WELDING AND METAL FABRICATION COURSE OUTLINE

Course Overview

The Welding and Metal Fabrication Course at the Zebra Liquid Vocational Institute is a rigorous 1-month intensive program designed to transform beginners into skilled technicians. This course focuses on the art and science of joining metals, covering various welding processes, structural fabrication, and industrial safety. By mastering these technical skills, participants are prepared for high-demand roles in construction, manufacturing, and independent workshop ownership.

Targeting aspiring welders, mechanics, and entrepreneurs, this program balances technical theory with extensive torch-time, ensuring graduates can produce high-quality, structurally sound welds that meet industry standards.

Course Objectives

By the end of the course, participants will:

• Understand the properties of different metals and alloys.

• Master Shielded Metal Arc Welding (SMAW) and an introduction to Gas Metal Arc Welding (GMAW).

• Interpret technical drawings and welding symbols for fabrication.

• Operate industrial cutting and grinding machinery safely.

• Apply quality control measures to identify and prevent weld defects.

• Develop the financial literacy required to manage a fabrication workshop.

Course Structure and Topics

Week 1: Safety, Tools, and Equipment

• Workshop Safety: Personal Protective Equipment (PPE), fire prevention, and electrical safety.

• Introduction to Metal Properties: Differentiating between ferrous and non-ferrous metals.

• Hand and Power Tools: Safe operation of angle grinders, drills, and measuring tools.

• Welding Machine Setup: Understanding Amperage, Voltage, and Polarity.

• Hands-On Practice:

• Setting up a welding workstation.

• Striking an arc and maintaining a consistent weld pool.

Week 2: Welding Techniques and Joints

• Basic Joints: Practicing Butt, Lap, Tee, and Corner joints.

• Welding Positions: Mastering Flat (1G/1F) and Horizontal (2G/2F) positions.

• Electrode Selection: Choosing the right rod (e.g., E6013, E7018) for specific tasks.

• Cutting Processes: Introduction to oxy-acetylene cutting and plasma cutting.

• Hands-On Practice:

• Executing multi-pass welds on mild steel plates.

• Performing "bead-on-plate" exercises to control heat input.

Week 3: Fabrication and Structural Assembly

• Reading Blueprints: Translating 2D sketches into 3D metal structures.

• Tacking and Fit-up: The importance of alignment and temporary welds.

• Distortion Control: Learning how to prevent metal warping during the cooling process.

• Finishing Techniques: Grinding, polishing, and anti-corrosion coating (painting/priming).

• Hands-On Practice:

• Fabricating a small utility project (e.g., a metal stool or window grill).

• Correcting distortions using heat and mechanical methods.

Week 4: Quality Assurance and Business Management

• Weld Inspection: Visual testing for porosity, undercut, and slag inclusion.

• Project Costing: Calculating material wastage, gas usage, and labor hours.

• Customer Relations: Quoting jobs and managing client expectations.

• Workshop Logistics: Inventory management and sourcing raw materials.

• Hands-On Practice:

• Final project: Designing and building a custom metal product.

• Conducting a "stress test" on welded joints to evaluate strength.

Training Approach

• Trainer-Learner Ratio: 1 trainer per 30 learners (with dedicated assistants for safety monitoring).

• 80% Practical Learning: Most of the day is spent in the welding booths.

• Follow-Up Support:

  • 6 months of mentorship for workshop setup and technical troubleshooting.

  • Assistance in sourcing reliable equipment and affordable raw materials.

  • Connections to local construction firms and industrial hubs.

Assessment and Certification

Participants will be assessed through:

1. Practical Weld Test: A "Bend Test" or visual inspection of a standardized joint.

2. Fabrication Project: Completion of a functional metal product from a technical drawing.

3. Graduates will receive a Certificate of Competency in Welding and Metal Fabrication from Zebra Liquid Vocational Institute, with pathways for DIT/Trade Test certification.

Community Impact and Market Access

Welding is the backbone of infrastructure. By training local youth and entrepreneurs, we reduce the community's reliance on imported metal products and create high-earning local jobs. Graduates gain access to the VSLA program for startup toolkits (welders, grinders, safety gear) to launch their own businesses.

Why Choose Zebra Liquid for Welding Training?

• Industry Standard Gear: Training on modern inverter and transformer welding machines.

• Focus on Durability: We teach you how to build structures that last a lifetime.

• Safety First: A rigorous culture of safety that prepares you for high-stakes industrial environments.

• Entrepreneurial Edge: We don't just teach you how to weld; we teach you how to run a shop.

Ignite your career with Zebra Liquid's Welding Course. Build the structures of tomorrow, today.