Fabrication

Teacher

Dillip Mohanta

Category

Certificate Courses

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Course Name: Certificate in Fabrication

 

Course Credits: 0-2-0

 

Course Description

 

The course involves identifying metals- tools; carrying out fitting and fabrication operations like measuring- marking out, welding & sheet metal work and inspecting of components in order to fit a component as per specifications.

Fabrication technology is the most important job skills for Mechanical Engineers. It is very essential technology in Industrial infrastructure development such as erection, commissioning of pipes, shipping, Power plants, steel plants, cement plants etc. This is pure workshop training and it gives the opportunity to the students, hands on experience on  fabrication equipment, safety engineering, plant technologies etc.

 

 

Course Objectives

 

1. Complying to the industry specifications, guidelines and safety standards during fabrication

2. Familiarization with the principles, materials, and tools required in the fabrication

3. Developing an end-to-end technical understanding 

 

Course Outcomes

 

Students will able

1. To read & interpret technical parameters/documentation, plan work, identify necessary
processes, materials, and tools

2. To design different sheet metal working processes

 

Course Syllabus

 

Module I: Introduction 

Recognize & comply with safe working practices, environment regulation and housekeeping, Demonstration of Standard Safety Practices (Personal Safety, Machine/Tool Safety, Lab Safety, etc.), Understand and explain different mathematical calculations & science in the field of study including basic electrical. [Different mathematical calculation & science -Work, Power & Energy, Algebra, Geometry, Mensuration, Trigonometry, Heat & Temperature, elasticity]; Interpret specifications, different engineering drawings and apply for different application in the field of work.

Practice 1: Demonstration and Visualization on all types of  Machines

Practice 2: Physical Involvement over machine throughout live production

Practice 3: Drawing study, process planning & material selection

 

Module II: Basic Concepts & Classification of Welding Processes

Arc Welding, Gas Welding, Resistance Welding, Miscellaneous welding processes, Adhesive Bonding, Soldering & Brazing, Weldability, Characteristics of welding processes, Welded Joints.

Practice 4: Join MS sheet by Gas welding in different positions.

Practice 5: Join MS plate by SMAW in different positions.

Practice 6: Perform straight, bevel & circular cutting on MS plate by Oxy-acetylene cutting process.

Practice 7: Perform different types of MS pipe joints by Gas welding (OAW).

Practice 8: Weld different types of MS pipe joints by SMAW.

Practice 9: Weld Stainless steel, Cast iron, Aluminium, and Brass by OAW or SMAW.

Practice 10: Perform Arc gauging on MS plate.

Practice 11: Join MS sheets/plates by GMAW in various positions using different modes of metal transfer.

Practice 12: Join Aluminium& Stainless Steel sheets by GTAW in different positions.

Practice 13: Weld pipe joints by GTAW.

Practice 14: Cut ferrous and nonferrous metal using plasma Arc cutting.

Practice 15: Join MS / Stainless Steel sheets by resistance spot welding.

Practice 16: Join Copper sheets by OAW in a flat position.

Practice 17: Join similar & dissimilar metals by Brazing operation.

Practice 18: Repair Cast Iron machine parts by welding.

 

Module III: Weld Defects & Weldability Tests

Classification & general sources of weld defects, Cracks in welds, Weldability assessment, Fabrication weldability tests, Service weldability tests

Practice 19: Tensile test of welded joints.

Practice 20: Hardness test of welded joints.

Practice 21: Tensile-shear test of welded joints.

Practice 22: Corrosion Testing

 

Module IV: Weld Inspection & Quality Control

Visual inspection & measurement, Destructive & non-destructive tests, Fitness for purpose

Practice 23: Test welded joints by visual inspection, Dye penetrant & Magnetic particle testing methods.

 

Module V: Repair & Maintenance Welding

Practice 24: Selection of welding process for repair works

Practice 25: Repair of rivetted and large structures, Filling-in large holes

Practice 26: Repair of castings & forgings

Practice 27: Use of grinder machine for smoother welding surface

 

Module VI: Sheet Metal Work 

Metals used in sheet metalworking, Sheet metal tools & Machines, Sheet metal operations, Sheet metal joints

Practice 28: Sheet metal operations

Practice 29: Painting(spray) of sheet metal

 

Module VI: Product Development

Decoding of a drawing, Identifying the raw materials and fittings, Preparing the cut-plan based on drawing, Assembling the product using machining processes with all fittings maintaining the standard quality

Practice 30: MS Table

Practice 31: Structural truss

Practice 32: MS Almirah

Session Plan

 

Session 1:  Introduction

https://www.youtube.com/watch?v=ze0lThBLY0E

https://www.youtube.com/watch?v=55m1IQWcOAE

https://www.youtube.com/watch?v=RL2bVxsdeJY

https://www.youtube.com/watch?v=OPs4MQOlZAQ

https://www.youtube.com/watch?v=VW6a1TIqjxA

 

Session 2:  Welding Concepts

https://www.youtube.com/watch?v=o8BGko__DlA

https://www.youtube.com/watch?v=mibENu9te20

https://www.youtube.com/watch?v=twUAa5LWUvk

https://www.youtube.com/watch?v=uO5pVLOAmD4

https://www.youtube.com/watch?v=amaHurtwYTc

 

Session 3:  Other Joining Processes

https://www.youtube.com/watch?v=AwL1CAg43PU

https://www.youtube.com/watch?v=U8o3pOuE_f8

https://www.youtube.com/watch?v=HJBrsSvwUII

 

Session 4 & 5: Weld Defects & Weldability Tests

https://www.youtube.com/watch?v=jy79I_AuXgc

https://www.youtube.com/watch?v=nof7wI47WSA

https://www.youtube.com/watch?v=oq0PblGi0G4

https://www.youtube.com/watch?v=4PbdRgyW0uI

https://www.youtube.com/watch?v=SHHGuDKqkbc

https://www.youtube.com/watch?v=PdJtZdHjLd0

https://www.youtube.com/watch?v=rDROTnq9rGI

https://www.youtube.com/watch?v=7tr4kVtNsrM

https://www.youtube.com/watch?v=B4aGiKmEuuI

 

Session 6 & 7: Weld Inspection & Quality Control

https://www.youtube.com/watch?v=cLqEojQmNp0

https://www.youtube.com/watch?v=V_Iqx78AYfg

https://www.youtube.com/watch?v=Ncguc7THEUY

 

Session 8 & 9: Repair & Maintenance Welding

https://www.youtube.com/watch?v=Xzrng6GrxXA

https://www.youtube.com/watch?v=kzbcVb2UymA

https://www.youtube.com/watch?v=YNGuALnRQe0

https://www.youtube.com/watch?v=ALLhN0j6ycw

https://www.youtube.com/watch?v=qYy3oxOhxAY

 

Session 10 & 11: Repair & Maintenance Welding

https://www.youtube.com/watch?v=SE-gMYZgUys

https://www.youtube.com/watch?v=633QHZ1Vt48

https://www.youtube.com/watch?v=q3jHLc6oATI

https://www.youtube.com/watch?v=o5zTUo2t7_w

https://www.youtube.com/watch?v=tSYAIivkfdo

 

Session 12, 13 & 14: Product Development

https://www.youtube.com/watch?v=bt5vwoRv8WU

https://www.youtube.com/watch?v=2I3MHBYsasc

https://www.youtube.com/watch?v=eI8KnylIc9g

https://www.youtube.com/watch?v=dFpe_v5TrgQ

https://www.youtube.com/watch?v=FVc_n9vyQJU

https://www.youtube.com/watch?v=NF-Qbl62_bY

 

 

 

 

Text Books:

1. Parmar R. S., "Welding Engineering & Technology”, 2nd Edition, Khanna Publishers.

2. Rao P.N., “Manufacturing Technology”, Volume 1, Mc-Graw Hill.

 

Reference Books:

1. Little R., “Welding & Welding Technology”, Mc-Graw Hill.

2. Rajput R. K., “A Textbook of Manufacturing Technology”, Laxmi Publications.

 

 

Course Outline Prepared by  Prof. D. Mohanta  

Source of Reference: NSQF, Level 3, Capital Goods & Manufacturing-Sector; Level 4, Fabrication-Sector

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