Welding (1G–6G, TIG, MIG)

Module 1: Introduction to Welding & Workshop Safety

• The Welding Trade: Introduction to career paths and high-demand global job opportunities.

• Personal Protective Equipment (PPE): Correct usage of welding helmets, leather aprons, gloves, and safety boots.

• Workshop Safety: Fire prevention protocols, electrical hazard awareness, and proper ventilation systems to manage hazardous fumes.

• Equipment Overview: Safe handling and operation of welding machines, power tools, and workshop accessories.

Module 2: Welding Fundamentals & Engineering Basics

• Process Overview: Introduction to the core welding methodologies: SMAW (Stick), TIG (Gas Tungsten), and MIG (Gas Metal).

• Electrical Principles: Understanding voltage, amperage, and electrical polarity ($AC$, $DCEN$, $DCEP$) in arc stability.

• Materials Science: Introduction to base metals (Carbon steel, Stainless Steel, Aluminum) and proper filler metal/electrode selection.

• Blueprints & Design: Reading standard welding symbols and preparing different joint designs (Butt, Lap, Tee, Corner, Edge).

Module 3: SMAW — Flat Position (1G)

• Electrode Management: Selection, baking, and handling of basic and rutile electrodes (e.g., E6010, E7018).

• Arc Mechanics: Striking the arc, maintaining the correct arc length, and controlling travel speed.

• Bead Formation: Executing clean, uniform weld beads on flat carbon steel plates.

• Troubleshooting: Identifying initial striking defects and mastering slag removal/interpass cleaning.

Module 4: SMAW — Horizontal Position (2G)

• Horizontal Mechanics: Plate and pipe preparation for horizontal alignment.

• Electrode Manipulation: Adjusting work and travel angles to combat gravity.

• Weld Pool Control: Managing the molten puddle to prevent sagging or undercut on the top edge.

• Inspection: Daily practical exercises followed by visual quality assessment.

Module 5: SMAW — Vertical Position (3G)

• Directional Techniques: Master both vertical-up (for structural strength) and vertical-down (for thin sheet metal) welding.

• Gravity Management: Techniques to keep the puddle from dropping out.

• Bead Styles: Practicing weave beads vs. stringer beads to achieve optimal penetration.

• Evaluation: Strict visual inspection for structural uniformity and sound root penetration.

Module 6: SMAW — Overhead Position (4G)

• Advanced Safety: Specific safety protocols to handle overhead sparks and molten metal spatter.

• Heat Input Management: Controlling amperage and travel speed to completely avoid “drop-through.”

• Uniformity: Achieving a flat, well-fused bead profile against gravity.

• Quality Check: Root and face inspection of overhead plate joints.

Module 7: Advanced Pipe Welding (6G Position)

• The 6G Challenge: Introduction to welding a fixed pipe angled at $45^\circ$ — the gold standard for high-paying welder certifications.

• Multi-Pass Sequencing: Detailed execution of the Root pass, Hot pass, Fill passes, and final Cap pass.

• Pressure Piping: Specialized techniques required for oil, gas, and high-pressure steam lines.

• Qualification Practice: Mimicking real-world industrial testing conditions.

Module 8: TIG Welding (GTAW — Gas Tungsten Arc Welding)

• TIG Setup: Assembling torch components, collets, gas lenses, and setting up high-frequency machines.

• Tungsten Preparation: Correct selection and precise grinding angles of tungsten electrodes.

• Gas Shielding: Flow meter settings and purging procedures using pure Argon gas.

• Exotic Metals: Practical hands-on training on Stainless Steel and Aluminum plates and pipes.

Module 9: MIG Welding (GMAW — Gas Metal Arc Welding)

• MIG Setup: Wire spool installation, tension adjustment, and contact tip maintenance.

• Parameter Tuning: Balancing wire feed speed (WFS) and voltage for short-circuit, globular, or spray transfer modes.

• Gas Blending: Using $CO_2$ and Argon mixtures effectively based on metal thickness.

• Productivity Practices: High-efficiency structural welding on mild steel plates.

Module 10: Weld Quality, Defects & Inspection

• Visual Inspection: Learning how to act like an inspector using welding gauges.

• Defect Identification: Root cause analysis and fixes for porosity, undercut, excessive spatter, lack of fusion, and cracking.

• Testing Methodologies: Basics of Destructive Testing (Bend tests) and Non-Destructive Testing (NDT) like Radiography ($X$-ray) and Dye Penetrant ($DP$).

• WPS Reading: Interpreting formal Weld Procedure Specifications used on industrial worksites.

Module 11: Practical Workshop Training & Simulations

• Intensive Boot Camp: Hours of dedicated, supervised shop time to perfect all positions (1G through 6G).

• Industrial Simulations: Working on mock-up structural frameworks and pipe manifolds.

• Time-Bound Tasks: Completing welds under strict industry time limits to build stamina.

• Mock AWS/ASME Tests: Pre-testing students to ensure they pass formal certification criteria.

Module 12: Industry Standards & International Codes

• Global Codes: Introduction to AWS D1.1 (Structural Steel Code) and ASME Section IX (Boiler & Pressure Vessel Code).

• Workplace Readiness: Jobsite hazard awareness, confined space protocols, and lockout/tagout procedures.

• Exam Prep: Theoretical and practical coaching tailored for international employment exams (Middle East, Singapore, Malaysia).

Module 13: Final Assessment & Certification

• Practical Exam: Multi-position welding test scored strictly under code requirements.

• Theory Examination: Comprehensive written test covering safety, metallurgy, and symbols.

• Graduation: Verification of scores and the EuroStar ETTC Certified Professional Welder Certificate distribution ceremony.