Basic Welding Course

Lesson 1 • Overview of Joining Process Categories

Surveys fusion welding, solid-state welding, brazing, soldering, and mechanical fastening. Provides a classification framework used throughout the course.

Lesson 2 • Core Welding Terminology

Defines essential vocabulary used across all welding processes. Precise terminology enables accurate reading of procedures, drawings, and standards.

Lesson 3 • Welding Safety Fundamentals

Covers hazard identification, personal protective equipment, and ventilation requirements. Safety compliance is prerequisite to all hands-on welding activities.

Lesson 4 • Physics of Heat and Fusion

Explains thermal energy transfer, melting points, and solidification behaviour in metals. Understanding heat flow predicts distortion and weld quality outcomes.

Lesson 1 • Non-Ferrous Metal Weldability

Addresses aluminium, copper, titanium, and nickel alloy characteristics affecting welding. Each metal family requires specific process adjustments covered in later chapters.

Lesson 2 • Steel Metallurgy for Welders

Explains carbon content, alloying elements, and phase transformations in steel. Metallurgical insight prevents cracking and controls mechanical properties in welds.

Lesson 3 • Filler Metal Selection Principles

Explains matching and over-matching filler strategies, classification systems, and storage requirements. Correct filler selection is critical to joint integrity and code compliance.

Lesson 4 • Mechanical and Physical Properties

Covers tensile strength, ductility, hardness, and thermal conductivity as they relate to weldability. Property knowledge predicts joint performance under service loads.

Lesson 1 • Engineering Drawing Fundamentals

Reviews orthographic projection, views, and dimensioning conventions used in fabrication drawings. Drawing literacy is prerequisite to interpreting weld symbol placement.

Lesson 2 • Joint Types and Groove Geometry

Identifies butt, T-, corner, lap, and edge joints and their groove configurations. Joint geometry directly determines fit-up requirements and welding sequence.

Lesson 3 • Weld Symbol Anatomy

Decodes the reference line, arrow, tail, and supplementary symbols per standard notation. Mastery of symbol anatomy enables accurate weld preparation and execution.

Lesson 4 • Bill of Materials and Fit-Up Documents

Covers material take-offs, assembly drawings, and fit-up inspection records. Accurate document use reduces rework and supports quality management systems.

Lesson 1 • Electrode Classification and Selection

Decodes electrode classification numbers and matches electrodes to base metal and position. Electrode choice determines mechanical properties, slag behaviour, and deposition rate.

Lesson 2 • Arc Striking and Bead Techniques

Develops scratch-start and tap-start methods, travel angle, and bead manipulation skills. Consistent technique produces uniform bead profile and fusion at the root.

Lesson 3 • Welding in Multiple Positions

Applies MMAW technique to flat, horizontal, vertical, and overhead positions. Positional welding demands adjusted parameters and body mechanics for quality results.

Lesson 4 • Common MMAW Defects and Remedies

Identifies porosity, undercut, overlap, and incomplete fusion causes and corrective actions. Defect recognition and correction are essential before advancing to other processes.

Lesson 1 • Shielding Gas Selection and Flow

Covers argon, CO2, and mixed gas blends and their effects on arc characteristics and spatter. Gas selection directly impacts bead appearance, penetration, and cost.

Lesson 2 • GMAW and FCAW Quality Control

Addresses burn-through, porosity, cold lap, and wire feed irregularities with systematic troubleshooting. Quality control skills reduce scrap and rework in production environments.

Lesson 3 • GMAW Equipment and Wire Feed Systems

Explains wire feeder mechanics, drive roll selection, and gun liner maintenance. Reliable wire delivery is the foundation of stable GMAW arc performance.

Lesson 4 • Flux-Cored Arc Welding Fundamentals

Introduces self-shielded and gas-shielded FCAW wire types, polarity, and slag removal. FCAW extends deposition rates and outdoor usability beyond standard MIG welding.

Lesson 1 • Tungsten Electrode Preparation

Explains tungsten alloy types, grinding geometry, and contamination effects on arc quality. Correct tungsten preparation is the single greatest factor in TIG welding arc stability.

Lesson 2 • GTAW Defect Analysis and Correction

Identifies tungsten inclusions, porosity, lack of fusion, and crater cracks with root causes. Defect analysis skills support qualification testing and production quality assurance.

Lesson 3 • TIG Welding on Stainless Steel and Aluminium

Applies process adjustments for austenitic stainless and aluminium alloys including purging and AC balance. Material-specific technique prevents sensitisation, porosity, and oxide inclusions.

Lesson 4 • Manual Torch and Filler Technique

Develops two-handed coordination of torch angle, arc length, and filler rod dipping. Consistent technique produces uniform ripple pattern and full fusion without contamination.

Lesson 1 • Torch and Furnace Brazing Methods

Compares torch, furnace, and induction brazing for production and repair applications. Method selection balances joint geometry, volume, and base metal sensitivity.

Lesson 2 • Flux Selection and Application

Covers flux chemistry, application methods, and post-braze cleaning requirements. Proper flux prevents oxidation during heating and ensures complete filler flow.

Lesson 3 • Solid-State Welding Processes

Introduces friction, ultrasonic, diffusion, and explosion welding mechanisms and applications. Solid-state processes join materials without melting, preserving base metal properties.

Lesson 4 • Brazing Principles and Filler Alloys

Explains capillary action, liquidus temperature, and filler alloy families for brazing. Brazing fills gaps without melting base metal, enabling joining of dissimilar materials.

Lesson 1 • Visual Inspection Techniques

Covers pre-weld, in-process, and post-weld visual examination using gauges and lighting. Visual inspection is the first and most cost-effective quality gate in any welding operation.

Lesson 2 • Non-Destructive Testing Methods

Introduces liquid penetrant, magnetic particle, ultrasonic, and radiographic testing principles. NDT method selection depends on defect type, material, and access constraints.

Lesson 3 • Destructive Testing Methods

Explains tensile, bend, macro-etch, Charpy impact, and hardness tests for weld qualification. Destructive testing validates procedure and welder qualification before production begins.

Lesson 4 • Quality Management in Welding Operations

Applies quality planning, traceability, nonconformance reporting, and corrective action systems. Systematic quality management reduces defect rates and supports continuous improvement.