Industrial Welding Course

Lesson 1 • Personal Protective Equipment Selection

Teaches correct PPE selection and fit for welding tasks. Connects hazard types to specific protective gear choices.

Lesson 2 • Fire Prevention and Emergency Response

Covers hot-work permits, fire watch procedures, and emergency action plans. Prepares students to prevent incidents and respond effectively when they occur.

Lesson 3 • Hazard Identification in Welding Environments

Covers electrical, thermal, fume, and radiation hazards specific to welding. Builds the risk-awareness foundation required for all subsequent hands-on work.

Lesson 4 • Regulatory Compliance and Documentation

Introduces safety data sheets, inspection records, and industry safety regulations. Students learn to maintain compliant documentation for professional welding operations.

Lesson 1 • Preheat, Interpass, and Post-Weld Heat Treatment

Teaches temperature control strategies that prevent cracking and restore material properties. Students apply heat treatment concepts to practical welding procedures.

Lesson 2 • Metal Properties and Classification

Covers ferrous and non-ferrous metal families, mechanical properties, and industry classification systems. Provides the material knowledge base for all process chapters.

Lesson 3 • Weldability Assessment of Common Metals

Evaluates weldability of carbon steel, stainless steel, aluminium, and cast iron. Students match material characteristics to appropriate welding processes.

Lesson 4 • Heat Effects on Base Metal

Explains heat-affected zones, grain growth, and phase transformations during welding. Students understand why controlled welding heat input is critical to weld quality.

Lesson 1 • Machine Calibration and Parameter Setting

Guides students through setting voltage, amperage, wire speed, and welding polarity. Establishes the parameter-setting discipline needed before every weld.

Lesson 2 • Electrode and Filler Metal Selection

Covers electrode classification systems, storage requirements, and matching filler to base metal. Students select correct consumables for each welding application.

Lesson 3 • Power Source Types and Characteristics

Covers transformer, rectifier, inverter, and engine-driven power sources. Students match power source output characteristics to process requirements.

Lesson 4 • Workstation Assembly and Cable Layout

Teaches proper torch, ground clamp, and cable routing for safe, efficient operation. Reduces arc blow and voltage drop through correct setup practices.

Lesson 1 • SMAW Process Principles

Explains arc physics, electrode coating functions, and slag formation in SMAW. Provides the theoretical basis for all hands-on SMAW practice.

Lesson 2 • Vertical and Overhead Position Welding

Addresses gravity effects on the weld pool in 3F, 4F, and overhead positions. Students adapt electrode angle and welding travel speed to control molten metal.

Lesson 3 • Flat and Horizontal Position Welding

Develops bead-on-plate, fillet, and groove welds in 1F and 2F positions. Builds foundational technique before progressing to out-of-position welding.

Lesson 4 • Electrode Striking and Arc Control

Teaches scratch and tap strike methods, arc length control, and welding travel speed. Students develop consistent arc initiation and maintenance skills.

Lesson 1 • Wire Feed and Gun Technique

Covers contact tip-to-work distance, gun angle, and travel direction. Consistent gun technique is the primary driver of GMAW bead quality.

Lesson 2 • GMAW Troubleshooting and Quality Control

Diagnoses wire feed problems, porosity, weld spatter, and weld burn-through in GMAW. Students apply systematic troubleshooting to restore weld quality quickly.

Lesson 3 • GMAW Process Modes and Transfer Types

Explains short-circuit, globular, spray, and pulse transfer mechanisms. Students select the correct transfer mode for each material and position.

Lesson 4 • Shielding Gas Selection for GMAW

Compares argon, CO2, and mixed gas blends for steel, stainless, and aluminium. Students match gas selection to transfer mode and base metal.

Lesson 1 • Filler Rod Addition and Torch Coordination

Develops two-handed coordination of torch movement and filler rod dipping. Consistent filler addition rate controls bead width, reinforcement, and fusion.

Lesson 2 • GTAW Pipe and Tube Welding

Covers open-root pipe joints, purge gas setup, and positional technique for pipe. Students complete full-penetration pipe welds meeting industry quality standards.

Lesson 3 • GTAW on Aluminium with AC Current

Explains AC cleaning action, balance control, and balled tungsten geometry for aluminium. Students weld aluminium sheet and plate with proper fusion and appearance.

Lesson 4 • GTAW Equipment and Tungsten Preparation

Covers torch types, collet bodies, gas lenses, and tungsten grinding geometry. Proper tungsten preparation directly determines arc stability and bead profile.

Lesson 1 • Submerged Arc Welding Principles

Explains flux blanket shielding, wire electrode feeding, and high-deposition SAW mechanics. Students understand why SAW is preferred for thick, flat-position structural work.

Lesson 2 • FCAW Parameter Optimisation

Guides voltage, wire feed speed, and stick-out adjustment for FCAW. Optimised parameters reduce weld spatter and achieve required mechanical properties.

Lesson 3 • FCAW Process Variants and Wire Types

Distinguishes self-shielded and gas-shielded FCAW and their wire classifications. Students select the correct FCAW variant for field versus shop applications.

Lesson 4 • SAW Setup and Operation

Covers flux hopper loading, lathe carriage alignment, and parameter setting for SAW. Students run straight-seam welds on heavy plate with consistent weld penetration.

Lesson 1 • Destructive Testing and Mechanical Evaluation

Covers bend, tensile, macro-etch, and hardness tests used to qualify welds. Students interpret test results against code acceptance criteria.

Lesson 2 • Welding Procedure Specifications

Explains WPS, PQR, and welder qualification record structure and purpose. Students read and apply a WPS to ensure every weld meets procedural requirements.

Lesson 3 • Industry Codes and Acceptance Standards

Surveys structural, pressure vessel, and pipeline welding code frameworks. Students apply code acceptance criteria to accept or reject completed welds.

Lesson 4 • Visual Inspection Techniques and Tools

Covers weld gauges, magnification, and lighting for systematic visual examination. Visual inspection is the first and most cost-effective quality gate for all welds.