Metal Fabrication Course

Lesson 1 • Reading Fabrication Drawings

Teaches orthographic projection, dimensioning, and tolerance notation used on shop drawings. Accurate drawing interpretation is prerequisite to all layout and cutting tasks.

Lesson 2 • Shop Safety and Personal Protection

Covers hazard identification, PPE selection, and emergency procedures. Establishes the safety mindset required throughout all fabrication work.

Lesson 3 • Measurement and Layout Tools

Covers precision measuring instruments and layout techniques for transferring drawing dimensions to raw stock. Accurate layout prevents costly material waste.

Lesson 1 • Filing, Deburring, and Finishing

Teaches file selection, stroke technique, and surface finishing to achieve smooth, safe edges. Proper finishing prepares parts for assembly and coating.

Lesson 2 • Drilling and Tapping by Hand

Introduces hand drilling, tap-and-die threading, and hole layout for fastener installation. These skills support mechanical assembly in all fabrication projects.

Lesson 3 • Cutting with Hand Tools

Covers hacksaws, aviation snips, and cold chisels for manual metal cutting. Proper technique reduces burrs and maintains dimensional accuracy.

Lesson 1 • Power Tool Maintenance Basics

Teaches inspection routines, lubrication schedules, and pre-use checklists for all shop power tools. Preventive maintenance extends tool life and prevents accidents.

Lesson 2 • Band Saw and Cold Saw Use

Introduces blade selection, fence setup, and feed technique for straight and contour cuts. Saw selection depends on material type and required cut quality.

Lesson 3 • Drill Press Operations

Teaches speed selection, feed rate, and workholding on the drill press for accurate hole placement. Drill press use extends hand-drilling skills to heavier stock.

Lesson 4 • Angle Grinder Safety and Technique

Covers wheel selection, guard adjustment, and controlled grinding strokes. Proper technique prevents wheel failure and maintains workpiece geometry.

Lesson 1 • Plasma Cutting Technique and Quality

Covers travel speed, arc angle, and cut quality evaluation for plasma processes. Proper technique minimizes dross and heat-affected zone width.

Lesson 2 • Thermal Cutting Safety and Fume Control

Addresses fire prevention, fume extraction, and hot-metal handling for all thermal cutting operations. Fume and fire hazards are highest during cutting processes.

Lesson 3 • Oxyfuel Cutting Fundamentals

Covers gas cylinder handling, regulator setup, and torch lighting for oxyfuel cutting. Safe gas management is the foundation of all flame-based processes.

Lesson 4 • Oxyfuel Cutting Technique

Teaches preheat time, travel speed, and kerf control for straight and bevel cuts. Consistent technique produces clean edges that require minimal post-cut finishing.

Lesson 1 • MIG Welding Setup and Technique

Teaches wire selection, shielding gas, voltage, and wire feed speed for GMAW. MIG welding is the most common production process in fabrication shops.

Lesson 2 • TIG Welding Fundamentals

Introduces tungsten preparation, filler rod selection, and foot-pedal amperage control for GTAW. TIG welding produces the highest-quality welds on thin and critical materials.

Lesson 3 • Weld Inspection and Defect Correction

Teaches visual inspection criteria, common defect identification, and repair methods. Defect recognition prevents structural failures in finished fabrications.

Lesson 4 • Shielded Metal Arc Welding

Covers electrode selection, machine setup, and bead technique for SMAW on carbon steel. SMAW is the baseline process for understanding arc welding fundamentals.

Lesson 1 • Bend Allowance and Springback

Covers bend allowance formulas, K-factor, and springback compensation for accurate formed parts. Correct calculations prevent scrap and rework on expensive stock.

Lesson 2 • Roll Forming and Plate Rolling

Introduces three-roll and four-roll machine setup for producing cylinders and cones. Roll forming is essential for tanks, pipes, and curved structural members.

Lesson 3 • Tube and Pipe Bending

Covers mandrel bending, rotary draw bending, and bend radius selection for tube and pipe. Proper technique prevents wall thinning and collapse at the bend.

Lesson 4 • Forming Defects and Correction

Identifies cracking, wrinkling, and orange-peel defects and their root causes. Corrective actions restore part geometry and prevent recurrence in production.

Lesson 1 • Distortion Control and Sequencing

Covers weld sequence planning, backstep welding, and pre-setting to minimize thermal distortion. Distortion control is critical for maintaining tolerances in large weldments.

Lesson 2 • Assembly Inspection and Documentation

Teaches dimensional inspection, weld map completion, and nonconformance reporting for finished assemblies. Proper documentation supports quality traceability and customer acceptance.

Lesson 3 • Fixturing and Jig Design

Introduces strongbacks, angle plates, and custom jigs for holding parts during assembly. Fixtures maintain geometry and reduce rework caused by weld distortion.

Lesson 4 • Fitup Principles and Gap Control

Covers root gap, land, and mismatch tolerances for weld joint fitup. Correct fitup directly controls weld quality and reduces post-weld distortion.

Lesson 1 • Coating Inspection and Maintenance

Teaches holiday testing, adhesion testing, and touch-up procedures for coated fabrications. Inspection confirms coating integrity before parts enter service.

Lesson 2 • Primer and Paint Application

Covers primer selection, spray gun setup, and topcoat application for industrial coatings. Correct application technique prevents runs, sags, and adhesion failures.

Lesson 3 • Chemical Cleaning and Passivation

Introduces degreasing, acid pickling, and passivation for stainless steel and aluminum. Chemical treatments remove oxides and restore corrosion resistance after welding.

Lesson 4 • Hot-Dip Galvanizing and Powder Coating

Introduces galvanizing process requirements and powder coat application for heavy-duty corrosion protection. These processes require specific design and preparation considerations.