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Arc and gas welding syllabus KBSM

MINISTRY OF EDUCATION MALAYSIA

SYLLABUS FOR

SECONDARY SCHOOL INTEGRATED CURRICULUM

ARC AND GAS WELDING

CURRICULUM DEVELOPMENT CENTRE


MINISTRY OF EDUCATION
KUALA LUMPUR
2004

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Syllabus Planarian Arc and Gas Welding KBSM

Introduction

Arc and Gas welding is one of the elective vocational subjects offered in the
upper secondary school under the Secondary School Integrated Curriculum
(KBSM). Pupils learning this subject will master the skills of cutting and joining
metals by using arc and gas welding as well as MIG welding. This is an
expansion of the Integrated Living Skills subject which was learnt in lower
secondary. Arc and Gas welding is part of the Ministry of Educations effort to
prepare pupils to become competent workforce especially in the manufacturing
industry. It is hoped that they will practise positive attitude and be alert of welding
technology development.

In this subject, pupils will master the skills in metal welding through three
methods which are arc, gas and MIG welding. By applying the basic principles,
pupils can practice their skills in cutting, joining, identifying and overcoming the
welding defects. Pupils will also be able to use and maintain various welding
equipment and machines. Other than using heat transfer welding works, pupils
will also gain experience in metal fabrication works. Through their career project,
pupils are given the opportunities to design and repair the metal-based materials.
Safety precautions are always emphasized in welding.

This subject is specially designed for pupils who are interested in welding. The
skills and experiences gained will enable them to pursue their career as welders
in manufacturing, petrochemical,and shipping industries or starting their own
business.

Aim

The aim of this subject is to produce skilled pupils especially in cutting, forming
and welding using the arc and gas welding techniques, as well as to produce
pupils with healthy working habit, positive working attitude and able to contribute
in the manufacturing industry.

Objective

Arc and Gas welding subject enables pupils to:-

1. Cut, form and join metal by using arc, gas and MIG welding

2. Form and join metal fabrication work

3. Install, set and use welding equipment

4. Cut pieces of metal in straight and oblique forms by using oxyacetylene


gas cutting torch

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Arc and gas welding syllabus KBSM

5. Use and maintain the welding equipment and machines

6. Design and produce welding projects

7. Practice safety precautions and healthy working ethics

8. Work in organized manner, record stock and communicate effectively

9. Prepare a simple business plan

CONTENT ORGANISATION

Arc and Gas Welding subject is divided into six learning areas. Each area is
divided into one learning unit which comprises of several topics. The list and
descriptions of the six learning areas are as follow:

1. Workplace Management

In this area, pupils will be introduced to various welding processes and


career prospects. They are trained to practise safety precautions during
welding activities. Besides that, they must possess good working ethics,
follow the rules and regulations. They must also conserve the environment
where welding is concerned. Pupils need to do stock inventory and
maintain all equipment and machines used.

1.1 Welding Introduction


a. Type of welding
b. Career prospects

1.2 Workshop Organization


a. Safety rules and precautions
b. First Aid
c. Fire extinguishing methods
d. Working ethics
e. Work rules and regulations
f. Conservation of environment where welding is concerned

1.3 Stock Management and Maintenance


a. Stock management and inventory
b. Maintenance of equipment and machines

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Syllabus Planarian Arc and Gas Welding KBSM

2. Welding Equipment and Machines

Here, pupils are exposed to various arc and gas welding equipment and
how to use them for measuring, marking, cutting and testing. Pupils are
also trained to use and maintain the various types of machines such as
forming and power machines. Safety precautions must always be taken
into consideration while handling these machines. They will also learn
metal fabrication and joining of metals without using any heat source.

2.1 Arc and Gas Welding Equipment


a. Hand tools
b. Marking equipment
c. Measuring equipment
d. Cutting equipment
e. Testing equipment

2.2 Forming Machine


a. Folding machine
b. Slip roll machine

2.3 Power Machine


a. Grinding machine
b. Drilling machine
c. Disc cutter / abrasive cut off machine
d. Hand lever shears
e. Squaring shears

2.4 Metal Fabrication Joints

a. Bolts and nuts


b. Various screws
c. Blind rivet

3. Arc Welding Skills

Here, pupils will be introduced to basic electricity and arc welding


principles. They will practice their skills to join plates and galvanized pipes
by using arc welding skills. They are trained to identify and repair welding
defects.Safety is always the priority during welding processes.

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Arc and gas welding syllabus KBSM

3.1 Basic Electricity

a. Alternating current (AC) and direct current (DC)


b. Current and voltage
c. Rectifier and polarity
d. Transformer

3.2 Arc Welding

a. Arc welding principles and safety


b. Equipment and installation of arc welding
c. Electrode classification
d. Arc welding basic joints
e. Welding position
f. Arc welding on carbon steel plate
g. Joint welding on carbon steel plate
h. Pipe welding on carbon steel plate

3.3 Arc Welding Defects

a. Type of welding defects


b. Ways to overcome defect

4. Oxyacetylene Gas Welding Skills

Pupils learned the principles of oxyacetylene gas welding and practice


them in joining carbon steel processes by using oxyacetylene gas welding.
They are also able to develop skills in metal cutting process using
oxyacetylene cutting torch either manually or semi-automatically.They are
trained to identify and to repair welding defects.

4.1 Oxyacetylene Gas Welding

a. Safety precautions and principles of oxyacetylene gas


welding
b. Equipment and installation of oxyacetylene gas welding
c. Types of oxyacetylene flames
d. Oxyacetylene gas welding basic joints
e. Welding position
f. To weld 1.5 mm to 2.0mm carbon steel plate without filler
rod
g. To weld 1.5 mm to 2.0mm carbon steel plate with filler rod.
h. Brazing process

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4.2 Oxyacetylene Gas Cutting

a. Manual cut
b. Semi-automatic cut

4.3 Oxyacetylene gas welding defects

a. Type of welding defects


b. Ways to identify welding defects

5.0 Metal Inert Gas (MIG) Welding

Pupils are exposed to the latest technology in manufacturing industry


which interrelated to MIG welding. Safety is always the priority during
welding processes.

5.1 Introduction to MIG Welding

5.2 MIG Welding Skills

a. Equipment and installation of MIG Welding


b. To weld 1.5 mm to 3.0 mm carbon steel plate

6. Entrepreneurship and Project Career

In this lesson pupils are exposed to communicative and decision making


skills. They have to prepare a business plan and identify the business
opportunities in welding before carrying out their career projects.

6.1 Entrepreneurship
a. Communicative skills
b. Decision making skills
c. Business planning
d. Agencies which assist entrepreneurs
e. Marketing
f. Job opportunities in relevant field

6.2 Career Project


a. Plan and design career project
b. Estimated costs
c. Produce career project

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