8 

      
(Perform Basic Welding Operations)
 

  
    
 
(Flames Produce different types of Oxy Acetylene Flames)    
 

  1
 

(Perform Oxy Acetylene Welding)       2
(Perform oxy-acetylene Flame Cutting Operations) 3
Perform Shielded Metal Arc Welding (SMAW) 4
(Perform Brazing Operation) 5
(Perform Post Welding Operations) 6

1  2 (General Fitter Basic)   

 1


  


  
(Produce different types of Oxy Acetylene Flames)
  
 

 



      
 

  

  (flame)   
  (Neutral flame)  
  (Carburizing flame)    
   (Oxidizing flame)    
 
 

       (Technique)  (heat)   

          
(Oxy Acetylene welding)     

 

 
       (Technique)  (heat)   
 (welding flame)         (oxy acetylene)  
 

       
     
 
        (oxy acetylene) 
   
        
  3200 
         (oxy acetylene)  

 -      
    
                 
   
       

(Types of Flames in Gas Welding)    

,   

(Neutral flame)  1

(Carburizing flame)   2

(Oxidizing flame)   
  3

 
   
      
 

 Oxy Acetylene        


(Neutral Flame) 
 (Neutral)   (chemically)   
 

 

2  2 (General Fitter Basic)   

   
  
                    


   Flame   (acetylene gas)
            
 

  
      (on)  
 
  ) ( (neutral flame) 
 (Envelop) 
         
 

 
 


 
 
 
  (aluminum)   (Cast iron)  (stainless steel)
      (neutral flame) 
    )  300  (3      000  6      
  
 
( Carburizing flame)    

   (neutral flame)
 
 
  (carburizing flame)    

  
    
           
 
         
  
     
 

 
   800  2     000  5     
 

  carbonize     

 
 
 (  (zone)   

  )  
       
 


             
 
   

 
   "     soft flame         (iron oxide)        

3  2 (General Fitter Basic)   

 
 

 (soft soldering) (Aluminum alloy)      "(reducing flame)
    (hard facing metals) 
Oxidizing flame     3

        (oxidizing flame)   
 
     
                

 
      (neutral flame)  (oxidizing flame)    
     
 
      
 


    


      
               
 

      
      
 
     (applications)
  
          
 

     (mechanical detriment)     
 (zinc compound)      (bronze)      

4  2 (General Fitter Basic)   

 2


    


 
(Perform Oxy Acetylene Welding)
  
 

  

      
 

  
       
     
       

     
  
  
  
 

        
       
    
(Advantages of Oxy Acetylene Welding)      

 

 
                 
         
 

          
 
     
       
         

      


  

(disadvantages of Oxy Acetylene Welding)    
  
       

    
 

       
     

Tool & Equipments 

(Gas Cylinders)  
         
 

    
 

5  2 (General Fitter Basic)   

 (Regulator)

        

(Welding Torch)   

                 

 

      
   

  
        
   1200   

   

    



 -  


            


  (oscillate)          


(Types of Welding Joints)    

         
(Butt Joint)   1


(Corner Joint)   2

"L"   

(T-Joint)   3
      
"T"        

    
(lap Joint)   4

    

6  2 (General Fitter Basic)   

 (Edge Joint )    5

            

      

 
\     
    1
\    2
    3
    
 

     4
  5
 /     6
      7
        8
    9
     10
     11
  
     12
 
      13
     14
     15
       16
      17
       18
 0     19
    20

7  2 (General Fitter Basic)   

 1 
    ) (Oxy Acetylene Welding      

         
(Butt Joint)  1
(Lap Joint)   2
(Corner Joint)   3
(T- Joint)  4
(Edge Joint)   5

8  2 (General Fitter Basic)   

 3
     
 

 
(Perform Oxy Acetylene Flame Cutting Operations)
  
 

 




   
   

  


   
  
     

  
(Oxy Acetylene Flame Cutting)    
 

 
    
            
        
   


          

  
   
"  "                 
  
 

          "    "    
       molten slag      
     
 

        
    low alloy steel       
  ) (50  2 
        
             

  economical          

         ) (900  35    


(Oxyfuel Cutting Advantages and Disadvantages)

 Advantages
       1
    

         
    2

    3
  4

        
  5
      6

9  2 (General Fitter Basic)   

  Disadvantages
      1
    
 2
 
     3

10   2 (General Fitter Basic)   

  
     1 
   2 
 

   
       

 

 
      



preheating   3 

 
  kindling       

    


  4 
   narrow      

 
  "    " 
5 
 oxidizing       

   
    
 

   6
 molten slag 
     

    
 7 
       
 

     

11   2 (General Fitter Basic)   

 2 
       


      
  ) (Oxy Acetylene Flame Cutting    
 

12   2 (General Fitter Basic)   

 4
    
(Perform Shielded Metal Arc Welding (SMAW)
  
    

   
     
  Consumables  WPS 
 WPS 
    2F,2G 1F,1G    
       
(Safety Preaction for Drilling)   

    1
  2
    
 3
   4
      5
     
 6
     7
(SMAW Process) SMAW

                              

 (SMAW)Shielded Metal Arc Welding
 
              Coated Electrode
  

             
                   


           
 

13   2 (General Fitter Basic)   

    6000C5000 C(9000 F)   SMAW
Steel Stainless, Low Alloy     
    
        SMAW   Steel

(Advantages of SMAW)  SMAW

      Equipment -1

       -2


  (Flux) (Granular)     -3

  -4

 Alloys     -5

     SMAW

  -6
(Disadvantages of SMAW)  SMAW
 Fume   SMAW -1

    inclusion Slag -2

     -3

(Equipment)    SMAW

    (Equipment)    SMAW

(Power Source) 
(Electrode Holder) 
(Welding Cables) 
  
 
 Earth Clamp  

  
(Welding Both)   
 

 
 
 
(Burner Plier)   
Personal Protective Equiment (PPE's) 

14   2 (General Fitter Basic)   

 (SMAW Power Sources) SMAW

             


   -1

    -2
   -3

(Welding Transformer)    

        

           

 Static       

 (Alternating Current)   
 


  
(Welding Rectifier)   

    DC AC      
   

            
  Polarity  (Reverse)   (Straight)  
 

(Welding Generator)  

                         

  D óC  A óC                  
  

15   2 (General Fitter Basic)   

 (Electrode Holder) 

        (Conduct)    


   (Amp) 

(Earth Clamp)  

 

 Workpiece       Workpiece 
     
 

      



(Welding Booth)  

                 

                 
       
 

(Lighting)

                
       

(Cutting Tools)  

    

 
(Gas Cutter) 1

  Acetylene   Low Alloy Steel  

            

16   2 (General Fitter Basic)   

    

(Shearing Tools/Machines)  / 2

               (Shearing) 

    

(Hand Grinder)  3

    (Angle Grinder)     
  
      (Bench Tools)   
  

(Wire Brush)

              


   

17   2 (General Fitter Basic)   

  
  
 1

       2
  (Single V Butt Joint)        /  W óP óS  4
 
      5

   
 6
    -7

               SMAW
 DC AC         
 
       (Flow) 

 
  


 
   
 


  


 "A"         



 


 "V"         
  

 


      
    
 

(Resistance)

    

 ohm    

  

 
     

  
 
  
   
 AC

  
    

    (Fix) AC 

 DC
        
            
 
         
(Polarity)

                   D/C
     

18   2 (General Fitter Basic)   

 (Stright Polarity)

    DC

(Reverse Polarity) 

    DC

    SMAW

       SMAW
     1
      2
(Work angle = 90 and Travel Angle = 70-80 )
    3
   3mm2      4
        5
       6
     7
          8

        

 9
      10
   11
     12

19   2 (General Fitter Basic)   

 1
     
(Make T-Joint in Flat by using SMAW process)
  
  
 -9 -8  -7
   -6 -5  -4   -3 -2  -1

  -13-12 -11 -10


      -1

       -2

    -3

  (1F)    -4

    -5

   8070       -6

      1F   -7

        -8


                 
      -1

 
     -2

      

  -3

   
      -4

   
       -5

   -6

20   2 (General Fitter Basic)   

 2
     
(Make Butt-Joint in Flat by using SMAW process)
  
  
-10  -9  -8  -7  
   -6  -5     -4     -3    -2  
    -1

-11


      -1

       -2

    -3

  (2F)     -4

   -5

         -6

   (2F) SMAW -7

        -8


                 
      -1

 
     -2

      

  -3

   
      -4

   
       -5

   -6

21   2 (General Fitter Basic)   

 5

Perform Brazing Operations

  
 

 



    

   joints   

    flux 
 Oxidation 


        brazing  
      technique           
    


   

        melting agent   


         


(Important Terminologies)   

    Base Metal

         Filler Metal

 
unwanted oxidation            : Flux
   
 :  Joint

       :  Brazing Temperature

           :   
  Capillary Action

     : 
  Oxidation

   
  1 
   Base Metal
   Filler Metal
 
 unwanted metal oxidation       Flux

22   2 (General Fitter Basic)   

 2 
 oxidation)       


  3 

position   joint     

 4 
       ) Filler Metal (
  5 
    ) Filler Metal (      

     6 

   material   ) Filler Metal (
 7 
   

23   2 (General Fitter Basic)   

 6
   
(Perform Post welding Operations)
  
 

 



  (Dressing)  
  (Dressing)   
 
  (Polishing) 
  
  
 
  (Pickling) 

  (Post-Inspection)
    

  
  Post welding Operations            
           


Post welding Operations     

(Dressing) 

           


(Grinding) 
           


(Polishing) 

                  


 
(Pickling)  
 
                    
  
(Post-Inspection)   

               

 

24   2 (General Fitter Basic)   

  

25   2 (General Fitter Basic)   

   

 

     1
  
       
   
 
  
  
      2
  
      
    
  
     3
    
 
        
  
      4
          5700      
   
  
        5
     
                 
      
 
 
   
        6
 
   
             
   
          7
 
    
                   
  
          8
  
                
  
        9
   
              
     
  
      10
  

               
  
        11
   
         

     
  
   12
    
  
      5700        
      13

              
 
        14


            


       15

         
      16

26   2 (General Fitter Basic)   

                
     17

           

 
  
         18
           
   19
           
     20

 
        
    21
    (filler metals)   
     22
               
     23
 
  

   1500  1100      
 

    24

  oxidation          

27   2 (General Fitter Basic)   

   
          



     1

 
 

      )  

  
 
   
  
   

 
       2
        
       


 

        3
     
   
 

       4
 300       
 5000   1000 
 

       5
     
        
 
 
 

     6
  
 

     

     
 
 

      7
  




  
    
 
   
  
 8

 
      
      

 
    

   9
           

    
 
 
    

 
    
  10

       
        



       

    11
      

 
      

28   2 (General Fitter Basic)   

      12
     
    
 
  
    
  13
      

      
      14
     
    
          15
       
  

     
          16
       
 

  
 
 
     
      17
      

  
   

    
 
  18
       


  
 

 
 19
    
    
     20
 
 
      
   




   

29   2 (General Fitter Basic)   

  

 
 1

 2

 3

 4

 5

 6

 7

 8

 9

 10

 11

 12

 13

 14

 15

 16

 17

 18

 19

20

30   2 (General Fitter Basic)   