Beginner Welding Course

Lesson 1 • Shop Layout and Equipment Handling

Orients students to a welding shop: workstation zones, tool storage, and emergency exits. Safe material and cylinder handling is introduced here.

Lesson 2 • Recognising and Controlling Welding Hazards

Identifies electrical, fire, fume, and radiation hazards common in welding. Students apply hazard controls to reduce risk before starting any weld.

Lesson 3 • Personal Protective Equipment Essentials

Covers required PPE for welding: helmets, gloves, jackets, and boots. Connects proper gear selection to burn, UV, and fume injury prevention.

Lesson 4 • Safety Standards and Documentation

Introduces industry safety standards and the role of safety data sheets. Students learn to read hazard labels and complete basic incident reports.

Lesson 1 • Hand Tools and Measuring Instruments

Introduces grinders, chipping hammers, wire brushes, and measuring tools. Accurate measurement and surface prep are foundational to weld quality.

Lesson 2 • Cutting Equipment and Techniques

Covers plasma cutters, angle grinders, and oxy-fuel cutting for stock preparation. Clean, accurate cuts reduce fit-up problems and improve weld quality.

Lesson 3 • Joint Fit-Up and Tack Welding Preparation

Explains how to align, clamp, and tack weld parts before full welding. Proper fit-up prevents distortion and ensures dimensional accuracy in finished welds.

Lesson 4 • Reading and Interpreting Metal Specifications

Teaches how to read mill certifications and material markings. Students match specifications to job requirements before cutting or welding.

Lesson 1 • Welding Positions Flat Through Overhead

Introduces 1G through 4G plate positions and 1F through 4F fillet positions. Position awareness shapes technique choices in all process chapters that follow.

Lesson 2 • Introduction to Weld Symbols

Teaches the reference line, arrow, and tail components of weld symbols. Students interpret simple symbols on drawings to set up joints accurately.

Lesson 3 • Weld Types: Groove, Fillet, and Plug

Distinguishes groove welds, fillet welds, and plug welds by geometry and function. Students match weld type to joint design in preparation exercises.

Lesson 1 • Flat and Horizontal Fillet Welds

Applies arc control skills to 1F and 2F fillet welds on T-joints. Students achieve specified leg size, fusion, and consistent profile through repetition.

Lesson 2 • SMAW Equipment Setup and Inspection

Covers transformer and inverter power sources, electrode holders, and work clamps. Correct setup prevents arc instability and equipment damage from the first strike.

Lesson 3 • Electrode Selection and Storage

Explains AWS electrode classification, coating types, and moisture control. Proper electrode choice and storage directly affect bead quality and mechanical properties.

Lesson 4 • Striking an Arc and Running Beads

Teaches scratch-start and tap-start techniques, travel angle, and work angle. Consistent bead geometry is developed through structured flat-position practice.

Lesson 1 • GMAW Equipment and Wire Feed System

Covers wire feeders, drive rolls, liners, and contact tips. Proper setup of the wire feed system prevents feeding problems that cause arc instability.

Lesson 2 • Transfer Modes and Parameter Selection

Distinguishes short-circuit, globular, and spray transfer and their voltage-amperage ranges. Students select transfer mode to match material thickness and position.

Lesson 3 • GMAW Flat and Horizontal Welds

Applies parameter knowledge to fillet and groove welds in 1F, 2F, and 1G positions. Students achieve consistent bead profile, fusion, and specified dimensions.

Lesson 4 • Flux-Cored Arc Welding Introduction

Introduces FCAW-G and FCAW-S wire types, polarity differences, and slag removal. Students compare FCAW bead characteristics to GMAW on identical joints.

Lesson 1 • GTAW on Aluminium with AC Current

Introduces AC balance and frequency controls for aluminium oxide cleaning action. Students weld aluminium butt joints and observe puddle behaviour differences from steel.

Lesson 2 • GTAW on Carbon Steel and Stainless

Applies DCEN technique to flat fillet and butt welds on mild steel and stainless. Students control heat input to prevent distortion and discolouration.

Lesson 3 • Filler Rod Handling and Dip Technique

Develops the two-handed skill of feeding filler rod while maintaining arc length. Consistent dip rhythm prevents tungsten contamination and porosity.

Lesson 4 • Tungsten Preparation and Arc Starting

Teaches grinding, balling, and truncating tungsten for different materials and currents. Proper tungsten geometry controls arc focus and prevents contamination.

Lesson 1 • Root Cause Analysis and Corrective Action

Teaches a structured approach to tracing defects back to process, parameter, or technique errors. Students document findings and adjust procedures to prevent recurrence.

Lesson 2 • Introduction to Non-Destructive Testing

Surveys dye penetrant, magnetic particle, and ultrasonic testing at an awareness level. Students understand when each method is specified and what it detects.

Lesson 3 • Common Weld Discontinuities and Defects

Identifies porosity, undercut, overlap, incomplete fusion, and cracks by appearance and cause. Defect recognition enables corrective action before parts are rejected.

Lesson 4 • Destructive Testing Methods

Introduces bend tests, nick-break tests, and macro-etch examination for weld evaluation. Students perform guided destructive tests to verify internal weld quality.

Lesson 1 • Overhead Welding Techniques

Applies arc control and body positioning to 4F and 4G overhead welds. Reduced amperage, faster travel, and PPE awareness are emphasised for safety and quality.

Lesson 2 • Capstone Project: Fabricated Assembly

Students design, fit up, and weld a multi-joint steel assembly using at least two processes. The project is evaluated against dimensional, visual, and destructive test criteria.

Lesson 3 • Pipe and Tube Introduction

Introduces 1G rolled and 2G fixed pipe positions as an extension of plate skills. Students practise root pass and fill pass on small-diameter carbon steel pipe.

Lesson 4 • Multi-Process Skill Comparison

Students weld identical joints using SMAW, GMAW, and GTAW to compare results. Process selection criteria based on speed, access, and quality are evaluated.