless steel, Cast iron, Brass & Aluminum by OAW.
• 7. Perform Arc gauging on MS plate.
• 8. Perform Plasma Arc cutting.
• 9. Perform fillet welding on M.S plates up to 1F, 2F, 3F, 4F & 5F positions by SMAW.
• 10. Perform Full penetration Single "V" butt joint on MS plates in 1G,2G,3G &4G position adapting root Inspection and clearance by D.P test.
• 11. Perform welding of M.S, S.S and Aluminium sheets, M.S tubes (square butt T,Y,K joints) by GTAW in down hand position.
• 12. Perform bending, straightening and edge planning for fabrication of structures.
• 13. Perform Double bevel butt joint on dissimilar thickness MS Flats in down hand positions by SMAW with root Inspection by D.P test and back gouging and with root Inspection by D.P test and back gouging and adapting skip welding & back step welding method for controlling distortion.
• 14. Perform welding of pipe joints in different positions by SMAW.
• 15. Perform Lap, T, Corner joints on GMAW and Flux Cored Arc welding process on M.S in down hand position.
• 16. Perform Automatic Submerged Arc Welding.
• 17. Manufacture simple structures with L angles, I section and channel sections using welding fixture by SMAW.
• 18. Fabrication of pipe/cone on M.S. sheet by SMAW.
• 19. Prepare a Weld test specimen as per a standard and carry out testing.
• 20. Carry out non destructive testing of welds.