Metal Processing Instructor's Guide Level I and Ii

REPUBLIC OF KENYA
NATIONAL VOCATIONAL CERTIFICATE OF EDUCATION

AND TRAINING (NVCET)
METAL PROCESSING TECHNOLOGY

LEVEL I AND II
INSTRUCTOR’S GUIDE
JUNE 2009
Kenya
FOREWORD
The Ministry of Youth Affairs and Sports was created in December 2005 with the single strategic
focus of addressing the needs of the Youth and with the mandate of mainstreaming youth issues
in the national development agenda.
In order to accomplish this task, the Ministry was also charged with the mandate of revitalizing
the Youth Polytechnics (YPs) which had been neglected over the years. This involved carrying
out a baseline survey of the existing YPs and establishing their status in terms of infrastructure,
curriculum, staffing and governance. The report revealed glaring gaps between the curriculum
that was being taught and the needs of the labour market.
In order to address the above anomalies, my Ministry developed a 5-year strategic plan with a
new 12 course YP curriculum in which, Metal Processing Technology is included. The
implementation of these courses required adequate and relevant teaching /learning resources,
hence the development of this Instructors’ Guide for Metal Processing Technology. This is
one of the major steps taken towards the revitalization of technical training in Youth Polytechnics
in Kenya in tandem with the Technical Industrial, Vocational and Entrepreneurship Training
(TIVET) Programme. It is also the aim of my Ministry to empower the youth with relevant
technical and vocational skills to meet the country’s manpower requirements in line with vision
2030. Thus, the development of this instructors’ guide is a major milestone towards the
revitalization process. I trust that the trainers will make full use of this manual to justify the time,
effort and resources that were used to develop it. If this is accomplished, it will be an echo of my
Ministry’s vision, “A responsible and empowered youth building a better Kenya.”
Hon. (Prof) Hellen Sambili EGH,

Minister for Youth Affairs and Sports
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PREFACE
Youth Polytechnics are basic education institutions intended to offer primary school leavers
opportunities to acquire quality technical skills and knowledge to make them employable while at
the same time providing avenues and paths for attaining higher education through Technical,
Industrial, Vocational and Entrepreneurship Training (TIVET) system. The institutions also equip
the youth with technical and entrepreneurial skills based on appropriate technology enabling them
unleash their entrepreneurial capacity in order to fully exploit local resources for employment
creation.
Local communities, religious groups and other non-governmental organizations with support
from the Government and development partners have over the last 30 years contributed to putting
up over 750 youth polytechnics in the country. The youth polytechnics have in the past been
neglected in the planning and implementation of education and training policies, and have as a
result suffered serious deterioration due to poor unregulated management and inadequate
training /learning materials. The deterioration has led to poor quality training and unemployable
graduates hence fanning the negative attitudes towards these institutions that are evident in the
communities.
In order to address the above anomalies, the ministry of youth Affairs and Sports developed a
new Youth Polytechnic curriculum which is being implemented on a pilot basis in selected Youth
Polytechnics (YPs). At the same time there has been an acute shortage of teaching/learning
resources to support the YP training programmes. In order to ensure a smooth implementation of
the new curriculum, my Ministry has developed curriculum support materials in 12 courses
which, includes this instructors guide.The development of this Instructors’ Guide for Motor
Vehicle Technology is guided by the recognition that technical and vocational training is an
investment and not a cost with significant returns including the well-being of youth, enhanced
productivity and competitiveness in a market economy. It is one of the interventions being put in
place aimed at transforming at least two youth polytechnics into Centres of Excellence in every
constituency.
The programmes are in tandem with Education for All (EFA) by 2015, a major goal of the
Government in line with its commitments to international declaration, protocols and conventions
as resolved in world conferences on EFA (Jomtien-Thailand 1990, and Dakar Senegal, 2000) and
by the Millennium Development Goals. These have been provided for in the Children Act (No. 8
of 2001). It is my hope and belief that, this first edition will go along way in assisting the YP
trainers in discharging their training more effectively.
JAMES M. WAWERU, EBS

Permanent Secretary
Ministry of Youth Affairs and Sports
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ACKNOWLEDGEMENT
The Ministry of Youth Affairs and Sports has developed this Instructors’ Guide through a
collaborative effort with UNDP. Without the support of each and every one of the key
stakeholders, this Metal Processing Technology Instructors’ Guide would not be a reality. In
view of this, I would like to take this opportunity to extend our special gratitude to UNDP-Kenya
for financing the development process and giving technical assistance to the Ministry of Youth
Affairs and Sports-Department of Youth Training. In particular, UNDP Country Director Ms.
Tomoko Nishimoto for buying our vision and believing in our youth, Mr. Fortunitus Okwiri,
Team Leader-Poverty Reduction Unit, for working with us throughout the process and Mr.
Boniface Mutia Kitili, UNDP Programme Officer-Youth Development and Training Programmes
for giving advisory, technical and logistical support to the coordinating team.
Our special mention goes to the focused leadership of the Minister for Youth Affairs and Sports,
Hon. (Prof). Hellen Sambili, EGH, the Hon. Assistant Ministers, Kabando wa Kabando and Hon.
Wavinya Ndeti, for their support. The dedication of the Permanent Secretary Mr. James Waweru,
EBS, all the Deputy Directors , their staff, Heads of Departments, and Private Sector Partners,
Directorate of Industrial Training, Kenya National Examinations Council and the Ministry of
Higher Education Science and Technology for their inputs.
Our special gratitude (posthumously) goes to the late Permanent Secretary, Mr. Kinuthia Murugu
for initiating the collaboration with UNDP and other development partners. Through him, the
Ministry received enormous financial resources to develop the 13 courses of the Youth
Polytechnic curriculum and this Instructors’ Guide. May God rest his soul in eternal peace.
Finally I wish to thank Director KIE, L.N. Nzomo, OGW (Mrs.) for guiding the development
process and assembling a team of experts in this field. We applaud the following subject
specialists; Mercy Karogo- Kenya Institute of Education, Mwangi Kahenu-Ministry of Youth
Affairs and Sports, Boniface Mutia Kitili-UNDP Kenya for their invaluable contribution. We
sincerely appreciate their long hours of sitting and going through the draft manuals
Having completed the development of this Instructors’ Guide, we now focus on the curriculum
implementation process. The journey has just begun. It is my hope and conviction that the
Ministry’s staff will remain focused, committed, and selfless in implementing this curriculum in
order to realize the desires and aspirations of our youth and the overall objectives of the country’s
vision 2030.
D.C. Mwinzi (Ph.D)

Director Youth Training
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TABLE OF CONTENTS
FOREWORD…………………………………………………………………………………………………2
PREFACE…………………………………………………………………………………………………….3
ACKNOWLEDGEMENT ………………………………………………………………………………….. 4
INTRODUCTION TO THE INSTRUCTORS’ GUIDE..................................................................................8

2.0 INTENT......................................................................................................................................8
3.0 OVERVIEW OF COURSE SYLLABUS..................................................................................8
4.0 TARGET GROUP AND COURSE OUTLINE.........................................................................9
METAL PROCESSING TECHNOLOGY LEVEL I.....................................................................................17
14.1.1.1 MODULE UNIT: ETHICS AND INTEGRITY.....................................................................17

14.1.1.2 MODULE UNIT: SAFETY....................................................................................................19
14.1.1.3 MODULE UNIT: QUALITY CONTROL..............................................................................22
14.1.1.4 MODULE UNIT: MATERIALS HANDLING AND WASTE DISPOSAL...........................24
14.1.1.5 MODULE UNIT: CULTURE OF MAINTENANCE.............................................................27
14.1.1.6 MODULE UNIT: ELECTRICAL MACHINE SAFETY.......................................................30
14.1.2.1 MODULE UNIT: ENGINEERING MATERIALS..............................................................33
14.1.2.2 MODULE UNIT: CLAMPING DEVICES.............................................................................36
14.1.2.3 MODULE UNIT: MEASURING AND CHECKING TOOLS..............................................38
14.1.2.4 MODULE UNIT: MARKING OUT TOOLS..........................................................................40
14.1.2.5 MODULE UNIT: MATERIAL REMOVAL..........................................................................43
14.1.2.6 MODULE UNIT: CUTTING TOOLS.....................................................................................46
14.1.2.7 MODULE UNIT: DRILLING................................................................................................50
14.1.2.8 MODULE UNIT: HAND THREAD CUTTING TOOLS......................................................54
14.1.2.9 MODULE UNIT: FASTENING DEVICES...........................................................................57
14.1.2.10 MODULE UNIT: MATERIALS ESTIMATING AND COSTING........................................61
14.1.3.1 MODULE UNIT: SHEET METAL WORK MATERIALS...................................................63
14.1.3.2 MODULE UNIT: SHEET METAL HAND TOOLS AND EQUIPMENT.............................66
14.1.3.3 MODULE UNIT: SHEET METAL JOINTS AND SEAMS..................................................70
14.1.3.4 MODULE UNIT: PATTERN LAYOUT AND DEVELOPMENT.........................................72
14.1.3.5 MODULE UNIT: SHEET METAL FORMING..................................................................76
14.1.3.6 MODULE UNIT: SHEET METAL EDGES.........................................................................78
14.1.3.7 MODULE UNIT: SOFT SOLDERING................................................................................81
14.1.3.8 MODULE UNIT: FABRICATION OF A SHEET METAL PRODUCT................................86
14.1.4.1 MODULE UNIT: OXY-ACETYLENE WELDING EQUIPMENT.......................................90
14.1.4.2 MODULE UNIT: OXY-ACETYLENE WELDING TECHNIQUES.....................................93
14.1.4.3 MODULE UNIT: QUALITY CONTROL IN GAS WELDING....................................96
14.1.4.4 MODULE UNIT: WELDING JOINTS AND SYMBOLS..................................................101
14.1.4.5 MODULE UNIT: OXY-ACETYLENE CUTTING..............................................................104
14.1.4.6 MODULE UNIT: BRAZING AND HARD SOLDERING................................................107
14.1.4.7 MODULE UNIT: FABRICATION OF A PRODUCT USING OXY-ACETYLENE.......110
14.1.5.1 MODULE UNIT: ARC WELDING PROCESS EQUIPMENT............................................114
14.1.5.2 MODULE UNIT: WELDING ELECTRODES...................................................................117
14.1.5.3 MODULE UNIT: ARC WELDING TECHNIQUES.........................................................120
14.1.5.4 MODULE UNIT: WELDING JOINTS AND SYMBOLS....................................................124
14.1.5.5 MODULE UNIT: QUALITY CONTROL IN ARC WELDING...........................................127
14.1.5.6 MODULE UNIT: FABRICATION OF A PRODUCT USING MILD STEEL...................129
14.1.6.1.1 MODULE UNIT : FORGING PROCESS.............................................................................135
14.1.6.1.2 MODULE UNIT: FORGING TOOLS AND EQUIPMENT.................................................138
14.1.6.1.3 MODULE UNIT: FORGING OPERATIONS.......................................................................141
14.1.6.2.4` MODULE UNIT: METAL HEAT TREATMENT PROCESSES.........................................147
14.1.6.2.5 MODULE UNIT: HEAT TREATMENT OPERATIONS.....................................................150
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14.1.6.3.1 MODULE UNIT: SAND CASTING...................................................................................153
14.2.1.1 MODULE UNIT: OCCUPATIONAL INFORMATION…………………………………159
14.2.1.2 MODULE UNIT: GENERAL SAFETY...............................................................................160
14.2.1.3 MODULE UNIT: PRODUCTION OF METALS (IRON AND STEEL)............................165
14.2.1.4 MODULE UNIT: CAST IRON...........................................................................................169
14.2.1.5 MODULE UNIT: CARBON STEELS.................................................................................170
14.2.2.1 MODULE UNIT: WORK HOLDING DEVICES............................................................173
14.2.2.2 MODULE UNIT: MEASURING AND MARKING OUT TOOLS....................................175
14.2.2.3 MODULE UNIT: CUTTING TOOLS AND EQUIPMENT................................................180
14.2.2.4 MODULE UNIT: PIPE AND PIPE FITTING......................................................................183
14.2.2.5 MODULE UNIT: FITTING WORK.....................................................................................187
14.2.3.1 MODULE UNIT: SHEET METAL BENDING, CUTTING AND FORMING MACHINES....
......................................................................................................................................................
191
14.2.3.2 MODULE UNIT: SHEET METAL JOINTS/WIRED EDGES...........................................195
14.2.3.3 MODULE UNIT: FABRICATION OF A GALVANIZED IRON (G.I) SHEET PRODUCT....
......................................................................................................................................................
199
14.2.4.1 MODULE UNIT: OXY-ACETYLENE WELDING EQUIPMENT...................................203
14.2.4.2 MODULE UNIT: QUALITY CONTROL IN GAS WELDING ALUMINIUM AND
STAINLESS STEEL....................................................................................................................................206
14.2.4.3 MODULE UNIT: POSITIONAL GAS WELDING OF MILD STEEL..............................209
14.2.4.4 MODULE UNIT: OXY-ACETYLENE WELDING OF STAINLESS STEEL AND
ALUMINIUM..............................................................................................................................................214
14.2.4.5 MODULE UNIT: FABRICATING THIN GAUGE MILD STEEL PRODUCT..............218
14.2.5.1 MODULE UNIT: ARC WELDING EQUIPMENT...........................................................221
14.2.5.2 MODULE UNIT: POSITIONAL ARC WELDING OF MILD STEEL................................224
14.2.5.3 MODULE UNIT: ARC WELDING OF CAST IRON.....................................................229
14.2.5.4 MODULE UNIT: ARC WELDING OF STAINLESS STEEL 233
14.2.5.5 MODULE UNIT: FABRICATION OF MILD STEEL SECTION PRODUCT...................237
14.2.6.1 MODULE UNIT: LATHE MACHINE..................................................................................241
14.2.6.2 MODULE UNIT: LATHE CUTTING TOOLS AND THEIR USES...................................245
14.2.6.3 MODULE UNIT: WORK HOLDING DEVICES................................................................248
14.2.6.4 MODULE UNIT: CUTTING SPEEDS................................................................................251
14.2.6.5 MODULE UNIT: LATHE MACHINE WORK...................................................................252
14.2.7.1 MODULE UNIT: MILLING AND BORING......................................................................257
14.2.7.2 MODULE UNIT: MILLING CUTTERS..............................................................................260
14.2.7.4 MODULE UNIT: MILLING MACHINE WORK................................................................265
14.2.8.1 MODULE UNIT: SHAPING AND SLOTTING MACHINE...............................................270
14.2.8.2 MODULE UNIT: SHAPER CUTTING TOOLS AND THEIR USES................................273
14.2.8.4 MODULE UNIT: SHAPING MACHINE WORK...............................................................278
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LEVEL I
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INTRODUCTION TO THE INSTRUCTORS’ GUIDE
1.0 RATIONALE
The instructors’ guide has been developed so as to:-

 Help the instructors’ interpret the course syllabus
 Harmonize teaching in all Youth Polytechnics in Kenya
 Equip the Youth Polytechnics’ instructors with a systematic approach to skills
dissemination at all stages of training
 Guide the Youth Polytechnic instructors in the modes of delivering the syllabuses
content and self-assessment.
The guide lays emphasis on the following:

1. Objectives / aims
2. Content to be covered
3. Competencies
4. Teacher / learner activities
5. Key resources
6. Assessment
7. Reference materials
2.0 INTENT
 The intention of introducing the instructors’ guide for the Youth Polytechnic
Vocational training programmes is to create a level and harmonized teaching
approach in all Youth Polytechnics
 The instructor is expected to use the guide as a source of basic minimum requirement
for instruction and is at liberty to make improvements and adjustments to these
requirements when using the guide during the course of instruction. The instructor
should prepare for lessons diligently and use the guide for guidance.
 The guide is a very useful tool to all levels of instructors giving instructions to
trainees in vocational training programmes of the Youth Polytechnics.
3.0 OVERVIEW OF COURSE SYLLABUS
The syllabus is modeled on modular approach and is trainee - centered.
The syllabus covers the following:-

 Communication skills, life skills, entrepreneurship education and information and
communication technology.
 Practical vocational training and education
 Vocational education (theory)
 Industrial attachment
The syllabus outlines the objectives of each module and also identifies the content that
should be covered under each module including the estimated time that should be spent
on the module. The course syllabus is designed for two levels with duration as indicated
below:
Level 1 - 1980 hours

Level 2 - 1980 hours
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The course is also structured to offer two options:
 Vocational training programmes (option I)
 Vocational training programmes (option 2)
The trainees will be allowed to select either option 1 or option 2
4.0 TARGET GROUP AND COURSE OUTLINE
 In option 1, the curricula will be offered in modular form to Primary School Leavers,
with KCPE certificate or its equivalent.
 The trainees will choose the order and number of modules to study and will be free
to terminate their vocational training after obtaining the required course modules.
They will be allowed to resume their studies at any time.
The course outline will be as follows:

1. Vocational trade areas
2. Communication skills
3. Entrepreneurship skills
4. Life skills
5. ICT studies
6. Technical drawing
 In option 2, the curricula will be offered in modular form to Primary School Leavers
with KCPE certificate or its equivalent. This option is open to trainees aspiring to
follow parallel secondary format with the aim of proceeding for further studies at
Diploma and Degree levels. The trainees will take vocational and academic subjects
for the award of a “National Vocational certificate in Education and Training
(NVCET)
The course outline will be as follows:-

 The vocational trade area
 Communication skills
 Entrepreneurship skills
 Life skills
 ICT studies
 Technical drawing
 Mathematics
 Physics
 Chemistry
 Biology
The course is designed such that the time spent in the institution will be translated as
follows:
 General Education – 580 hours = 30%
 Vocational (Practice) – 1100 hours = 55%
 Vocational Education (Theory 300 hours) = 15%
After Level 1, the trainees will be expected to spend 900 hours in industrial attachment
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5.0 ABOUT THIS GUIDE
 This guide is designed to assist the instructor in disseminating knowledge, skills and
attitudes to the trainees in the most effective way.
 In implementing this guide the instructor should lay more emphasis on the practical
component of the course with approximately 80% of the time being spent on
manipulative skills and about 20% of time given to other areas
 The guide should be used together with the syllabus and any other teaching / learning
resources at the disposal of the instructor
 For ease of cross-referencing, the same coding has been used in the guide as well as
in the syllabus. The guide gives a list of the essential resources and the teaching aids
that will be required for organizing the activities for each module or module unit.
The list is a guide only and the instructor is at liberty to organize for other learning
resources if and when appropriate and available and improvise where necessary but
the alternatives must be suitable and appropriate for the course level.
 The guide is structured in such a way that it will guide the instructor to effectively
teach and monitor the progress of the trainees and thereafter assess them
appropriately both in theory and practice
 In order for the instructor to effectively disseminate knowledge and skills to the
trainees the following areas are also considered:
 Instructor preparedness
 Learning environment
 Resource management
 Quality of products and services
5.1 Instructor Preparedness

 Scheming
 Lesson planning
 Preparation of lesson notes
 Selection / or preparation of teaching / learning resources
5.2 Learning Environment

 Preparation of learning environment, Supervision of class activity, assisting
learners with difficulties and ensuring correct work is being done.
 Observe change in behaviour
 Ensure quality standards
The instructor will have variety of facilities at his/her disposal while conducting
theoretical and practical sessions. These facilities include classrooms,
workshops etc. the choice of the facility to be used will be dictated by the
activity being carried out. Whichever facility the instructor chooses as the most
appropriate learning environment for a given activity the instructor should take
into account the following factors.
- Safety and comfort of the trainees
- Lighting and ventilation of the facility
- Ease of movement for both the trainees and the instructor
- Viewing level for both the instructor and the trainees.
- Ease of movement of teaching aids, tools and equipment.
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5.2.1 Organization
The instructor will decide how the class will work, either as individuals
or in groups. Individual work is encouraged but groups are divided
depending on the following factors:
- The equipment available
- The working space in class
- The size or largeness of the class i.e. the number of trainees.
- In each group a group leader should be appointed.
5.2.2 Supervision of class activity
It is of utmost importance that the instructor supervises trainees to see

that the correct methods are being used and the exercise is done neatly
and orderly. The instructor should check for the following:
- whether the class is carrying out exercises correctly.
- whether all the trainee are taking part.
- whether there are any new ideas coming from trainees.
- any general problem coming up from the activity at hand or in the
group
During this time the instructor can stop the class and demonstrate
again if he/she notices that the groups or individuals are not carrying
out the activity correctly.
5.3 Resources Management

Determination of appropriate utilization of the tools, materials and equipment
(reduce wastage - ensure proper handling and maintenance)
During the practical and theoretical learning activities, the instructor will use
many types of key learning resources. These resources include; workshop tools
and equipment, teaching aid, textbooks, etc. there is need to manage these
resources properly.
Workshop tools and equipment are expensive to buy and maintain. And for
these reasons it is important for the instructor to closely monitor the status of
these facilities to avoid theft, breakage, misuse and mishandling.
Reconditioning and maintenance of tools and equipment make them last longer
and safe to use.
Teaching aids, such as, charts, diagrams, drawings, etc. take a lot of time and
patience to make. It is important that they are handled carefully during the use
and also stored properly after use so that they will be durable and be used for a
longer period.
The instructor should involve the trainees in ensuring that these facilities are
cared for and maintained by making trainees responsible for their actions.
5.4 Quality products and services
The aim of this course is to equip the trainee with skills that will enable him/her
to produce quality products and services. The quality products produced by the
trainee or graduate of this course should be strong, safe to use and beautiful to
look at. The quality products can only be guaranteed by selecting the
appropriate materials for a job at hand and using the correct tools, equipment
and proper techniques or fabricating and repairing metal articles, tools and
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equipment. Communication skills, entrepreneurship education, life skills and
ICT are meant to produce graduates who can function efficiently in society.
6.0 MODE OF DELIVERY
There are a number of teaching methods which the instructor can employ to facilitate
practical learning. Some of the methods include; demonstration, discussion, lecture, field
visits, and the questioning technique
6.1 Demonstration method
This is a method in which the instructor shows and explains to the trainee how
to carry out a certain procedure. The method is appropriate when teaching
practical skills. It can also be used when resources are limited. The instructor
carries out demonstration as the trainees watch and later imitate.
Perhaps the most widely used teaching method is the demonstration. In this
method the instructor shows the trainees the techniques of performing an
activity. The trainees should always be involved in the demonstration be
carrying out specific tasks e.g. making key observations, recording results and
repeating the technique on their own.
The instructor should be able to demonstrate all the skills stated in the syllabus.
When carrying out a demonstration it is important to have clear objectives in
mind and also make sure in advance that the demonstration works.
For a demonstration to be effective, the instructor should:

- be brief and clear
- explain and demonstrate the same point at the same time
- see that the demonstration table or equipment is neatly kept throughout.
- make sure that all the trainees can see clearly what he/she is doing.
- re-enforce the demonstration with illustrations, posters and other visual aids.
- divide the demonstration into stages if it is complicated
- supervise and guide the trainees to master the skill.
6.2 Discussion method

A discussion is a purposeful conversation proceeding towards a certain objective.
As a method of teaching, a discussion is an activity where a teacher and learners
talk together in order to share views or information about a topic or a problem. It
can be an exchange of ideas between the teacher and learners in a whole class
discussion or among the learners. The instructor should ensure that there is
instructor - trainee and trainee – trainee interaction. In order to enhance
participation, it is better to use small group discussion. The instructor should make
sure that every group has a chairperson to coordinate the discussion and a secretary
to note down the main points
The discussion method is a valuable teaching technique. It involves active
instructors and trainees participation and provides means by which individual
trainee may develop knowledge, social skills and effect attitudinal changes.
In this teaching method, the instructor introduces an activity and explains its uses
and limitations. He/she then asks the trainees to relate the activity to previous
lessons by posing some questions. Then the trainees engage in some discussion by
giving their opinions or ideas. This ensures that passive listening or mere copying
of notes is reduced to a minimum. The instructor must ensure that the control of
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the discussion is maintained and that tension and friction are not allowed to
develop.
6.3 Lecture method

In the lecture method, the instructor explains or describes an activity or process and
the trainees are expected to listen, observe and take notes. The advantage of this
method is that the instructor can be able to cover a lot of materials in a short time.
However, this method is said to create passive listening with very little participation
by the trainees in the lesson. It must be used together with other training methods in
the practical training session.
6.4 Visit / Field Trip
Field trip is a method of teaching-learning method where trainees are taken to venues
of learning to make use of community based resources such as places, things,
activities and resource people.
The instructor should formulate clear objectives for the field trip.
Importance of field trips:
 They enable trainees to observe the world around them closely, accurately and
intelligently.
 They widen trainees understanding of the world in which they live.
 They bring trainees into contact with tangible remains of history thus developing
a sense of reality.
 They enable trainees to undertake simple research projects which can greatly
increase their ability to think.
 They enable trainees develop love for adventure.
 They enhance good relationship between the YP and the wider community.
 They give trainees a chance to find out information for themselves.
Trainees can learn and derive a lot of pleasure from visiting places of interest. The
instructor should identify such places, examine the learning and aesthetic
opportunities available, and evaluate the relevance and usefulness to the trainees.
He/she should organise the visit. Some of the places that could be visited are local
metal fabrication workshops, hardware shops or electrical/electronic repair
workshops.
Before the visit:
Set out the aims and objectives of the visit. Obtain permission from the
administration
Write to the person from the place you intend to visit. Get parents/guardians consent
Explain to the trainees what the visit is all about and what they are expected to do,
such as answering questions and recording their observations.
6.5 Debates
A debate is a method of teaching and learning which requires learners to hold formal
argument on a given issue. Debate encourages argument, deliberation and discussion
of opposing points of view. It allows trainees to apply the knowledge they have
acquired. It also helps them to develop the skills of preparing arguments for or
against an issue.
Preparations for a debate can give valuable training in research, organization and
presentation of material, and the skilful expression of a viewpoint. If a debate is to
be held, the trainees should be given adequate guidance and time for preparation.
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6.6 Question and Answer Method
This is a method of teaching and learning where the instructor asks questions to find
out what the trainees know. In this method there is usually a flow of information
from the instructor to the trainee and vice versa. In order to use questions
effectively, the instructor should make sure that the questions are clear; the language
should be to the level of the trainees and should pause to give the trainees time to
think about the questions. The instructor should first ask the question and then select
a trainee who is to answer the question.
6.7 Project Method

A project is a piece of work that the instructor assigns to the trainees on a given
topic. A project requires skills, effort and careful planning. It is a trainee- centered
approach.
A good project should:
 Be relevant and focused to a specific instructional objective or topic.
 Be challenging, interesting and appealing to the trainees.
 Assist in enriching historical information to be achieved within specified period.
6.8 The instructor should play the role of a guide throughout the project.
6.9 Games
These are interesting and exciting activities, which have set rules.
Games can be used when:
1. clarifying difficult issues
2. discussing sensitive issues
3. learning and practicing new skills
4. enhancing the quality of interaction in the group
5. increasing the participants knowledge of each other
6. making presentations interesting
6.10 Case Study
This is an account depicting a real life situation, a scenario or problem.

Sometimes it offers clues on how to solve a problem or provokes the trainee’s
ability to solve the problem. Case studies should therefore be interesting and
appealing and relevant to the trainee’s imagination.
6.11 Infusion and Integration of Human Rights, Gender, Environment, Drug &
Substance Abuse and Life Skills
6.11.1 The Concept of Infusion

It is possible to incorporate emerging issues content into the existing
subjects. This means that the messages will be taught at appropriate
topics when the main subject is being taught. This is referred to as
infusion by their own nature, some subjects render themselves more
suitable to teaching about emerging issues than others. However,
infusion should not be seen to be confined to any subjects. In fact
emerging issues can be taught alongside any other subject. All that is
required is imagination.
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6.11.2 Assessment and Certification
This guide suggests some appropriate methods that the instructor can
use to assess learning or acquisition of skills by the end of module
unit. The specific objectives and the learning activities listed under
the various module unit of the course should form the basis for
assessing trainees work. The information got from such assessment
should form the basis for evaluating oneself or the level of mastery of
skills by the trainees. The instructor should ensure that the grades
attained by a trainee are not records for administrative purposes only
but should be used as basis for improving learning and acquisition of
skills by the trainee.
Some of the common assessment methods included in the guide are

1. oral tests
2. written tests
3. assignments
4. assessment of practical work
5. observation of trainees behaviour as they perform practical
work/assignments
6. grading of products.
7. field reports / project reports
6.11.3 Use of questions

Whatever teaching methodology an instructor uses, he/she should
pay particular attention to the type of questions he/she asks.
Questions should always be challenging and never to insult the
intelligence of the trainees. Always think about the way you expect
trainees to respond when you ask a question.
Occasionally the instructor should give a quick quiz at the beginning
of the session. These quizzes should be mental exercises to practice
on basic uses of safety, tools equipment, etc. and to revise at frequent
interval the work done earlier.
6.11.4 Self assessment

The instructor should assess his/her own contribution towards the
acquisition of skills by the trainee by asking the trainees or his/her
peers to give opinion on his/her methods of delivery. This will help
the instructor to improve on the areas he/she is weak on.
6.11.5 Peer assessment

Practical products are tangible and visible and therefore lend
themselves to display. The displaying of these products is important
for trainees to share with others their creative experiences and also
assess their products for quality. The trainees will also want
recognition of their work. This can best be achieved by displaying as
much of their work as often as possible. The instructor should select
and involve trainees in preparation or presentation of trainees’ work
for display.
There are certain factors, which the instructor need to consider when
planning a display, namely;
space, such as, walls of the classroom, tables
- floor areas, lines.
- eye level of the viewer
15
- lighting
- ventilation
6.11.6 Follow up Activities

After a session or demonstration the instructor is expected to make
necessary arrangements for the trainees to carry out activities or
assignments that will enhance the skill being taught. This could be
in form of writing a report, drawing/sketching of parts of product,
fabricating a product etc.
Any assignment that has been given to trainees must be assessed to
ensure that the trainees have done the exercise and mastered the
skills that are required
6.11.7 Continuous Assessment

It is expected that the instructor will monitor the performance of the
trainee by giving them class test, assignments, end of term tests,
practical work etc. By assessing the trainees this way the instructor
can form an opinion on the progress of the whole class or individual
trainee rather than wait for the end of term tests or final assessment
test when it is too late
The continuous assessment marks for the course work must be kept
by the training institution. The continuous assessment marks shall be
used when assessing the trainee at final assessment test.
6.11.8 Final assessment Test

At the end of the course, the trainees will be registered for the final
grade assessment test. It is important for the instructor to prepare the
trainees well for this test.
7.0 RESOURCES
7.1 Guest Speakers/Resources Persons

A resource person is a person with specialized information or skill. For
example a teacher, a farmer, a doctor or a trader may be used as a
resource person, provided the information sought from them is relevant
to the situation.
Sometimes it may be useful to invite a speaker such as an engineer or an

entrepreneur to give a talk on specific topic. The guest speaker would
need to be requested for the presentation in good time. Full details of
what would be expected of him/her should be given. The topic, data,
time and duration of the talk should be communicated. The trainees
should also be informed in advance so that they can prepare for the
topic.
7.2 Picture Code

A picture code is usually a poster sized visual aid which represents
an illustration of a problem that is common to the group you are
dealing with. The picture code is presented to a group in order to
encourage discussion.
16
LEVEL I
14.1.1.1T MODULE UNIT: ETHICS AND INTEGRITY
THEORY
14.1.1.1T1 Specific Objectives
At the end of this module unit, the trainee should be able to:
a) define ethics and integrity
b) explain the meaning and importance of ethics and integrity
c) explain how values are acquired, developed and sustained
d) discuss the significance of values in society
14.1.1.1T2 Content
 Ethics and integrity
- Definition of terms ethics & integrity
- Importance of ethics and integrity
- meaning of ethics
- meaning of integrity
 Importance of ethics and integrity
 How values are acquired developed and sustained
- professionalism
- morality
- team work
- religion and it’s influence in society
- courtesy
- accountability
- social responsibility
- diligence
- fairness
 Significance of values in society
- individual
- community
- society
Competences
Ability to:
 define ethics and integrity
 explain the meaning and importance of ethics and integrity
 explain how values are acquired, developed and sustained
 discuss the significance of values in society
Teaching/Learning Activities
Defining of Ethics and Integrity

The instructor should
 Define the words ethics and integrity to include
- values
- honesty
- trustworthiness
17
Explaining importance of Ethics and Integrity

The Instructor should
 Explain the importance of work ethics and integrity to include
- morality
- courtesy
- fairness
- accountability
- hard work
Discussing the significance of values, development and Sustainability

 Discuss how values are acquired, developed and sustained to include:
- professionalism
- morality
- teamwork
- religion and its influence in society
- courtesy
- accountability
- diligence
- fairness
Discussing significance of values in Society

 Discuss and emphasize on the factors that influence values in society to
include
- individual tastes
- community traditions and culture
- society expectations
The trainee should

 make key observations and take notes on ethics and integrity
 outline the importance of work ethics and integrity
 outline how values are acquired, developed and sustained
 state the significance of values in a society and the factors that influence
them
Key learning Resources

 Public lectures from relevant people
 Charts sourced from department dealing with ethics and governance
 Case studies of role models in the society
Assessment method
 Oral test
- On meaning of ethics
- On meaning of integrity
- Society values
 Written test on
- Importance of ethics and integrity
- Factors that influence values in a society
18
References
 KIE text book on Ethics and Integrity
14.1.1.2T MODULE UNIT: SAFETY
THEORY

a) define terms related to safety
b) list types and causes of accidents in the workshop
c) list the classifications of fires
d) list fire fighting equipment
14.1.1.2T2 Content
 Terms related to safety
- safety
- first aid
 Accident in the workshop
- Types
 falls
 burns
 cuts and bruises
 electric shock
- causes
 slippery floors
 spills on floors
 obstructions
 carelessness
 poor visibility
 un-safe work habits
 lack of appropriate protection
o head gear
o foot wear
o eye protection
 fatigue
 ignorance
 failure to follow instructions/rules
 Classifications of fire
- class A Fires
- class B fires
- class C fires
 Fire fighting equipment
- container with water
- asbestos blankets
- foam
- sand or soil
- hose reels
PRACTICE:
14.1.1.2 P1 Specific Objectives

a) identify causes of accidents in a workshop
19
b) identify causes of fires
c) demonstrate fire fighting drills
d) identify fire fighting equipment
e) practice safety in the workshop
14.1.1.2P2 Content
 Causes of accidents
- faulty equipment
- faulty tools
- carelessness
- not observing safety rules
- slippery floors
 Causes of fires
- presence of oxygen
- heat
- fuel
 Fire fighting drills
- type of fire
- identify right extinguisher
- raising the alarm
 Fire fighting equipment
- hose reels
- dry risers
- wet risers
- fire extinguishers
 water
 foam Co2
 Safety in the workshop
- personal safety
- tools safety
- materials safety
- other users safety
Competences
Ability to:
 identify causes of accidents in a workshop
 identify causes of fires
 demonstrate fire fighting drills
 identify fire fighting equipment
 work safely
Learning/Teaching Activities
Identifying causes of accidents in the workshop

 Discuss and identify causes of accidents in the workshop to include
- Faulty equipment and tools
- Carelessness
- Failure to observe safety rules
- Slippery floor
- Sharp objects
- Naked electrical conductors
20
Identifying possible causes of fire
 Discuss and identify possible causes of fires to include
- Leaking gases
- Flammable liquids
- Flammable material
- Faulty electrical circuits
- mishandling of tools
Demonstrating fire fighting drills
 demonstrate fire fighting drills to include
- Class ‘A’ fires
- Class ‘B’ fires
- Class ‘C’ Fires
Causes to include
- flammable materials such as petrol, kerosene and oils
- chemicals
- electrical appliances
- rags and cotton waste
- presence of oxygen and heat
Practicing safety in the workshop

 Demonstrate safe working habits in the workshop to include
- safety gear
- equipment safety
Identifying fire fighting equipment

 Display and discuss the various fire fighting equipment to include
- Fire extinguisher
 Water
 Foam
 CO2
- Hose reels
- Dry rises
- Wet risers
The trainee should

 identify causes of accidents in a workshop
 identify causes of fires
 demonstrate fire fighting drills
 identify fire fighting equipment
 work safely
Key Learning resources

 Posters, charts and pictures with safety messages
 Fully equipped first aid kit
 Functional fire extinguishers
 Protective gears
21
 Films with safety messages
 Guest speakers from
 Red cross society
 Red crescent society
 St John’s ambulance
 Fire brigade
Assessment
 Tests for mental exercises and practice on safety precautions
- Oral
- Written
 Assignments to follow-up activities
 Fire fighting drills
 First aid drills and procedures
 Continuous observation on change of behaviour
Suggested references
- Metal work pupils book 1,2,,3 and 4 by KIE
14.1.1.3T MODULE UNIT: QUALITY CONTROL
THEORY
a) explain the meaning of quality control
b) outline the procedure of the work process
c) enumerate the advantages of good workmanship
d) list factors contributing to marketability of products
14.1.1.3T2 Content
 Meaning of quality control
 Procedure of the work process
- sequence of activities
 Advantages of good workmanship
- quality products
- customer satisfaction
 Factors contributing to marketability of products
- durability
- finishing
- quality of selected materials
- intended purpose
PRACTICE:
14.1.1.3P1 Specific Objectives

a) control the work process
b) ensuring good workmanship on products
c) produce marketable products
14.1.1.3P2 Content
 Control the work process
- sequencing of activities
 Ensure good workmanship
- quality products
22
 Produce marketable products
- durability
- finishing
- serves intended purpose
- aesthetic value
Competences
Ability to:
 Control work process
 Ascertain good workmanship
Controlling the work pieces

The instructor should be able to:
 discuss how to control work
- sequencing of activities
 choice of materials
 sourcing of the material
 production method
 finishing method
 pricing
Ensuring good workmanship

 explain good workmanship on products by ensuring the following
- quality products
- aesthetic value
Producing marketable products

 discuss how to market products to include the following
- durability
- finishing
- serving intended purpose
Trainee should
 Control work process
 Ascertain good workmanship
Key learning resources

 manufactured/finished products e.g. chair, table or tray
 assorted quality materials e.g. stainless steel, aluminium or brass
 charts showing quality manufactured products
 ISO/KEBS manuals
Assessment
 Tests
- Oral
23
 on the sequencing of activities for control of work pieces
- Written on
 sequencing activities
 good workmanship on products
 Practical
- on observation of finished products and making reports
- producing a simple component following the sequencing of activities
- pricing the product
 Industrial visit
- To a manufacturing firm to observe and note the sequence of activities
Reference
 Internet browsing
- For production and pricing techniques
14.1.1.4T MODULE UNIT: MATERIALS HANDLING AND WASTE

DISPOSAL
THEORY
a) list various methods of handling materials appropriately
b) outline methods of disposing waste materials
14.1.1.4T2 Content
 Methods of handling materials appropriately
- delicate materials to be handled with care
 Methods of disposing waste materials
- burning: carbonaceous materials e.g paper
- burying: broken glass or recycling
- feeding domestic animals with:
 food left- overs
 banana/ potatoes peelings
- recycling
 glass
 paper
 wood shavings
 textile wastes
PRACTICE:

a) identify appropriate methods of handling materials
b) demonstrate methods of disposing waste appropriately
14.1.1.4P2 Content
 Appropriate methods of handling materials
- heavy materials
- delicate materials
24
 Appropriate methods of disposing waste
- type of materials
- consider recycling
- environmental considerations
- Health and safety requirements
- Local Authority’s Bye-Law requirements on:
 waste Disposal
 siting of dump sites
 proximity to residential areas
 proximity to water catchments areas
Competences
Ability to:
 identify appropriate methods of handling materials safely
 demonstrate methods of disposing wastes appropriately
Identifying appropriate methods of handling materials

Instructor should
 Discuss and cite appropriate methods of handling materials to include the
following type of materials
- Heavy/bulky materials
- Delicate materials
Demonstrating methods of disposing waste

 Outline and demonstrate methods of disposing waste appropriately by
considering the following factors
- type of material
- re-using/recycling
- environmental effects
- health and safety requirements
- local authority’s by law requirements on
 waste disposal
 siting of dumpsites
 proximity of residential areas
 proximity to water catchment areas
The trainee should

 identify appropriate methods of handling materials
 demonstrate methods of disposing waste appropriately
Key Learning Resources

 Handouts on waste disposal of materials
 Charts – showing how to handle
- Heavy material in the workshop
- Bulky material
- Long pieces of materials
 Visiting lectures
 Dumpsite – within the vicinity
 Trolleys, handcarts and wheel barrows
 Mobile and fixed cranes
Assessments
25
 Tests
- Oral
 Naming possible methods of handling common materials in the
workshop e.g. m. steel plates, mils steel sections and mild steel
bars
- Written
 Explanation of possible methods of handling the materials
mentioned above giving reasons
- Practice
 Choice of disposing waste within the workshop vicinity giving
reasons
- Site visits to
 A local authority dump site
 Local rivers to assess the environmental interferences
 A busy manufacturing industry handling both bulky and heavy
materials
- Observation
 Material handling and waste disposal behaviour of trainees while
working
Reference
 Internet browsing – on waste disposal
26
14.1.1.5T MODULE UNIT: CULTURE OF MAINTENANCE
THEORY
a) explain the meaning of culture of maintenance
b) explain the need for maintenance
c) describe types of maintenance
14.1.1.5T2 Content
 Explaining the culture of maintenance
 Explaining the need for maintenance
- restoring good working order
 tools
 materials
 equipment
 structure
 components
- maintaining health standards
- avoiding deterioration or decay of components/materials/tools/
equipment
 Types of maintenance
- routine maintenance
- preventive maintenance
- planned maintenance
PRACTICE:

a) justify need for maintenance
b) discuss maintenance procedure
c) observe safety precautions during maintenance
d) costing maintenance tasks
14.1.1.5P2 Content
 Justifying need for maintenance
- Continuous functionability
- To avoid plant breakdown
- To save time
- Save on cost
- To avoid accidents
- observing
- recording
- reporting
- costing the tasks
 Discussing maintenance procedures
- identification
- trouble shooting analysis
- operations implications
- cost implications
- procurement of components/parts
- actual maintenance
- testing
27
 Observe safety precautions
- care for existing undamaged parts or components
- personal safety
- materials safety
- other operatives safety
- tools and equipment safety
 Costing maintenance tasks
- materials estimation
 by calculation
 past experience/similar tasks
- labour requirements and availability
 types of labour
o skilled
o semi-skilled
o casual
 availability
 skills assessment
 number of persons required for the task(s)
 maintenance time/duration
 alternative arrangement at time of maintenances
o cost implication
o convenience
- costing works/tasks
 materials cost
o item cost
o transport cost
o cost of storage
o storage safety
o contingencies
 labour cost
 profit and over heads
Competences
Ability to:
 justify need for maintenance
 discuss maintenance procedure
 observe safety precautions during maintenance
 costing maintenance tasks
Teaching/learning Activities
Explain meaning of culture of maintenance

 Explain the importance for maintenance to include
- continuous functionability of machine/equipment
- to avoid plant breakdown
- to save time
- to save on cost
- to avoid accidents
28
Discussing the need for maintenance
 Discuss maintenance procedure to include
- identification
- trouble shooting
- operations implications
- cost implications
- procurement of components/parts
- actual maintenance
- testing
Observing safety precautions during maintenance

 Discuss care and maintenance in regard to:
- personal safety
- material safety
- operations safety
Costing maintenance tasks

 Demonstrate how to cost maintenance to include
- material estimation
- labour cost for
 skilled
 semi-skilled
 casual
- number of persons required for a given task
- maintenance time/duration
- alternative arrangement at time of maintenance
- contingencies
- profit and overheads
The trainee should

 justify need for maintenance
 discuss maintenance procedure
 observe safety precautions during maintenance
 costing maintenance tasks

 maintenance manuals
 Equipment in need of maintenance
Assessment Methods
 Oral test
- on importance of maintenance procedure and care
 Written test
- on maintenance procedure and care
 Practical test
- demonstrate maintenance procedure on equipment
Reference
 Relevant manual charts
29
14.1.1.6T MODULE UNIT: ELECTRICAL MACHINE SAFETY
THEORY
a) name various types of electrical machines and electrical materials used in
metal processing workshop
b) name various types of sources of power supply in a metal workshop
c) state the sources of an accident and precautions to be taken when using
electrical machines in a metal workshop
d) state the procedures of rescuing a victim from a live wire and administer
first aid
14.1.1.6T2 Content
 Electrical machines and materials
- electrical machines
- motors
- generators
- welding transformers
- hand grinding machines
- hand drilling machines
 Electrical materials
- conducting materials
- insulating materials
 Causes of accidents
- faulty equipment
- exposed wires
- misuse of equipment
 Types of power supply
- Alternating current (AC)
- Direct current (DC)
PRACTICE:

a) identify various electrical machines and materials used in metal processing
workshop
b) identify switch gear of machines and power points in a workshop
c) care for and maintain electrical machines and materials
d) observe safety precautions when using electrical machines in a workshop
14.1.1.6P2 Content
 Electrical machines and materials used in a workshop
electrical machines:
- motors
- generators
- welding transformers
- hand grinding machines
- hand drilling machines
- conducting materials
- insulating materials
30
 Identification of switch gear and power points in a workshop
- Switch gear
 main switches
 emergency switches
 equipments switches
- Power points
 plugs
 extension cables
 Care and maintenance of electrical machines and materials
- avoiding scratches and cuts on conducting cables of servicing
machines
- using surfaced machines
- wiping and dusting
 Safety
- use of well protected machines
- using guards on welding transformers
- not working on wet surfaces
- use of proper testing machines and equipment
- use of boots
Competencies
Ability to:
 identify various electrical machines and materials used in metal processing
workshop
 identify switch gear for machines and power points in a workshop
 care for and maintain electrical machines and materials
 observe safety precautions when using electrical machines in a workshop
Identifying various electrical machines and materials used in metal

processing workshop
 introduce and discuss various types of electrical machines and materials
used in metal processing workshop to include
electrical machines:
 electrical machines
 motors
 generators
 welding transformers
 hand grinding machines
 hand drilling machines
- Electrical materials
 Conducting materials
 Insulating materials
Identifying Sources of power

 Explain the various types of power supply in metal workshop to include
Electric alternating current A.C., direct current D.C.
- fuel
- manual
31
 Explain how to identify switch gear for machines and power points in a
workshop to include
Switch gears:
 Main switches
 Emergency switches
 Equipment switches
- Power points
 Plugs
 Extension cables
Caring and maintaining electrical machines and materials

 Demonstrate safe working habits when using electrical machines and
materials to include
- Care and maintenance of electrical machines and materials
 Avoiding scratches and cuts on conducting cables
 Using surfaced machines
 Wiping and dusting
- Safety
 Use of well protected machines
 Using guards on running machines an welding transformers
 Not working on wet surfaces
 Use of proper testing machines and equipment
 Use of boots
The trainee should

 identify various electrical machines and materials used in metal processing
workshop
 identify switch gear for machines and power points in a workshop
 care for and maintain electrical machines and materials
 observe safety precautions when using electrical machines in a workshop

 Charts, pictures
- Showing various electrical machine tools used in metal workshop
- Various electrical machines
- Motors
- Generators
 Safety gear
- Overalls
- Goggles
- Helmets
Assessment methods
 Oral/written tests
- Types of electrical machines and materials
- Switch gear
- Power points
- Sources of power
- Safety and care of machines tools and materials
 Observation
- trainee change of attitude and behaviour
32
Assignment
 Write notes on the same
References
 Metalwork pupils book 1, 2, 3, and 4 by KIE
 Metal work Book 1and 2 by F.M. Njuguna
 Teaching Yourself welding by L. Gourd
 Workshop Technology by G.H. Thomas
14.1.2.1T MODULE UNIT: ENGINEERING MATERIALS

THEORY

a) name common engineering materials
b) state the uses of common engineering materials
c) list properties of engineering materials
d) state different forms of materials supply
e) outline workshop tests used to identify materials.
f) state safety precautions to be observed in handling and storing materials
14.1.2.1T2 Content
 Engineering materials
- ferrous metals
- non-ferrous
- plastics
- rubber
- wood
- glass
 Properties of engineering materials
- physical properties
- mechanical properties
 Materials supply
 Tests
● Safety
PRACTICE:

a) identify different types of metals
b) select appropriate materials for a given task
c) identify different types of forms of supply
d) perform simple workshop tests to determine given properties
e) demonstrate safe working habits
14.1.2.1P2 Content
 Types of metals
- Ferrous
 mild steel
 cast iron
 high carbon steel
- Non – ferrous
 aluminium
33
 copper
 Methods of identification
- grinding ( sparks)
- weight
- colour
- appearance
 Materials selection
- mild steel
- cast iron
- medium carbon steel
- high carbon steel
 Forms of material supply
- Flat bars
- Plate or sheet
- Tubes
- Channel
- ‘Z” section
- “T” section
 Workshop tests
- hardness test
- spark test
- magnetism test
- sound test
 Safety
- wearing of hand gloves
- use of welding shield
- wearing safety boots
- using grinding goggles
- using tongs when handling hot metals
- using tools correctly
Competencies
Ability to:
 identify metals
 select appropriate materials
 identify forms of supply
 perform simple workshop tests
 demonstrate safe working habits
Identifying metals
 Display and discuss samples of ferrous metals and non-ferrous to include
- ferrous metals – mild steel, cast iron
- non-ferrous metals – copper, aluminium
Selecting appropriate materials

 Discuss and demonstrate criteria used for selecting appropriate engineering materials
to include:
- mild steel
- cast iron
34
- high carbon steel
Identifying forms of supply

 Discuss and display various forms of material supply to include:
- Flat bars
- Plate or sheet
- Tubes
- Channel
- “Z” section
- “T” section
Performing workshop tests

 Discuss and Demonstrate the following workshop tests
- hardness test
- spark test
- magnetism
- sound test
Demonstrating safe working habits

 Discuss and demonstrate safety procedure to be followed when handling engineering
materials to include
- appropriate dress and safety gear
- handling hot metals
- proper handling of tools
The trainee should

 identify metals
 select appropriate materials
 identify forms of supply
 perform simple workshop tests

 Material samples – Ferrous Metals
- mild steel flat bars
- pieces of cast iron
- carbon steel material e.g. car spring, drill bit etc
- stainless steel e.g. utensils, cooking vessels etc
 Non-ferrous
- copper wire, copper rod
- aluminium wire, aluminium utensil
- brass fittings, window stays etc
- lead – battery plates
- zinc – dry cells
 Bench grinder/hand grinder
 Bar magnet
 Assorted files
 Charts and posters with safety messages
Assessments
 Tests – oral/written tests
35
 Practical exercise – Identification of metals
- Workshop test, e.g. Bend test
 Assignments as follow-up activities on materials identification and application in
engineering
Suggested References
1. Metalwork Technology by G.H. Thomas
2. Introduction to Workshop Technology – By M.H.A. Kempster
3. Workshop Processes for Mechanical Engineering Technicians – Vol. 2 by R.T.
Pritchard
14.1.2.2T MODULE UNIT: CLAMPING DEVICES

THEORY

(a) At the end of this module unit, the trainee should be able to:
(b) name various types of clamping devices used in a workshop
(c) name parts of bench vice and the material they are made of
(d) explain the correct methods of maintaining and caring for bench vice
14.1.2.2T2 Content
 Types of clamping devices
- bench vice, hand vice, leg vice, pipe vice
- ‘G’ clamp, tool makers clamp, sash clamp
 Parts of the bench vice
- movable jaw
- fixed jaw
- screw and handle
- nut and collar
- serrations
- body
 Care and maintenance of clamping devices
- cleaning
- oiling or greasing
PRACTICE:
a) identify clamping devices
b) select appropriate clamp for a given job
c) care for and maintain clamping devices
d) observe safety precautions when using clamping devices
14.1.2.2P2 Content
 Types of clamping devices
- bench vice
- hand vice
- leg vice
- pipe vice
- G clamp
- Tool maker’s clamp
- Sash clamp
36
 Clamping devices
- material shape
- material size
- surface finish
 Care and maintenance of clamp devices

- cleaning
- oiling and greasing
- handling and storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify types of clamping devices
 select appropriate clamping devices for a given job
 care for and maintain clamp devices
 observe safety precautions
Identifying types of clamping devices

 Display and discuss various types of clamping devices to include
- bench vice
- hand vice
- leg vice
- pipe vice
- g-clamp
- sash clamp
- tool maker’s clamp
Selecting appropriate clamping devices

 Discuss and demonstrate how to use various types of clamping devices taking
into consideration
- Shape of materials
- Material size
- Surface finish
Caring for and maintaining clamping devices

 Discuss and demonstrate how to care for and maintain clamping devices to
include
- cleaning
Observing safety precautions when using clamping devices

37
 Discuss and demonstrate safety precautions to be observed when handling
clamping devices in terms of
- personal safety
- equipment safety
The trainee should

 identify types of clamping devices
 select appropriate clamping devices for a given job
 care for and maintain clamp devices

 Charts, posters, pictures and actual clamping devices
 Protective safety gears
 Assorted work pieces
 Assorted relevant working tools
Assessment
 Written test
On clamping devices
Bench vice
 Oral test
 Practical test
- identification
- application
 Metalwork by GH Thomas
 Metalwork Pupils Book 1, 2 3 and 4 by KIE
 Metalwork book 1 and 2 by F.N. Njuguna
14.1.2.3T MODULE UNIT: MEASURING AND CHECKING TOOLS

THEORY

(a) name various measuring tools
(b) state the uses of each of the measuring tools
(c) explain how to care for and maintain measuring tools
14.1.2.3T2 Content
 Measuring tools:
- steel rule
- vernier caliper
- tape measure
- calipers ( outside and inside)
 Uses of measuring tools
 Care and maintenance of measuring tools
- cleaning
- oiling
PRACTICE:
38
(a) identify measuring tools
(b) use measuring tools to take measurements and check squareness and parallelism
(c) care and maintain measuring and checking tools
(d) Practice safety when checking and taking measurements
14.1.2.3P2 Content
● Measuring and checking tools
- steel rule
- calipers
- try square
- vernier calipers
- tape measure
● Usage of measuring and checking tools
- sizes
- parallelism
- squareness
● Care and maintenance of measuring and checking tools

- cleaning
- oiling
- proper handling
- storage
● Safety
- personal safety
Competencies
Ability to:
● identify measuring and checking tools
● use tools to take measurements
● care and maintenance of measuring and checking tools
● practice safety when measuring and checking
Identifying measuring and checking tools

The instructor should:
 Display and discuss various measuring and checking tools to include:
- Features and application of the following tools
 steel rule
 tape measure
 vernier caliper
 calipers (outside and inside)
 try square
Taking measurements
 Discuss and demonstrate correct procedure of taking measurement to include
39
- Length and diameters
- Parallelism
- Squareness
- Right angles
Caring and maintaining of measuring and checking tools

 Discuss and demonstrate the procedure of caring and maintaining measuring
and checking tools in terms of
- handling
- cleaning
- oiling
- storage
Observing safety precaution when handling measuring and checking tools

 Discuss and demonstrate safety precautions to be observed when handling measuring
and checking tools in terms of
- Personal safety
- Equipment safety
The trainee should

● identify measuring and checking tools
● use tools to take measurements
● care and maintenance of measuring and checking tools
● practice safety when measuring and checking

 Charts, posters, pictures with relevant information on measuring and checking
tools
 Protective gears
 Assorted work pieces and finished products
Assessment
 Written tests on measuring tools and checking
 Oral tests – name various measuring and checking tools
 Practical tests
- identification of tools and equipment
- application
 taking measurement
 checking parallelism
 checking angles
 Observation
- On tools usage
- Safety
 Metalwork by G.H. THOMAS
 Metal Work Pupils Book 1, 2, 3, 4, by KIE
 Metal work books 1 & 2 by E.N. Njuguna
 Workshop processes for Mechanical Engineering Technicians Vol. 1 by R.T.
Pritchard
40
14.1.2.4T1 MODULE UNIT: MARKING OUT TOOLS
THEORY

a) name various marking out tools
b) state the uses of each marking tool
c) explain how to care for and maintain marking out tools
d) observe safety when handling marking out tools
14.1.2.4T2 Content
 Marking out tools
- try square
- surface plate
- angle plate
- scriber
- scribing block
- odd leg caliper
- dividers
- dot punch
- centre punch.
 Uses of marking out tools
- straight lines
- arcs and curves
- profiles
 Care and maintenance of measuring tools
- cleaning
- oiling
 Safety
- personal safety
PRACTICE:
a) identify marking out tools
b) use marking out tools
c) care for and maintain marking out tools
d) observe safety when marking out.
14.1.2.4P2 Content
 Marking out tools
- surface plate
- angle plate
- scriber
- scribing block
- odd leg caliper
- dividers
- dot punch
- centre punch
 Uses of marking out tools
- straight lines
41
- circles, arcs and profiles
- dot punching
- centre punching
 Care and maintenance of marking out tools
- cleaning
- oiling / greasing
- handling
- storage
 Safety
- personal safety
Competencies
Ability to:
 identify marking out tools
 use marking out tools
 care for and maintenance of marking out tools
 observe safety precautions when marking out
Identify marking out tools

 Display and discuss various marking out tools to include features and uses of the
following tools
- try square
- surface plate
- scriber
- odd leg caliper
- dot punch
- centre punch
- angle plate
- scribing block
- divider
Using marking out tools

 Discuss and demonstrate how to use marking out tools to include
- squareness
- flatness
- scribing lines
- transferring measurements
- marking out centres of holes to be drilled
- witness marks (outline of the marked component)
- drawing parallel lines
- supporting the work on the surface plate
- drawing arcs and circles
Caring for and maintaining marking out tools

 Discuss and demonstrate how to care for and maintain marking out tools to include
- handling
- usage
- cleaning
- oiling
42
- storage
Observing safety precaution when handling marking out tools

 Discuss and demonstrate safety precautions to be observed when handling marking
out tools to include
- Personal safety
- Tools and equipment safety
The trainee should

 identify marking out tools
 use marking out tools
 care for and maintenance of marking out tools
 observe safety precautions when marking out

 Charts, posters, pictures with the relevant information on marking out tools
 Protective gear
 Assorted workpieces
 Finished products
Assessments
 Written tests to include
 Types, features uses and application of marking out tools
 Oral tests to include
 Types feature and uses of marking out tools
 Practical tests
- identification of tools and equipment
- application on:
 marking out angles
 marking out parallel links
 marking out centres
 marking out right angles
 marking arcs and circles
 Observation
- Trainee attitude towards practical work
- Trainees ability to demonstrate team work and organization skills
i) Metalwork pupils book 1, 2, 3 and 4 by KIE
ii) Metalwork book 1 and 2 by F.N. Njuguna
14.1.2.5T MODULE UNIT: MATERIAL REMOVAL

THEORY

At the end of this module unit, the training should be able to:
a) name various types of tools used for materials removal
b) state the uses of each of the tools
c) explain how to care for and maintain materials removal tools
d) demonstrate safety precautions when removing materials
43
14.1.2.5T2 Content
 Types of tools
 files
 scrapers
 emery cloth
- Types of files
 flat
 square
 hand file
 triangular
 round
 half round
- Features of files
 length
 shape of cross – section
 coarseness of teeth
- Hand scrapers
 flat
 triangular
 half round
- Grades of emery cloth
 grades
 Uses of material removal tools
- Files
 roughing
 draw filing
 smoothening of surfaces
 removal of sharp edges
- Scrapers
 flat surfaces
 internal cylindrical surfaces
- Emery cloth
 hand polishing
 flat surfaces
 cylindrical surfaces
 Care and maintenance of materials removal tools
- cleaning
- oiling/greasing
 Safety
- personal safety
PRACTICE:

a) identify various types of material removal tools
b) use material removal tools to produce a component to the required dimensions
c) use emery cloth for polishing
d) care for and material removal tools
e) observe safety precautions when removing materials
44
14.1.2.5P2 Content
 Types of material removal tools
- files
- scrapers
- emery cloth
 Usage of material removal tools
- files
 roughing
 draw filing
 smoothening of surface
 removing of sharp edges
- Scraper
 smoothening of surfaces
 removing sharp edges
 awkward angular surfaces
 bearing/bushes
- Emery cloth
 polishing rough surfaces
 Care and maintenance of material removing tools
- cleaning
- sharpening
- oiling/greasing
 Safety
- personal safety
- equipment safety
Competencies
Ability to
 Identify material removal tools
 Use material removal tools
 Care for and maintain material removal tools
Identify material removal tools

 display and discuss the various types of tools used for material removal to include
- features
- files
- scrapers
- emery cloth
Using material removal tools
Instructor should
 Discuss and demonstrate how to use material removal tools to include operations
such as:
- roughing
- draw filing
- smoothening of surfaces
- removal of sharp edges
- production of flat surfaces
- polishing
Caring for and maintaining material removal tools
45
 Discuss and demonstrate how to care for and maintain material removal tools to
include:
- Cleaning
- handling
- oiling
- storage
Observing safety precautions

 Discuss and demonstrate safety precautions to be observed when handling material
removal tools to include
- Personal safety
- Tool and equipment safety
The trainee should

 Identify material removal tools
 Use material removal tools
 Care for and maintain material removal tools

 charts to include
- various material removal tools
- assorted material removal tools
- assorted work pieces
Assessment method
 Oral/written exams to include
- Identification and uses of material removal tools
- Care and maintenance of material removal tools
- Safety in handling of material removal tools
 Practical
- A class project to involve the use of various material removal tools
 Observation
- The trainee to have positive attitude toward practical work
References
 Metal work pupils book 1, 2, 3 and 4 by KIE
 Metal work Technology by G.H. Thomas
 Metal work book 1 & 2 by F.J. Njuguna
14.1.2.6T MODULE UNIT: CUTTING TOOLS
THEORY

a) name various types of cutting tools
b) state the uses of each cutting tool
c) explain how to care for and maintain cutting tools
d) observe safety when handling cutting tools.
46
14.1.2.6T2 Content
 Types of cutting tools
- Types of chisels
 flat
 cross-cut
 half round
 diamond point
- Types and parts of hacksaws
 Types
- pistol grip
- straight handle
- junior hacksaw
 Parts
- frame
- blade
 Uses of cutting tools

- chipping
- sawing
 Care and maintenance of cutting tools
- cleaning
- oiling/greasing
- grinding ( mushroom head)
 Safety
- personal safety
PRACTICE:

a) identify various types of sawing and chipping tools
b) use sawing and chipping tools to saw and chip to size
c) care for and maintain sawing and chipping tools.
d) observe safety when sawing and chipping
14.1.2.6P2 Content
 Types of sawing and chipping tools
- Sawing
 pistol clip saw
 straight handle
 junior hacksaw
- Chipping tools
 flat chisels
 cross – cut chisel
 diamond point chisel
 half round chisel
 Sawing and chipping tools
- Hacksaw
 straight cutting
 profile cutting
- Chipping
 general chipping (flat and straight)
47
 oil grooves
 key ways
 Care and maintenance of sawing and chipping tools
- cleaning
- grinding of chisel edge
 Safety
- personal safety
 grinding mushroom head of chisels
 loose hammer heads
Competencies
Ability to:
 identify sawing and chipping tools
 use sawing and chipping tools
 care for and maintain sawing and chipping tools
 observe safety precautions when handling sawing and chipping tools
Identifying sawing and chipping tools

Instructor should
 Display and discuss various types of sawing and chipping tools to include the
following
- Sawing
 Piston grip saw
 Straight handle
 Junior hacksaw
- Chipping
 Flat chisels
 Cross-cut chisel
 Diamond point chisel
 Half-round chisel
Using sawing and chipping tools

 Demonstrate the use of sawing and chipping tools to cut material to size to include
the following
Sawing and chipping tools
- Hacksaw
 Straight cutting
 Profile cutting
- Chipping
 General chipping (flat and straight)
 Oil grooves
Caring for and maintaining sawing and chipping tools

 Demonstrate care and maintenance of sawing and chipping tools to include
- Cleaning
- Grinding of chisel edges
- Handling and storing
Observing safety precautions when handling sawing and chipping tools
48
 Demonstrate safe habits when handling sawing and chipping tools to include
- Personal safety
 Grinding mushroomed head of chisels
 Fixing loose hammer heads
The trainee should

 identify sawing and chipping tools
 use sawing and chipping tools
 care for and maintain sawing and chipping tools
 observe safety precautions when handling sawing and chipping tools
Key Learning/Teaching resources

 Sawing and chipping tools to include
- Sawing
 Pistol grip hacksaw
 Straight handle saw
 Junior saw
- Chipping
 Hat chisel
 Cross-cut chisel
 Diamond chisel
 Half round chisel
 Samples of workpieces to be cut
 Relevant tools like hammers and vices
 Charts showing cutting and sawing tools
Assessment methods
 Oral test on the use of sawing and chipping tools
 Written test on
 The use of sawing and chipping tool
 Practice
 cut keyway on a given piece of work
 practical exercise involving straight and profile hack sawing
 Observation
 Observing safety precautions when sawing and chipping
Reference
1. Workshop Technology by J.W. Chapman Part 1
2. Metalwork Technology – by G.H. Thomas
3. Basic Fabrication and Welding engineering by J. Smith
49
14.1.2.7T MODULE UNIT: DRILLING
THEORY

At the end of this module unit, the training should be able to:
a) name various types of drilling machines
b) name parts of sensitive drilling machine
c) list various types of drill bits
d) state various operations carried on drilling machine
e) explain how to care for and maintain drilling machine
f) state safety precautions to be observed when drilling
14.1.2.7T2 Content
 Types of drilling machines
- sensitive drilling machine
- hand drilling machine
- pillar drilling machine
 Parts of a sensitive drilling machine
- base
- column
- vee belt and pulleys
- belt cover
- adjustable table
- feed handle
- chuck
- motor
 Types and parts of drill bits
- Types
 parallel shanks
 taper shanks
- Parts
 tang
 body
 shank
 flute
 land
 tip
 chisel edge
 Drilling machines operations
- drilling of hole
- counter boring
- counter sinking
 Care and maintenance
- cleaning
- oiling/greasing
- adjusting
 Safety
- personal safety
50
PRACTICE:

a) identify various types of drilling machines
b) identify various types of drill bits
c) use drilling machine to perform a given task
d) demonstrate safe working habits when using a drilling machine
e) care for and maintain drilling machine and drill bits
14.1.2.7P2 Content
 Types of drilling machines
- pillar type drilling machine
 Types of drill bits
- parallel shank
- taper shank
- counter sinking bits
- counter boring bits
 Drilling to specified dimensions
- drilling of holes
- counter boring
- counter sinking
 Care and maintenance of drilling machine and bits
- cleaning
- oiling/greasing
- grinding bits to required angles
- handling and storage of drill bits
 Safety
- personal safety
Competencies
Ability to:
- identify types of drilling machines
- identify types of drill bits
- use drilling machine to perform given task
- care for and maintain drilling machine and bits
- demonstrate safety precautions
Identifying types of drilling machines

 Display and discuss various drilling machines to include parts, features and uses
of the following drilling machines
- Sensitive drilling machines
- Hand drilling machine
- Pillar drilling machine
51
Parts to include
- base
- column
- vee belt, pulleys, cover
- adjustable table
- feed handle
- drill chuck, motor, chuck key use to include:
- drilling
- boring
- counter boring
- spot facing
- counter sinking
Identifying types of drills

 display and discuss features of the following drilling bits
- parallel shanks
- taper shanks
features to include
- tang
- body
- shank
- flute
- land
- tip
- chisel edge
Using drilling machine

 Discuss and demonstrate various drilling operations to include
- centre punching
- work holding
- speed selection
- drill bit mounting
- drilling
- counter boring
- counter sinking
- spot facing
Caring for and maintaining drilling machine and drill bits

 Demonstrate proper care and maintenance of drilling machines to include
- cleaning
- oiling/greasing
- handling
- storage
Demonstrating safety precaution

 Demonstrate safe working habits when operating a drilling machine and
performing drilling operations to include
- safety gear
- clear goggles
- overall
52
- safety boots
- gloves
- swarf removal
- chuck key removal
- removal of drill bit
Trainee should
 identify types of drilling machines
 identify types of drill bits
 use drilling machine to perform given task
 care for and maintain drilling machine and bits
 demonstrate safety precautions
Learning Resources
 Labelled charts of various drilling machines to include:
- pilar drilling machine
- drill bits
- counter boring tools
- counter sinking tools
- wall pictures
- spot facing tool
- spot faced work pieces
- text books
- drilled work pieces
- counter bored work pieces
- counter sunk work pieces
- assorted working tools to include
 scriber
 centre punch
 hammer
 hacksaw
Assessment method
 Oral test on types of drilling machines, their parts and operation
 Written test on types of drilling machines, their parts, operation, care and
maintenance
 Practical test on a class project to involve all the drilling operations e.g. a door hinge
References
1. Metal work pupils book 1, 2, 3 and 4 by KIE
2. Metal Work by F.N. Njuguna
3. Metal work Technology by G. H. Thomas
53
14.1.2.8T MODULE UNIT: HAND THREAD CUTTING TOOLS
THEORY

a) name various types of hand thread cutting tools
b) state the uses of hand thread cutting tools
c) explain how to care for and maintain hand thread cutting tools
d) practice safe working habits
14.1.2.8T2 Content
 Types of hand thread cutting tools
- taps
- dies
 Uses of hand thread cutting tools
- Taps for internal threads
 first tap
 second tap
 bottom tap
- Tap wrenches
 solid tap wrench
 adjustable tap wrench
- Dies for external threads
 circular dies
 rectangular dies
 die nuts
- Die stocks
 rectangular die stock
 circular die stock
- solid dies
- split dies
 Care and maintenance of hand thread cutting tools
- cleaning
- oiling
 Safety
- personal safety
PRACTICE:

a) identify hand thread cutting tools
b) select the correct tap and dies for a given thread
c) drill appropriate hole for tapping
d) use the taps to cut internal threads
e) use dies to cut external threads
f) care and maintain taps and wrenches
g) observe safety precautions when drilling and tapping
54
14.1.2.8P2 Content
 Thread cutting tools
- Taps
 first tap
 second tap
 bottoming tap
- Tap wrenches
 solid tap wrenches
 adjustable tap wrenches
- Dies
 circular dies
 rectangular dies
 Selection of thread cutting tools
- type of thread e.g. metric, BA, BSW
- number of teeth per given length
 Tapping holes
- drill size selection
- drilling operation
 Internal threads
- first tap
- second tap
- bottoming tap
- use of cutting oil
 External threads
- die and die nut
 Care and maintenance of taps and dies
- cleaning
- oiling or greasing
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify hand thread cutting tools
 select correct taps and dies
 drill appropriate tapping hole
 cut internal threads
 cut external threads using dies
 care for and maintain taps and dies
 observe safety precaution
Identifying hand thread cutting tools

 Display and discuss the various hand thread cutting tools to include parts, types and
uses of the following:
- taps
55
 metric
 imperial
- dies
 metric
 imperial
 die nut
 cutting oil
Selecting correct taps and dies

 Discuss and demonstrate how to select taps and dies in terms
- Pitch of thread
- Size
- Tap drill size
- Correct procedure
- Rectifying damaged bolt thread
Drilling appropriate tapping hole

 Discuss and demonstrate how to drill a tapping hole to include
- Size of thread
- Pitch
- Pilot drilling
Cutting internal thread

 Discuss and demonstrate how to make internal thread by hand tools to include
- First tap
- Second tap
- Bottoming tap
- Tap wrench
- Cutting oil
Cutting external threads using dies

 discuss and demonstrate how to cut external threads using dies to include
- Size of thread
- Pitch
- Squareness of die to rod being cut
- Forward and backward movement
- Oiling
- Taps
Caring for and maintaining taps and dies

 Discuss and demonstrate how to care for and maintain taps and dies in terms of
- cleaning
- oiling
- storage
Observing safety precaution

 Discuss and demonstrate safety procedures to be observed when handling taps and
dies to include
- Personal safety
56
The trainee should

 identify hand thread cutting tools
 select correct taps and dies
 drill appropriate tapping hole
 cut internal threads
 cut external threads using dies
 care for and maintain taps and dies
 observe safety precaution

 labeled charts, pictures, to include
- details of hand thread cutting tools
 Workpieces with threaded parts to include
- bolts (bolts with damaged thread)
- nuts
- water pipes
 taps and dies of various sizes, types and pitches
 assorted working tools to include
- drills,
- centre punch
- try square
- oil
- bench vice
 work pieces
Assessment methods
- Oral test to include - types features and uses of hand thread cutting tools
- Written test to include – types, features, uses and application of hand thread cutting
tools
- Practical test to include a class project involving thread cutting both internal and
external
References
 Metal work by F.N. Njuguna
 metal work by GH Thomas
14.1.2.9T MODULE UNIT: FASTENING DEVICES

THEORY

a) name various types of fastening devices
b) name various types of locking tools
c) state uses of each fastening device
d) describe various types of rivets
e) explain how to care for and maintain fastening devices
f) explain how to observe safety precautions
57
14.1.2.9T2 Content
 Types of fastening devices
- rivets
- bolts and nuts
- washers
 Locking tools
- spanners
- screw drivers
- allen keys
 Uses of fastening devices
- permanent locking devices
 rivets
- temporary locking devices
 bolts and nuts
 Types of rivets and the materials they are made from

- Types of rivets
 solid
 hallow (pop rivet)
- Types of rivet heads
 snap head
 flat head
 countersunk head
 pan head
 bifurcated head
- Types rivet materials
 mild steel
 aluminum
 copper
 brass
 Care and maintenance of fastening devices
- cleaning
 Safety
- personal safety
PRACTICE:

a) identify various types of locking devices
b) identify tools and equipment used in making various riveted and bolted joints
c) use tools and equipment to make a riveted or bolted joint
d) assess the quality of a riveted or bolted joint
e) care for and maintain tools and equipment used for making riveted and bolted
joints
f) observe safety when making riveted or bolted joints
14.1.2.9P2 Content
 Locking devices
- rivets and riveted joints
- bolts, nuts, washers and bolted joints
 Tools and equipment used in making various riveted and bolted joints
58
- Riveted joints
 drill bits
 hammers
 dolly
 files
- Bolted joints
 drill bits
 spanners
 screw drivers
 allen keys
 taps and wrenches
 Usage of tools and equipment to make riveted or bolted joints
- Riveted joints
 selecting the appropriate rivet
 drilling appropriate hole size
 forming rivet head
- Bolted joints
 selection of appropriate bolt, nuts and washers
 drilling holes
 tapping where appropriate
 locking the joint
 Assessing the quality of a riveted or bolted joint
- Riveted joints
 shearing of rivets
 formation of rivet head
 tearing of plates between the rivets
 crushing of both rivets and plates
 bursting of plates in front of rivets
- Bolted joints
 loose joints
 misalignment of parts
 Care and maintenance of tools equipment and articles
 cleaning
 oiling / greasing
 handling and storage
 Safety
 personal safety
 tools and equipment safety
Competencies
Ability to:
- identify various types of locking devices
- identify tools and equipment used in making various riveted and bolted joints
- use tools and equipment to make a riveted or bolted joint
- assess the quality of a riveted or bolted joint
- care for and maintain tools and equipment used for making riveted and bolted
joints
- observe safety when making riveted or bolted joints
Identifying locking devices

 display and discuss various fastening devices to include
- solid rivets
59
- hollow rivets
- bolts and nuts
- washers
Identifying tools and equipment used in making riveted and bolted joints
 Display and discuss tools and equipment used in making riveted and bolted
joints to include
- solids rivets
- hollow rivets
- bolts and nuts
- washers
Identifying tools and equipment used in making riveted and bolted joints
 Display and discuss tools and equipment used in making riveted and bolted joints
to include
- spanners
- screw drivers
- allen keys
- rivet set (dolly)
- ball pen hammer
- taps and wrenches
- dies and stock
Assessing quality of riveted or bolted joint

 Discuss and demonstrate how to assess riveted or bolted joint in terms of
- Riveting joints
 shearing of rivets
 formation of rivet head
 tearing of plates between rivets
 crushing of both rivets and plates
 bursting of plates in from of rivets
- bolted joints
 loose joints
 misalignment of parts
Caring and maintaining tools and equipment used for making riveted and
bolted joints
 Discuss and demonstrate how to care and maintain tools and equipment used for
making riveted or bolted joints to include
- Cleaning
- Oiling/greasing
- Handling and storage
Observing safety precaution when making riveted and bolted joints

 Discuss and demonstrate safety precautions when handling riveting and bolting
equipment in terms of
- Personal safety
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The trainee should
 identify various types of locking devices
 identify tools and equipment used in making various riveted and bolted joints
 use tools and equipment to make a riveted or bolted joint
 assess the quality of a riveted or bolted joint
 care for and maintain tools and equipment used for making riveted and bolted
joints
 observe safety when making riveted or bolted joints
Learning resources
- charts to include various fastening and locking devices
- charts to include various locking tools
- fastened parts to include
 riveted parts
 welded parts
 bolted parts
 soldered parts
- assorted working tools to include
 spanners
 drill bits
 hammer
 rivet set, lazzy tong
 various types of rivets
Assessment Methods
- Oral test to include
 types of fasteners
 types of locking devices
 tools used for fastening and locking devices
- Written test to include
 types of fasteners
 types of locking devices
 tools for locking devices
 application of locking and fastening devices
- practical test to include a class project where they will use fasteners, and locking
devices.
References:
 Metal Work Pupils Book 1, 2, 3, 4, by KIE
 Metal Work by F.N. Njuguna
 Metal Work by GH Thomas
14.1.2.10P MODULE UNIT: MATERIALS ESTIMATING AND COSTING

a) estimate the quantities of materials required for a product from a working
drawing
b) cost the product
c) state the economic factors to be considered while costing the product
14.1.2.10P2 Content
 Estimating the quantities of materials
- Preparing cutting list to include
 materials being used
61
 number of pieces
 part names
 actual sizes (length, width and thickness)
 cutting size (length, width and thickness)
 Costing the material for the product

- number of pieces
- cutting size of each materials used and other consumables e.g rivets,
- emery cloth, paint
- unit cost
- total cost
- type of material
 Economic factors
- waste
- labour
- aesthetic
Competencies
Ability to:
 estimate the quantities of materials
 cost the material for the product
Estimating the quantities of materials

 Discuss and demonstrate how to estimate quantities of materials required to
produce a given component in terms of
-Materials being used
-Number of pieces
-Actual sizes (length, width, and thickness)
-Cutting size (length, width and thickness)
Costing the material for the product

 Discuss and illustrate how to cost the materials used to make a product in terms of
-number of pieces
-cutting sizes of each piece
-unit cost
-total cost
The trainee should:

 estimate the quantities of materials
 cost the material for the product
Learning resources
 Charts to include
-Assembly drawing
-Working drawing
 Catalogues to include
-Price lists
-Quotations
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-Types of materials
Assessment methods
 Oral questions to include
-Material cost
-Labour cost
- Overhead cost
- Total cost
 Written questions to include
- Material cost
- Labour cost
- Overhead cost
- Total cost
- Working drawing
- Cutting size
 Practical test to include
- Cost estimation of an assembled project e.g. G-clamp, metal chair/stool
 Observation - monitor positive attitude towards
- Minimizing material costs
- Labour cost
- Aesthetic value
References
 workshop technology by – Hastle Hurst
14.1.3.1T MODULE UNIT: SHEET METAL WORK MATERIALS

THEORY
14.1.3.1T1 specific Objectives

a) list down various types of sheet metals commonly used in metal industry
b) state typical applications of sheet metals in the metal industry
c) state the properties and characteristics of the sheet metal materials
d) explain the differences between the sheet metals and plate
e) state the safety precautions to be observed when handling sheet metal
14.1.3.1T2 Content
 Types of sheet metal commonly used in metal industry
- Black mild steel
- Galvanized iron
- Copper sheets
- Aluminium
- Tin sheet
- Stainless steel sheet
- Brass sheet
 Typical application of sheet metals in the metal industry
- Black mild steel sheet
 door
 windows
 storage tanks
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 trucking
 cabinets
 office furniture
- Galvanized iron
 Storage tank
 Trunking
 Cabinets
 Buckets
 Heat ducts
 Gutters
- Copper sheets
 Kitchen ware
 Domestic appliances
 Kitchen cabinets
 Milk cans
 Windows and door frames
- Aluminium
 Food containers
 Edible oils and ghee containers
 Aeroplane bodies
 Pans
 Daily equipment
 Cans
- Stainless steel sheet
 Kitchen ware
 Food handling equipment
 Daily equipment
 Laundry equipment
 Food processing plan
 Household utensils
- Brass sheet
 Trophies
 Chains
 Wrist watches
 Containers
 Properties and characteristics of sheet metal materials
- Properties
 Malleable
 Ductile
- Characteristics
 Light
 Non ferrous sheets (non-corrosive
 Easier to work on
 Good appearance
 Plates and sheet metal
- Thickness
- Materials
 Safety
- Personal safety
- Materials safety
PRACTICE:

64
a) identify various sheet metal work materials
b) select sheet metal material for a given job
c) observe safety when handling sheet metal materials
14.1.3.1P2 Content
 Sheet metal materials
- black mild steel
- galvanized iron sheet
- copper sheet
- stainless steel sheet
- aluminium sheet
- tin plated sheet
- brass sheet
 Sheet metal selection
- steel door panels, boxes, cabinets
- water tanks, trunking
- kitchen equipment
- cans
- food containers
- trophies
Competencies
Ability to:
 identify various sheet metal work materials
 select sheet metal material for a given job
 observe safety when handling sheet metal materials
Identifying various sheet metal work materials

 Display and discuss various sheet metal products to include
- Chicken feed trough
- Sheet metal bucket
- Scoop for sugar, flour, grains
- Roof gutters etc
Selecting sheet metal material for a given job

 Discuss various types and uses of sheet metals commonly used in metal industry to
include
- Galvanized sheet – used in storage tanks, trucking, gutters
- Tin plates – used in food, containers
- Stainless steel sheet – used in kitchen ware, dairy equipment
- Aluminium sheet – used in food containers, aeroplane bodies
- Mild steel sheet door, windows, office furniture
- Copper sheet used in kitchenware, milk cans, window frame
- Brass sheet – used in trophies, chairs, wrist watches, containers
Observing safety when handling sheet metal materials

 Discuss and demonstrate how to observe safety when handling sheet metal materials
to include:
- Sheet metal handling (safety gear)
- Proper storage avoid kincking
65
- Avoid using still hammers when handling sheet metal
- Avoid scratching
The trainee should

 identify various sheet metal work materials
 select sheet metal material for a given job
 observe safety when handling sheet metal materials
Learning Resources
- Various sheet metal products
- Various sheet metal materials and tools
 Various sheet metal products to include
- Trays
- Buckets
- Chicken feed troughs
- Cans
- Cabinets
Assessment Methods
- Types of sheet metal products
- Types of sheet metal materials and their uses
- Types of sheet metal tools
- Properties of sheet metal
 Written test to include
- Types of sheet metal materials and their uses
- Types of sheet metal tools and their uses
- Applications of sheet metal
- Properties of sheet metal
 Practical test
- Selection of material and construction of a sheet metal product to include
 Chicken feed trough
 Bucket
References
 Metal work book by J.N. Njuguna
14.1.3.2T MODULE UNIT: SHEET METAL HAND TOOLS AND

EQUIPMENT
THEORY

a) classify sheet metal hand tools and equipment according to their uses
b) explain how to care for and maintain sheet metal work tools
c) state the safety precautions to be observed when using the hand tools
14.1.3.2T2 Content
 Hand tools and equipment used in sheet metal work
- Laying out tools
 steel rule
 flat square
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 scratch awl
 scriber
 pencil
 dividers
 tape measure
 straight edge
- Cutting tools
 tin snips or shears
 punches
 chisels
- Forming tools
 stakes
 mallets
 hammers
- Jointing tools
 grooving tools
 grooving set and hammers
- Edge preparation
 mallets
 tacking hammers
 Care and maintenance of sheet metal tools and equipment
 Safety
- personal safety
- equipment safety
PRACTICE:

a) identify various hand tools and equipment used in sheet metal work
b) use sheet metal hand tools and equipment to perform a given task
c) care and maintain sheet metal hand tools
d) observe safety when handling sheet metal hand tools and equipment.
14.1.3.2P2 Content
 Hand tools and equipment used in sheet metal work
- marking out tools
- cutting tools
- forming tools
 Usage of hand tools
- measuring
- cutting
- marking
- forming
 Care and maintenance of sheet metal hand tools and equipment
- Oiling/greasing
- sharpening
- storage and handling
 Safety
- personal safety
Competencies
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Ability to:
 identify various hand tools and equipment used in sheet metal work
 use sheet metal hand tools and equipment to perform a given task
 care and maintain sheet metal hand tools
 observe safety when handling sheet metal hand tools and equipment.
Identifying and classifying hand tools and equipment used in sheet metal
 classify and discuss various sheet metal tools and their uses to include:
- Marking out tools
 steel rule
 flat square
 scratch awl
 scriber
 pencil
 dividers
 tape measures
 straight edge
- Cutting tools
 tin snips and sheers
 punches
 chisels
- Forming tools
 stakes
 mallets
 hammers
- Joining tools
 grooving tools
 grooving set and hammers
- Edge preparation tools
 mallets
 tacking hammer
Using sheet metal hand tools and equipment to perform a given task
 Demonstrate the use of various sheet metal hand tools and equipment (above) to
perform a given task to include
- marking out
- cutting to shape
- folding
- bending
- forming
- beading
- hemming
Caring and maintenance of sheet metal and equipment

 Demonstrate proper care and maintenance of sheet metal hand tools and equipment
to include
- Cleaning
- Oiling/greasing
- Maintaining
68
- Storage
Observing safety
 Demonstrate safe working habits when using sheet metal hand tools and equipment
to include
- handling (proper safety gears)
- proper usage
- storage
Trainee should
 identify various hand tools and equipment used in sheet metal work
 use sheet metal hand tools and equipment to perform a given task
 care and maintain sheet metal hand tools
 observe safety when handling sheet metal hand tools and equipment.
Learning Resources
- Various sheet metal – hand tools and equipment
- Finished sheet metal products
 Assorted sheet metal hand tools and equipment to include
- layout tool
 scribers
 steel rule
 dividers
 flat square
 tape measure
- cutting tools
 tin snips
 bench sheers
 chisels
 punches
- forming tools
 stakes
 folding bars
 mallets/hammers
- jointing tool
 grooving tool
 grooving set and hammer
Assessment Methods
 Oral test to include
- layout tools
- cutting tools
- forming tools
- jointing tools
- layout tools
- cutting
- forming tools
- jointing tools
- application
 Practical test to include the following operations
- marking out
- cutting
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- folding
- bending
- To produce a given product
References
 Metal work book FN Njuguna
 Metal work book by G.H. Thomas
14.1.3.3T MODULE UNIT: SHEET METAL JOINTS AND SEAMS

THEORY

a) Classify sheet metal hand tools and equipment according to their uses
b) explain how to care for and maintain tools and equipment used in sheet metal work
c) explain the safety precautions to be observed when preparing given sheet metal
joint/seam
14.1.3.3T2 Content
 Sheet metal joints and edge treatment
- Joints
 lap
 seam
 locked seam
 grooved seam
- Edge treatments
 hem
 false wired edge
 wired edge
 Typical applications of sheet metal joints and edge treatment
- Joints
 lap –soldered/riveted
 locked seam –positive grip strength
 grooved seam –water and air tight
- Edge treatment
 strength
 beauty
 safety of edge
 Tools/equipment used for making joint/seam treatment
- Lap – steel rule
 odd leg calipers
 riveting tool/soldering tools
- Locked seam
 steel rule
 odd leg caliper
 mallet
 hatchet stake
- Grooved seam
 steel rule
 odd leg caliper
 mallet
70
 grooving tool
 hatchet stake
- Edge treatment
 steel rule
 odd leg caliper
 mallet
 stakes
 Safety
- personal safety
- equipment safety
PRACTICE:

a) identify joints commonly used in sheet metal work
b) make given sheet metal seams and edge treatments
c) observe safety precaution when making sheet metal joints and seams
d) care for and maintenance of tools and equipment
14.1.3.3P2 Content
 Sheet metal joints
- plain lap seam
- corner lap (inside)
- corner lap (outside)
- grooved seams
- knocked up
 Sheet metal seams and edge treatment making
- marking
- cutting
- forming/folding
 Safety
- personal safety
- equipment safety
 core and maintenance
- oiling
- cleaning
- storage
Competencies
Ability to:
 identify sheet metal joints commonly used in sheet metal work
 make given sheet metal seams and edge treatments
 observe safety precaution when making sheet metal joints and seams
 care and maintain tools and equipment
Identifying sheet metal joints commonly used in sheet metal work

 Show and explain various sheet metal joints in sheet metal to include
- lap joint
- grooved seam
- locked seam
- paned down joint
71
- knocked up joint
Making sheet metal seams and edge treatment

 demonstrate the correct procedure for making various sheet metal seams and edge
treatments to include
- water tight joints
- stiffening
- safety
- beauty (decorative)
Observing safety when making sheet metal joints and seams

 Demonstrate safe working habits when making sheet metal joints and seams to
include
- safety gear
- equipment safety
- tools and equipment handling
Caring and maintaining tools and equipment

 Demonstrate the correct procedure of care and maintaining sheet metal tools and
equipment to include
- oiling
- cleaning
- storage
The trainee should

 identify sheet metal joints commonly used in sheet metal work
 make given sheet metal seams and edge treatments
 observe safety precaution when making sheet metal joints and seams
 care and maintain tools and equipment

- Various sheet metal joints and edge treatment
 Handouts on various sheet metal joints and edge treatment
 Assorted sheet metal working tool and equipment
Assessment Methods
 Oral/written test to include:
- types of sheet metal joints and edge treatment
- application of sheet metal joints
- safety and proper care of sheet metal tools and equipment
 Practical test to include a class project involving the following joints

- lap joint
- seam joint
- grooved seam
- knocked up seam
- stiffening
- safe edges
- decoration
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14.1.3.4T MODULE UNIT: PATTERN LAYOUT AND DEVELOPMENT
THEORY
14.1.3.4t1 Specific Objectives

a) define the term pattern in sheet metal work
b) state importance of pattern development in sheet metal work
c) name the tools used for pattern layout
d) explain the operation procedure for developing the pattern for a given components
e) state the necessary safety precautions to be observed when developing a pattern
14.1.3.4T2 Content
 Definition of the term pattern
- Component surface development
 Importance of surface development
- proper layout of an object
- used as a template
- economical method of production
 Hand tools used for pattern layout
- steel rule
- dividers
- trammel
- odd leg calipers
- flat square
- hollow punches
- snips/ shears
 Operation procedures for pattern development
- interpretation of the drawing
- preparation of the materials for laying out
- laying down the pattern
- cutting pattern size
 Safety
- personal safety
- equipment safety
PRACTICE:

a) identify tools used for pattern layout and development of given sheet metal
components
b) make pattern layout and development of given sheet metal components
c) care and maintain tools and equipment used for laying out patterns and developments
d) observe safety precautions when handling tools for pattern layout and development
14.1.3.4P2 Content
 Tools for pattern layout and development
- marking out tools
- cutting tools
- forming tools
 Pattern layout and development
- materials for making pattern layout and development
- storage of patterns
 Care and maintenance of tools and equipment
73
- cleaning
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify tools used for pattern layout and development of given sheet
metal components
 make pattern layout and development of given sheet metal components
 care and maintain tools and equipment used for laying out patterns and developments
 observe safety precautions when handling tools for pattern layout and development
Teaching/Learning activities
Identifying tools used for pattern layout and development of sheet metal components
 Display and discuss pattern layout tools to include
- steel rules
- dividers
- trammel
- odd leg calipers
- flat square
- hollow punches
- tin snips/bench shears
Making pattern layout and development of sheet metal components

 Demonstrate and explain methods of developing sheet metal patterns to include
- interpretation of sample drawings
- preparation and selection of material for the pattern
- drawing the pattern on the material
- cutting the material to required shape/pattern
- folding the pattern to produce the component
Caring and maintaining tools and equipment used for laying out and developing
patterns
 Demonstrate proper care and maintain tools and equipment used for laying out and
developing patterns to include:
- cleaning of tools
- handling and storage of patterns
Observing safety
 Demonstrate safe working habits when using pattern layout and development tools to
include:
- marking out tools
- cutting tools
- forming tools
The trainee should

 identify tools used for pattern layout and development of given sheet
74
metal components
 make pattern layout and development of given sheet metal components
 care and maintain tools and equipment used for laying out patterns and developments
 observe safety precautions when handling tools for pattern layout and development

 posters, charts and pictures with developed sheet metal components, marking out,
cutting and forming tools
 samples of developed sheet metal components marking out, cutting and forming tools
 samples of materials used for making patterns e.g. paper, hard board, soft board
Assessment
 written tests to include
- Definition of the term pattern development
- Drawing of patterns for given components
- Establishing material size for a given component
- Sketching of marking out, cutting and forming tools
 Production of templates from drawn patterns
- Identification of tools used for layout and development of patterns
- Handling and maintaining tools mentioned above
 Practical tests – on pattern making
1. G.H. Thomas
2. Longman Industrial Arts Book Four
75
14.1.3.5T MODULE UNIT: SHEET METAL FORMING
THEORY
a) distinguish between forming and bending of sheet metal
b) state typical applications of each process
c) name types of folding and bending tools/equipment used in sheet metal work
d) explain the correct method of forming various sheet metal components
e) explain how to care for and maintain folding and bending tools/equipment
f) list the safety precautions to be observed when folding and bending sheet metal.
14.1.3.5T2 Content
 Distinguish between forming and bending
- Forming
 deflection of metal is sharp and the radius small
- Bending
 bending the curvature is large and the deflection covers a large area
 Tools and equipment used for forming and bending sheet metal
- stakes
- mallets
- G- clamps
- folding bars
 Application of each operation
- Forming
 angular folds for:
 tool boxes
 cabinets
 trunking
 air ducts
- Bending
 cylindrical shape forming
 conical shapes forming
 Water tanks
 tubes
 funnels
 scoops
 chutes
 car silencers
 Methods of forming and bending
- angular folds
- cylindrical shapes
- conical shapes
 Care and maintenance of forming and bending tools/equipment
- cleaning
 Safety
- personal safety
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PRACTICE:

a) identify sheet metal forming tools and equipment
b) select and use forming tools and equipment for a given job
c) care and maintain sheet metal forming tools and equipment
d) observe safety precautions when using forming tools and equipment
14.1.3.5P2 Content
 Sheet metal forming tools and equipment
- forming stakes
- forming machines
 Tools and equipment
- straight and sharp bends
- short and abrupt tapers
- cylindrical objects
- conical shaped objects
- hems
- wired edges
- angular bends
 Care and maintenance of sheet metal forming tools and equipment
- storage
 Safety
- personal safety
Competencies
Ability to:
 identify sheet metal forming tools and equipment

 select and use forming tools and equipment for a given job
 care and maintain sheet metal forming tools and equipment
 observe safety precautions when using forming tools and equipment
Identifying sheet metal forming tools and equipment

Instructor should
 Display and discuss features of sheet metal forming tools to include
- stakes
- mallets
- folding bars
- G-clamps
Selecting and using forming tools and equipment

 Demonstrate how to use farming tools to produce a sheet metal component to
include the use of tools mentioned above.
77
Caring and maintaining of sheet metal forming tools and equipment
 Demonstrate proper care for and maintain sheetmetal forming tools and
- Oiling and greasing
Observing safety
 Demonstrate safe working habits when using farming tools and equipment to
include
- Wearing appropriate safety gear
- Careful handling of tools and equipment
The trainee should

 identify sheet metal forming tools and equipment
 select and use forming tools and equipment for a given job
 care and maintain sheet metal forming tools and equipment
 observe safety precautions when using forming tools and equipment

 Posters, charts and pictures with information on various sheet metal forming tools
and equipment
 Samples of various sheet metal forming tools and equipment
 Sample of sheet metal components which have been produced by the forming
process
Assessment
 Tests
- Oral tests
 Identification of different sheetmetal forming tools and equipment
- Written tests
 Sketching and naming parts of sheetmetal forming tools and equipment
 Writing operation procedures for making given sheet metal component
- Practice
 Practical project where the trainees are required to produce a sheet metal
product by the forming process
- Observation
 The trainee should display safe working habits
 The trainee should display correct attitude towards practical work
 Organization skills and team work spirit for the trainee
- Assignments
 Students to look for fabricated sheet metal products which could be
better made by forming process and prepare an operation procedure
sheet
Suggested references
 Metalwork Technology – by G.H. Thomas
 Basic Fabrication and Welding Engineering by F.J.M. Smith
14.1.3.6T MODULE UNIT: SHEET METAL EDGES

THEORY

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a) list down the various types of edges formed on sheet metal products
b) state the purpose of forming edges on a sheet metal product
c) name various tools and equipment used in forming edges
d) state the operational procedure used in forming various edges
e) state safety precautions to be observed during edge forming
14.1.3.6T2 Content
 Types of edges
- flanging
- joggling
- swaging
- crimping
- hem
- double hem
- wired edge
- capped edge
 Purpose of forming edges
- strength
- safety
- decoration
 Tools and equipment used in edge forming
- stakes
- mallets
- folding bars
 Operational procedure used in forming edge
- marking out
- notching
- folding/bending
 Safety
- personal safety
- tool and equipment safety
PRACTICE:

At the end of the module unit, the trainee should be able to:
a) identify various types of edges formed on sheet metal
b) select tools and equipment to produce a given type of edge formation
c) care and maintain tools and equipment used for making sheet metal edges
d) observe safety precautions when using tools and equipment to make edge formation
on sheet metal.
14.1.3.6P2 Content
 Types of edges formed on sheet metal
- hem – wired edge
- double hem
- false wired edge
- capped edge
- flanging
- joggling
- swaging
- crimping
 Tools and equipment for a given edge preparation
- folding machine
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- jennying machine
- bench mandrel
- rolling
- mallets
- hatchet stakes
 Care and maintenance of tools and equipment used for making edge formations
- servicing machines
 Safety
- personal safety
Competencies
Ability to:
 identify various types of edges formed on sheet metal
 select tools and equipment to produce a given type of edge formation
 care and maintain tools and equipment used for making sheet metal edges
 observe safety precautions when using tools and equipment to make edge formation
on sheet metal
Identifying types of edges formed on sheet metal

 Display and discuss various types of edge formed on sheet metal to include
- hem-wired edge
- double hem
- false wired edge
- capped edge
- flanging
- joggling
- swaging
- crimping
Selecting tools and equipment for producing edge formation

 Demonstrate the proper procedure for selecting tools and equipment for producing a
given type of edge formation to include
- Types of edge required
- Type of tool to be used
Caring and maintaining tools and equipment used for making sheet metal edges
 demonstrate proper care and maintenance of tools and equipment used for making
sheet metal edge preparation to include
- cleaning
- oiling/greasing
Observing safety
 Demonstrate safe working habits when using sheet metal tools to make sheet metal
edge preparations to include
- Personal safety
80
The trainee should

 identify various types of edges formed on sheet metal
 select tools and equipment to produce a given type of edge formation
 care and maintain tools and equipment used for making sheet metal edges
 observe safety precautions when using tools and equipment to make edge
formation on sheet metal

 posters, charts and pictures with information on various sheet metal edges
 samples of sheet metal edge preparations
 tools and equipment for making sheet metal edges preparation to include
- hatchet stakes
- mallets
- paring hammer
- folding machine
- jennying machine (with assorted where wheels for plaguing, joggling,
swaging, crimping and shearing)
- folding machine
- bench mandrel
- creasing stake
Assessment
 Tests
- Oral test
 Identification of various sheet metal edge preparations
 Identification at various sheet metal edge preparation tools
- Written
 Sketching of sheet metal edge preparations
 Explain procedure of making given edge preparation
- Observation
 The trainee should demonstrate correct attitude towards practical
work
 The trainee should display good organization skills and team work
spirit.
 Metalwork Technology by G.H. Thomas
14.1.3.7T MODULE UNIT: SOFT SOLDERING

THEORY

At the end of this module unit, the trainee will be able to:-
a) define the term soft soldering
b) state common uses of soft soldering process
c) list typical applications of soldering
d) name various types of solders and their compositions
e) name various types of fluxes
f) state functions of fluxes
81
g) list various soldering tools and equipment
h) list various sheet metal work joints
i) state the factors to be considered when soldering
j) state qualities of a well soldered joint
k) explain the correct procedure of soft soldering process
l) state safety precautions to be observed when soft soldering
14.1.3.7T2 Content
 Definition of the term soft soldering
 Uses of soft soldering
- joining of thin sheet metal
- sealing of joints to make them water tight or air tight
 Typical applications of soft soldering

- water tanks
- funnels
- radio and television circuits
- mop buckets
- various types of cylinders
- repair of motor vehicle radiators
 Types of solders and their compositions
- tinman’s solder
- plumber’s solder
- general purpose solder
- resin cored solder
 Types of fluxes
- Active fluxes (corrosive)
 hydrochloric acid
 zinc chloride
 ammonium chloride(Sal ammonia)
- Passive fluxes (non-corrosive)
 resin base
 olive oil
 tallow
 Functions of fluxes
- cleaning
- breaking down surface tension
- prevention of formation of oxides
 Tools and equipment for soldering
- soldering Iron (straight and hatchet)
- wire brush
- file
- heat Source (Stove/ blow lamp)
 Sheet metal work joints
- lap
- grooved seam
- knocked up
 Factors to be considered when soldering
- material being soldered
- joint design
- type of solder
- type of flux
- heat source
- soldering technique
82
 Qualities of a well soldered joint
- proper fitting
- proper bonding
- uniformity of soldering
- cleanliness of soldered joint
 Procedure of carrying out soft soldering operation
- cleaning work pieces
- fitting work pieces
- cleaning and tinning soldering bit
- applying flux on work piece
- applying solder on work pieces
- cleaning the joint
 Safety
- personal safety
- equipment safety
PRACTICE:

a) select tools and equipment for a given task
b) select a flux suitable for a given joint
c) select solder suitable for a given joint
d) produce a soft soldered joint
e) perform visual inspection
f) perform a simple leak test
g) demonstrate safety when handling soft soldering
14.1.3.7P2 Content
- heat source equipment
- tools for preparation of work piece
 Suitable fluxes
- material
- type of supply
- active and non- active
 Suitable solder
- material
- form of supply
 Soldered joint
- tinning
- sweating
 Visual inspection
- bonding
- cleanliness
- solder film
 Leak test
- air
- water
 Demonstrate safety
- personal safety
- equipment safety
Competencies
Ability to:
83
 select tools and equipment for a given task
 select a flux suitable for a given joint
 select solder suitable for a given joint
 execute a soft soldered joint
 perform visual inspection
 perform a simple leak test
 demonstrate safety when handling soft soldering
Selecting tools and equipment for a given task

 Display and discuss features of tools and equipment used for soldering to include
- Soldering iron
- Wire brush
- Heat source (stove, blow lamp, forge, charcoal burner)
Selecting flux and solder for a given job

 Display and discuss various types of solders and fluxes and their uses to include
- soldering
 tinman’s solder
 plumber’s solder
 general purpose solder
 resign cored solder
- Fluxes
Active (corrosive) fluxes
 Hydrochloric acid
 Zinc chloride
 Ammonium chloride (salammoniac)
Passive (non-corrosive) fluxes
 Resin base
 Olive oil
 Tallow
Executing soft soldered joint

 Demonstrate how to make and solder various sheet metal joints to include
- lap joint
- grooved seam joint
- knocked-up joint
Performing visual inspection and simple leak test

 Discuss and demonstrate evaluation of quality soldered joints to include
- visual inspection of defects
- leak test
Observing safety
 Discuss and demonstrate safe working habits to include
- hazards associated with handling chemicals
- hazards associated with handling hot work pieces
84
Caring and maintaining soft soldering tools and equipment
 Discuss and demonstrate how to care for and maintain soft soldering equipment to
include
- cleaning
The trainee should

 select tools and equipment for a given task
 select a flux suitable for a given joint
 select solder suitable for a given joint
 execute a soft soldered joint
 perform a simple leak test
 demonstrate safety when handling soft soldering
 Posters, charts and pictures with information on soft soldering

 Samples of components where soft soldering has been used
 Tools and equipment used for soldering
Assessment
 Tests
- Oral test
 Identification of various soldering tools and equipment
- Written test
 Sketching of soldering tools and equipment
 Explanation of soldering process
 Procedure of soft soldering
 Soldering process
- Practice
 Practical project involving soldering as a joining method of fabrication
- Observation
 The trainee should demonstrate correct attitude towards practical work
 The trainee should display good organization skills and team work
spirit
 Workshop processes for Mechanical Engineering Technicians I – By R.T.
Pritchard
PROJECT WORK:
85
14.1.3.8P MODULE UNIT: FABRICATION OF A SHEET METAL PRODUCT

At the end of this module unit, the trainee should be able to:-
a) carry out product survey
b) read and interpret a working drawing
c) estimate and cost the materials
d) select the appropriate tools and equipment
e) prepare the parts of the product
f) join the parts of the product
g) carry out the finishing process
h) carry out quality control measures
i) observe safety precautions when fabricating a sheet metal product
14.1.3.8P2 Content
 Product survey
- visiting hardware shops and workshops
- making observations on various similar products
- recording and reporting the findings of the visit
 Read and interpret working drawing
- product design
- type of sheet metal to be used
- the scale
- dimension/symbols
- type of finish
 Estimate and cost the materials required
- Materials
 galvanized sheet
 soft solder
 flux
 solder
 rivets
- Costing
 number of parts
 flux
 unit price
 computing total cost
- measuring and marking out tools
- cutting tools
- forming tools
- soldering tools
 Safety precautions to be observed when fabricating the product
- personal and other workmates safety
 Preparation of individual parts
- development of angular pattern
- cutting to size
- forming to shape
 Parts of the product
- cleaning the work pieces
- soldering
- riveting
 Finishing process
- washing out the flux with water
86
- deburring sharp edges
 Quality control measures
- dimensions
- quality of laps and edges
- quality of soldering
- squareness of edges/parallelism
- surface finish (free of dents)
- quality of soldered joints
- quality of riveting
- proper fitting of parts
- proper finishing.
Competencies
Ability to:
 carry out product survey
 read and interpret working drawing
 estimate and cost the materials required
 select appropriate tools and equipment
 prepare the product parts
 join parts of the product
 carry out finishing process
 carry out quality control measures
 observe safety precautions when fabricating the product
Carrying out product survey

 discuss and explain the correct procedure for carrying out a product survey to include
- visiting hardware shops and workshops
- making observation on various similar products
Reading and interpreting working drawing

 Demonstrate the correct procedure for interpreting and reading a working drawing to
include
- product design
- the scale
- dimension/symbols
- types of finish
Estimating and costing of material

 Illustrate the procedure of material estimating and costing to include
- Materials
 galvanished sheet
 soft solder
 flux
 solder
 rivets
87
- Costing
 material cost
 direct labour cost
 unit price
Selecting appropriate tools and equipment

 Explain the procedure for selecting appropriate tools and equipment for a task to
include
- type of metal product
- type of operation to be performed
- type of surface finish
- correct tools to be used
Making a product
 Demonstrate the correct procedure of making a component to include
- preparation of parts
- joining of parts
- checking dimensions
- good workmanship and finishing
Carrying out quality control measures

 Demonstrate methods of carrying out quality control measures on sheet metal
products to include
- dimensional control
- proper finishing
Observing safety
 Demonstrate safe working habits when handling sheet metal tools and equipment to
include
- personal safety
- tool and equipment safety
Caring and maintaining sheet metal tools and equipment

 Demonstrate proper procedure for caring and maintaining sheet metal tools and
The trainee should

 estimate and cost the materials required
 prepare the product parts
 join parts of the product
88

 Assorted sheet metal tools and equipment
 Adequate supply of metal sheet
 Safety gear
Assessment
 Oral test
- Identification of various sheet metal tools and equipment
 Practical
- Calculation of quantity of materials
- Ability to produce a component from a drawing
 Observations
- The trainee should display safe working habits
- The trainee should demonstrate correct attitude towards practical work
- The trainee should display good organization skills and teamwork spirit
 Basic fabrication and Welding Engineering – by F.J.M. Smith
89
14.1.4.1T MODULE UNIT: OXY-ACETYLENE WELDING EQUIPMENT
THEORY

a) define the term oxy-acetylene welding
b) name typical applications of oxy-acetylene welding in metal processing industry
c) name oxy-acetylene gas welding tools and equipment
d) outline the uses of gas welding equipment and tools
e) list the steps to be followed when setting up gas welding equipment
f) outline the various gas supply systems
g) care for gas welding equipment
h) state safety precautions to be observed when using oxy-acetylene welding
14.1.4.1T2 Content
 Definition of the term oxy-acetylene welding
 Applications of oxy-acetylene welding
- motor vehicle body repair
- containers fabrication and repair
- cabinet making
 Gas welding tools and equipment
- gas economizer unit
- oxygen cylinder
- acetylene cylinder
- cylinder key
- hose fittings
- regulators/gauges
- hoses
- flashback arrestors
- blowpipe/torches
- nozzles/tips
- spanners
- nozzle cleaners
 Uses of gas welding tools and equipment named above
 Steps to be taken when setting up the equipment
- connecting regulators
- opening cylinders
- checking for leakages
 Supply systems
- manifold
- pipelines
- mobile (trolley)
 Care for and maintenance of gas welding equipment
- keeping cylinders upright
- maintenance
 Safety
- always wear safety clothing
- avoid oil close to acetylene cylinders
- avoid copper wires on acetylene hoses
90
PRACTICE:

a) identify the various gas welding equipment and tools
b) assemble basic oxy-acetylene equipment and carry out leak tests
c) care for gas welding equipment
d) demonstrate safe working habits when handling the equipment
14.1.4.1P2 Content
 Equipment and tools
- gas economizer unit
- cylinder key
- hose fittings ( union nuts and nipples, hose clips, hose couplings )
- cylinders
- regulators/gauges
- hoses
- blowpipes/torches
- nozzles
- nozzle cleaners
- flashback arrestors
- spanners
 Assembly of the equipment and tools above and carrying out leak tests
- use of soapy water
 Safety
- personal safety
Competencies
Ability to:
 identify oxy-acetylene equipment and tools
 assemble oxy-acetyle equipment and carry out leat tests
 carry out leak tests
 care for gas welding equipment
 demonstrate safety during welding
Identifying oxy-acetylene equipment and tools

 Display and discuss various gas welding equipment and tools to include the
following
- Gas economizer unit
- Cylinder key
- Hose fittings
- Cylinders (oxygen and acetylene)
- Regulators/gauges
- Hoses
- Blowpipes/torches
- Nozzles and nozzle cleaners
- Flashback arrestors
- Spanners
91
Assembling oxy-acetylene equipment and test for leakage
 Demonstrate assembly of the equipment above and how to carry out leak tests using
soapy water
Caring and maintaining of gas welding equipment

 Demonstrate how to care for gas welding equipment to include:
- Storage
- Handling
- Maintenance
Observing safety
 Demonstrate safe working habits when handling the equipment to include:
- Personal
- Tools and equipment
The trainee should

 identify oxy-acetylene equipment and tools
 assemble oxy-acetyle equipment and carry out leat tests
 carry out leak tests
 care for gas welding equipment
 demonstrate safety during welding

 Oxy-acetylene gas welding equipment and tools
- Oxy-acetylene gas welding cylinders and accessories
- Oxy-acetylene tools e.g. cylinder key, assorted spanners and nozzle cleaners
 Soapy water and brush
 Safety gear
Assessments
 Tests
- Oral – various oxy-acetylene gas welding equipment and tools
- Written – description of oxy-acetylene gas welding tools and equipment
 Practice
- Assembly of tools and equipment
- Safety gear
 Assignments
- On oxy-acetylene tools and equipment
- On safety gear when exercising welding
References
1. Basic Welding and Fabrication – By J. Smith
2. Metalwork Technology – by G.H. Thomas
3. Basic welding and Fabrication – By Kenyon
92
14.1.4.2T MODULE UNIT: OXY-ACETYLENE WELDING TECHNIQUES
THEORY

a) differentiate rightward and leftward welding techniques
b) name types of flames in gas welding and their uses
c) state the factors influencing nozzle selection
d) state the edge preparation necessary for various material thicknesses
e) state various welding positions
f) list various sizes of filler rods and state their application
14.1.4.2T2 Content
 Rightward and leftward welding techniques
 Types of flames and their uses
- neutral
 welding of mild steel, stainless steels, cast iron, copper
- oxidizing
 welding brasses and bronzes
- carburizing
 surface hardening, brazing of aluminum
 Factors influencing nozzle selection
- metal thickness to be welded
- type of metal to be welding
 Edge preparation for various thicknesses
- single vee
- double vee
- square butt
- flanged edges
 Welding positions
- horizontal
- inclined
- flat
 Sizes of filler rods
PRACTICE:

a) assemble welding equipment and carry out leak tests
b) select suitable nozzle for given materials size
c) set the correct flame for a given material
d) execute a weld in the leftward and rightward techniques
e) set the correct flame for a given job
f) select the correct nozzle for a given job
g) prepare the edge for a given material thickness
h) select the correct filler rod for a given task
i) execute a weld in the various welding positions
j) care for and maintain oxy-acetylene gas welding equipment
k) demonstrate safe working habits when welding
l) care for and maintain oxy-acetylene gas welding equipment.
93
14.1.4.2P2 Content
 Welding equipment
- cylinders
- regulators/gauges
- hoses
- blowpipes/torches
 Nozzles size selection
- Thickness 1.5mm, 2mm, 3mm, 4mm
 Flame setting
- neutral
- carburizing
- oxidizing
 Execution of welds in leftward and rightward techniques
 Setting of correct flame for a given
- Brazing > oxidizing
- Welding mild steel > neutral
- Hard facing > carburizing
 Edge preparation for a given material thickness
 Selection of correct filler rod for the job
- material thickness
 Execution of weld in various positions
- horizontal
- vertical
- horizontal/vertical
 caring for and maintaining oxy-acetylene equipment
 safe working habits
- personal safety
Competencies
Ability to:
 assemble welding equipment
 select correct nozzle for the given job
 set correct flame type
 execute welds in leftward and rightward techniques
 prepare the edge for a given material thickness
 select the correct filler rod for the job
 execute weld in various welding positions
Assembling welding equipment

 Display and explain how to assemble gas welding equipment ready for welding
- Welding equipment
 Cylinders
 Regulators/gauges
94
 Hoes
 Blowpipes/torches
 Nozzles
Selecting correct nozzle for a job

 Demonstrate how to select suitable nozzle for various metal thicknesses
- 1.5mm
- 2mm
- 3mm
- 4mm
Setting correct flame type

 Demonstrate how to set the types of flames as follows:
- Neutral
- Carburizing
- Oxidizing
Executing weld techniques

 Demonstrate the execution of the two welding techniques
- Leftward techniques
- Rightward techniques
Preparing the edge for a given thickness

 Demonstrate and explain how to prepare edges for various material thicknesses to
include the following:
- Square
- V-preparation
- bevel
- u-preparation
Selecting of filler rod

 demonstrate the selection of correct filler rod for various jobs as per their thicknesses
Executing various welding positions

 demonstrate the execution of welds in various positions as follows:
- horizontal
- vertical (up and down)
- horizontal vertical
Observing safety
 demonstrate safe working habits to include
- personal safety
95
Trainee should
 assemble welding equipment
 select correct nozzle for the given job
 set correct flame type
 execute welds in leftward and rightward techniques
 prepare the edge for a given material thickness
 select the correct filler rod for the job
 execute weld in various welding positions
Key teaching/Learning resources

 Manuals and charts for
- Oxy-acetylene gas welding equipment and accessories
- Filler rods and application
- Material thicknesses preparation
- Nozzle selection
 Oxy-acetylene equipment and accessories
 Assorted nozzles
 Sample of material pieces (thicknesses of metal pieces ms)
 Various sizes of filler rods
Assessment
 Practical exercise on assembly of gas welding equipment
 Tests
- Oral
 Welding equipment and accessories
 Types of flames
- Written
Description of
 Welding equipment
 Welding techniques
 Preparation of material edges
 Project involving execution of welds in
- Horizontal position
- Vertical position
- Horizontal vertical position
 Assignments
- On safety precautions required when performing welding
References
1. Basic Welding & Fabrication - by Smith
2. Metal Work Technology - by G.H. Thomas
14.1.4.3T MODULE UNIT: QUALITY CONTROL IN GAS

WELDING
THEORY

a) state the qualities of a good weld
b) name weld defects, causes and their remedies
c) describe various types of distortions and their control
d) describe a given weld test
96
14.1.4.3T2 Content
 Qualities of a good weld
- smoothness of joint
- even ripples
- free from visible defects
 Weld defects, their cause and remedies
- undercut
- porosity
- formation scale
- lack of penetration
- entrapped (slag inclusion)
- spatter
- overlapping
 Distortions and their controls
- Distortion
 angular
 longitudinal
 buckling
 warping
- Methods of control
 clamping
 pre-setting
 strong backing
 tack welding
 step welding
- Description of weld tests
- bending
- macro-etching
- visual inspection
- nick break
PRACTICE:

a) identify a good weld
b) identify weld defects and their remedies
c) identify various types of distortions and their controls
d) perform a given weld test
e) demonstrate safe working habits when carrying out weld tests
14.1.4.3P2 Content
 Good weld
- smooth, uniform, even ripples and no defects
 Weld defects
 Types of distortions
- angular
- transverse
- longitudinal
- buckling
 Weld test
- bend
- visual examination
- nick-break
97
 Safety
- personal safety
Competencies
Ability to:
 identify a good weld
 identify weld defects
 identify types of distortions
 perform a given weld test
 demonstrate safe working habits when carrying out weld tests
Identifying a good weld

 Discuss and illustrate qualities of a good weld to include the following
- smoothness
- uniformity
- even ripples
- penetration
- absence of defects
Identifying weld defects

 illustrate and discuss weld defects, their causes and remedies to include
- undercut
- porosity
- scale formation
- lack of penetration
- spatter
- slag inclusion
- overlapping
Identifying types of distortions

 Illustrate and explain various types of distortions and their controls to include:
- Types
 angular
 transverse
 longitudinal
 bucking
 warping
- Control methods
 Clamping
 Pre-setting
 Strong backs
 Tack welding
 Step welding
Performing a given weld test

 Demonstrate various weld tests to include the following
98
- Macro-etching
- Visual inspection
- Nick-break
Demonstrate safe working habits

 Demonstrate safe working habits when carrying out weld test to include
- Safety gear
- Personal safety
- Equipment safety
- Specimen handling
- Tools and equipment handling
The trainee should

 identify a good weld
 identify weld defects
 identify types of distortions
 demonstrate safe working habits when carrying out weld tests

 Engineering welding products e.g.
- Trays, pipes, cans
- Gutters
 Gas welded sheet samples where defects and distortions can be clearly identified
 Weld test samples including tools and equipment for use in bend and macro-
examinations
Assessments
 Tests
- Oral
 Qualities of good weld
 Various types of weld defects
 Various types of distortions and their controls
- Written
 Explanation of the qualities of a good weld
 Types of distortions their causes and controls
 Types of weld defects and their causes
- Practical exercises to include
 Weld exercises in
 Horizontal
 vertical
 weld tests to include
 bend
 visual examination
 nick-break
- Continuous Assessment Tests on:

 Qualities of a good weld, defects and weld tests
 Safe working habits when carrying out weld tests
- Assignments
 To come up with explanation on qualities of a good weld, distortion
and controls and weld tests
 Safety precautions
99
References
 Basic Welding and Fabrication by J. Smith
 Metal Work Technology by G.H. Thomas
100
14.1.4.4T MODULE UNIT: WELDING JOINTS AND SYMBOLS
THEORY

a) name different types of welding joints
b) identify welding symbols and their application
14.1.4.4T2 Content
 Types of joints
- butt
- fillet
- lap
- edge
- corner
 Welding symbols and their uses
- Identification
 Symbols
 Arrow
 Reference line
 Arrow side
 Other side
- Application
 Fillet
 Square
 Single V-butt
 Double V-but
 Single U-butt
 Double U-butt
PRACTICE:

a) carry out edge preparation for a given joint
b) produce a desired weld joint from a given working drawing
c) care for and maintain tools and equipment used for edge preparation
d) demonstrate safe working habits when carrying out edge preparation
14.1.4.4P2 Content
 Carry out edge preparation for
- Vee
- bevel
- U-preparation
 Weld joint using information on welding drawings
- cleaning
- oiling/greasing
- servicing
 Safe working habit when
- preparing the edges
- welding
101
Competencies
Ability to:
 carry out edge preparation for a given joint
 produce a desired weld joint from a given working drawing
 care for and maintain tools and equipment used for edge preparation
 demonstrate safe working habits when carrying out edge preparation
Learning/Teaching activities
Carrying out edge preparation for a given joint

 Demonstrate edge preparation for various joints to include
- vee
- bevel
- u-preparation
Producing a desired weld joint

 Illustrate and explain welding joints with their respective symbols to include
- fillet
- square butt
- single vee – butt
- double vee – butt
- single U – butt
- double U – butt
- use of arrows
- reference line
 Demonstrate how to produce a desired weld joint from a given working drawing
joint from a given working drawing
- Weld joint using information on working drawing
Caring for a maintaining tools and equipment

 demonstrate and discuss the care and maintenance of tools and equipment used for
edge preparation to include
- cleaning
- oiling/greasing
- servicing

 Demonstrate safe working habits when carrying out edge preparation and welding to
include
- personal safety
- equipment safety
Trainee should
 produce a desired weld joint from a given working drawing
 care for and maintain tools and equipment used for edge preparation
 demonstrate safe working habits when carrying out edge preparation
102
Key Learning/Learning Resources
 Samples of various welded joints to include
- Butt
- Fillet
- Lap
- Edge
- Corner
 Samples of edge prepared materials to include
- Vee
- Bevel
- U-preparation
 Edge preparation tools and equipment to include

- Oxy-acetylene cutting equipment
- Hand grinders
- Files
 Charts depicting welding joints with their respective symbols
Assessments
 Practice
- practical project involving various welding joint using information from welding
drawing
- Maintaining and caring for tools and include
 Cleaning
 Oiling/greasing
 Servicing
 Observation on
- Proper safe working habits when carrying out edge preparation
- Correct attitude towards practical work
 Tests
- Oral
 On names and identification of various welding joints
- Written
 Explanation of the welding symbols and their application
- Insert welding symbols on a given drawing
 Assignment
- Illustration of edge preparation for various joints to include
 Vee
 Bevel
 U-preparation
References
 Basic Fabrication and Welding Engineering - by F.J.M. Smith
 Basic Welding and Fabrication – By W. Kenyon
103
14.1.4.5T MODULE UNIT: OXY-ACETYLENE CUTTING
THEORY

a) state the principle of oxy-acetylene gas cutting
b) list oxy-acetylene gas cutting equipment and their uses
c) describe various cutting techniques
d) state the factors that determine quality of cut
e) state the safety precautions to be observed when gas cutting
14.1.4.5T2 Content
 Principle of oxy-acetylene gas cutting
 Oxy-acetylene gas cutting equipment
- torches
- nozzles
- nozzle cleaners
 Cutting techniques
- straight
- circular
- bevel
 Factors
- pressure setting
- speed
- nozzle selection
- height of nozzle from plate
 Safety
- use of goggles
- dressing properly
- using tongs
- hot metals
PRACTICE:

a) set up oxy-acetylene equipment ready for cutting
b)select the correct size of cutting nozzle for a given task
c) adjust the correct flame for cutting
d)execute a smooth cut
e) perform visual inspection for surface defects
f) observe safety precautions when cutting
14.1.4.5P2 Content
 Oxy-acetylene equipment
 Cutting nozzles
- nozzle sizes
 Adjusting the flame
- neutral
 Executing a smooth cut
- straight cut
- bevel cut
- circular or curved cut
- speed of travel
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- height of flame from work surface
- angle of the flame
 Visual inspection
- cleanliness of cut surface
- lack of dross
- straightness of cut
 Safety when cutting
- person safety
- equipment safety
Competencies
Ability to:
 set up oxy-acetylene equipment
 select cutting nozzles
 adjust the flame
 execute a smooth cut
 observe safety when cutting
Setting up oxy-acetylene equipment

 Demonstrate the setting up of oxy-acetylene equipment ready for cutting to include
- oxy-acetylene cylinders, regulators
- torches/blowpipes
- nozzles/hoses
Adjusting the flame

 Explain factors which determine quality of a cut to include
- pre-heating flame
- pressure setting
- speed of travel
- nozzle selection
- height of nozzle from plate being cut
Executing a smooth cut

 Demonstrate the execution of a smooth cut on mild steel to include
- straight cut
- bevel
- circular cut
Performing visual inspection

 Explain how to carry out visual inspection for surface defects to include
- cleanliness of cut surface
- absence of dross
- straightness of cut
Observing safety when cutting

 Demonstrate safe working habits when gas cutting to include
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- Personal safety
- Equipment safety
The trainee should

 set up oxy-acetylene equipment
 select cutting nozzles
 adjust the flame
 execute a smooth cut
 observe safety when cutting
Key Learning/Teaching Resources

 oxy-acetylene gas cutting equipment and accessories
 assorted thicknesses of mild steel plates
 oxy-acetylene cutting aids for
- straight cutting
- circular cutting
 sample of correctly cut profiles of mild steel plates
 charts and hand outs showing the cut profiles
 hand outs on the oxy-acetylene gas cutting equipment and accessories
Assessments
 tests
Oral
 gas-cutting equipment
 cutting techniques
 qualities of a good cut
Written
 principles of oxy-acetylene gas cutting
 procedure for setting up gas-cutting equipment
 description of various cutting techniques
 factors for good quality cut
 Assignment
On setting up of oxy-acetylene equipment
Safety precautions to be observed when cutting
- Observation
On safety when performing gas-cutting
- Practice
Setting up of oxy-acetylene gas-cutting equipment
Execution of various smooth cuts on mild steel
 Straight cut
 Circular cuts
 Bevel cuts
Practical work on production of
References
1. Basic Fabrication and welding engineering by F.J.M Smith
2. Basic welding and Fabrication – By W. Kenyon
3. Metal Work Technology – by G.H. Thomas
106
14.1.4.6T MODULE UNIT: BRAZING AND HARD SOLDERING
THEORY

a) define the terms brazing and hard soldering
b) list typical applications of brazing and hard soldering
c) name various types of fluxes
d) state functions of fluxes
e) list various brazing tools and equipment
f) list various brazed joints
g) state the factors to be considered when brazing and hard soldering
h) state qualities of a well brazed joint
i) explain the correct procedure for brazing and hard soldering
j) state safety precautions to be observed when brazing and hard soldering
14.1.4.6T2 Content
 Definition of terms brazing and hard soldering
 Typical application of brazing and hard soldering
- bicycle repair
- joining of dissimilar metals
- spot brazing of stainless steel containers
 Types of fluxes used in brazing and hard soldering
- brazing
 borax
- hard soldering
 easy flow flux
 Functions of fluxes
- cleaning work pieces
- breaking down surface tension
- preventing oxidation during the operation
 Brazing tools and equipment
- heat source
 oxy-acetylene welding equipment
 blow lamp
- wire brush
- files
- pliers
- tongs
 Types of brazed joints
- lap
- butt
 Factors to be considered when brazing and soldering
- metals to be joined
- filler metal composition
- flux to be used
- joining technique
- heat source
- strength and heat considerations
 Qualities of a well brazed and soldered joint
- filing of parts
- proper bonding
- uniformity
- cleanliness
 Brazing procedures
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- cleaning of parts
- filing of brazed material
- wetting work pieces and spelter
- heating to the correct temperature
- dipping the spelter into the flux
- executing brazing operation
- cleaning of the joint
 Safety
- personal safety
- equipment safety
PRACTICE:

a) select appropriate equipment for brazing
b) select suitable brazing rod for a given task
c) select suitable brazing flux
d) prepare the materials for the task
e) perform brazing task
f) assess the quality of brazed joints
g) demonstrate safe working habits when brazing
14.1.4.6P2 Content
 Equipment for brazing
- oxyacetylene welding equipment
- blow lamp
 Brazing rods
- materials
- size
 Brazing fluxes
 Material for brazing
- cleaning
- joint preparation
 brazing procedure
- fitting of parts
- application of filler metal and flux
 Quality of brazed joints
- bonding/strength
- neatness
- uniformity of beads
 Demonstrate safe working habits
Competencies
Ability to:
 select equipment for brazing
 select suitable brazing rods
 select suitable flux
 prepare the material for brazing
 perform brazing task
 assess the quality of brazed joints
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Selecting equipment for brazing
 Demonstrate and discuss equipment used in brazing to include
- oxy-acetylene welding equipment
- blow lamp
- brazing rods
- brazing fluxes
Selecting suitable brazing rods

 Explain factors that govern the selection of suitable brazing rods to include:
- Material to be joined
- Thickness of materials
Selecting suitable flux

 explain factors that govern the selection of suitable flux to include
- functions of the flux
- cleanliness of the joint
- brazing and braze welding
Preparing the material for brazing

 Demonstrate the preparations of the material ready for brazing operation to include
- cleanliness
- gap of the work pieces
- setting of the correct flame
Performing brazing task

 Demonstrate the brazing procedure to include
- setting the correct flame
- application of flux
- heating the joint
- cleaning the brazed joint
Assessing the quality of a brazed joint

 Outline the qualities of a well brazed joint to include:
- Proper bonding/strength
- Neatness
- Uniformity
- Filing of parts

 Demonstrate safe working habits to include:
- personal safety
- equipment and tools safety
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The trainee should
 select equipment for brazing
 select suitable brazing rods
 select suitable flux
 prepare the material for brazing
 perform brazing task
 assess the quality of brazed joints

- Oxy-acetylene welding equipment
- Blow lamp
- Types of brazed joint
 Brazing equipment and tools
 Brazing rods (spelters) and fluxes
 Samples of brazed joints, silver soldered joint and braze welded joints
Assessment Method
 Oral test to include:
- defining the terms brazing, braze welding and silver soldering
- showing the difference between brazing and silver soldering
- types of brazed joints
- functions of flux
- qualities of a good brazed joint
- safety in brazing
- Brazing
- Braze welding
- Silver soldering
- Brazing equipment and tools
- Brazing procedure
- Types of joints
- Functions of flux
- Qualities of a good joint
- Safety precautions while brazing
 Practical test
- A class project involving various brazed joints
- Safety observations
References
1. Basic Fabrication and Welding Engineering by F.J.M. Smith
2. Metal work Technology by G.H. Thomas
14.1.4.7P MODULE UNIT: FABRICATION OF A PRODUCT USING OXY-ACETYLENE

b) read and interpret working drawing
f) joint the parts of the product
110
i) observe safety precautions when fabricating black mild steel product
14.1.4.7P2 Content
 Product survey
- Visit local garages and local automobile hardware
- Make observation of
 various designs
 dimensions
 materials
- Recording and reporting
 various designs
 sketches
 prices
 Working drawings
-dimensions
-materials
-scale
-joining methods
 Estimating and costing
- Estimating the material
 size of sheet to be used
 filler metal
 paint
 gas (oxygen and acetylene)
- Costing
 unit cost
 Selection of tools and equipment
-measuring and marking out tools
-cutting tools
-finishing tools
-drilling machines
 Preparation of parts of the product
 Joining of parts by oxy – acetylene welding
-conformity to dimensions
-symmetry of parts
-workmanship
-lack of kinks
-lack of dents
-lack of scratches
-quality edges and welds
-quality of painting
-appearance
 Safety
-personal safety
-tools and equipment safety
Competencies
Ability to:
111
 estimate and cost the materials
 select the appropriate tools and equipment
 prepare the parts of the product
 joint the parts of the product
 carry out the finishing process
 observe safety precautions when fabricating black mild steel product
Carrying out the product survey

 Organize and facilitate product survey within locality to include
- a visit to a local hardware
- a visit to a local small/medium workshop with oxy-acetylene welding activities
- identification of products made using oxy-acetylene

 Discuss and demonstrate how to read and interpret working drawing to include
- determination of overall size of a component (scale)
- material suitable to make a component
- joining methods e.g. welding symbols
- product design
- type of finish
Estimating and cost the materials

 Illustrate the material estimate and cost to include
- size of the sheet to be used – galvanized sheet
- filler metal required e.g. soft solder
- paint
- rivets
- gas (oxygen and acetylene)/charcoal/paraffin
- unit cost
- total cost of production
Selecting the appropriate tools and equipment

Instructor should
 Guide on appropriate tools and equipment to be used to include:
- cutting tools
- soldering tools
- heat sources (Charcoal burner, Oxy-cetylene equipment, blow lamp)
Preparing the parts of the product

 Demonstrate the preparation of the products parts to include
- development of parts
- cutting to size
- forming to shape
- clearing the parts
Joining the parts of the products
112
 Demonstrate the finishing process of a product to include
- Soldering
- Riveting
Carrying out the finishing process

- Cleaning the work piece
- Washing out the flux
- Debarring shaped edges

 Outline the quality control measures to include
- dimensions
- surface finish (free dents)
- proper finishing
The trainee should

 estimate and cost the materials
 select the appropriate tools and equipment
 joint the parts of the product
 observe safety precautions when fabricating black mild steel product

 charts to includes
- sources of heat
 oxy-acetylene equipment
 forge/charcoal burner
 blow lamp
- soldering equipment
 oxy-acetylene
 forge/charcoal burner
 blow lamp
 soldering bits
 solder and flux
 work pieces to include sample of good soldered pieces and product
 assorted tools to include
- stakes
- emery cloth
- soft hammers
- marking out tools
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Assessment Methods
 Oral test on
- Soldering equipment
- Solder and flux
- Safety

- Soldering equipment
- Soldering procedure
- Qualities of a good soldered joints
- Material estimating and costing
- Safety precaution
- Product design
- Material t be used
- Dimension control and symbols
- Quality finishing
- Quality soldering
- Quality forming
- Safety observation
 Assignment to include
- Soldering equipment – drawing and labeling
References
 Metalwork technology – by G.H. Thomas
 Basic Fabrication and Welding Engineering – by F.J.M. Smith
14.1.5.1T MODULE UNIT: ARC WELDING PROCESS EQUIPMENT

THEORY
a) define arc welding process
b) name various types of welding processes
c) name typical applications of arc welding in metal processing
d) identify various arc welding equipment and tools
e) state the uses of arc welding equipment
f) explain how to care for arc welding equipment.
g) state safety precaution to be observed when arc welding
14.1.5.1T2 Content
 Arc welding process
- generation of heat by electric arc
- melting of the parent metal and electrode
- fusion
 Types of welding processes
- manual arc welding
- metal inert gas welding (MIG)
- tungsten inert gas welding (TIG)
- plasma
114
- resistance pressure welding
- spot welding
 Applications of manual metal arc welding
- fabrication of steel door frames
- windows
- gates
- grills
- metal table
- chairs
- wheel barrows
- metal beds
- steel structures
 Arc welding equipment
- A.C welding machines
- D.C welding machines
- shield /helmet
- chipping hammer
- wire brushes, pliers
- goggles, tongs, electrode holders
- leads
 Care and maintenance of arc welding equipment
- cleaning
- handling
- proper storage of tools
- servicing of the machine
 Precautions to be observed when arc welding
- personal safety
- equipment safety
- protecting others from welding rays and flying sparks
PRACTICE:

a) set -up the metal arc welding equipment
b) strike an arc
c) demonstrate correct use and maintenance of arc welding equipment
d) demonstrate correct safe working habits when using welding equipment
14.1.5.1P2 Content
- connecting the leads
- setting current
 Arc Striking
- tapping
- scratching
 Use and maintenance of arc welding equipment
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 set the arc welding equipment
115
 strike an arc
 use and maintain arc welding equipment
 demonstrate safe working habits when using welding equipment
Setting the arc welding equipment
 Demonstrate and discuss the various arc welding equipment and its accessories to
include
- A.C. Welding m/c
- D.C. welding m/c
- shield/helmet
- chipping hammer
- wire brushes, pliers
- goggles, tong,
- electrode holder
- lead/cables
Striking the arc

 Demonstrate arc striking properly to include
- Tapping method
- Scratching method
Using and maintaining of arc welding equipment:

The instruction should
 Demonstrate how to care and maintain arc welding equipment to include:
- Oiling
- Cleaning
- Handling

 Demonstrate safe habits when using arc welding equipment to include
- personal safety
The trainee should

 set the arc welding equipment
 strike an arc
 use and maintain arc welding equipment
 Charts and pictures demonstrating arc welding equipment and tools

 Charts showing the arc stream – principle of arc welding
 Arc welding equipment and tools
 Typical products made by arc welding process
 Manuals for arc welding
Assessment
 Observation
116
- The trainee should display correct attitude towards practical work and show
organizational skill and team work
 Oral test
- Identify the arc welding equipment
- Identify safety equipment used in arc welding
 Written tests on
- Principle of arc welding
- Arc welding equipment
- Factors considered when selecting current
- Methods of striking an arc
- Electrode selection angle
- Safety in arc welding
- Welding exercise with various joints
- A class project to produce a function product
 Assignment
- Students to make labeled sketches of the arc welding equipment and tools
References
 Basic Fabrication and welding engineering – by F.J.M. Smith
 Basic Welding and Fabrication – by W. Kenyon
14.1.5.2T MODULE UNIT: WELDING ELECTRODES

THEORY

a) state factors determining choice of electrodes
b) name the uses of electrodes
c) name the parts of an electrode
d) state the functions of electrode coating
e) explain factors that govern the electrode selection.
14.1.5.2T2 Content
 factor determining choice of electrodes
- parent metal
- weld strength
- weld position
- type of current
 Uses of electrodes
- creating the arc
- filler metal
 Parts of electrode
- core wire
- flux coating
 Electrode coating
- types of coating
- methods of coating
 Functions of electrode coating
- arc creation
- shielding molten metal
117
- floating the imparities
- improves deposit rates
 Factors that govern electrode selection
- base metal composition
- welding current ( A.C or D.C)
- materials thickness
- type of joint
- weld position
PRACTICE:

a) identify various types of electrodes
b) select correct electrode for a given task
c) care for maintain welding electrodes
d) observe safety when handling welding electrodes/equipment
14.1.5.2P2 Content
 Types of electrodes
Ferrous electrodes
- mild steel electrodes
- low alloy electrodes
- corrosion resistance electrodes
 Non – ferrous electrodes
- Copper
- Aluminium
- Bronze
- Nickel
 Welding electrode for a given task
- types of metal
- current (a.c/d.c)
- position of welding
- type of joint
- mechanical properties of the weld
- heat input
 Care and maintenance of welding electrodes
- dampness on flux coating
- damage to flux coating
 Safety
- personal safety
Competencies
Ability to:
 identify various types of electrodes
 select correct electrode for a given task
 care for and maintain welding electrodes
 observe safety when handling welding electrodes/equipment
118
Identifying various types of electrodes
 Display and discuss various types of electrodes to include
- Ferrous electrode
 Mild steel
 Low alloy
 Corrosion resistance electrodes
- Non-ferrous electrodes
 Copper
 Aluminium
 Bronze
 Nickel
Selecting correct electrode for a given tasks

 Discuss and explain the factors that govern the choice of electrode to include:
- Parent metal
- Weld strength
- Weld position
- Type of current
Caring for and maintaining welding electrodes

 Demonstrate how to care for and maintain welding electrode to include
- Proper storage
- Proper handling
Observing safety
 Demonstrate safe working habits when handling electrode/equipment
The trainee should

 identify various types of electrodes
 care for and maintain welding electrodes
 observe safety when handling welding electrodes/equipment

 Charts to display electrode parts and classification
 Various types of electrodes to include
- Ferrous electrodes
- Non-ferrous electrodes
 Empty electrode packets/manuals
Assessment Methods
 Observation
- Trainee should show organization skill and teamwork
 Oral test
- On type of electrodes
- Methods of electrode classification
119
- Functions of electrode coating
- Factors that govern electrode selection
- Safety and care of electrodes
 Written test on
- Types of electrodes
- Electrode specification
- Functions of electrode coating
- Safety and care of electrodes
 Practical test
- Demonstrate how to care for electrodes
- Demonstrate how to store electrodes
References
1. Basic Fabrication and Welding Engineering by FJM Smith
2. Basic Welding and fabrication – by W. Kenyon
14.1.5.3T MODULE UNIT: ARC WELDING TECHNIQUES

THEORY

a) describe the two methods of striking an arc
b) state the factors influencing current setting.
c) state the factors that govern quality of weld
d) state the importance of electrode manipulation in various weave motions
14.1.5.3T2 Content
 Methods of striking an arc
- tapping
- scratching
 Factors that influence current setting
- edge preparation
- types of electrode
 Factors that govern quality of weld
- angle of electrode
- speed of travel
- current setting
- electrode manipulation
 Weave motions
PRACTICE:

a) select electrode for a given task
b) set current for a given task
c) execute welding using various weaving motions
d) execute a desired weld in any position when using the proper welding techniques
e) Care for and maintain welding equipment
f) demonstrate safe working habits when using welding equipment
120
14.1.5.3P2 Content
 Electrode
- materials
- size
 Current setting
- material size
- position
- electrode size
 Welding using weaving motions

- circular
- half-moon or crescent
- figure of eight
 Weld execution
- striking arc
- arc length
- speed of travel
- weave motion
 Care and maintenance of arc welding machine
- cleaning
 Safety
- hand shield/ helmet
- goggles (clear)
- gloves
- leggings (spats)
- sleeves
Competencies
Ability to:
 select electrode for a given task
 set current for a given task
 execute welding using weaving motions
 execute desired weld
 care for and maintain arc welding machine
Selecting electrode for a given task

 Discuss the factors that influence selection of an electrode to include
- materials to be welded
- thickness of the material
- weld position
Setting current for a given task

 Discuss factors that govern quality of a good weld to include
121
- edge preparation
- type of electrode
- weld position
Executing weaving motions

 Demonstrate the weaving motion of the electrode to include
- circular motion
- crescent motion
- figure of 8 motion
Executing a desired weld

 Demonstrate how to execute a weld to include
- Striking the arc
- Arc length
- Speed of travel
Caring for and maintaining arc welding machine

 Demonstrate how to care for and maintain welding equipment to include
- Cleaning
- Handling
- Storage

 Demonstrate safe working habits when using welding equipment to include
- Use of hand shield/helmet
- Use of clear goggles
- Use of legging (spats)
- Use of welder’s jacket with long sleeves
- Use of a leather apron
The trainee should

 select electrode for a given task
 set current for a given task
 execute welding using weaving motions
 execute desired weld
 care for and maintain arc welding machine
122
 Charts illustrating methods of
- Striking the arc
- Edge preparation
- Weaving motion
 Welding equipment and assorted accessories
 Welding electrodes
 Assorted safety gear to include
- Hand shield/helmet
- Leggings
- Leather apron
- Clear goggles
 Work pieces
 Manuals for arc welding
Assessment Methods
 Observation
- The trainee should show cooperation and teamwork spirit
 Oral test: Trainee to
- Name methods of striking an arc
- Name factors that govern quality of a good weld
- Safety precaution
 Written test on
- methods of striking an arc
- factors that influence current setting
- factors that govern quality of a good weld
- methods of weaving electrodes
- safety precautions
 Practical test on
- How to execute a weld on a class project
- Carry out weaving motion on given practical exercise
- Demonstration on how to care and maintain welding of equipment
 Assignments on
- Method of striking an arc
- Weaving motions
Reference
1. Basic Fabrication and welding Engineering , By F.J.M. Smith
2. Basic Welding and Fabrication – By w. Kenyon
123
14.1.5.4T MODULE UNIT: WELDING JOINTS AND SYMBOLS
THEORY

a) name different types of welding joints
b) identify welding symbols and their uses
c) state various types of joints, their symbols and uses
14.1.5.4T2 Content
 Types of joints
- butt
- fillet
- lap
- edge
- corner
 Welding symbols
- square butt
- single v- butt
- double v- butt
- single u- butt
- fillet weld
- single j- butt
- arrow line
- reference line
- symbol above reference line
- symbol below reference line
- symbol on both sides of reference line
- weld on site
- backing or sealing run
PRACTICE:

a) carry out edge preparation for a given joint
b) produce a desired weld joint from a given working drawing
c) demonstrate safe working habits when carrying out edge preparation
14.1.5.4P2 Content
 Edge preparation
- Vee
- bevel
- U-preparation
 Weld joint using information from welding drawings
 Safety
- preparing the edges
- welding
Competencies
Ability to:
 produce desired weld joint using information from welding drawings
 demonstrate safe working habit when preparing weld joints
124
Teaching / learning activities
Carry out edge preparation for a given joint

 Demonstrate the edge preparation for a given joint to include
- Single U-butt
- Double U-butt
- Single V-joint
- Double V joint
Producing desired weld joint from welding drawings

 Illustrate various types of welding symbols to include
- Square butt
- single V-butt
- single U-butt
- fillet weld
- single J-butt
- arrow line
- reference line
- symbol above reference line
- symbol below reference line
- symbol on both sides of reference line
- weld on site
- backing on site
- backing or sealing run

 Demonstrate safe working procedure when carrying out edge preparation and
welding operations to include
- safety gear
- maintenance of tools and equipment
The trainee should:

 produce desired weld joint using information from welding drawings
 demonstrate safe working habit when preparing weld joints

 Charts to include:-
- various types of welded joints
- various types of welding symbols
- welding procedure
 Hand out to include:-
- various types of welding joints
125
- various types of welding symbols
- welding procedures
- welding tools
 Assorted welded products with the following joints

- butt
- fillet
- lap
- edge
- corner
 Assorted hand tools to include and equipment
- Tools
 hacksaw
 files
 try square
 scriber
- Equipment
 Oxy-acetylene gas equipment
 Portable grinder
Assessment
 Oral and written test to include
- types of welded joint and application
- types of welding symbols
- types of edge preparation
- welded procedure
 Practical test
- class project to include:-
 edge preparation
 welding of the following joints
 butt
 fillet
 lap
 edge
 corner
- proper care and maintenance of tools and equipment while observing safety
References
 Metal work pupils book 1,2,3,and 4 by KIE
 Metal work by E. N. Njuguna
 Metal work technology by G. H. Thomas
126
14.1.5.5T MODULE UNIT: QUALITY CONTROL IN ARC WELDING
THEORY
At the end of this module unit, the learner should be able to:
a) state the qualities of a good weld
b) state weld defects and their controls
c) outline various types of distortions and their control
d) describe a given weld test
14.1.5.5T2 Content
 Qualities of a good weld
 Weld defects and their control
- entrapped slag (slag inclusion)
- blow holes
- spatter
- lack of fusion
 Types of distortions
- transverse/angular
- longitudinal
 Weld tests
- visual test
- bend test
PRACTICE:

At the end of this module unit, the learner should be able to:
a) identify the features of a good weld
b) identify arc weld defects and their remedies
c) perform a given weld test
14.1.5.5P2 Content
 Features of a good weld
- smooth
- clean
- even ripples
- good reinforcement
 Welds defects and remedies
 Weld test
- bend test
- nick break test
- visual inspection
Competencies
Ability to:
 identify the features of a good weld
 identify welding defects and remedies
127
Identifying the features of a good weld

 Illustrate qualities of a good weld to include:
- smoothness
- cleanliness ripples
- good reinforcement
- good root penetration
Identifying welding defects and remedies

 Illustrate and discuss various weld defects and their control to include
- defects
 entrapped slag
 blow holes
 spatter
 lack of fusion
 overlap
- control
 current selection
 electrode selection
 speed
 electrode angle
 edge preparation
Performing a given weld test

 Demonstrate the procedure of performing various weld test to include:
- visual test – observation with naked eye
- bend test, U-bend test
- nick break test
 notching
 hammering
Trainee should
 identify the features of a good weld
 identify welding defects and remedies

 Charts to include:
- A good quality weld
- Poor welded joints with the following defects
 Slag inclusion
 Blow holes
 Spatter
128
 Lack of fusion
- Types of distortions and their remedies:

 Transverse/angular
 longitudinal
- types of weld tests
 Assorted welded parts with weld defects clearly exposed
 Good welded joint
 Assorted hand tools to include

- Bench vice
- hack saw
- Hammer
Assessment Method
 Oral test on
- Qualities of good weld
- Weld defects and control
- Types of distortions
- Safety
 Written tests on
- Description of a good weld
- Types of weld defects and their control
- Types of weld distortions their causes and remedies
- Types of weld tests and procedures of carrying out the tests
- Safety procedures on handling and storage of tools and equipment
 Practical test
- A class project to include
 Producing a good quality weld and carrying out the various weld test on the
work piece
- Write a report on the findings
- Procedure to follow when handling tool and equipment
References
1. Basic Fabrication welding Engineering FJM Smith
2. workshop technology by G.H. Thomas
PROJECT WORK:
14.1.5.6P MODULE UNIT: FABRICATION OF A PRODUCT USING MILD STEEL

SECTIONS/PLATES

f) join the parts of the product
129
i) observe safety precautions when fabricating the product
14.1.5.6P2 Content
 Product survey
- Visiting local workshops
- Making observations
 various products
 various sizes
 materials used
 listing down various designs
 making sketches
 noting prices of various products
 Reading and interpreting working drawing

- dimensions
- materials
- scales
- joining method
 types of materials
 amount of material required
- Costing
 total number of parts
 unit cost
- cutting tools
- bending and forming tools
- welding equipment
- finishing tools
 Preparation of parts of the product
 Joining parts of the product by arc welding
- tacking
- welding
 Finishing processes
- deburring
- cleaning by wire brush
- dimensions control
- alignment
- symmetry of parts
- function ability
- fitting of parts
- quality of weld
- squareness and flatness
- quality of paintings
- general appearance
 Safety
- personal safety
130
Competencies
Ability to:
 estimate and cost of the product
 select tools and equipment
 prepare parts of the product
 join parts of the product by arc welding
 demonstrate safe working habits when fabricating the product

 Discuss and explain how to carry out product survey to include:
- Visiting local workshop
 various products
 various sizes
 materials used
 making sketches
 noting prices of various products
Reading and interpreting working

 illustrate and explain procedure of interpreting working drawings and assembly
drawings to include
- dimensions
- materials
- scales
- joining methods (symbols)
Estimating and costing the product

 Discuss the procedure of estimating and costing of material for a given product to
include:
- Types of material
- Size of material and allowances
- Total amount of material required
- Unit cost
- Total cost
- Product cost
131
Selecting the tools and equipment
 Demonstrate the correct preparation of parts of the product ready for fabrication to
include
- Material selection
- Cutting to size
- Filing and deburring
Joining parts of the product

 Demonstrate the procedure of joining parts of the product by a arc welding to
include
- Taking
- Welding
Carrying out finishing process
 Carry out the finishing process to include:-
- Deburring
- Cleaning by wire brush

 Demonstrate how to carry out quality control measures to include:-
- dimension control
- alignment
- symmetry of parts
- functionability
- fitting of parts
- quality of welds
- squareness and flatness
- quality of painting
Practicing safe working habits when fabricating the product

 Demonstrate how to practice safe working habits to include
- Personal safety
 Handling of tools
 Maintenance of tools and equipment
Trainee to:-
 estimate and cost of the product
132
 demonstrate safe working habits when fabricating the product

 Charts to include:-
- steel windows
- steel sections
 Steel sections – square, Z-section, round bars
 Assorted hand tools to include:-
- measuring
- marking out
- cutting
- bending
- welding
- finishing
Assessment methods
 Oral test
- applications of steel sections
- tools and equipment used in fabrication
- costing elements
- quality control terms
 Written test
- product of working reporting
- production of working drawing from assembly drawing
- costing of a product
- tools and equipment used in fabrication their uses
- preparation of parts and joining procedure
- steps involved in quality control
- safety
 personal
 tools and equipment
 Observation on:-
- trainees working habits
- trainees correct attitude towards practical work
- trainees team work and organization skills
 Assignment:-
- report writing on industrial / workshop visit
Practical
- a functional class project to include
 costing
 producing working drawing
 preparation parts and joining to give quality product
References
133
 Basic fabrication and welding engineering by FJM Smith
 Metal work technology by GH Thomas
 Workshop technology by Hursle Hust
134
14.1.6.1.1T MODULE UNIT : FORGING PROCESS
THEORY
14.1.6.1.1T1 Specific objectives

a) define the term forging
b) list down the advantages of forging over other production process
c) list down typical applications of forging in metal work
d) name various materials that are suitable for forging
e) name various types of fuels used for heating
f) state safety precautions to be observed when forging
14.1.6.1.1T2 Content
 The term forging
- temperature
- forming process
 Advantages of forging operation
- metal structure refining
- strengthening the metal
- time saving
- reduction of machining
 Typical applications of forging
- motor vehicle parts
- gears
- crank shafts
 Farm implements
- ploughs
- jembes / hoes
 Cutting tools
- cold chisels
- dot punches
- milling machine cutters
 Materials for forging
- iron
- mild steel
- aluminum
- copper
- brass
 Types of heating fuels
- charcoal
- coal
- oil
- gas
 Safety
- personal safety
- tools and equipment
PRACTICE:
14.1.6.1.1P1 Specific Objectives

a) identify various components produced by forging
b) identify suitable materials for forging a given component
c) identify types of heating fuels for forging
d) perform a simple forging operations using appropriate tools
135
e) observe safety precautions when forging
14.1.6.1.1P2 Content
 Components produced by forging
- ploughs
- crankshafts
- chisels
- axes
- ploughs
- hoes
 Materials for forging
- aluminium
- copper
- brass
- iron
- mild steel
 Types of heating fuels
- charcoal
- coal
- oil
- gas
 Simple forging operation
- forging of a hoe
- forging of an axe
 safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various components produced by forging
 identify suitable materials for forging a given component
 identify types of heating fuels for forging
 perform a simple forging operation
 observe safety precautions when forging
Identifying various components produced by forging

 Display and discuss typical forged components to include
- Jembes
- Chisels
- Axes
Identifying suitable materials used for forging

 Display and explain suitable materials used for forging products to include
- Mild steel (Black mild steel) plates
- Black mild steel bars
- Twisted bars
- Brass
- Copper
136
Identifying types of heating fuels for forging
 Display and explain types of fuels used for heating in forging to include
- Charcoal
- Coal
- Oil
- Gas
Performing a simple forging operation

 Demonstrate and explain how to perform a simple forging operations to include
- Forging of a hoe (Jembe)
- Forging of an axe
Observing safety precautions when forging

 Demonstrate how to observe safety precautions when carrying out forging to include
- Personal safety
- Equipment safety
The trainee should

 identify various components produced by forging
 identify suitable materials for forging a given component
 identify types of heating fuels for forging
 perform a simple forging operation

- Various forging process
- Types of furnaces used in forging
- Typical forged components
 Assorted forged components to include
- Jembes
- Gears
- Hoes
- Ploughs
 Materials to include
- Mild steel
- Copper
- Brass
 Fuels to include
- Charcoal
- Oil
- Gas
 Assorted forging tools to include
- Tongs
- Hammers
Assessment Methods
 Observation on
- Working habits
- Team work and organization skills
137
 Oral test on
- Definition of forging
- Advantages of forging
- Application of forging
- Types of fuels
- Safety procedures
 Practical work – on forging of a hoe or an axe
 Written test on
- Description of forging process
- Definition of forging
- Types of forging application
- Tools and equipment used in forging procedure of a forging operation
- Safety precautions
Assignments
 Identify a forged component and establish the material use and the forging process
used and write a report.
References
1. basic Fabrication and Welding Engineering – By F.J.M. Smith
2. Workshop Technology - by G.H. Thomas
14.1.6.1.2T MODULE UNIT: FORGING TOOLS AND EQUIPMENT

THEORY
14.1.6.1.2T1 Specific Objectives

a) name various tools and equipment used in metal forging
b) state the uses of each tool and equipment
c) explain how to care for and maintain tools and equipment used in metal forging
d) state safety precautions to be observed when forging
 Tools and equipment used in forging
- Heating equipment
 forge or hearth (open fire or stoke fire)
- Cutting tools
 hot set
 punches and drift
 hardies
- Forming tools
 hammer
 anvil
 swage block
 fullers
 swages
 flatter
- Holding tools
 tongs
 open mouth
 close month
 hollow bit
 Vee – bit
138
 round mouth
 Care and maintenance forging tools and equipment
- cleaning
- proper handling
- proper storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various tools and equipment used in metal forging
 select tools to produce a given component by forging
 care and maintain tools and equipment used in metal forging
 observe safety precautions when handling forging tools and equipment
PRACTICE:

a) identify various tools and equipment used in metal forging
b) select tools to produce a given component by forging
c) care and maintain tools and equipment used in metal forging
d) observe safety precautions when handling forging tools and equipment.
 Tools and equipment used in metal forging
- Heating equipment
 forge or hearth
 gas manifold
 oil system
 Cutting tools
- cold set
- punches
- drift
- hardies
- hot set
 Forming tools
- hammer
- fuller
- anvil
- swages
- swage block
- flatters
 Holding tools
- tongs
- open mouth
- close mouth
- hollow bit
- Vee bit
- round mouth
 Forging tools and equipment to produce a given component
- heating equipment
- cutting tools
139
- forming tools
- holding tools
 Care for and maintain tools and equipment used in metal forging
- servicing
 Safety
- personal safety
Identifying various tools and equipment used in metal forging

 Display and discuss various tools and equipment used in metal forging to include
- Cutting tools
 Hot set
 Punches and drifts
 Hardies
- Forming tools
 Hammer
 Anvil
 Swage block
 Filler
 Swages
 Flatters
- Holding tools
 Tongs – open mouth
 Closed mouth
 Hollow bit
 Vee – bit
 Round mouth
- Heating equipment
 Forge or hearth
Selecting correct tools to produce a given component by forging

 Demonstrate the use of the tools to produce given forging components to include the
following components
- Chisel – fullers, swage block, hammer
- Tongs
- Axe – swage block, flatter drifts and punches
Carrying and maintaining tools and equipment

 Demonstrate the proper use and care of forging tools and equipment to include
- Proper handling
- Proper maintenance
 Cleaning
 Oiling
 Storage
Observing safety precautions when handling forging tools and equipment

 Demonstrate and explain how to observe safety precautions when handling forging
tools and equipment to include
140
- Personal safety
- Tool safety
The trainee should

 identify various tools and equipment used in metal forging
 select tools to produce a given component by forging
 care and maintain tools and equipment used in metal forging
 observe safety precautions when handling forging tools and equipment

- Forging equipment – forge or hearth and their applications
- Various cutting tools and their application
- Various cutting tools and their application
- Various holding tools and their applications
- Assorted forging tools
- Assorted forged parts
Assessment Methods
 Oral tests
- To include naming and identifying various tools and equipment
- Uses of various tools and equipment
 Written test
- Sketching various tools and equipment and stating their uses
- Illustrating the applications of the various tools and equipment
 Observation
- On trainees working habits
- Correct attitude towards practical work and organization skills
 Practice
- Class project to include the identification, use and proper application of forging
tools and equipment
References
 Metal Work Pupils Book 1, 2, 3, and 4 by KIE
 Basic Fabrication and Welding Engineering – By F.J. M. Smith
 Workshop Technology – By G.H. Thomas
14.1.6.1.3T MODULE UNIT: FORGING OPERATIONS

THEORY

a) name various forging operations
b) state typical application of various forging operations
c) explain the correct procedure of performing a given forging operation
d) state safety precautions to be observed when performing a given forging operation
141
 Forging operations
- drawing down
- twisting
- forge welding
- up setting or jumping up
- cutting
- bending
- punching
- finishing
 Typical applications of forging applications
- Drawing down
 drawing down a round taper
 chisels
- Twisting
 reinforcement bars
 decorative grills
- Forge welding
 joining scarf weld
 butt weld
 Vee weld
- Upsetting or jump up
 increasing cross section area of a metal in a point e.g bolt head
- Cutting
 cutting to size
 using hot sets
- Bending
 produce different shapes such as angles, ovals and circles
- Punching
 producing holes on metal using punches
- Finishing
 flattening of an even surface by flatter or set hammer
 Procedures for forging
- measuring and marking out
- cutting to size
- forming to the required shape
- finishing
 Safety
- personal safety
PRACTICE:

a) carry out product survey of forged items.
b) make working drawings of the items identified.
c) estimate and cost the materials required to fabricate the items
d) select appropriate tools and equipment to be used
e) perform a forging operation of the article
f) carry out quality control measures
g) care for and main forging tools and equipment
h) observe safety precautions when forging
142
 Product survey
- Visit to local workshops/hardware
 making observations
 recording and reporting the observations
 Working drawing
- materials for the project
- scale ( half size, full size, twice full size)
- dimension (linear and angular) measurements
- tolerances
- type of finish ( painting or polishing)
 Estimating and costing of materials
 Estimating of material ( type of material sizes)

- costing
- unit cost of the material size
- total cost of the material
 Tools and equipment.
- cutting tools
- heating equipment
- forming tools and holding tools
- finishing tools
 Forging process
- cutting to size the materials required
- heating to correct temperature for a given operation
- forming to the required shape
- filing
- grinding
- polishing
- material selection
- uniform thickness
- dimension control
 linear
 angular
- tolerances
 positive
 negative
 positive/negative
- flatness and straightness of parts
- workmanship
- lack of dents
- good surface texture
- tears
- surface cracks
 Care for and main forging tools and equipment
- cleaning
- oiling/greasing
143
 Safety
- personal safety
Competencies
Ability to:
 carry out product survey of items
 make working drawing
 estimate and cost the materials for the product identified.
 select tools and equipment.
 perform forging process
 care for and maintain forging tools and equipment
Carrying out product survey of items

 Discuss and explain how to carry out product survey of products to include
- Visit to local workshops/hardware
 Make observations
 Recording and reporting the observations
Making working drawings

 Illustrate and explain the procedure of making working drawings from an
assembly to include:
- Parts list
- Materials for the parts
- Scale (full, half size, enlarged)
- Tolerances
- Type of finish (painting or polishing)
Estimating and costing the materials for the product identified

 Explain the procedure of estimating and costing of material for a given product
to include
- Type of material
- Size of material and allowances
- Unit cost of materials
- Total cost of material
Selecting tools and equipment

 Demonstrate the use of various tools and equipment used in forging the tools to
include
- Measuring and cutting out tools
- Heating equipment
- Forming tools and holding tools
- Finishing tools
144
Performing forging
The instruction should
 Demonstrate the process of forging a component to include
- Selection of the correct materials
- Measuring and marking out with correct allowances
- Cutting to size the material required within the tolerances and allowances
- Heating the material to correct temperature for a given operation
- Forming the material to the required shape
- Cleaning, polishing and checking for application appearance and if done as
pr the drawing

 Demonstrate the various finishing operation to the product to include
- Filing
- Polishing
- Grinding
Carry out quality control measures

 Demonstrate how to carry out quality control measures by emphasizing on the
need for proper quality control checks on good workmanship by checking
- quality of material selected in terms of
 uniform thickness
 flatness and straightness
- dimensional control in terms of
linear
angular
tolerances
- proper workmanship to include
 proper use of correct tool
 good surface texture
 lack of dents
 application of set standards
 suitability for use
 appearance
 marketability
Caring for and maintaining forging tools and equipment

 Demonstrate proper care and maintenance of forging tools and equipment in
terms of
- Handling
- Maintenance
 Cleaning
 Oiling
 Storage
Observing safety precautions when forging

 Demonstrate safe working habits when performing forging operations to include
- Personal safety
- Tool and equipment safety
145
The trainee should
 carry out product survey of items
 make working drawing
 estimate and cost the materials for the product identified.
 select tools and equipment.
 perform forging process
 care for and maintain forging tools and equipment

- Various forging operation
- Various forging tools and equipment
- Assembly drawing/working drawings
- Material and cost estimation of products
 Assorted forged components
 Assorted forging tools and equipment
Assessment Methods
 Oral test on
- Various forging operations
- Forging applications
- Naming and identification of tools and equipment
- Types of finishing process
- Types of quality control measures
- Safety and precautions
- Care and maintenance of tools
 Written test on
- Illustration of various forging operation
- Estimation of material and total cost of a product
- Production of working drawings
- Quality control measures
- Care and maintenance of tools and equipment
- Safe working habits
 Observation on
- Trainees working habits
- Team work and organization skills
 Assignment
- Report writing on industrial/workshop visit
 Practice
A functional class project to include
- Costing of project
- Producing working drawings
- Performing the forging process to give the required product
- Observation of safety and care of tools and equipment
References
 Basic Fabrication and welding engineering by F.J.M. Smith
 Metal work Technology by F.G.H. Thomas
146
 Workshop Technology by Harshest
147
14.1.6.2.4T` MODULE UNIT: METAL HEAT TREATMENT PROCESSES
THEORY

a) identify heat treatment tools and equipment
b) identify various cooling media used in heat treatment
c) carry out heat treatment processes for given applications
d) care and maintain heat treatment tools and equipment
e) observe safety precautions when performing heat treatment process
 Identification of heat treatment tools and equipment
- Heat source (heating equipment)
 Blow lamp/burner
 Oxy-acetylene gas
 Furnace
 Hearth/forge
 Gas burner
- Tools
 Wire brush
 Pair of tongs
- Annealing
 Furnace
 Lime
 Ash
- Hardening
 Oil
 water
 brine
- Tempering
 Oil
 Water
 brine
- Normalizing
 air
 Heat treatment processes and application
- Hardening
 Cutting tools
 Gears
 Drive shafts
- Tempering
 Cutting tools
 Gears
 Drive shafts
- Annealing
 Welded components
 Work hardened components
 Steel castings
 Forgings
-
- Cleaning
- Storage
148
 Safety precautions
- Personal
- Equipment
Competencies
Ability to
 Identify heat treatment tools and equipment
 Identify various cooling media used in heat treatment processes
 Carry out heat treatment processes for given applications
 Care and maintain heat treatment tools and equipment
 Observe safety precautions when performing heat treatment process
Identifying heat treatment tools and equipment

 Display and explain heat treatment tools and equipment to include
- Heating equipment
 Blow lamp/burner
 Oxy-acetylene gas
 Furnace
 Hearth/forge
 Gas burner
- Tools
 Pair of tongs
 Wire brush
Identifying various cooling media used in heat treatment processes

 Display and explain the various heat treatment processes and their applications to
include
- Hardening
 Oil
 Water
 Brine
- Temperate
 Oil
 Water
 Brine
- Annealing
 Furnace
 Lime
 Ash
- Normalizing
 Air
Carrying out heat treatment processes for given applications

 Demonstrate and explain how to carry out heat treatment processes for given
applications to include
- Hardening
 Cutting tools
 Gears
 Drive shafts
- Tempering
149
 Cutting tools
 Gears
 Drive shaft
- Annealing
 Welded components
 Work hardened components
 Steel casting
 Forgings

 Demonstrate and explain how to care and maintain tools and equipment used in
forging work to include
- Cleaning
- Storing
Observing safety precautions when performing heat treatment

 Demonstrate how to observe safety precautions when performing heat treatment
processes to include
- Personal
- Equipment
The trainee should

 Identify heat treatment tools and equipment
 Identify various cooling media used in heat treatment processes
 Carry out heat treatment processes for given applications
 Care and maintain heat treatment tools and equipment
 Observe safety precautions when performing heat treatment process
Key learning resource

 Heat treatment tools and equipment like: blow lamp/burner, oxy-acetylene gas,
furnace, hearth/forge, gas burner pair of tongs and wire brush
 Chartes – showing heat treatment processes
 Industrial/site visits to a heat treatment industry
Assessment
 Tests (oral and written)
- Heat treatment tools and equipment
 Assignment
- Heat treatment processes and application
 Practical
- Performing a given heat treatment process on given components e.g. gears and
cutting tools
 Observation
- On attitudes towards safety precautions
- Maintenance of tools and equipment
References
 Practical metallurgy by John E. Neely
 Engineering Metallurgy by R.A. Higgins
150
PROJECT WORK:
14.1.6.2.5P MODULE UNIT: HEAT TREATMENT OPERATIONS

a) carry out heat treatment operation
b) clean the component to remove dust, scales and rust
c) heat component to the right temperature
d) carry out quality control measures when heat treating metal components
e) observe safety precautions when carrying out a heat treatment operation
14.1.6.2.5P2 Contents
 Heat treatment operations
- heat treatment process
 hardening
 tempering
 annealing
 normalizing
- checking out component design and materials
- selecting heating equipment
- identifying cooling media
 Component to remove dust, scales and rust
 Heating and quenching of components to the right temperature
- Temperature range
- Quenching
 oil
 water
 brine
 current of air
 Quality control
- checking for cracks
- distortions
- burnt out
- fitting of parts
- alignment
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 carry out heat treatment operations
 clean component to remove dust, scales and rust
 heat and quench components to the right temperature
 carry out quality control
 observe safety when carrying out heat treatment operations
151
Carrying out heat treatment operations
 Demonstrate how to carry out heat treatment operation on a given task to
include
- hardening
- tempering
- annealing
- Normalizing
Cleaning component to remove dust/scales

 Demonstrate how to remove dust, scales after doing heat treatment
operations
Heating and quenching components to the right temperature

 Demonstrate how to identify the right temperature for the following
operation in steel
- Hardening – cherry red
- Tempering - straw, blue colours
- Annealing – cherry red
- Normalizing – cherry red
Carrying out quality control

 Demonstrate quality control in heat treatment operation to include:
- Checking for cracks
- Distortion control
- Burnt out
- Fitting parts
- Alignment
Observing safety when carrying out heat treatment

 demonstrate safe working habits in respect to heat treatment operation to
include:
- personal safety
The trainee should

 carry out heat treatment operations
 clean component to remove dust, scales and rust
 heat and quench components to the right temperature
 observe safety when carrying out heat treatment operations

 Heat treatment of graphical charts showing heat treatment processes,
colours and temperatures
 Samples of heat treated items
 Work pieces to be heat treated
 Heat treatment equipment, tools and material
Assessment Methods
152
 Observation
- The trainee should be able to observe safety precautions
- Exhibit teamwork and cooperation
 Oral test on
- Naming various heat treatment operations
- Purposes of various heat treatment process
- Identify the equipment required in heat treat operation
 Written test
- Heat treatment operations
- Purposes of heat treatment
- Heat treatment equipment
- Tools and materials
 Practical test
- Carry out heat treatment on an identified made project in the workshop
 Assignment on
- Various heat treatment operations
Reference
1. Workshop process for Mechanical Engineering Technicians volume 1 by
R.T. Pritchard
2. Workshop Technology by G.H. Thomas
153
14.1.6.3.1T MODULE UNIT: SAND CASTING

a) explain the term casting as an engineering manufacturing process
b) state typical applications of sand casting
c) list typical types of castings
d) name materials suitable for sand casting
e) list the materials used in pattern making
f) describe the pattern making process
g) name the features of a mould
h) list equipment used in mould making
i) describe the process of sand casting
j) explain finishing processes carried out on castings
k) care for and maintain tools and equipment used in sand casting
l) state safety precautions to the observed
 Casting as an engineering manufacturing process
 Typical applications of sand castings
- automobile components
- aeroplane components
- agricultural implements
- turbine vanes
- sanitary fittings
 Types of castings
- Ferrous castings
 Grey cast iron
 White cast iron
 Malleable cast iron
- Non ferrous castings
 alluminium
 copper
 brass
 bronze
 Raw materials for casting
- cast iron
- aluminium alloys
- brass
- bronze
 Materials for pattern making
- plastic
- wood
- mild steel
- clay
- wax
 Pattern making
- Machining allowance
- shrinkage allowance
- core prints
- rivets
- drafts
 Types of sands
154
- green sand
- parting sand
 features of a Mould
- cope
- runner
- riser
- vents
- drag
 Sand casting process
 Finishing processes of castings
- grinding
- fettling
 Care and maintenance for tools and equipment
 Safety
PRACTICE:
14.1.6.3.1P Specific Objectives

a) Select materials suitable for sand casting
b) Select equipment for pattern making
c) Produce pattern from a given component drawing
d) Select types of sand for moulding
e) Identify equipment to be used in sand moulding
f) Produce a sand mould using a given pattern
g) Perform a casting process to produce a component
h) Care for and maintain tools and equipment
i) Practice safe working habits when casting
 Sand casting materials

- cast iron
- aluminium alloys
- copper based alloys
 Equipment for pattern making
- pattern makers rule
- carpenters hand tools
- carpenters machine tools
 Pattern making
- component drawing
- planing
- turning
- fitting
 Types of sands
- green sand
- facing sand
- backing sand
- parting sand
 Moulding equipment
- moulding boxes
- spade
- wooden pins
- trowel
155
- wedges
- turning overboard
 Production of a sand mould
- Tools and equipment selection
- Mould making procedures
- Treatment of the mould
 Casting process
- melting
- pouring
- mould breaking
- fettling/grinding
- sand blasting
- cleaning
 Safety
- personal safety
Competencies
Ability to:
 select materials suitable for sand casting
 select equipment for pattern making
 produce pattern from a given component drawing
 select types of sand for moulding
 identify equipment to be used in sand moulding
 produce a sand mould using a given pattern
 perform a casting process to produce a component
 care for and maintain tools and equipment
 practice safe working habits when casting
Teaching/learning activities
Selecting materials suitable for sand casting

 explain and outline the materials that are suitable for sand casting to include
- cast iron
- aluminium
- brass
- copper
Selecting equipment for pattern making

 Display and discuss the equipment used in sand moulding to include
- Moulding boxes
- Space
- Wooden pins
- Trowel
- Wedges
- Turning overboard
Producing pattern from a given component drawing
 Outline how to produce pattern from a given component drawing to include
- Component drawing
- Planning
156
- Turning
- Fitting
Selecting type of sand for moulding

 Discuss the selection of types of sand for moulding to include
- Green sand
- Facing sand
- Backing sand
- Parting sand
Identifying equipment to be used in sand moulding

 Display and discuss the equipment used in sand moulding to include
- Moulding boxes
- Space
- Wooden pins
- Trowel
- Wedges
- Turning overboard
Producing a sand mould using a given pattern

 Explain the production of sand mould using a given pattern to include
- Tools and equipment
- Mould making procedure
- Treatment of the mould
Performing a casting process to produce a component

 Discuss a casting process to produce a component to include
- Melting
- Pouring
- Mould breaking
- Fretting/grinding
- Sand blasting

 Explain how to care for and maintain tools and equipment to include
- Cleaning
Practising safe working habits

 Discuss safe working habits when casting to include
- Personal safety
The trainee should

 select materials suitable for sand casting
 select equipment for pattern making
 produce pattern from a given component drawing
 select types of sand for moulding
157
 identify equipment to be used in sand moulding
 produce a sand mould using a given pattern
 perform a casting process to produce a component
 practice safe working habits when casting
Key Teaching/learning Resources

 Tools and equipment to include
- Equipment
 Pattern makers rule
 Carpenters hand tools
 Carpenters machine tools
 Moulding box
- Tools
 Spade
 Wooden pins
 Trowel
 Wedges
 Materials to include
- Green sand
- Facing sand
- Backing sand
- Parting sand
- Pattern materials
 Plastic
 Wood
 Mild steel
 Clay
 Wax
 Hand-outs depicting
- Pattern making process
- Features of a mould
- Stages of producing a pattern
Assessments
 Tests
- Oral on
 ‘term’ explanation
 Materials for sand costing
 Materials for pattern making
- Written on
 Description of pattern making process
 Production of patterns from component drawings
 Features of a mould
 Assignments on
- Equipment used in sand moulding
- Steps in production of sand mould
- Casting process
 Practical exercise on
- Selection of the equipment for pattern making
- Production of a component from a given drawing
- Production of a sand mould using a given pattern
 Observation on
158
- Caring and maintaining tools and equipment
- Practices of safe working habits when casting
 Project
- To produce a given component by casting process e.g. an ash tray
Reference
1. Metal work technology - by G.H. Thomas
2. Workshop processes and materials by Black
159
14.2.1.1T MODULE UNIT: OCCUPATIONAL INFORMATION
THEORY

a) state job opportunities for a metal processing person
b) list further training programs available for a metal processing person.
c) state the relationship between metal processing industry and other related trades
14.2.1.1T2 Content
 Job opportunities
- public sector
- private sector
- self employment
 Training programs
- other certificates
- diploma
- degree (B. Tech)
 Relationship
- related trades
- work interaction
- servicing
Competencies
Ability to:
 state job opportunities for a metal processing person
 list further training programs available for a metal processing person.
 state the relationship between metal processing industry and other related trades
Job opportunities for a metal processing person

 Discuss job opportunities available for a person who is skilled in metal
processing to include:
- public sector
- private sector
- self employment
Further training for a metal processing person

 Explain and discuss further training programmes available for a metal processing
person to include:
- other certificates
- diploma
- degree (bachelor of technology)
Relationship between metal processing industry and other related trades

Instructor should
 Discuss the relationship between metal processing industry and other trades to
include:
- automotive, electrical, building
- work interaction
- servicing
160
The trainee should
 identify job opportunities available for a person who is skilled in metal
processing techniques
 identify further training programmes available for a metal processing person
 explain the relationship between metal processing industry and other related
trades.

 textbooks
- on training programmes
 Handouts
- On careers and training opportunities
 resource persons
- to lecture and explain about job opportunities
 industrial visits
- to different industries dealing with metal processing
Assessment
 written tests on job opportunities, further training and on relationship between
metal processing industry and other related trades
References
 Practical Metallurgy by John E. Neely
 Workshop Technology Volume I by H.S. Bawa
14.2.1.2T MODULE UNIT: GENERAL SAFETY

b) state safety rules and regulations to be observed in the workshop.
c) name classes of fires
d) name fire fighting media for various classes of fires
e) state the first aid procedure in the workshop
f) state the importance of the Factories Act, CAP. 514
14.2.1.2T2 Content
 Safety rules and regulations to be observed in the workshop
- Behaviour in the workshop

 non-interference with fellow trainees in the workshop
 no playing, shouting and running around in the workshop
 not operating machines without permission from the instructor
 reporting any accidents which occur in the workshop
 dressing properly
- Cleanliness:
 cleaning the floors and pathways
 dusting benches and machines
- Issuing and checking of materials, tools and lubricants
 materials such as bars, sections, flats, plates, sheets and electrodes
 tools and welding equipment
 lubricants such as oil or grease.
- Dressing (protective clothing)
 overalls , aprons, boots, hand gloves, helmet, goggles and leggings
161
- Personal appearance
 long hair, beard
 long finger nails
 rings and watches
 long sleeves and head scarf
 personal hygiene
- Health hazards
 toxic substances
 fumes
 dust from fabricating materials
 petroleum products and fluxes
 Types of fires
- Class A
 wood, cloth, paper, solid combustible materials
- Class B
 flammable liquids e.g. petrol, oils, grease, fats
- Class C
 electrical equipment
 Fire fighting media
- Class A
 water from buckets
 horse reel
 sand
 soda/acid
- Class B
 asbestos blanket
 dry powder
 carbon dioxide
 foam
- Class C
 carbon dioxide
 fire drills
● First aid procedures
- cleaning and dressing of cuts, burns, bruises and bites
- treatment of shock by mouth to mouth, artificial respiration
- cleaning and removing a foreign body in the eye using eye lotion
- dressing of sprains
- reporting any accident or injury
● The importance of the Factories Act – CAP 514
162
PRACTICE:
14.2.1.2P GENERAL SAFETY

a) identify the health hazards in a working situation and take the appropriate action
b) wear appropriate working clothing
c) demonstrate first aid in the workshop
d) practice fire fighting drills
e) observe safety awareness
14.2.1.2P2 Content
 Health hazards
- slippery floors
- round bars
- combustible materials
- naked live wires
- gas leakage
- arc welding in the open
- mushroomed hammer heads
- files without handles
- welding in enclosed areas
- repair of petrol tanks
 Appropriate working clothes

- leather aprons
- leather gloves
- welding shield/helmets
- welding goggles
- safety boots
 First aid
- cuts and bleeding
- mouth to mouth artificial respiration
- shock treatment
- eye lotion for arc eye
- burns
- foreign bodies in the eye
 Fire fighting drills.( Class A, B, and C fires)
- Paper, sawdust fire ( water)
- electrical fires ( CO2)
- chemical or petroleum fires ( dry powder / sand asbestos blanket
 Safety awareness
- demonstrate safe working habits
- checking for gas leakages
 Importance of the Factory Act – CAP 514
Competencies
Ability to:
 identify health hazards

 wear appropriate working clothes
 demonstrate first aid
163
 practise fire fighting drills.( class a, b, and c fires)
 observe safety awareness
 observe the importance of the factory act – cap 514
Identifying possible causes of hazards in a working situation

 Discuss and identify possible causes of hazards in a working situation to include:
- slipper floors
- round bars
- combustible materials
- naked live wires
- gas leakage
- arc welding in the open
- mushroomed hammer heads
- files without handles
- welding in enclosed areas
- petrol/fuel tanks
Wearing appropriate working clothes

 Demonstrate how to wear appropriate working clothes to include:
- leather aprons
- leather gloves
- welding shield/helmets
- welding goggles
- safety boots
Carrying out first aid

 Discuss and demonstrate how to carry out first aid to include:
- cuts and bleeding
- mouth to mouth artificial respiration
- shock treatment
- use of eye lotion for arc eye
- burns
- foreign bodies in the eye
Fire fighting drills

 Discuss and demonstrate fire fighting drills for different classes of fire to include:
- class A (Combustible materials)
- class B (Electrical fires)
- class C (Chemical or petroleum fires)
Demonstration of safety measures

 Discuss and demonstrate safety measures to include:
- safe working habits
- checking for gas leakages
- factory Act – CAP 514
164
The trainee should
 identify possible causes of hazards in a working situation
 wear appropriate working clothes
 carry out first aid
 perform fire fighting drills
 observe safety measures

 fire fighting equipment
- like water, Co2, dry powder and blanked
 protective clothing
- ovarall
 first aid kit
- overcoats
 text books
- aprong
 Charts
- On fire fighting
 Manuals
- On classes of fires
Assessment Methods
 Oral test
- identification of possible causes of hazards in a working situation
 Written test
- listing safety clothes and equipment
- listing classes of fires and appropriate fire fighting agents
 Demonstration
- fire fighting drills
References
 Metalwork Technology by G.H. Thomas
 Factory Act – CAP 514
165
14.2.1.3T MODULE UNIT: PRODUCTION OF METALS (IRON AND
STEEL)
THEORY
a) list various types of iron ores in their natural state
b) name additional charging materials in a furnace and their effects in iron and steel
c) describe the construction and operational principles of furnaces
d) care for and maintain blast furnace
e) explain safety precautions to be observed in blast furnaces
14.2.1.3T2 Content
 Types of iron ores
- magnetite
- hematite
- limonite
- siderite
 Materials charging in furnaces
- coke
- limestone
 Construction and operational principles of furnaces
- blast furnace
- cupola
- open hearth
- Bessemer converter
- oxygen processes
- electric furnace
 Care and maintenance of blast furnaces
- cleaning
- oiling/greasing
- service
 Safety
- personal safety and safety for others
PRACTICE:

a) identify various types of ores
b) identify additional charging materials for furnaces
c) identify various types of furnaces
d) operate various types of furnaces
e) care for and maintain various types of furnaces
f) observe safety precautions when handling furnaces
14.2.1.3P2 Content
 Identification of types of ores
- magnetite
- hematite
- limonite
- siderite
 Additional charging materials
- coke
- limestone
166
 Types of furnaces
- blast furnace
- cupola
- open hearth
- bessemer converter
- oxygen processes –L-D, Kaldo, Rotor
- electric furnace
 Care and maintenance of furnaces
- cleaning
- oiling/greasing
- servicing
 Safety
Competencies
Ability to:
 identify various types of ores
 identify additional charging materials for furnaces
 identify various types of furnaces
 operate various types of furnaces
 care for and maintain various types of furnaces
 observe safety precautions when handling furnaces
Identifying ores
 Discuss and display various types of iron ores to include
- magnetite
- hematite
- lionize
- siderite
- pyrite
Identifying charging materials

 Discuss and display additional charging materials for furnaces to include
- coke
- limestone
Identifying types of furnaces

 Discuss types of furnaces to include
- blast furnace
- cupola
- open hearth
- bessemer converter
- oxygen processes – L.D., Kaldo, Rotor
167
- electric furnace
Operating a furnace
 explain and demonstrate how to operate furnaces to include:
- charging
- temperature control
- quality control
Caring for and maintaining furnaces

 Discuss how to care for and maintain furnaces to include
- cleaning
- oiling/greasing
- serving
Safety Precaution for furnaces

 Discuss and demonstrate safety precautions to be observed when handling
furnaces to include
- personal safety
- equipment safety
The trainee should

 identify various types of iron ores
 identify additional charging materials for furnaces
 identify types of furnaces
 be able to care for and maintain given furnace
 be able to demonstrate safe working habits when handling furnaces

 materials samples
- types of ores (magnetic, hematite, limonite, siderite)
 thermometers
- coke
 seger cones
- limestone
 pyrometers
 furnaces
- blast furnace cupola, open hearth, besemer, converter, oxygene process, (LD,
Kaldo, Rotor), Electric furnace
 charts/diagrams
168
- furnaces, furnace temperature control
Assessment
 Oral test
- identification of various types of ores and furnaces
 Written test
- ores and furnaces
References
 Practical metallurgy by John E. Neely
 Engineering matallurgy by R.A. Higgins
169
14.2.1.4T MODULE UNIT: CAST IRON

a) name types of cast iron and describe their structures
b) state applications of cast iron
c) care for and handle cast iron devices
14.2.1.4T2 Content
 Types of cast iron and their structures
- grey
- white
- nodular
 Properties of cast iron
- brittleness
- compression strength
 Application of cast iron
- machine beds
- engine blocks
- drainage pipes
 Care and handling of cast iron
- cleaning
 Safety
PRACTICE:

a) identify types of cast iron
b) identify various applications of cast iron
c) care for and handle cast iron items
d) practice safety when handling cast iron items
14.2.1.4P2 Content
 Types of cast iron
- grey
- white
- nodular
 Application of cast iron
 Care and handling of cast iron items
- cleaning
 Safety
- personal safety
- materials safety
Competencies
Ability to:
 identify types of cast iron
170
 identify various applications of cast iron
 care for and handle cast iron items
 practice safety when handling cast iron items
Identifying cast iron

 Display components made from different types of cast iron and discuss properties
of various types of cast iron to include:
- brittleness
- compression strength
Identifying application of cast iron

 Discuss the application of cast iron and display cast iron components to include:
- machine beds
- engine blocks
- drainage pipes
Caring for and handling of cast iron components

 Discuss and demonstrate how to care for and handle cast iron components to
include:
- cleaning
Safety when handling cast iron components

 Discuss safety measures to be observed when handling cast iron components to
include:
- personal safety
- materials safety

 samples of components made from different types of cast iron
 safety gear
Assessment
 Oral test
- identifying components made from different types of cast iron
 Written tests
- properties of cast irons
- application of cast irons
171
14.2.1.5T MODULE UNIT: CARBON STEELS
THEORY
a) name various types of plain carbon steels and their carbon content in percentage
b) state properties of plain carbon steels
c) state suitable application of plain carbon steels
d) care for and maintain carbon steels
e) state safety precautions when handling carbon steel items
14.2.1.5T2 Content
 Types of plain carbon steels and their carbon content in percentage
- dead mild
- mild
- medium carbon
- high carbon
 Properties of plain carbon steels
- cold rolled
- drop forged
- hardness
- toughness
 Applications of plain carbon steels
- Chain
- Rivets
- Structural
- Crankshafts
- hammers
- drills
- files
- saws
 Care and maintenance of carbon steel devices
- cleaning
- oiling/greasing
 Safety
- personal safety
PRACTICE:

a) identify types of plain carbon steels by spark test
b) identify various items produced by cold rolling and drop forging
c) care for and maintain carbon steel devices
d) practice safety precautions when handling carbon steels
14.2.1.5P2 Content
 Types of plain carbon steels
- dead mild
- mild
172
- medium carbon
- high carbon
 Cold rolled and drop forged items
 Care and maintenance of carbon steels
- cleaning
 Safety
- personal safety
Competencies
Ability to:
 identify various types of plain carbon steels by spark test
 identify items produced by cold rolling and drop forging
 care for and maintain carbon steels
 observe safety precautions when handling carbon steels
Identifying types of plain carbon steel

 Discuss and demonstrate how to identify types of plain carbon steels using spark
test to include:
- dead mild steel
- mild steel
- high carbon steel
Identifying items produced by cold rolling and drop forging to include:

 Discuss and display items made by cold rolling and drop forging
- cold rolling
 bright drawn mild steel rods
- drop forging
 railway wheels
Caring for and maintaining plain carbon steel items

 Discuss and explain the nature of care and maintenance that should be carried out
when handling plain carbon steel items to include
- cleaning
Observing safety precautions when handling carbon steel products

 State and discuss the safety precautions to be observed when handling carbon
steel items to include
- personal safety
173
The trainee should
 identify various types of plain carbon steels
 identify items produced by cold rolling and drop forging
- to care for and maintain carbon steel items
- to display safe working habits when handling carbon steel items

 Components made from various types of plain carbon steels
- steel furniture,
- vehicle springs, coil springs
- twist drills, files
 Charts/diagrams
- rolling machines
- drop forging
Assessment
 Oral test
- identifying items made from various types of plain carbon steels
 Written test
- listing types of plain carbon steel and their carbon content
- stating properties of plain carbon steels
- stating procedure for caring and maintaining of plain carbon steel items
References
 Practical metallurgy by John E. Neely - Publisher John Willy & sons
 Engineering Metallurgy Part I by Raymond A. Higgins (2nd Edition) - English
Universities Press Ltd
14.2.2.1T MODULE UNIT: WORK HOLDING DEVICES

THEORY

a) name various work holding devices used in bench work and fitting
b) explain the use of each work holding device
c) explain the correct method of maintaining and caring for work holding devices
14.2.2.1T2 Content
 Work holding devices engineers vice/ machine vice
- tool makers clamp
- hand vice
- G- clamps
- pliers
 Usage of work holding devices
- Tool makers clamp -
for assembling, riveting or screwing
- hand vice
for drilling and riveting
- G-Clamp
for assembling and marking out
- Pliers
for general purpose and for cutting
 Care and maintenance of work hold devices
174
- cleaning
- oiling /greasing
- proper handling
- storage
PRACTICE:

a) identify various work holding devices used in bench work and fitting
b) select suitable work holding device for a given work piece
c) care for and maintain work holding devices
d) observe safety precautions when using work holding devices
14.2.2.1P2 Content
 Work holding devices
- machine vice
- tool makers clamp
- hand vice
- G- clamps
- bench vice
 Selection of work holding device
- drilling
- cutting
- assembling
- riveting
- screwing
 Care and maintenance of work holding devices
- oiling greasing
- servicing
- handling
- storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various work holding devices used in bench work and fitting
 select suitable work holding device for a given work piece
 care for and maintain work holding devices
 observe safety precautions when using work holding devices
Identifying various work holding devices used in bench work and fitting
 Display and explain various work holding devices used in bench work and fitting
to include
- machine vice
- tool makers
- hand vice
- g-clamp
- bench-vice
175
Selecting suitable work holding device for a given work piece
 Discuss and explain how to select suitable work holding device for a given work
piece to include the following operations
- drilling
- cutting
- assembling
- riveting
- screwing
Caring for and maintaining work holding devices

 Discuss and explain how to care for and maintain work holding devices to
include
- Oiling/greasing
- servicing
- handling
- storage
Observing safety precautions when using work holding devices

 Discuss how to observe safety precautions when using work holding devices
- personal safety
- equipment safety
The trainee should

 identify various work holding devices used in bench work and fitting
 select suitable work holding device for a given work piece
 care for and maintain work holding devices

 Work holding devices to include
- engineers vice/machine vice, tool makers clamp, hand vice, G-Clamp, pliers
 Charts and handouts showing the above mentioned devices
Assessment
 Oral test
- naming of work holding devices
 Written test
- explaining the use of various work holding devices
 Assignment
- To explain the correct method of maintaining a given holding device
 Practice
- Identifying different types of holding devices
- exercise involving the use of holding device e.g. when riveting
 Observation
- observation of safety precaution while using a holding device
14.2.2.2T MODULE UNIT: MEASURING AND MARKING OUT

TOOLS
THEORY
176
a) name various measuring and marking out tools
b) state the uses of each of the marking out tools
c) explain how to care for and maintain measuring and marking out tools
14.2.2.2T2 Content
 Measuring and marking out tools
- vernier height gauge
- micrometer
 outside micrometer
 inside micrometer
- scribing block / surface gauge
- trammel
- combination set
- centre square
- vee blocks
- spirit level
- depth gauge
- dial test indicator ( D.T.I)
 Usage of measuring and marking out tools
- drawing linear and angular lines
- taking measurements of:
 length
 width
 thickness
 diameters and angles
- checking for:
 squareness
 parallelism
 Care and maintenance of measuring and marking tools
- cleaning
- proper handling
- proper storage
PRACTICE

a) identify measuring and marking out tools
b) select and use suitable measuring and marking out tools for a given job
c) care and maintain measuring and marking out tools
d) observe safety precautions when handling measuring and marking out tools
14.2.2.2P2 Content
 Measuring and marking tools
- measuring tools
 vernier caliper
 micrometer ( inside and outside micrometer)
 depth gauge
 bevel gauge
 combination set
 protractor
177
- marking out tools
 vernier height gauge
 scribing block/surface gauge
 centre square
 trammel
 veeblocks
 angle plate
 spirit level
 dial test indicator ( d.t.i)
 surface table
 surface plate
 deviders
 calipers ( inside calipers and outside calipers)
 scribers
 rule
 try square
 Selection and usage of measuring and marking out tools

- measuring
 taking measurements of
 length
 width
 thickness
 diameters and angles
 Marking out
 drawing linear and angular lines
 Squareness
 parallelism
 Care and maintenance of measuring and marking out tools
- cleaning
- proper handling
- proper storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify measuring and marking out tools

 select and use suitable measuring and marking tools for a given job
 care and maintain measuring and marking out tools
 observe safety precautions when handling measuring and marking out tools
Identifying measuring and marking out tools

 display and explain measuring and marking out tools to include the following
- measuring tools
 vernier caliper
178
 micrometer (inside and outside)
 depth gauge
 bevel gauge
 combination set
- marking out tools
 vernier height gauge
 scribing block/surface gauge
 centre square
 trammel
 vee block
 angle plate
 spirit level
 dial test indictor (DTI)
 surface table
 surface plate
 dividers
 calipers (inside calipers and outside calipers
 scribers
 rule
 try square
Selecting and using suitable measuring and marking out tools for a given job
 explain and demonstrate the use of suitable measuring and marking out tools to
include the following
- measuring
 taking measurements of
 length
 width
 thickness
 diameters and angles
- marking out
 drawing linear and angular lines
 squareness
 parallelism
Caring and maintaining measuring and marking out tools

 demonstrate and discuss care and maintenance of measuring and marking out
tools to include
- cleaning
- proper handling
- proper storage
Observing safety precautions when handling measuring and marking out tools
 Demonstrate how to observe safety precautions when handling measuring and
marking out tools to include
- Personal safety
- Equipment safety
The trainee should

 identify measuring and marking out tool
179
 select and use suitable measuring and marking tools for a given job
 care and maintain measuring and marking out tools
 observe safety precautions when handling measuring and marking out tools

 Marking out tools to include vernier height, gauge, scribing block/surface gauge,
centre square, trammel, vee blocks, angle plate, spint level, dial test indicator
(dti), surface table, surface plate, dividers, calipers, odd leg calipers, scribers, rule
and try square
 Measuring tools – to include vernier caliper, micrometer (inside and outside),
depth gauge, bevel gauge, combination set and protractor
 Charts and hand outs on the above mentioned tools
 Working drawings of exercises
Assessments
 Tests (written and oral) on measuring and marking out tools
 Assignments - On selection and use of suitable measuring and marking out tools
on given tasks.
 Practice – Practical exercise of projects which involve measuring and marking
out
 Observation – on use of the tools and their care and maintenance
180
14.2.2.3T MODULE UNIT: CUTTING TOOLS AND EQUIPMENT
THEORY

a) name various types of cutting tools and equipment
b) state the uses of each cutting tool and equipment
c) name parts of given cutting tools and equipment
d) explain how to care for and maintain given cutting tools and equipment
e) state safety precautions to be observed when using cutting tools and
equipment.
14.2.2.3T2 Content
 Cutting tools and equipment
- grinding machines
- bench grinder
- pedestal grinder
- surface grinder
- cylindrical grinder
- electric hand drill
- manual hand drill
 Parts of cutting tools and equipment
- bench grinder
 motor
 grinding wheel
 guard
 eye shield
 switch
- Hand drill
 motor
 chuck
 switch
 handle
 Care and maintenance of cutting tools and equipment
- cleaning
 Safety precautions to be observed when using cutting tools and equipment
- personal safety
- equipment safety
PRACTICE:
a) identify various types of cutting tools and equipment
b) select and use appropriate cutting tools and equipment for a given job
c) care for and maintain given cutting tools and equipment
d) observe safety precautions when using cutting tools and equipment
181
14.2.2.3P2 Content
 Cutting tools and equipment
- bench grinder
- pedestal grinder
- manual hand drill
- portable grinder
- surface grinder
- angle grinder
- abrasive wheel cutting off machine
 Selection and usage of cutting tools and equipment
- cutting to size
- grinding to size
- drilling holes
 Care and maintenance of cutting tools and equipment
- oiling
- greasing
- wheel dressing
- storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various types of cutting tools and equipment
 select and use appropriate cutting equipment for a given job
 care for and maintain given cutting equipment
 observe safety precautions when using cutting equipment
Identifying cutting tools and equipment

 Show and explain various types of cutting tools and equipment to include
- chisels
- files
- bench grinders
- manual hand drill
- portable grinder
- surface grinder
- angle grinder
- abrasive wheel cutting off machine
Selecting and using appropriate cutting tools and equipment for a given job
 Discuss the selection and usage of cutting tools and equipment to include
- cutting to size
- grinding to size
- drilling holes
182
Caring for and maintaining given cutting tools and equipment
 Demonstrate hot to care for and maintain given cutting tools and equipment to
include
- oiling
- greasing
- wheel dressing
- storage
Observing safety precautions when using cutting tools and equipment

 Demonstrate and explain how to observe safety precautions when using cutting
tools and equipment to include:
- personal safety
- equipment safety
The trainee should

 identify various cutting tools and equipment
 select and use appropriate cutting equipment for a given job
 care for and maintain given cutting equipment
 observe safety precautions when using cutting equipment

 Cutting tools and equipment to include
- tools
 file
 chisel
 hacksaws
- equipment
 grinding machines
 surface grinder
 cylindrical grinder
 bench grinder
 pedestal grinder
 electric hand drill
 hand drill
 portable grinder
 abrasive wheel cutting off machine
- charts showing the tools and equipment usage
- handouts – on the cutting tools and equipment
- working drawings for practical exercises
Assessment Tests
 Oral
- naming cutting tools and equipment
 Written
- explaining parts of cutting tools and equipment
- explaining how to care for and maintain tools and equipment
 Assignments
- selection of appropriate tool for a given operation
 Practical
- practical exercise which will involve cutting, grinding and drilling
 Observation
- on attitude towards personal and equipment safety
- on attitude towards caring for and maintaining the equipment
183
14.2.2.4T MODULE UNIT: PIPE AND PIPE FITTING
THEORY

a) name various types of pipes
b) state various uses of pipes
c) list various types of pipe fittings
d) list types of tools and equipment used in pipe work
e) name various methods of joining pipes
f) explain how to care for and maintain tools and equipment used in pipe work
14.2.2.4T2 Content
 Types of pipes
- mild steel pipes
- galvanized iron pipes
- cast iron pipes
- polyvinyl chloride ( PVC)
- copper pipes
 Pipe uses
- Water delivery
 GI pipes
 PVC brass
- Oils / Fuels
 copper
 brass
- Drainage
 PVC
 cast iron
 Pipe fittings
- stop corks
- gate valves
- flanges
- taps
- elbows
- unions
- reducers
- tees
- crosses
- sockets
- nipples
- plugs
- non return valve
 Tools and equipment used in pipe work
- work bench
- vices
- wrenches
- pliers
- threading dies and taps
- hacksaws
- files
 Methods of joining pipes
- screwed connections
- flanged connections
184
- use of adhesive ( gluing)
- welded connections
- soldered connections
 Care for and maintenance of tools and equipment
- cleaning
PRACTICE:

a) read and interprete pipe work drawing
b) select appropriate pipes and pipe fittings for a given job
c) select the correct tools and equipment for a given job
d) prepare pipes and pipe fittings for joining
e) join the pipes using the correct fittings
g) care for and maintain pipe work tools and equipment
h) observe safety precautions when doing pipe work.
14.2.2.4P2 Content
 Interpreting drawings
- dimensions
- symbols
- scale
 Appropriate pipes and pipe fittings
- water distribution
- fuels / oils
- gases and steam
- compressed air
- drainage
 preparing pipes and pipe fittings
- measuring
- cutting to size
- threading
- bending
- beveling
 Joining of pipes
- screwed joints
- welded joint
- soldered joint
- bolted joints
- adhesive joints
 Quality control in pipe work
- proper dimensions
- pipe alignment
- leakages
- workmanship
- fitting of parts
- lack of dents or scratches
 Care and maintenance of pipe work tools and equipment
- cleaning
185
- proper handling
- storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 read and interpret drawings

 select appropriate pipes and pipe fittings
 prepare pipes and pipe fittings
 join pipes
 carry out quality control in pipe work
 care and maintain pipe work tools and equipment
Reading and interpreting pipe drawings

 Discuss and illustrate pipe drawings to include
- dimensions
- symbols
- scale
- line drawing
- pictorial drawing
Selecting appropriate pipes and pipe fittings

 Explain the selection of appropriate pipes and pipe fittings for the following
- water distribution
- fuels/oils
- gases and steam
- compressed air
- drainage
Preparing pipes and pipe fittings

 Demonstrate the preparation of pipes and pipe fittings to include the following
- measuring
- cutting to size
- threading
- bending
- beveling
Carrying out quality control measures in pipe work

 Discuss and explain how to carry out quality control in pipework to include
- proper dimensions
- pipe alignment
- leakages
- workmanship
- fitting of parts
- freedom from dents or scratches
186
Caring and maintaining pipework tools and equipment
 Demonstrate how to care for and maintain pipe work tools and equipment to
include
- cleaning
- proper handling
- storage
Observing safety precautions when doing pipework

 Explain how to observe safety precautions when doing pipe work to include
- personal safety
- equipment safety
The trainee should

 read and interpret pipe drawings
 select appropriate pipes and pipe fittings
 prepare pipes and pipe fittings for joining
 join pipes using correct fittings
 carry out quality control measures in pipework
 care and maintain pipework tools and equipment
 observe safety precautions when doing pipework

 Tool and equipment
- tools
 pliers
 hacksaws
 files
 wrenches
 taps and dies
 die stocks
- equipment
 work bench
 threading machines
 Pipes and pipe fittings
- pipes
 mild steel pipes
 galvanized pipes
 cast iron pipes
 PVC pipes
 copper pipes
- pipe fittings
 stop corks
 gate valves
 flanges
 elbows
 unions
 taps
 reducers
 tees
 crosses
 sockets
187
 nipples
 plugs
 non return valves
 Charts showing pipes and pipe fittings
 Pipe drawings
Assessments
 Tests (written and oral)
- on types of pipes and pipe fitting
- on pipe joining
- on quality control
 Assignments
- on pipes, Pipe fittings and symbols
 Practicals
- practical exercise involving threading of pipes joining and fitting
 Observations
- on safety gear
- on attitudes towards maintenance and caring for tools and equipment
PROJECT WORK:
14.2.2.5P FITTING WORK

a) read and interpret given working drawing of a product
b) select tools and equipment required to make the product
c) measure and mark out the required profiles
d) cut to the required shape
e) fit the parts to the given tolerances
g) care for and maintain tools and equipment used in fitting work
h) observe safety precautions during fitting work.
14.2.2.5P2 Content
 Reading and interpretation of working drawing
- parts of the product
- dimensions
- symbols
- scales
- materials
- measuring and marking out tools and equipment
- cutting and material removal tools
- threading tools
- finishing tools
 Measuring and marking out the profiles
- straight lines
- arc and circles
- centre lines
 Cutting to shape
- hack sawing
- chiseling
- drilling
188
 Fitting the thread cut parts to given tolerances
- filing
- scraping
- proper dimensions
- proper tolerances
- workmanship
 freedom from dents
 freedom from scratches
- cleaning
- handling and storage of tools and equipment
 Safety
- personal safety
- equipment safety
Competencies
Ability to:

 select tools and equipment required to make the product
 measure and mark out the profiles
 cut to shape
 fit the cut parts to given tolerances
Reading and interpreting working drawings

 Illustrate and discuss working drawings of given products to include
- parts of the product
- tolerances
- dimensions
- symbols
- scales
- materials
Selecting tools and equipment required to make the product

 Explain the selection of tools and equipment required to make a given product to
include the following
- measuring and marking out tools and equipment
- cutting and material removal tools
- threading tools
- finishing tools
189
Measuring and marking out the profiles
 Demonstrate and explain how to measure and markout the required profile to
include
- straight lines
- arc and circles
- centre lines
Cutting to required shape

 Demonstrate how to cut to required shape to include the following
- hacksawing
- chiseling
- drilling
Fitting the cut parts to given tolerance

 Discuss and demonstrate how to fit the cut parts to given tolerance to include
- filing
- scraping

 Explain how to carry out quality control measures to include the following
- proper dimensions
- proper tolerances
- workmanship
- free from dents
- free from scratches

 Demonstrate how to care for and maintain tools and equipment used in fitting
work to include:
- cleaning
- handling and storage of tools and equipment
Observing safety precautions during fitting work

 Explain how to observe safety precautions during fitting work to include
- personal safety
- equipment safety
The trainee should

 read and interpret working drawings
 select tools and equipment required to make the product
 measure and mark out the required profiles
 cut the required shape
 fit the cut parts to given tolerances
 care for and maintain tools and equipment used in fitting work
 observe safety precautions during fitting work
190
 Marking out tools to include – steel rule, scriber, centre punch, vernier height
gauge, surface gauge, calipers
 Cutting tools to include – files, chisels, drills, hacksaws and hand grinder
 Measuring tools including – Vernier calipers, bevel protractor, combination set,
steel rule, tape measure, micrometers
 Work pieces including plates, sections and bars
 Charts showing the use of
- Measuring tools
- Cutting tools
- Marking out tools
 Hand out on the above tools
Assessment
 Tests (oral and written)
- on measuring, marking out and cutting tools
 Assignment on
- quality control checks on products
 Practical
- assessment of the given project in terms of quality, dimensions,
functionability and good workmanship
 Observation
- on safety gear
- attitudes towards care and maintenance of tools and equipment
- disposal of waste products (swarfs)
Reference for Module 2

(Bench work and Fitting)
 Welding and welding Technology by Richard L. Little TMH Edition 1976

 Engineering Metallurgy – Raymond A Higgins (The English University Press
Ltd)
 Workshop Technology by H.S. Bawa (Tata McGraw – Hill Publishing Co. Ltd)
 Workshop by E.N. Njuguna
 Metal Work Pupils Books 1, 2, 3 and 4 by KIE
191
14.2.3.1T MODULE UNIT: SHEET METAL BENDING, CUTTING AND
FORMING MACHINES
THEORY

a) list various sheet metal bending, cutting and forming machines
b) name the parts of a given sheet metal machine
c) state the uses of bending, cutting and forming machines used in sheet metal
work
d) explain how to care for and maintain bending, cutting and forming machines
e) state the safety precautions to be observed when using bending, cutting and
forming machines
14.2.3.1T2 Content
 Listing various sheet metal bending, cutting and forming machines
- Bending machines
 bar folder
 box and pan brake
- Forming machines
 slip roll former
 rotary machine
 tube benders
 hand press
 fly press
 hydraulic press
 power press
 engravers
- Cutting machines
 hand lever bench shears
 treadle guillotine
 nibbling machine
 Bending, cutting and forming machines
 Stating uses of bending cutting and forming machines
- Bar and pan brake
 angular bends
 folding hems
 folding seams
- Box and Pan brake
 forming boxes and pans
- Slip roll former
 rolling of sheet metal
- Rotary machine
 forming grooves for wired edge
 closing the wired edge
 deburring
 bending
- Hand lever bench shears
 cutting sheet metal (up to 3 mm)
- Treadle guillotine
 straight metal cutting
- Nibbling machine
 straight shearing
192
 profile cutting
- Hand press
 used for notching
 punching holes
- Fly press
 hydraulic press
 power press
 Explaining how to care for and maintain bending, cutting and forming sheet
metal
machines
- cleaning
- handing
 Safety
- personal safety
- machine safety to include safety guards
PRACTICE:

a) identify various sheet metal bending, cutting and forming machines
b) identify parts of a given sheet metal bending, cutting and forming machine
c) select and use sheet metal bending, cutting and forming machine to perform a
given task
d) care for and maintain sheet metal bending, cutting and forming machines
e) observe safety precaution when handling sheet metal bending, cutting and
forming machines
14.2.3.1P2 Content
 Identifying various sheet metal bending cutting and forming machines
- Bending
 bar folder
- Forming machines
 ship rolling machines
 rotary machining
- Cutting machines
 hand lever
 bench shears
 nibbling machines
 hand press
 Parts of sheet metal bending, cutting and forming machines
 Selection and usage of sheet metal bending, cutting and forming machines
- making rectilinear shapes
- rolling cylindrical and conical shapes
- cutting sheet metal
- cutting plates
- punching holes
 Care and maintenance of sheet metal bending, cutting and forming machines
- cleaning
- servicing
 Safety
193
- personal safety
- equipment safety
Competencies
Ability to:
 identify various sheet metal bending, cutting and forming machines
 identify parts of a given sheet metal bending, cutting and forming machine
 select and use sheet metal bending, cutting and forming machine to perform a
given task
 care for and maintain sheet metal bending, cutting and forming machines
 observe safety precaution when handling sheet metal bending, cutting and
forming machines
Identification of various sheet metal bending, cutting and forming machines

 Identify and list the various sheet metal bending, cutting and forming machines
to include:
- bending machines
 bar folder
- forming machines
 slip roll former
 rotary machine
 tube benders
 hand press
 fly press
 hydraulic press
 engravers
- cutting machines
 hand lever bench shears
Identifying parts of a given sheet metal bending, cutting and forming machines
 Discuss and name parts of a given sheet metal bending, cutting and forming
machine to include
- bending machines
 bar folder
- forming machines
 sip roll former
 rotary machine
 tube bender
 hand press
 fly press
 hydraulic press
 engraves
- cutting machines
 hand lever bench shear
194
Selecting and using sheet metal bending, cutting and forming machine to
perform a given task
 Demonstrate how to use a selected metal bending machines to perform a given
task
 Demonstrate how to use a selected sheet metal cutting machine to perform a
given task
 Demonstrate how to use a selected sheet metal forming machine to perform a
given task
Caring and maintaining sheet metal bending, cutting and forming

 Explain how to care and maintain bending, cutting and forming sheet metal
machines to include:
- cleaning
- handing
Observing safety when handling sheet metal bending, cutting and forming
 Demonstrate safe working habits when handling sheet metal bending, cutting and
forming to include:
- personal safety
- machine safety
The trainee should

 indentify various sheet metal bending, cutting and forming machines
 name parts of a given sheet metal bending, cutting and forming machine
 sheet and use sheet metal bending, cutting and forming machine to perform a
given task
 demonstrate care for and maintenance of sheet metal bending, cutting and
forming machines
 demonstrate safe working habits when handling metal bending, cutting and
forming machines

 bending machines
 forming machines
 cutting machines
 work pieces
 charts
Assessment Methods
 oral test on bending, cutting and forming sheet metal machines
 written test on bending, cutting and forming sheet metal machines
 quizzes on bending, cutting and forming sheet metal machines
 practical exercise on bending, cutting and forming sheet metal machines
 Workshop Technology I & II By H.S. Bawa
 Metal work Technology by G.H. Thomas
195
14.2.3.2T MODULE UNIT: SHEET METAL JOINTS/WIRED EDGES
THEORY

a) name sheet metal joints and edge treatments used in sheet metal work
b) state typical applications of sheet metal joints and edge treatment used in sheet
metal work
c) list down machines used for making sheet metal joints and edges
d) explain how to care for and maintain sheet metal machines
e) explain the safety precautions to be observed when making sheet metal joints
and
wired edges
14.2.3.2T2 Content
 Sheet metal joints
- Joints edge treatments
 knocked up
 locked up
 locked seam
- Edge treatments
- wired edge
- false wired edge
 Typical applications of joints and edge treatments
- Joints
 water tanks
 boxes
- Edge treatment
- bucket
- boxes
 Machines used for making joints and edge treatments
- bar folder
- box and pan brake
- rotary machine
 Care for and maintenance metal joints and edge treatment
machines
- cleaning
- proper handling
 Safety
- personal safety
- machine safety
PRACTICE:

a) identify various sheet metal joints and edge treatment used in sheet metal work
b) select and make a given sheet metal joint or edge treatment
c) identify for machines for making sheet metal joints/ wired edges
d) care for and maintain sheet metal machines
e) observe safety precautions when using machines for making sheet metal joints and
edge treatment
196
14.2.3.2P2 Content
 Joints and edge treatments
- Joints
 knocked up
 locked up
 locked seam
- edge treatment
 wired edge
 false wired edge
 Machines for making sheet metal joints and wired edges
- bar folder
- box and pan brake
- rotary machine
 Making of sheet metal joints and edge treatments

- cutting to size
- forming the joint/wired edge
- finishing
 Care and maintenance of sheet metal machines
- cleaning
- oiling/greasing
- handling
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various sheet metal joints and edge treatment used in sheet metal work
 select and make a given sheet metal joint or edge treatment
 identify machines for making sheet metal joints/ wired edges
 care for and maintain sheet metal machines
 observe safety precautions when using machines for making sheet metal joints
and
edge treatment
Identifying various sheet metal joints and edge treatment used in sheet
metalwork The instructor should
 Demonstrate various sheet metal joints to include:
- knocked up joint
- locked up joints
- locked seam
 Demonstrate and discuss the edge treatment in sheet metal work to include
- wired edge
- false wired edge
Selecting and making a given sheet metal joint or edge treatment

 Demonstrate the making of sheet metal joint and edge treatment to include
- cutting to size
- forming the joint/wired edge
197
- finishing
Identifying machines for making sheet metal joints/wired edges

 Demonstrate how to use machines for making sheet metal joints and wired edges
to include:
- bar folder
- box and pan brake
- rotary machine
Caring for and maintaining sheet metal machines

Instructor should
 Demonstrate care and maintenance of sheet metal machines to include
- cleaning
- oiling/greasing
- handling
Observing safety precautions

 Demonstrate safe habits when using machines for making sheet metal joints and
edge treatment to include
- personal safety
- equipment safety
Trainee should
 sketch and identify various sheet metal joint and edge treatment used in sheet
metal work
 select and make a given sheet metal joint or edge treatment
 identify machines for making sheetmetal joints/wired edges
 demonstrate how to maintain and care for sheet metal machines
 demonstrate safe habits when using machines for making sheet metal joints and
edge treatment

 Machines for making sheet metal joints and wired edges, namely
- bar folder
- box and pan brake
- rotary machine
 Charts/wall charts of machines to include
- Bar folder
- Box and pan brakes
- Rotary machines
 Workpieces and relevant sheet metal tools and equipment
Assessment Methods
 Oral quizzes on sheet metal joints and edge treatment, machines for sheet metal
joint and safety
 Written test – on sheet metal joints edge treatment and machines for sheet metal
joints
 Practical project involving sheet metal joints and use of machines
 Observation – Safety precautions in respect to personal safety and equipment
safety
References
 Metal work by G.H. Thomas
198
 Basic welding and Fabrication by J. Smith
 Longman industrial Arts Book Four
199
PROJECT WORK:
14.2.3.3P MODULE UNIT: FABRICATION OF A GALVANIZED IRON (G.I)
SHEET PRODUCT

At the end of this module unit, the trainee will be able to:-
a) observe safety precautions when fabricating a G.I sheet product
b) carry out product survey
c) read and interpret a working drawing
d) estimate and cost the materials
e) select the appropriate tools and equipment
f) prepare the parts of a product
g) join the parts of a product
h) carry out the finishing process
i) carry out quality control measures
14.2.3.3P2 Content
 Carrying out product survey
- visit to hardware shops and workshops
- make observations on various types of a G.I product
- record and report the findings of the visit
- Design product
- the scale
- dimension/symbols
- type of finish
 Estimation and costing of materials
- materials
 soft solder
 flux
 rivets
- Costing
 number of parts
 flux
 unit price
- cutting tools
- forming tools
- soldering tools
- riveting tools
 Preparation of parts
- developing the parts
- cutting to size
- forming to shape
 Joining of parts
- joining by riveting
- soldering the joints
200
- washing out the flux with water
- Dimensions control
- proper finishing.
 Safety
- personal and other workmate safety
Competencies
Ability to:

 read and interpreting working drawing
 estimate and costing the materials required
 prepare parts
 join parts by riveting/soldering
Observing safety precautions when fabricating a product

 Discuss and outline the safety precautions to be observed when fabricating a
given sheet metal product to include
- personal and other workmate safety
 Demonstrate safe working habits when fabricating a selected product.

 Explain and organize how to carry out a product survey to include
- visiting local workshops and hardware shops
- making observations and identifying various types of galvanized iron
products

 Discuss and demonstrate how to read and interpret a working drawing to include
- design of a product
- the scale
- dimensions/symbols
- types of finish
201
Estimating and costing the materials required
 Discuss and explain how to estimate and cost a product to include
- material cost
 soft solder
 flux
 rivets
- costing
 number of parts
 units price
 computing total costs
Selecting appropriate tools and equipment

 Outline how to select appropriate tools and equipment to include
- cutting tools
- forming tools
- soldering tools
- riveting tools
Preparing parts
 Demonstrate and discuss the preparation of parts to include
- developing the parts
- cutting to size
- forming to shape
Joining parts by riveting/soldering

 Explain and demonstrate the joining of parts to include
- joining by riveting
- soldering the joints
Finishing Process
- washing out the efflux with water

 Discuss and explain quality control measures to include
- quality of fitting parts
- proper finishing
202
The trainee should
 observe safety precautions when fabricating a galvanished iron sheet product
 read and interpret a working drawing
 work out the estimate and cost of the materials
 identify the appropriate tools and equipment to make a selected product
 prepare the parts of a product
 join the parts of a product

 sheet metal material for fabrication
 relevant measuring and cutting tools and equipment
 relevant forming tools and equipment
 soldering equipment
 solder and flux
 riveting tools
 work pieces
 charts and working drawings
Assessment methods
 Oral test on safety precautions, product survey, reading and interpretation of
working drawings
 Written test on safety, product survey, reading and interpretation of drawing,
materials estimation, soldering and riveting procedures
 Assignments on material estimation and costing, product survey, and quality
control measures
 Observation on safety precautions tools and equipment handling
 Project work – carry out a selected project work
References
1. Basic Engineering and Fabrication by F.J. Smith
2. Metalwork by G.H. Thomas
3. Longman Industrial Arts Book IV
203
14.2.4.1T MODULE UNIT: OXY-ACETYLENE WELDING EQUIPMENT
THEORY

a) explain the working principle of gas welding equipment
b) explain advantages and disadvantages of various gas supply systems
c) describe the construction of various gas welding equipment
d) explain how to care for and maintain gas welding equipment
e) state safety precautions to be observed when using gas welding equipment
14.2.4.1T2 Content
 Explaining working principles of gas welding equipment
 Explaining advantages and disadvantages of gas supply systems
- manifold systems
- single cylinders on trolley
 Describing the construction of gas welding equipment
- Gas cylinders
 oxygen
 acetylene
- Regulators
 single stage
 two stage
 Explaining how to care for and maintain gas welding equipment
- cleaning
 Stating safety precautions observed when gas welding
- personal safety
- equipment safety
PRACTICE:

a) identify various units of oxy-acetylene gas welding set
b) dismantle and assemble units of an oxy-acetylene welding set
c) check for gas leakages
d) care for and maintain oxy acetylene welding equipment
e) observe safety precautions when handling oxy-acetylene equipment
14.2.4.1P2 Content
 Identifying various units of an oxy-acetylene welding set
- Single cylinders
 gas cylinders
 regulators
 hoses
 welding torch
 nozzle
- Manifold system
 bank of cylinders
 acetylene safety valve
 line pressure gauges
204
 pressure regulators
 Dismantling and assembling units of an oxy-acetylene welding set
- Regulators
- Hoses
- Blowpipes/torches
 Checking for gas leakages
- soapy water
- brush
 Caring for and maintaining oxy-acetylene welding equipment
- storage
- handling
 Observing safety precautions when handling oxy-acetylene welding equipment
- personal safety
- equipment
Competencies
Ability to:
 identify various units of oxy-acetylene gas welding set
 dismantle and assemble units of an oxy-acetylene welding set
 check for gas leakages
 care for and maintain oxy- acetylene welding equipment
 observe safety precautions when handling oxy-acetylene equipment
Identifying various units of oxy-acetylene welding equipment

 identify various units of oxy acetylene welding equipment to include:
- gas cylinders
- regulators
- hoses
- welding torches
- manifold systems
- safety valves
- line pressure gauges
Dismantling and assembling units of an oxy-acetylene welding set

 Demonstrate how to dismantle and assemble units of an oxy-acetylene welding
set to include
- cylinders in use
- hoses
- regulators
- torches (blowpipes)
Checking for gas leakages

 Demonstrate how to check for gas leakages to include the use of
- soapy water
- brushes
Caring for and maintaining oxy-acetylene welding equipment

 Care for and maintain oxy-acetylene welding equipment to include:
- storage
205
- handling
Observing safety precautions when handling oxy-acetylene welding equipment
 Discuss how to observe safety precautions when handling oxy-acetylene
welding equipment to include:
- personal safety
- equipment
The trainee should

 make key observations and take notes
 dismantle and assemble units of an oxy-acetylene welding set
 check for gas leakage
 care for and maintain oxy-acetylene welding equipment
 observe safety precautions when handling oxy-acetylene equipment

 Charts on oxy-acetylene gas welding equipment and accessories
 Oxy-acetylene gas welding equipment and accessories
 Manifold system
 Industrial/site visit
Assessment Methods
 Practical exercise to include

- dismantling and assembling of oxy-acentylene welding equipment
- checking for gas leaks
 Observation on
- caring and maintaining oxy-acetylene welding equipment
- handling of oxy-acetylene equipment
 Tests
- oral oxy-acetylene gas welding sets
 Written
- on procedures of assembling and dismantling oxy-acetylene gas welding
equipment
- how to check for gas leaks
 Assignments
- on care and maintenance of oxy-acetylene gas welding equipment
References
 Basic welding and fabrication by F.J. M. Smith
 Basic Fabrication and Welding by Kenyon
206
14.2.4.2T MODULE UNIT: QUALITY CONTROL IN GAS WELDING
ALUMINIUM
AND STAINLESS STEEL
THEORY

a) describe various types of distortions which occur during welding of aluminum
and
stainless steels
b) describe methods of controlling distortions
c) describe procedure of carrying out a given weld test
d) state safety precautions to be observed when carrying out quality control test in
gas
welded joints
14.2.4.2T2 Content
● Types of distortions during welding of aluminum and stainless steels
- Aluminum
 buckling
- Stainless steel
 angular distortions
 longitudinal distortions
 transverse distortions
● Methods of controlling distortions
- manipulation of electrode and flame
- pre-setting
● Weld tests
- macro etching
- nick break
- penetrant test
● Safety
- personal safety
- equipment safety
PRACTICE:

a) identify various types of distortions which occur during gas welding of
aluminium and stainless steel
b) identify methods of controlling distortions, when gas welding aluminium and
stainless steel
c) carry out a given weld test on aluminium and stainless steel gas welded joints
d) observe safety precautions when carrying out quality control test on aluminium
and stainless steel gas welded joints
14.2.4.2P2 Content
● Types of distortions
- Alluminium
 buckling
- Stainless steel
 angular distortions
207
 longitudinal distortion
 traverse distortion
● Methods of controlling distortions

- pre setting
- manipulation of filler rod and flame
● Carrying out given weld test
- macro etching
- nick break
- dye penetrant
● Safety
- personal safety
- equipment safety
Competencies
Ability to:
● identify various types of distortions which occur during gas welding of
● identify methods of controlling distortions, when gas welding aluminium and
stainless steel
● carry out a given weld test on aluminium and stainless steel gas welded joints
● observe safety precautions when carrying out quality control test on aluminium
and stainless steel gas welded joints
Identifying various types of distortions which occur during gas welding of

aluminium and stainless steel:
 illustrate and discuss the types of distortions which occur during gas welding of
aluminium and stainless steel to include
- aluminium – buckling
- stainless steel
 angular distortion
 longitudinal distortion
 transverse distortion
Identifying methods of controlling distortions when gas welding aluminium and

stainless steel joints
 demonstrate and explain methods of controlling distortions when gas welding
aluminium and stainless steel to include
- pre-setting
- manipulation of filler rod and flame
- tack-welding
- skip welding
Carrying out a given weld test on aluminium and stainless steel gas welded joint
 demonstrate how to carry out a given weld test on aluminium and stainless steel
gas welded joints to include
- macro etching examination
- nick break test
- dye penetrant test
208
Observing safety precautions when carrying out quality control test on
aluminium and strainless steel gas welding joint
 Explain how to observe safety precautions when carrying out quality control test
on aluminium and stainless steel gas welded joints to include:
- personal safety
- equipment safety
The trainee should

 identify various types of distortions which occur during gas welding of
 identify methods of controlling distortions when gas welding aluminium and
stainless steel
 carry out a given weld test on aluminium and stainless steel gas welded joints
 demonstrate safety precautions when carrying out quality control test on
aluminium and stainless steel gas welded joints

 industrial/jua kali site visit
 charts on types of distortions occurring in metal gas welded joint
 macro, nickbreak and dye penetrant testing equipment
Assessment
 Tests
- oral
 on various types of distortions
- written
 on procedures of carrying out given tests to include macro, nick break
and dye penetrant tests
 Assignments
- on methods of controlling distortions in gas welding.
 Practical exercise
- performing a given weld test to include macro, nick break and dye penetrant
tests
 Observation
- on attitudes towards safety precautions when carrying out the given tests
References
 Basic Fabrication and Welding by F.J.M. Smith
 Basic Welding and Fabrication by W. Kenyon
209
14.2.4.3T MODULE UNIT: POSITIONAL GAS WELDING OF MILD
STEEL
THEORY

a) describe various gas welding positions
b) name typical applications of oxy-acetylene gas welding
c) state factors to be considered when gas welding a given material
d) name various types of edge preparations for gas welding
e) state factors to be considered when determining working pressures for gases
during gas welding
14.2.4.3T2 Content
 Gas welding positions
- overhead
- vertical
- inclined
 Typical applications of gas welding
- Welding of steel products
 articles fixed in position ( in – situ)
 pipe work
 Factors considered when welding
- Material
 mild steel
- Weld positions
 over head
 vertical
 inclined
- Joint design
- Manipulation of nozzle and filler rod
- Weld positions
- Direction and speed of travel
- Rate of weld deposition
 Types of edge preparations for gas welding
- single vee butt
- square butt
- double Vee butt
- single U – butt
- double U butt
 Factors considered when determining working pressures for gases
- materials thickness
- joint design
- position of the weld
- welding technique
210
PRACTICE:

a) select appropriate gas welding equipment
b) set up gas welding equipment for vertical, inclined and overhead
welding
c) select the correct filler metal for a given task
d) prepare the edges for welding
e) set up the work in the correct position for welding
f) join the work pieces using the correct welding procedure
g) carry out quality control measures
h) care for and maintain gas welding equipment
i) observe safety precautions when carrying out positional welding
14.2.4.3P2 Content
 Appropriate welding equipment
- single cylinder systems (trolley)
- manifolds systems
- stationary manifolds
- portable manifolds
 setting up gas welding equipment for
- vertical
- inclined and horizontal
- overhead
 Correct filler metal
- material
- size
 Edge preparation for welding
- single and double Vee
- single and double U
 Setting up work for welding
- tacking
- presetting
 Joining work pieces using correct procedure
- angles of filler rod and flame
- speed of travel
- manipulation of rod and flame
- maintenance of weld pool
- welding method for over-head vertical and horizontal welding
- Visual examination
 uniformity of beads
 straightness of weld
 free from surface defects
- Macro etching tests
 cracks
 slag inclusion
 lack of fusion
 penetration
 porosity
- Nick break tests
 malleability of joint
211
 strength
- Dye penetrant test

 defects open to the surface
- cleaning
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 select appropriate welding equipment

 set up gas welding equipment
 select correct filler metal
 prepare the edges for welding
 set up the work for welding
 join work pieces using correct procedure
 care for and maintain gas welding equipment
 observe safety precautions when carrying out positional gas welding
Selecting appropriate welding equipment

 Discuss and display the appropriate gas welding equipment to include
- single cylinders
- manifold system
- welding accessories
Setting up gas welding equipment for welding

 Demonstrate the setting up of gas welding equipment ready for welding to
include
- checking for leaks
- setting working pressures
Selecting correct filler metal for a given job

 Explain the selection of correct filler metal for the given task to include
- material thickness consideration
- type
- size of filler metal
Preparing the edge for welding

 Demonstrate and discuss the preparation of edges for welding to include
- square
- single and double vee
212
Setting up the work in the correct position for welding
 Demonstrate the setting up of work in the correct position for welding to include
- Cleaning the work
- tacking the work
- presetting
- correct root gap
Welding the work pieces using correct procedures

 Demonstrate and explain the procedure for carrying out welding on work pieces
to include
- angles of filler rod and flame
- speed of travel
- manipulation of rod and flame
- maintenance of weld pool
- welding method for overhead welding

 Discuss and explain how to carry out quality control measures on welds to
include
- visual inspection
 freedom from of surface defects
- macro-etching tests
 cracks
 slag inclusion
 porosity
 incomplete fusion
 penetration
- nick break tests
 malleability of joint
 strength
- dye penetrant
 defects open to the surface
Caring for maintaining gas welding equipment

 Demonstrate how to care for and maintain gas welding equipment to include
- cleaning
Observing safety precaution when carrying out positional welding

 Discuss safety precaution to be taken when carrying out positional welding to
include
- personal safety
- equipment safety
The trainee should
213
 set up gas welding equipment
 select the correct filler metal for a given task
 set up the work pieces using the correct welding procedure
 observe safety precautions when carrying out positional gas welding

 gas welding equipment
 assorted mild steel plates
 various sizes of filler rods
 charts showing oxy-acetylene welding set-up in vertical, horizontal and
overhead positions
 safety gear
Assessment
 Tests
- oral – on welding equipment
- written
 on edge preparation
 procedure of executing a weld in a given position
- assignments
 on quality control measures of a welded bead
 execution of a visual inspection test
 macro-etching test
 dye penetrant test
- observation
 on attitudes towards safety and maintenance of welding equipment
- Practical – execution of the following tests
 visual inspection
 macro-etch
 dye penetrant
214
14.2.4.4T MODULE UNIT: OXY-ACETYLENE WELDING OF
STAINLESS STEEL AND ALUMINIUM
THEORY

a) outline the procedure for setting up gas welding equipment fro welding given
materials
b) state the type of filler rod and flux for the given materials
c) explain the edge preparation and cleaning of the given material for welding
d) explain the setting up of work in the correct position for welding
e) explain the procedure for carrying out the welding of a given metal
f) state the quality control measure for a weld in the given metal
g) state the procedure for caring and maintaining gas welding equipment
h) state safety precautions to be observed when carrying out welding on the given
metal
14.2.4.4T2 Content
● Procedure for setting up gas welding equipment
- pressure adjustment
- flame setting
 Filler rods and flux for
- stainless steel
- aluminium
 Edge preparation
- square
- bevel
- single and double vee
- cleaning of materials
● Setting up of work
- position
- horizontal/flat/inclined
- size of gap
● Welding procedure
- treatment before welding
- speed of travel
- manipulation of torch
- after treatment
● Quality control measure
 profile of weld (uniformity of beads)
 freedom from surface defects
 freedom from distortion
 straightness of beads
● Care and maintenance
- cleaning
- handling
● Safety
- personal safety
- equipment safety
215
PRACTICE

a) select appropriate gas welding equipment
b) set up gas welding equipment for flat and horizontal gas welding
c) select the correct filler rod and flux for a given task
d) prepare the edges, and clean the work for welding
e) set up the work in the correct position for welding
f) join the work piece using the correct welding procedure
g) carry out quality control measures
h) care for and maintain gas welding equipment
14.2.4.4P2 Content
 Setting up equipment
 Filler rod and fluxes selection
- material being welded
- appropriate flux
 Preparation of edges for welding
- edge preparation – square, bevel
- joint design
 Work preparation
- removing grease and oil
- removing of rust and dirt
 Setting up work for welding
- flat ( stainless steel)
- horizontal vertical ( for aluminum)
 Joining of work pieces
- cleaning work
- tacking
- proper angles of flame and filler rod
- use of correct flame
- correct speed of travel
- pre- heating of aluminum castings before welding
 Gas welding equipment selection
 Quality control
- Visual examination
 uniformity of bead
 freedom from surface defects
 freedom from distortion
- Surface appearance
 Freedom from flux residue
 Freedom from oxides and scales
 Care and maintenance of gas welding equipment
- cleaning
 Safety
- personal safety
- equipment safety
216
Competencies
Ability to:
 set up equipment
 select correct filler rod and flux
 prepare edges and clean the work
 set up work for welding
 join the work pieces
 observe safety precautions when carrying out positional welding of stainless
steel and aluminum
 Demonstrate the setting up welding equipment for welding a given metal to
include
- oxy-acetylene cylinders
- correct nozzles
- correct pressure
Selecting correct filler rod and flux

 Discuss and explain the selection of the correct filler rod and flux for welding
the given material to include
- stainless steel
 appropriate flux
 composition of filler rod
- aluminium
 appropriate flux
 composition of the filler rod
Preparing edges and cleaning the work

 Discuss and demonstrate how to prepare edges and clean the work for welding
to include the following
- edge preparation
 material thicknesses
 joint design
- cleaning work
 removing grease and oil
 removing of rust and dirt
Setting up the work in the correct position for welding

 Demonstrate the setting up of the work in the correct position to include
- leveling the work flat (stainless steel)
- inclining or horizontal vertical (aluminium)
Joining the work pieces using correct welding procedure

 join the work pieces using the correct procedure as follows
- cleaning work
- tacking
- proper angles of flame and filler rod
217
- correct flame
- correct speed of travel
- pre-heating of aluminium casting before welding

 Demonstrate and discuss how to carry out quality control measures to include
- quality control
 visual examination
 lack of surface defects
 freedom from distortions
- surface appearance
 freedom from flux residue
 removal of oxides and scales
Caring for and maintaining gas welding equipment

 Demonstrate how to care for and maintain the gas welding equipment to include
- cleaning
Observing safety precautions when carrying out welding

 Discuss how to observe safety precautions when carrying out welding of the
given metals to include
- personal safety
- equipment safety
The trainee should

 set up gas welding equipment for flat and horizontal welding
 select the correct filler rod and flux for a given task
 prepare the edges and clean the work
 set up the work in the correct positon for welding
 join the work pieces using the correct welding procedure
 observe safety precautions when carrying out welding

 oxy-acetylene welding equipment
 aluminium and stainless steel work pieces
 charts on filler rods and flux for aluminium and stainless steel
 charts – on oxy-acetylene equipment
Assessment
 Tests
- written
 on welding procedures
 Oral
- on types of flux used for both aluminium and stainless steel
 Assignments
- preparation of edges for welding
 Practical – practical welding exercise
218
- on quality control measures
 Observation
- attitudes towards the safety and maintenance of oxy-acetylene tools and
equipment
Reference
 Basic welding and fabrication Engineering by F.J. M. smith
PROJECT WORK:
14.2.4.5P MODULE UNIT: FABRICATING THIN GAUGE MILD STEEL
PRODUCT

b) state the procedure of recording and reporting
c) read and interpret working drawing
d) estimate and cost the materials
e) select the appropriate tools and equipment
f) prepare the parts of the product
g) joint the parts of the product
h) carry out the finishing process
i) carry out quality control measures
j) observe safety precautions when fabricating thin gauge mild steel product
14.2.4.5P2 Content
 Product survey
- visit local garages/local hardware
- make observation of various products and their designs
- dimensions
- materials
 Recording and reporting
- designs
- sketches
- prices
 Reading and interpretation of working drawings
- dimensions
- materials
- scale
- joining methods (symbols)
- tolerance
 filler metal
 paint
- Costing
 unit cost
219
- cutting tools
- finishing tools
 Preparation of product parts
- prepare main parts
 Joining of parts by oxy – acetylene welding
- deburring
- painting

- conformity to dimensions
- symmetry of parts
- workmanship- kinks, dents scratches
- quality of edges and welds
- appearance
- functionability
 Safety
- personal safety
Competencies
Ability to:
 carry out recording and reporting
 carry out estimating and cost
 join parts by oxy – acetylene welding

 Discuss how to carry out product survey to include
- product survey
 visit to local garages/local hardware
 marketing observation of various products and their designs
 dimensions
 materials
- recording and reporting
 designs
 sketches
 prices
Reading and interpret working drawings

 Illustrate and explain how to read and interpreting working drawings to include
- dimensions
- materials
220
- scale
- joining methods
- symbols
- tolerance
Estimating and costing

 Explain how to estimate and cost the materials to include
- estimating
 filler metal
 paints
- costing
 unit costs
 computing total costs
Selecting the appropriate tools and equipment

 Explain the selection of the appropriate tools and equipment to include
- cutting tools
- finishing tools
- drilling machines
Preparing the parts of the given product

 Explain the preparation of the products parts to include
- component parts
- main parts
Joining the parts of the product by oxy-acetylene welding

 Explain the joining of the component parts of the product to include
- Tacking the parts
- Welding the component parts together
Carrying out the finish process

 Discuss the finishing process of the component to include
- De-burring
- Cleaning
- Panting
Carrying out quality control measures for the product

 Demonstrate how to carry out quality control measures for the product to
include:
- conformity to dimensions
- symmetry of parts
- workmanship – kinks, dents and scratches
- quality of edges and welds
- appearance
221
Observing safety precautions when fabricating the product
 Explain safety precautions to be when fabricating the thin gauge mild steel
product to include
- personal safety
The trainee should

 estimate and cost
 join the parts by oxy-acetylene welding
 carry out quality control measures on the product
 demonstrate safety precautions when fabricating thin gauge mild steel product

 measuring and marking out tools
 cutting tools and equipment
- steel rule, try square, hacksaw blade, tape measure, chisel, centre punch,
guillotine, tinsnip
 forming tools
- set of stakes
- box bender
- rolling machine
 oxy-acetylene welding equipment finishing tools
 working drawings
 farm products such as
- chicken feeds
- watering cans
- gutters
Assessment
 Tests
- oral
 on the necessary steps in coming up with a product survey
- written
 estimating and costing a given product
 Assignment
- to carry out a product survey and write down the findings
 Practical
- to fabricate the product that has been identified
 Observation
- the attire of the trainee and the attitudes towards the workmanship
14.2.5.1T MODULE UNIT: ARC WELDING EQUIPMENT

THEORY
222
a) name various types of arc welding processes
b) explain the working principle of a given arc welding equipment
c) describe the construction of the arc welding equipment
d) explain how to care for and maintain arc welding equipment
e) state the safety precaution to be observed when using arc welding machines
14.2.5.1T2 Content
 Types of arc welding processes
- manual metal arc welding
- TIG and MIG arc welding
- plasma welding
- resistance welding
 Principle of a given arcwelding equipment
 Arc welding equipment construction
- A.C transformer
- D.C welding machine
- welding cables
- electrode holder
- return cable
 Care and maintenance of welding equipment
- cleaning
- maintenance
 Safety
- personal safety
- equipment safety
PRACTICE:

a) identify various types of arc welding equipment
b) identify main parts of arc welding equipment
c) care for and maintain arc welding equipment
d) observe safety when using arc welding equipment
14.2.5.1P1 Content
 Types of arc welding equipment
- A.C transformers
- D.C welding machines
- air cooled transformers
- oil cooled transformers
 Parts of welding machines
- laminated core
- coils
- adjustment screw
- fan
- oil
- generator
- diesel engine
- winding
- commutator
- brushes
- Stator coil
223
- cleaning
- servicing
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various types of arc welding equipment
 identify main parts of arc welding equipment
 care for and maintain arc welding equipment
 observe safety when using arc welding equipment
Identifying various types of arc welding equipment

 Display and discuss various types of arc welding equipment to include
- A.C. transformers
- D.C. welding machines
- Air cooled transformers
- Oil cooled transformers
Identifying main parts of electric arc welding equipment

 Display and discuss parts of welding machines to include:
- laminated core
- coils
- adjustment screw
- fan
- oil
- generator
- diesel engine
- winding
- commutator
- brushes
- stator coil
Identifying various types of arc welding processes

 discuss and display various welding processes to include:
- manual metal arc welding or electric arc welding
- MIG welding
- TIG welding
- plasma welding
- resistance welding
Caring and maintaining of arc welding equipment

 Discuss and demonstrate how to care for and maintain arc welding equipment to
include:
- cleaning
- servicing
224
Safety when using arc welding equipment
 Discuss and demonstrate safety measures to be observed when handling arc
welding equipment to include:
- personal safety
- equipment safety
The trainee should

 identify various types of arc welding equipment
 identify main parts of electric arc welding equipment
 identify various types of arc welding processes
 display safe working habits when handling electric arc welding equipment
Key learning Activities
 AC welding transformer and accessories
 DC welding machine and accessories
 TIG welding equipment and accessories
 MIG welding equipment and accessories
 plasma welding equipment and accessories
 resistance welding equipment and accessories
 engine driver generator
 welding manuals/charts
Assessment
 Oral test
- identify equipment for various welding processes
- identify various types of electric arc welding equipment
- identify main parts of electric arc welding equipment
 Written tests
- listing various welding processes
- listing various types of electric arc welding equipment
- stating main parts of electric arc welding equipment
- stating procedure for caring and maintaining of electric arc welding
equipment
References
 Welding and welding Technology by Richard L. Little
Tata Mcgraw – Hill Publishing Company
14.2.5.2T MODULE UNIT: POSITIONAL ARC WELDING OF MILD STEEL

a) name various arc welding positions
b) name typical applications of positional arc welding
c) state factors to be considered when arc welding a given material
d) name various types of edge preparation for arc welding
14.2.5.2T2 Content
225
 Arc welding positions
- over head
- vertical
- inclined
- horizontal
 Typical applications of arc welding in overhead and vertical positions
- tanks
- steel structures
- pipe work
- articles in fixed positions
 Factors considered when arc welding materials
- joint designs
- weld positions
- manipulation of electrodes
- angle of the electrodes
- direction and speed of travel
- rate of weld deposition
 Types of edge preparation for arc welding
- single and double vee butt
- single and double u butt
- square butt
PRACTICE

a) read and interprete the working drawing
b) select appropriate arc welding equipment
c) set – up equipment for vertical and overhead welding
d) select the correct electrode for a given task
e) prepare the edges for welding
f) join the work pieces using the correct welding procedure
g) carryout quality control measures
h) care for and maintain arc welding equipment
14.2.5.2P2 Content
 Reading and interpretation of a working drawing
- Welding symbols
- Orthographic drawings
- A.C transformer welding equipment
- D.C welding equipment
 Selection of electrodes
- materials
- weld position
- joint design
 Setting up Welding equipment for vertical and overhead positional welding
 Preparation of the edges for welding
- Square butt
- single and double Vee
 Joining the work pieces using the correct welding procedures
- tacking the work
- maintaining the correct
226
 arc length
 angle of the electrode
 speed and direction of travel
 weld pool
 Carrying out quality control measures
- Visual examination tests
 lack of distortions
- Macro etching tests
 preparation of joint for macro etching testing
 Caring for and maintaining arc welding equipment

- cleaning
- proper handling
 Observing safety
- personal safety
- equipment safety
Competencies
Ability to:
 set up welding equipment for positional welding
 join the work pieces using the correct welding procedures
 observe safety precautions when carrying out positional arc welding

 Discuss and illustrate the application of welding symbols in working drawings
to include:
- Arrow line
- type of weld
- size of weld
- special instructions
- other side
- reference line
- orthographic projection drawings
Selecting appropriate welding equipment

 Discuss criteria for selecting welding equipment to include:
- AC transformers
- DC welding equipment
- AC/DC rectifiers
227
Selecting correct electrode for a given task
 Discuss the criteria to be followed when selecting electrode for a given task to
include:
- material to be welded
- joint design
Setting up welding equipment for vertical and overhead positional welding

 Discuss and demonstrate how to set up equipment for vertical and overhead
positional welding to include:
- joint accessibility
- welder’s safety
Preparing edges for welding

 Discuss and demonstrate how to prepare work piece edges ready for welding to
include:
- square butt
- single and double U butt
Joining work pieces using correct welding procedures

 Discuss and demonstrate how to join work pieces using correct welding
procedures to include:
- tacking work pieces
- maintaining correct
 arc length
 angle of the electrode
 speed and direction of travel
 weld pool

 Discuss and demonstrate how to carry out quality control measures when
welding to include:
 lack of distortion
- macro examination
 preparation of joint for macro etching
Caring for and maintaining arc welding equipment

include
- cleaning
228
- servicing
- handling
Observing safety precautions when carrying vertical and overhead positional

welding
 Discuss and demonstrate safety precautions to be observed when carrying out
vertical and overhead positional welding to include
- personal safety
- equipment safety
The trainee should

 read and interpret working drawings correctly
 set up welding equipment for vertical and overhead positional welding
 prepare work piece edges ready for welding procedures
 carry out quality control measures in welding
 care for and maintain welding equipment

 display safe working habits when carrying out vertical and overhead positional
welding

 arc welding equipment – AC transformers, DC welder, AC/DC rectifier
 electrodes – mild steel
 cutting tools – hacksaws, chisels
 charts/diagrams – mild steel electrodes, positional welding
 working drawings – on welding exercises
Assessment
 Oral tests
- interpreting welding symbols
- identifying arc welding equipment
- identifying welding electrodes
 Written tests
- welding symbols
- welding equipment
- selection of electrodes
- edge preparation
- quality control of welds
- care and maintenance
- safety
 Practice test
- setting up welding equipment
- joint preparation
- joining workpieces by welding
- quality control
References
 Basic welding and Fabrication by W. Kenyon
 Basic Fabrication and Welding Engineering by F.J. Smith
229
14.2.5.3T MODULE UNIT: ARC WELDING OF CAST
IRON
THEORY

a) name typical components made of cast iron
b) state factors which should be considered when arc welding cast iron
c) explain the procedure of welding a damaged cast iron component
d) care and maintain arc welding equipment
e) state safety precautions which should be observed when arc welding cast iron
14.2.5.3T2 Content
 Typical components made of cast iron
- lathe machine bed
- motor vehicle brake wheel drums
- water pump bodies
- electric motor bodies
 Factors which should be considered when welding cast iron
- preheating
- post heating
- overall size of component
- risk of warpage
 Procedure of welding a damaged cast iron component
- Edge preparation of broken (grooving) post
- drilling at the end of crack
- studding technique
- use short weld lengths
- avoid large weld metal deposits
- use down hand welding position only
- slow cooling of the work piece after welding
 Caring and maintaining arc welding equipment
- cleaning
 Safety precautions to be observed when welding cast iron
- personal safety
- equipment safety
PRACTICE:

a) read and interpret a working drawing
c) select appropriate electrode
d) prepare the edges of the work pieces for welding
e) join the work piece using the correct welding procedure
g) care for and maintain arc welding equipment
h) observe safety precaution when welding cast iron
230
14.2.5.3P2 Content
 Reading and interpretation of a working drawing
- materials being welded
- dimensions
- welding procedures
 Selection of arc welding equipment
- A C transformer equipment
- D.C welding equipment
 Selection of electrode
- cast iron electrode type
- size of electrode
 Preparation of edges for welding
- single and double Vee butt joint
- single and double U butt joint
- square butt
 Joining work pieces by welding
- tacking of the work pieces
- pre- heating
- peening
- use of maximum heat
- visual examination for:
 straightness of welds
 lack of distortions
- cleaning
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 select appropriate arc welding equipment
 select the correct electrode
 prepare the edges of the work pieces for welding
 join the work pieces using the correct welding procedures
 observe safety precautions when welding cast iron

231
 Discuss and illustrate use of welding symbols on working drawings to include:
- material being welded
- dimensions
- welding procedure
Selecting arc welding equipment
 Discuss features and characteristics of arc welding equipment to include:
- AC transformers
- DC welding equipment
Selecting the correct electrode

 Discuss criteria for selecting an electrode in terms of
- type of material being welding
Preparing work piece edges for welding

 Discuss and demonstrate how to prepare work pieces ready for welding to
include
- square butt joint
- single and double vee butt joint
- single and double U butt joint
Joining work pieces using the correct welding procedures

 Discuss and demonstrate how to join work pieces correctly to include:
- tacking work pieces
- pre-heating
- peening
- use of maximum heat
Carrying out quality control in welding cast iron

 Discuss and demonstrate how to carry out quality control when welding cast
iron to include:
- uniformity of beads
- lack of surface defects
- straightness of welds
- lack of distortions
Caring for and maintaining arc welding equipment

include:
- cleaning
Observing safety
 Discuss and demonstrate safe working habits when welding cast iron to include:
- personal safety
- equipment safety
232
The trainee should
 interpret welding working drawing
 select arc welding equipment
 select the correct type of electrode for a given task
 prepare work piece edges as indicated on the drawing
 join work pieces by welding correctly
 carry out quality control of cast iron welding task
 demonstrate safety working habits when welding cast iron

 arc welding equipment – welding transformer, angle grinder
 electrodes – machineable cast iron electrodes, non-machinable
 work pieces – cast iron pieces
 working drawing – on the component to be welded
Assessment
 Oral Test
- identification and interpretation of welding symbols
- identification of welding equipment
- identification of electrodes
- identification of various edge preparations
- identification of surface defects on a weld
 Written test
- inserting welding symbols on a drawing
- features and characteristics of arc welding equipment
- procedure of welding cast iron
- quality control on welded cast iron
- care and maintenance of welding equipment
 Practical test
- repairing a broken cast iron equipment
References
 Welding and welding Technology by Richard L. Little
 Basic Fabrication and welding Engineering by F.J.M. Smith
233
14.2.5.4T MODULE UNIT: ARC WELDING OF STAINLESS
STEEL
THEORY

a) name typical components made of stainless steel
b) state factors which should be considered when arc welding stainless steel
c) explain the procedure of welding stainless steel components
d) care and maintain arc welding equipment
e) observe safety precautions when welding stainless steel
14.2.5.4T2 Content
 Typical components made of stainless steel
- kitchen structures
- kitchen wares
- pipes
- chemical tanks
- medical equipment
 Factors to consider when arc welding stainless steel
- Type of steel
 austenitic stainless steel
 martensitic stainless steel
 ferritic stainless steel
 heat resistant chromium steels
 austentic chromium steels
- Welding of dissimilar steels
 austenitic and plain carbon steels
 stainless steel and medium carbon steel
- Temperatures
- Dilution
 Welding of stainless steel components
- edge preparation
- type of electrode
- current setting
- carrying out welding process
- preheating of component
- heating and tempering of component after welding
- cleaning
- servicing
 Safety
- personal safety
- equipment safety
234
PRACTICE

a) read and interpret working drawing
c) prepare edges of the work pieces for welding
d) join work pieces using correct welding procedure
e) carry out quality control measures
f) care for and maintain arc welding equipment
g) observe safety precautions when welding stainless steel
14.2.5.4P2 Content
- welding symbols
- interpreting technical drawings
 Selection of welding equipment
- A.C transformer
- D.C welding machine
 Edges preparation
- single Vee butt
- square butt
- single U-butt
- double vee butt
- double U-butt
 Welding of work pieces
- avoid excessive heat
- ensure minimum parent metal penetration
- slow cooling of work piece
- spatter
- undercuts
- uniform bead
- uniform ripples
- crater formation
- cleaning
- servicing
 Safety
- personal safety
Competencies
Ability to:

 prepare edges of the work pieces for welding
 join work pieces using correct welding procedure
 observe safety precautions when welding stainless steel
235

 Discuss and illustrate how to interpret working drawing in terms of :
- welding symbols
- interpreting technical drawings
Selecting appropriate arc welding equipment

 Discuss features to consider when selecting appropriate welding equipment for
stainless steel to include:
- A.C. transformer
- D.C. equipment
Preparing work piece edges for welding

 Discuss and demonstrate how to prepare work piece edges ready for welding to
include:
- square butt
- single and double U butt
Joining work pieces using correct welding procedure

 Discuss and demonstrate the correct procedure of joining stainless steel work
pieces by arc welding:
Carrying out quality control measures when welding stainless steel

 Discuss and demonstrate how to carry out quality control measures when
welding stainless steel to include:
- spatter
- undercuts
- uniform bead
- uniform ripples
- crater formation
Caring for and maintaining of arc welding equipment

 Discuss and demonstrate how to care for and maintain arc welding equipment in
terms of
- cleaning
- servicing
Observing safety when welding stainless steel

 Discuss and demonstrate safety measures to be observed when welding stainless
steel in terms of
- personal safety
- equipment safety
236
The trainee should
 prepare edges for stainless steel workpieces ready for welding
 join stainless steel work pieces using correct arc welding procedure
 carry out quality control measures on arc welded stainless steel work
 display safe working habits when welding stainless steel

 stainless steel work pieces
 stainless steel electrode
 arc welding transformers
 D.C. welding machines
 welding symbols charts
 cutting equipment
Assessment
 Oral tests
- identifying welding symbols
- identifying various arc welding equipment
- identifying various workpiece edge preparations
- identifying welding defects
 Written tests
- drawing and inserting appropriate welding symbols on a working drawing
- stating welding defects
- stating correct procedure of welding stainless steel products
- listing safety precautions to be observed when welding stainless steel
 Practical test
- joining stainless steel workpieces using correct welding procedure
References
 Basic fabrication and welding Engineering by F.J.M. Smith
 Basic Welding and fabrication by W. Kenyon
237
PROJECT WORK:
14.2.5.5P MODULE UNIT: FABRICATION OF MILD STEEL SECTION
PRODUCT

e) prepare the parts of the article
f) join the parts of the article
i) observe safety precautions when fabricating mild steel sections product
14.2.5.5P2 Content
 Product survey
- Visit local workshop
 various products and their designs
 various sizes
 materials used
 noting prices of various designs
- dimensions
- materials
- scales
- joining method
 Estimate and cost materials
- Estimating the materials
- Costing
 unit cost
- cutting tools
- welding equipment
- finishing tools
 Preparations of parts of the product
 Joining of parts of the product by arc welding
- tacking
- welding
 Quality control
- alignment
- symmetry of parts
- fitting of parts
238
- quality of weld flatness
- squareness
 Safety
- personal safety
Competencies
Ability to:

 estimate and cost materials
 observe safety precautions when fabricating the steel section product

 Discuss the procedure of carrying out product survey to include:
- visit to local workshops
- making observations
 various products and their designs
 various sizes
 materials used
- recording and reporting
 noting prices of various designs

 Discuss and demonstrate how to interpret working drawing to include
- dimensions
- materials
- scales
- joining method
Estimating and costing the material

 Discuss the process of estimating and costing the material for making the
components in terms of
- estimating the materials
- costing
 unit cost
239
Selecting tools and equipment
Instructor should
 Discuss the procedure of selecting tools and equipment in terms of
- cutting tools
- welding equipment
- finishing tools
Preparing parts of the products

 Discuss and demonstrate how to prepare various parts of the product
Joining of parts by arc welding

 Discuss and demonstrate how to join various parts of the component using arc
welding

 Discuss and demonstrate how to carry out finishing processes on the component
to include
- grinding
- polishing
- painting
Carrying out quality control on the product

 Discuss and demonstrate how to carry out quality control procedures in terms ot
- dimension control
- alignment
- symmetry of parts
- fitting of parts
- quality of welds
- squareness
- flatness
Observing safety
 Demonstrate safety precautions which should be observed when fabricating
components in terms of
- personal safety
- equipment safety
The trainee should

 read working drawings and interpret it correctly
 estimate and cost amount of material required to make a product
 select appropriate tools and equipment to enable making of the product
 prepare individual parts ready for joining
 carry out finishing process on the product
 various parts using arc welding
240
 carry out quality control on the product
 display safe working habits when making the product

 welding equipment
- AC welding transformer, angle grinder
 welding materials
- channel sections, tee-section, Z-section
 measuring and marking out tools
- Tape measure, steel rule , try square, scriber
 cutting tools and equipment
- Hacksaw, cutting of girnder, guillotine
 forming tools and equipment
- box bender, roller machine
 Handouts
- Welding equipment, bending and rolling
- on products to be produced
Assessment
 Oral test
- identifying various welding symbols on the working drawing
- identifying various tools and equipment
- safety measures
 Written test
- sketching of various welding symbols
- estimating and costing the materials from a given working drawing
- listing tools and equipment for a given task
- procedure of fabricating a given product
- listing quality control measures for a given product
- listing finishing activities for a given product
- listing safety precautions to be observed.
 Practical test
- produce a product from working drawing
 Assignment
- make working drawings and produce a component for a given purpose
241
14.2.6.1T MODULE UNIT: LATHE MACHINE
THEORY

a) name various types of lathes
b) explain the use of lathe machine
c) name various general lathe operations
d) name the main parts of the lathe and their uses
e) explain how to care for and maintain the lathe
f) list down the safety precautions to be observed when working on the lathe
14.2.6.1T2 Content
 Types of lathes
- centre lathes
- capstan lathes
- turrets lathes
 Uses of lathes
- machine cylindrical components
- flat surfaces
 Lathe operations
- straight or parallel turning
- facing
- taper turning
- drilling
- boring
- knurling
- reaming
- screw cutting
 Parts of centre lathe
- The bed
 supporting the machine
 aligning the centre lathe
- The head stock
 holding headstock spindle
 bearing the support for the headstock
 gear unit
- The tailstock
 holding dead centre for turning
 drilling and reaming support
 adjustment for taper turning
- The carriage
 holding compound rest
 holding the cross slide
 holding the saddle
 holding the apron
 Care and maintenance of the lathe
- cleaning
- oiling/greasing
- proper handling
 Safety
- Personal safety
 dressing
 behavior
242
- Machine safety
 switching on and off
 proper handling
PRACTICE
14.2.6.1P1 Specific Objectives:

a) identify parts of the lathe
b)operate the lathe
c) care for and maintain a lathe machine
d)observe safety precaution when operating the lathe machine
14.2.6.1P2 Content
 Parts of the lathe
- bed
- head stock
- tail stock
- carriage
 Operation of the lathe
- fixing work holding devices
- setting the work
- setting the cutting tool
- machining
 Care for and maintenance of the lathe machine
- cleaning
- oiling / greasing
- proper handling
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify parts of the lathe
 operate the lathe
 care for and maintenance of the lathe machine
 observe safety precautions when operating the lathe machine
Identifying types of lathe machine

 identify and discuss the various types of lathe machines to include
- centre lathe
- capstan lathe
- turret lathe
Using lathe machine for machining

 display and discuss various components made by a lathe machine to include
- Cylindrical shafts
- Hollow shaft
- Tapered shaft
- Threaded shaft
243
- Stepped shaft
Identifying parts of a lathe machine
The instructor to
 Discuss the various parts and uses of a lathe machine to include
- Bed
 supporting the machine
 aligning the centre lathe
- headstock
 holding head stock spiddle
 gear unit
 bearing support for the heedstock
- tail stock
 holding dead centres
 drilling and reaming support
 adjustment for tape turning
- carriage
 holding compound rest
 holding the cross slide
 holding the saddle
 holding the apron
- tool post
 holding various tools and tool holders
Operating the lathe machine

 Discuss and demonstrate the various lathe operations to include
- straight or parallel turning
 work holding
 tool holding
 speed selection
 feed
 application of coolant
- facing
 working holding
 tool holding
 speed selection
 feed
 application of coolant
- taper turning
 work holding
 tool holding
 tail stock
 off setting
 tape turning attachment
 compound angle setting
 tool forming
 speed selection
 feed
 coolant application
- drilling
 work holding
 tool holding
 speed selection
 feed
244
 coolant application
- knurling
 work holding
 tool holding
 speed selection
 feed
- screw cutting
 work holding
 tool selection and holding
 gear selection
 speed selection
 tool setting
 thread dial engagement
Care and maintenance of lathe machine

 Demonstrate safe working habits when operating the lathe machine to include
- Care and maintenance of machine, tools and equipment
- Safety
 personal
 machine
The trainee should

 identify parts of the lathe
 operate the lathe
 care for and maintain a lathe machine
 observe safety precaution when operating the lathe machine

 Charts to include types of lathe machines and various operations
 Assorted components made by lathe machines
 Lathe machine
 Assorted relevant tools and equipment
Assessment Methods
 Oral/written test on
- types of lathe machines and their differences
- parts of lathe machine and their functions
- calculations of feeds and speeds for particular operation
- operation procedure for a particular task
 Assignment on operation procedure for assorted work
 Observation: trainees attitude towards practical work and team work
 Practical
- practical project work to include all the lathe operations
 turning
 boring
 threading
 reaming
 drilling
 knurling
References
 Metal work by E.N. Njuguna
245
 Metal work technology by G.H. Thomas
246
14.2.6.2T MODULE UNIT: LATHE CUTTING TOOLS AND THEIR USES
THEORY

a) name various lathe cutting tools
b) list materials from which tools are made
c) name lathe tool angles
d) explain how to care for and maintain lathe cutting tools
e) explain safety precautions to be observed when grinding lathe tools
14.2.6.2T2 Content
 Lathe cutting tools
- solid tools
- tipped brazed tools.
 Materials from which lathe tools are made
- carbon steel
- high speed steel ( HSS)
- carbide – tipped tool
 Lathe tool angles
- top rake angle
- side rake angle
- front clearance angle
- side clearance angle
 Care and maintenance of lathe cutting tools
- grinding to shape
- use of coolant
 Safety
- personnel safety
- wearing of goggle
- using gloves
- machine safety
- use of guard
PRACTICE:

a) identify various types of lathe cutting tools
b) grind lathe tool for a given task
c) care for and maintain lathe cutting tools
d) observe safety precautions when using lathe cutting tools
14.2.6.2P2 Content
 Types of lathe cutting tools
- solid tools
- tipped brazed tools
 Lathe cutting tool angles
- top rake angle
- side rake angle
- front cleanance
- side clearance
247
 Care and maintenance of lathe cutting tools and equipment
- handling
- sharpening
- storage
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various types of lathe cutting tools

 grind lathe tool for a given task
 care for and maintain lathe cutting tools
 observe safety precautions when using lathe cutting tools
Identifying various types of lathe cutting tools

 identify and discuss various types of lathe cutting tools to include
- solid tools
- butt brazed tool
- inserts
Grinding lathe tools for a given task

 Discuss and demonstrate the need for and proper procedure for grinding a lathe
tool to include
- top rake angle
 to help aim the cutting edge towards the work so that it shears the
material with an upward thrust - 15° to 20°
- clearance angles or relief angles – to keep the surface of the tool clear of the
work piece
 front clearance – 7° - 15°
 side clearance - 7° - 15°
Caring and maintenance of lathe cutting tools

 Discuss and demonstrate the proper care and maintenance of lathe cutting tools
to have correct angles to include:
- proper grinding procedure
 grinding
 cooling
- use of proper coolant
 Demonstrate safe working habit when grinding a lathe cutting tool to include
- personal safety
 wearing of goggles
 using gloves
- machine safety
 use of guards
248
The trainee should
 identify various types of lathe cutting tools
 grind lathe tool for a given task
 care for and maintain lathe cutting tools
 observe safety precautions when using lathe cutting tools

 Charts of various lathe cutting tools showing various angles
 Assorted relevant tools to include
- angle gauge
- various lathe tools
 Square bars for practicing grinding
Assessment Methods
 Oral/written test to include
- types of lathe cutting tools
- tool angles and their functions
- care and maintenance
- safety
 Observation
- change of attitude of trainee to practical work and team work
 Practical
- project work on grinding a tool for a specific task while observing the
necessary safety
References
 Metal work pupils book 1, 2, 3, and 4 by KIE
 Metal work by GH Thomas
 Metal work book 1 & 2 by E.N. Njuguna
 Workshop Technology Vol. I and II by HS Bawa
249
THEORY

a) name work holding devices
c) name various tool holding devices
d) explain how to care for and maintain work holding devices
e) state safety precautions to be observed when using work holding devices
14.2.6.3T2 Content
- three jaw chuck
- four jaw chuck
- holding between centres
- holding on face plates
 Uses of work holding devices
- Three jaw chuck
 holding round and hexagonal shaped bars
- Four jaw chuck
 stronger grip when turning
 for eccentric turning
- Holding between centres
- for turning long bars
- taper turning on long bars
- Holding on face plates
- for irregular shapes of castings and forgings
 Care and maintenance of lathe work holding devices
- cleaning
- proper handing
 Safety
- personal safety
- equipment safety
PRACTICE

a) identify various work holding devices
b) select and use work holding devices for a given work piece
c) care and maintain work holding devices
14.2.6.3P2 Content
- three jaw chuck
- four jaw chuck
- holding work between centres
- face plates
- fixed steadies
- traveling steadies
250
 Work holding device selection
- cylindrical work
- irregular shapes and castings
- long thing round rods
- square bars
- hexagonal bars
- machining between centres
- cleaning
- servicing
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify various work holding devices
 select and use work holding devices for a given work piece
 care and maintain work holding devices
Identifying working holding devices

 identify and discuss various work holding devices to include
- three jaw chuck
- four jaw chuck
- holding between centres
- face plates
Using work holding devices

 select and demonstrate the correct use of a work holding device for a given tasks
to include
- three jaw chuck
 round and hexagonal shapes,
 self centering work
- four jaw chuck
 square, round oral/irregular
 offers stronger grip
 for eccentric turning
- Holding between centre
 for turning long bars
 taper turning on long bars
- face plates
 irregular shapes of casting and forgings
 Caring and maintaining of work holding devices while observing safety to
include
- Care and maintenance
 cleaning
 oiling and greasing
 proper handling and storage

251
- safety
 personal safety
 equipment safety
The trainee should


 charts and pictures to include various work holding devices
 assorted work pieces with different shapes
 various work holding devices
 Lathe machine and its accessories
Assessment methods
- types of work holding devices
- application of various work holding devices
- care and maintenance of work holding devices
- safety on work holding devices
 Observation
- attitude of trainee towards practical work and team work
 Practical
- selection and clamping of a given task on a proper work holding device
References
 Metal work Pupils book 1, 2, 3, and 4 by KIE
 Metal work book 1 and 2 by E.N. Njuguna
 Workshop Technology Vol. I and II by H.S. Bawa
252
14.2.6.4T MODULE UNIT: CUTTING SPEEDS
THEORY

a) state factors to be considered when determining cutting speeds
b) calculate spindle speed
14.2.6.4T2 Content
 Factors to be considered when determining spindle speeds
- cutting speed of the material
- the feed of the tool bit
- diameter of the work piece
 Calculating the spindle speed
- cutting speed of the materials
- diameter of the material
PRACTICE:

a) determine cutting speeds on the lathe
b) set spindle speed on the machine
c) care for and maintain lathe machine
14.2.6.4P2 Content
 Cutting speed
- materials being machined
- tool bit feed
- diameter of the work piece being machined
 Setting spindle speed
 Care and maintenance of lathe machine
- cleaning
- oiling/greasing
Competencies
Ability to:
 determine spindle speeds on the lathe
 set spindle speed on the machine
 care for and maintain lathe machine
Teaching/learning activities
Determining spindle speeds

 Identify and discuss factors to be considered when determining spindle speeds to
include
- cutting speed of the material
- Type of material being machined
- tool bit feed
- diameter of the work
253
 Calculate the spindle speed for a given work piece to include
- The use of formula
N = 1000 CS
Πd
Where N = spindle speed in revolutions per minute
CS = cutting speed in meters per minute
d = diameter of work piece in mm
Setting spindle speed on the machine

 Demonstrate the selection and setting of spindle speed on the machine to include
- engaging of correct gears
- switching machine on and off
Caring and maintaining lathe machine

 Demonstrate proper care and maintenance of lathe machine when selecting
spindle speed to include
- Proper engagement of gears when machine is not running
- Testing machine after selection of spindle speed
- cleaning
- oiling/greasing
- proper handling
The Trainee should

 determine spindle speeds on the lathe
 set spindle speed on the machine
 care for and maintain lathe machine
Assessment Method
 Oral/Written test on – calculation of spindle speeds
 Practical – practical exercise on spindle speed setting
References
PROJECT WORK:
14.2.6.5P MODULE UNIT: LATHE MACHINE WORK

b) select work holding device and cutting tools to be used for a given operation
c) mount work holding device on the lathe machine
d) set the work on the lathe for machining
e) set the cutting tools for machining
f) determine the turning speed
g) machine to the required dimensions
h) observe safety precautions when machining.
254
14.2.6.5P2 Content
- lathe operations
 parallel / straight turning
 facing
 taper turning
 drilling
 parting
 boring
 knurling
 reaming
 screw cutting
- dimensions
 lengths
 diameters
 taper angles
 recesses
 under cuts
- scale
 half size
 full size
 double size
- material for the work piece
 mild steel
 Work holding device and cutting tools selection
- work holding devices
 three jaw chuck
 four jaw chuck
 holding work between centres
 holding work on face plate
- cutting tools
 operation to be done
 rough cutting
 smooth cutting
 Work holding device on the lathe machine
- locking the spindle
- fixing the work holding devices
 Work setting
- use of dial testing indicator ( DTI)
- use of surface gauge
- use of counter weights on face plate
- setting work between centres
 Tools setting
- fixing the tool on the holder
- setting the height of the tool
- setting the position of tool angles
 Turning speed
- material to be machined
- cutting speed
- diameter of work piece
 Machining to the required dimensions
- feed
- depth of cut
255
- taking of measurements
- use of coolants
 Safety
- personal safety
- machine safety
Competencies
Ability to:

 select work holding device and cutting tools
 mount work holding device on the miller machine
 set the work for machining
 determine the turning speed
 machine to the required dimensions
 observe safety precautions when machining on the lathe

 Discuss and demonstrate how to read and interprete working drawing to include
- determination of overal size of a component
- determination of lengths, diameters, taper angles, recesses and undercuts
- conversion of scales half size, full size, double size
- machining operation symbols
- work piece materials
- type of finish
Work holding device and cutting tool selection

 Guide on appropriate work holding device and cutting tool selection for a given
task to include
- work holding devices
 three jaw chuck
 four jaw chuck
 holding work between centres
 holding work on face place
- cutting tool
 rough cutting
 smooth cutting
Mounting work holding device on lathe machine

 Demonstrate the proper procedure of mounting work holding device on the lathe
machine to include
- use of soft surface like wood to prevent damage of bed
- use of mallets in fixing
- proper fixing of work holding device on the spindle face using screws
Setting work on lathe machine for machining

 Demonstrate the proper procedure of work setting on the lathe to include
256
- use of dial testing indicator (DTI)
- use of counter weights on face plate
- setting work between centres
Setting tool on lathe machine

 Demonstrate the correct procedure of tool setting on lathe machine to include
- fixing the tool on holder
Selecting turning speed and machining to the required dimensions

 Demonstrate the correct procedure of selecting turning speed, and machining a
component to the required dimension to include
- identification of material to be machined
- determination of diameter of workpiece
- calculating of turning speed
- selecting and engaging correct turning speed
- calculating and engaging correct feed
- determining and taking correct depth of cut
- confirmation of measurement
- application of coolant when machining
- deburring of work piece
- cleaning of work piece after finish
Caring and maintaining of lathe machine and its accessories

 Demonstrate safe working habits when machining on the lathe to include
- personal safety (safe gear)
- handling of tools and equipment when turning on lathe machine
- Demonstrate proper care and maintenance of the lathe machine and
accessories
 cleaning
 oiling/greasing
 proper handling and storage
The trainee should

 mount work holding device on the miller machine
 determine the turning speed
 observe safety precautions when machining on the lathe

- various working drawing
- machining symbols/finishing symbols
- various scale drawings
- various machining operations
- various working holding devices
257
 Assorted turning tools to include
- dial test indicators
- surface gauges
- vernier calipers
- cutting tools
 Lathe machine and its accessories
- Cutting tools
 Smoothing tool
 Roughing tools
 Threading tools
 Chucks
 Measuring and testing tools
- Dial test indicator (DTI)
- Surface gauge
- Vernier Calipers
Assessment Methods
- reading and interpretation of working drawing
- selection of work holding devices for given tasks
- calculation and selection of turning speed
- work setting on lathe machine
- mounting of work holding device on lathe machine
 Observation
- the trainee should display safe working habits
- the trainee should show organization skills and team work
 Practical test
- class project to machine a given work piece to the correct dimensions using
the correct work holding device, speed and to the required surface finish.
References
258
14.2.7.1T MODULE UNIT: MILLING AND BORING
THEORY

a) explain the use of milling machines
b) name various types of milling machines
c) name various general milling operations
d) name the main parts of the miller and their uses
e) explain how to care for and maintain the miller
f) list down the safety precautions to be observed when working on the miller
14.2.7.1T2 Content
 Uses of a milling machine
- machine flat surfaces
 Types of milling machine
- horizontal and vertical
- universal milling machine
 Milling operations
- plain
- slotting
- slitting
- gang and straddle milling
- end milling
- simple and direct indexing
- drilling
- boring
- knurling
 Parts of the milling machine
- base
- column
- support arm bracket
- table
- spindle
- arbor
- over arm bracket
 Care and maintenance of the milling machine
- cleaning
- oiling/greasing
- proper handling
 Safety
- Personal safety and safety for others
 dressing
 behaviour
- Machine safety
 switching on and off
 proper handling
259
PRACTICE:

a) identify parts of a milling, boring and hobbing machines
b) operate a milling machine
c) care for and maintain a milling, boring and hobbing machines
d) observe safety precaution when operating machines
14.2.7.1P2 Content
 Parts of a milling machines
- Base
- Column
- Support arm bracket
- Table
- Spindle
- Arbor
- Over arm bracket
 Operation of machines
- fixing work holding devices
- setting the work
- machining
 Care for and maintenance of machines
- cleaning
- oiling / greasing
- proper handling
 Safety
- equipment safety
Competencies
Ability to:
 identify parts of a milling machine

 operate a milling machine
 care for and maintain a milling, boring and hobbing machines
 observe safety precaution when operating machines
Identifying parts of milling, boring and hobbing machines

 identify and discuss parts of a milling machine to include
- milling machines
 base
 column
 support arm bracket
 table
 spindle
 arbor
 over arm bracket
260
Identifying uses of milling machine
 Identify and demonstrate various uses of milling machine to include:
- milling machines
 plain milling
 slotting
 slitting
 gang and straddle milling
 end milling
 simple and direct indexing
 drilling
Operating milling machine

Instructor should
 Demonstrate the correct procedure for operating milling machine to include
- fixing work holding device
- setting the work
- selecting correct gear drives (hobbing)
- machining
- application of coolant
Caring and maintaining milling machine

 Demonstrate the correct procedure for caring and mainting milling machines to
include:
- Proper service
- Cleaning
- Oiling and greasing
- Proper handling
 Demonstrate safe working habits when using milling machines to include
- Personal safety
 Safety gears
 Safety of others
- Machine safety
 Guards
 Handling
The trainee should

 identify parts of a milling machine
 operate a milling machine
 care for and maintain a milling, boring and hobbing machines
 observe safety precaution when operating machines

- milling machine and its parts
- milling operations
- assorted tools
- assorted work pieces
Assessment methods
- parts of a milling machine
261
- uses of a milling machine
- care and maintenance of milling machines
- safety
 Observation
- attitude of trainee towards practical work and team work
- trainee observing safety
- Practical test - Project work to include
 milling operation
References
 Workshop Technology Vol. I & II by H.S. Bawa
14.2.7.2T MODULE UNIT: MILLING CUTTERS

THEORY

a) name various milling cutters
b) explain how to care for and maintain milling cutters
c) explain safety precautions to be observed when using milling cutters
14.2.7.2T2 Content
 Milling cutters
- end mills
- side and face
- slotting mills
- gear cutters
- end drilling bits
 Care and maintenance of milling cutters
- use of coolant
- storage
 Safety
- personnel safety
- machine safety
PRACTICE:

a) identify various types of milling cutters
b) select cutters for a given job
c) care for and maintain milling cutters
d) observe safety precautions when using milling cutters
14.2.7.2P2 Content
 Types of milling cutters
- solid tools
262
 Milling cutters
- cylindrical cutters
- gear cutters
- end mills
- slotting cutters
- form relieved cutters
 Care and maintenance of milling cutters
- cleaning
- handling
- grinding
- storage
 Safety
- equipment safety
Competencies
Ability to:
 identify various types of milling cutters

 select cutters for a given job
 care for and maintain milling cutters
 observe safety precautions when using milling cutters
Identifying various types of milling cutters

 Identify and discuss various types of milling cutters to include
- solid tools
 cylindrical cutters
 gear cutters
 slotting cutter
 for relieved cutter
- butt grazed tools
Selecting of a cutting tool for a given task

 Demonstrate the correct procedure for selecting a cutter for a given task to
include;
- type of material to be cut
- type of operation to be performed
- size of work
- type of surface finish required
- speeds and feeds to be used
Caring and maintaining milling cutters

 Demonstrate the proper procedure for caring and maintaining milling cutters to
include
- cleaning
- handling
- grinding
- storage
 Demonstrate safe working habits when using milling cutters to include
263
- personal safety (safety gears), safety for others
The trainee should

 identify various types of milling cutters
 select cutters for a given job
 care for and maintain milling cutters
 observe safety precautions when using milling cutters
Key Learning Activities

 Charts of
- various milling machine cutters
- milling machine operations
 Assorted relevant tools to include
- spanners
- angle gauges
 Assorted milling machine cutters
Assessment methods
- types of milling cutters
- selection of milling cutter for a given task
- care and maintenance of milling cutters
- safety when using milling cutters
 Observation
- change of trainees attitude towards practical work and team work
- trainee to observe safety when using milling cutter
 Practical test on: project work on grinding of milling cutter for a given task
References
 Metal work book by G.H. Thomas
 Metal work book 1 and 2 E.N. Njuguna
264
THEORY

d) explain how to care for and maintain work holding devices
14.2.7.3T2 Content
- vices
- clamps
- rotary tables
- indexing heads
- vices
- clamps
- rotary tables
- indexing heads
 Care and maintenance of miller work holding devices

- cleaning
- proper handing
PRACTICE

c) care and maintain work holding devices
14.2.7.3P2 Content
- vices
- clamps
- rotary tables
- indexing heads
 Selection and use of work holding devices
- cleaning
- proper handling and storage
 Safety
- equipment safety
Competencies
265
Ability to:
Identifying various work holding devices

 Identify and discuss various work holding devices to include
- vices
- clamps
- rotary table
- indexing heads
- T-bolts and nuts
Using work holding devices

 Select and demonstrate the correct use of a work holding device for a given task
to include
- vices for small and medium work
- clamps for bulky work that require direct mounting on the table
- rotary table – for circular work
- indexing head – for work that requires indexing
 Caring and maintaining of work holding devices while observing safety to
include
- cleaning
- safety
 personal safety and safety for others
Trainee should
 observe and take notes
 select and demonstrate the correct use of a work holding device for a given task
 demonstrate proper care and maintenance for work holding devices to include
- cleaning
- oiling/greasing
 demonstrate safe working habits when using work holding devices to include
 personal safety and safety for others

 charts and pictures to include
- various work holding devices
- uses of work holding devices
- clamping of work holding devices
 assorted work pieces with different shapes
 various work holding devices.
 milling machine and its accessories
266
Assessment Methods
 oral/written test to include
- types of work holding devices
- application of various work holding devices
- care and maintenance of work holding devices
- safety on work holding devices
 observation
- attitude of trainee towards practical work
- trainee to observe safety
 practical test
- selection and camping of a given task on a proper work holding device
References
 Workshop Technology vol. I & II by H.S. Bawa
PROJECT WORK:
14.2.7.4P MODULE UNIT: MILLING MACHINE WORK

c) mount work holding device on the milling machine
d) set the work on the milling machine
e) set the work on the miller for machining
f) set the cutting tools for machining
g) determine the machining speed
h) machine to the required dimensions
i) care for and maintain the milling machine and its accessories
j) observe safety precautions when machining.
14.2.7.4P2 Content
- Milling operations
 Plain milling
 slotting
 slitting
 gang and straddle milling
 end milling
 simple and direct indexing
 drilling
 boring
 gear cutting
- Scale
 half size
 full size
 double size
- Material for the work piece
 mild steel
 Selection of work holding device and cutting tools
267
- Work holding devices
 vices
 clamps
 rotary tables
 fixtures
 dividing heads
 arbor
 stub arbor
- Cutting tools
 end mills
 side and face cutters
 slotting mills
 gear cutters
 end drilling bits
 Mounting of work holding device
 Setting of the work for machining

- use of dial testing indicators ( DTI)
 Setting and fixing of the cutters for machining
- fixing the cutters tool on the arbor
- setting the position of the cutting tool
 Cutting speed
- spindle speed
- size of work piece
- feed
- depth of cut
- use of coolants
 Care and maintenance of milling machine with its accessories
- cleaning
- oiling/greasing
 Safety
- machine safety
Competencies
Ability to:
268
Reading and interpreting working drawings
 Discuss and demonstrate how to read and interpret working drawings to include
- interpretations of milling operation symbols
 plain milling
 slotting
 slitting
 gang & straddle milling
 boring
 gear cutting
- determination of overall size of the work piece
- determination of lengths, diameters recesses and undercuts
- conversion of scales half size, full size, double size
- work piece material
- type of surface finish
Work holding device and cutting tool selection

 Guide on appropriate work holding device and cutting tool selection for a given
task to include
- work holding device
 vices
 clamps
 rotary table
 fixtures
 dividing heads
 arbor
 stub arbor
- cutting tool
 end mills
 side and face cutter
 slotting mills
 gear cutters
 end drill bits
Mounting of work holding device on milling machine

 Demonstrate the proper procedure of mounting work holding device on the
milling machine to include
- use of soft surface like wood to prevent damage of table, slideways and the
holding device
- use of mallets in fixing
- proper fixing and clamping of the device
Setting work on milling machine for machining

 Demonstrate the proper procedure of work setting on the milling machine to
include
- use of dial testing indicators (DTI)
269
Setting and fixing of the cutter for machining
 Demonstrate the correct procedure of cutter setting and fixing to include
- fixing the cutter tool on the arbor
- setting the position of the cutter
- tightening the cutter
Selecting cutting speed and machining to the required dimension

 Demonstrate the correct procedure of selecting cutting speed and machining a
component to the required dimension to include
- identification of material to be cut
- determination of size of work
- calculation of spindle speed
- selecting and engaging the correct cutting speed
- calculating and engaging correct feed
- determining and taking correct depth of cut
- confirmation of measurement
- application of coolant when machining
- deburring of work piece
- cleaning of work piece after finish
Caring and maintaining of milling machine and its accessories

 Demonstrate proper care and maintenance of milling machine and its accessories
to include
- cleaning
- oiling/greasing
 Demonstrate safety precautions when machining on a milling machine to include
- personal safety (safe gears)
- machine safety
The trainee should

 Observe and take notes
 Read and interpret working drawing to include
- overall size
- length and diameters
- scales
- machining symbols
- surface finish symbols
 Select the correct work holding device and cutting tool for a given task to include
- shape of work
- size of work
- type of operation
- type of finish
 Demonstrate the correct procedure of mounting a work holding device on the
milling machine for given task to include:
- locking of spindle
- use of soft surfaces
- use of mallets
- proper fixing and clamping
 Demonstrate the correct procedure of setting work for machining to include
- the use of dial test indicator (DTI)
- the use of surface gauge
270
 Demonstrate the correct procedure for setting the tool for machining to include
- fixing tool on arbor
- setting position of tool
- calculating and selecting the correct spindle speed for a given task
- machine a given workpiece to the correct dimension and surface finish
 Demonstrate safety working habits when machining on a milling machine to
include
- use of proper safe gear
- personal safety
- machine safety
- equipment handling
 Demonstrate proper care and maintenance of milling machine and equipment to

include:
- proper servicing
 cleaning
 oiling/greasing
 proper storage

- various working drawing
- machining symbols/finishing symbols
- various scale drawing
- various machining operations
- various work holding devices
 Assorted milling machine tools and accessories to include
- cutters
- T- bolts and nuts
- machine vices
 Measuring and testing tools to include
- Dial test indicator (DTI)
- Surface gauge
- Vernier caliper
 Assorted work piece materials with different shapes and sizes
Assessment Methods
- reading and interpretation of working drawing
- selection of work holding devices for given tasks
- calculations and selections of spindle speed
- work setting on milling machine
- mounting of work holding devices on milling machine
 Observation
- the trainee should show organization skills and team work
 Practical test
- class project to machine a given workpiece to the correct dimensions using
the correct work holding device, speed and to the required surface finish.
References
 Metal work pupil book 1, 2, 3 and 4 by KIE
271
14.2.8.1T MODULE UNIT: SHAPING AND SLOTTING MACHINE
THEORY

a) explain the use of shaping machine
b) explain the use of slotting machine
c) name various general shaping operations
d) name the main parts of the shaper and their uses
e) explain how to care for and maintain the shaping machine
f) list down the safety precautions to be observed when working on the shaper
14.2.8.1T2 Content
 Uses of a shaping machine
 Slotting machine operations
- internal services
- angular and rotary cuts
- keyways
- radiuses
- square and rectangular work
 Shaping operations
- angular shaping
- plain shaping
- key-way cutting
- serrating
 Parts of the shaping machine
- frame and bed
- ram
- cross-rail
- table
- main gearbox
- feed mechanism
- claPper box
- tool holding device
 Care and maintenance of the shaping machine
- cleaning
- oiling/greasing
- proper handling
 Safety
- Personal safety and safety for others
- dressing
- behaviour
- Machine safety
- switching on and off
- proper handling
PRACTICE:

a) identify parts of a shaping machine
b) operate a shaping machine
c) operate slotting machine
d) care for and maintain a shaping machine
e) observe safety precaution when operating a shaping machine
272
14.2.8.1P2 Content
 Parts of a shaping and slotting machine
- frame and bed
- ram
- cross-rail
- table
- main gearbox
- feed mechanism
- clamper box
- tool holding device
 Operation of a shaping machine
- angular shaping
- plain shaping
- key-way cutting
- serrating
 Operation of a slotting machine
- internal services
- keyways
- radiuses
 Care for and maintenance of a shaping machine
- cleaning
- oiling / greasing
- proper handling
 Safety
- personal safety
- equipment safety
Competencies
Ability to:
 identify parts of a shaping and slotting machine

 operate a shaping and slotting machine
 care for and maintain shaping and slotting machine
 observe safety precaution when machining
Identifying parts of a shaping and slotting machine

 Demonstrate and discuss the parts of shaping and slotting machine to include:
- frame and bed
- ram
- cross-rail
- table
- main gearbox
- feed mechanism
- clapper box
- tool holding
273
Operating a shaping and slotting machine
 Demonstrate and discuss the operations of a shaping machine to include
- plain shaping
- angular shaping
- key way cutting
- serrating
 Demonstrate and discuss the operations of a slotting machines to include

- internal services
- keyways
- radiuses
Caring for and maintaining shaping and slotting machine

 Demonstrate how to care and maintain shaping/slotting machine to include
- cleaning
- oiling/greasing
- proper handling
Observing safety precaution when machining

 Demonstrate safe working habits to include
- personal safety
- equipment safety
The trainee should

 identify parts of a shaping and slotting machine
 operate a shaping and slotting machine
 care for and maintain shaping and slotting machine
 observe safety precaution when machining

 Shaping and slotting machines
 Charts
 Wall charts of shaping and slotting machines
 Relevant accessories of shaping an slotting machines
Assessment Methods
 oral test on uses of a shaping and slotting machine
 written test of shaping and slotting machine, care and maintenance of the
machines and safety precautions.
 observation through attitudes on safety precautions and application of the same
References
 Workshop technology book 2 by J. Chapman

 Workshop technology by Pritehard
274
14.2.8.2T MODULE UNIT: SHAPER CUTTING TOOLS AND THEIR USES
THEORY

a) name various shaper cutting tools
b) list materials from which tools are made
c) name shaper tool angles
d) explain how to care for and maintain shaper cutting tools
e) explain safety precautions to be observed when grinding shaper tools
14.2.8.2T2 Content
 Shaping machine cutting tools
- solid tools
 Shaper machine tools materials
- carbon steel
- high speed steel ( HSC)
- carbide – tipped tool
 Tool angles
- top rake angle
- side rake angle
- front clearance angle
- side clearance angle
 Care and maintenance of shaper cutting tools
- grinding to shape
- use of coolant
 Safety
- personnel safety and safety for others
- machine safety
PRACTICE:

a) identify various types of shaping machine cutting tools
b) grind tools for a given task
c) care for and maintain shaping cutting tools
d) observe safety precautions when using cutting tools
14.2.8.2P2 Content
 Types of shaping machine cutting tools
- solid tools
 Cutting tools angles
- top rake angle
- side rake angle
- front cleaning
- side clearance
 Care and maintenance of lathe cutting tools and equipment
- handling
- sharpening
- storage
275
 Safety
- equipment safety
Competencies
Ability to:
 identify various types of shaping machine cutting tools
 grind tools for a given task
 care for and maintain cutting tools
 observe safety precautions when using cutting tools
Identifying various types of shaping machine cutting tools

 Discuss and demonstrate various types of shaping machine tools to include
- solid tools
- carbide – tipped tools
 Discuss and identify shaper machine tools materials to include
- carbon steel
- high speed steel (HSC)
- carbide – tipped tools
Grinding tools for a given task

 Demonstrate the grinding of a cutting tool angles to include:
- top rake
- side rake
- front rake angle
- front cleaning
- side clearance
 Explain the purposes of having cutting tool angles to include
- efficient cutting
- friction reduction
- smooth surface finish
Caring for and maintenance of cutting tools

 Demonstrate the care and maintenance of lathe cutting tools and equipment to
include
- handling
- sharpening
- storage
Observing safety precautions when using cutting tools

 Demonstrate and discuss safe working habits when using cutting stools to
include
- personal safety and safety for workmates
- equipment safety
The trainee should

 identify various types of shaping machine cutting tools
 grind tools for a given task
 care for and maintain cutting tools
276
 observe safety precautions when using cutting tools
 shaping machine and its accessories
 shaping tools
 bench grinder
 charts/diagram
 shaping tool blanks
Assessment Methods
 oral test on cutting tools types, angles and safety precautions
 written test on cutting tools types, angles and safety precautions
 assignments on cutting tool angles
 observation on attitudes and application of safety precautions
Reference
 Workshop the technology, book 2 by J. Chapman
 Workshop Technology by Prithard

THEORY

b)explain the use of each work holding device
d)explain how to care for and maintain work holding devices
14.2.8.3T2 Content
- tables
- machine vice
- gripping
- rotating work
- inclining work
 Tool holding devices
- clapper box
- tool slide
- cleaning
- oiling / greasing
- proper handling
PRACTICE:

c) care for and maintain work holding devices
277
14.2.8.3P2 Content
- tables
- machine vice
 Work holding device selection
- regular shapes
- square bars
- hexagonal bars
- cleaning
- oiling/ greasing
- servicing
 Safety
- equipment safety
Competencies
Ability to:
Identifying various work holding devices

 Demonstrate and discuss various work holding devices to include
- tables
- machine vice
Selecting and using work holding devices for a given work piece
 Discuss and outline how to select and use work holding devices for a given work
piece to include
- regular shapes
- square bar
- hexagonal bars
Caring and maintaining work holding devices

 Demonstrate proper care and maintenance of work holding devices to include
- cleaning
- oiling/greasing
- servicing
Observing safety precautions when using work holding devices

 Demonstrate safe working habits when using work holding devices to include
- personal safety and workmate safety
- equipment safety
278
The trainee should

 plain or parallel vice
 swivel machine vice
 universal vice
 compound machine vice
 work piece
 charts/diagram
 shaping machine and its accessories
Assessments Methods
 Oral quiz on work holding devices
 Written test on work holding devices, selection of holding devices, care and
maintenance
 Observing safety precautions when using work holding devices
 Project work for shaping while using work holding devices
References
 Workshop Technology bk 2 by J. Chapman
 Workshop Technology by Pritchard
 Workshop technology by G.H. Thomas
279
PROJECT WORK:
14.2.8.4P MODULE UNIT: SHAPING MACHINE WORK

c) mount work holding device on the shaping machine
d) set the work on the shaper for machining
e) set the cutting tool for machining
f) set the stroke length
g) machine to the required dimensions
h) observe safety precautions when machining.
14.2.8.4P2 Content
- Shaping operations
 angular shaping
 plain shaping
 key-way cutting
 serrating
- Dimensions
 lengths
 recesses
 under cuts
- Scale
 half size
 full size
 double size
- Material for the work piece
 Selection of work holding device and cutting tools
- Work holding devices
 table
 machine vice
- Cutting tools
 rough cutting
 smooth cutting
 Mounting work holding device on the shaping machine
 Setting of the work for machining
- use of dial testing indicators ( DTI)
 Setting of the tool for machining
 Stroke length
- cutting speed
- work size
280
- feed
- depth of cut
 Safety
- machine safety
Competencies
Ability to:
 mount work holding device on the shaping machine
 set the tool for machining
 determine the shaping speed
 observe safety precautions to be observed when machining on the shaper

 Discuss and explain the reading and interpreting of working drawing to include
- scales
 half size
 full size
 double size
- dimensions
 lengths
 recesses
 undercuts
- shaping operations
 angular shaping
 plain shaping
 key-way cutting
 serrating
Selecting the work holding device and cutting tools to be used for a given
operation
 Discuss the factors that influence the selection of work holding device and
cutting tools to be used for a given operations to include
- holding devices
 table
 machine vices
- cutting tools
 rough cutting
 smooth cutting
281
Mounting work holding device on the shaping machine
 Demonstrate the mounting of work holding device on the shaping machine to
include
Setting the work for machining

 Demonstrate the setting of the work for machining to include
- use of dial testing indicators (DTI)
Setting the tool for machining

 Demonstrate the setting of the tool for machining to include
Determining the shaping speed

 Discuss and demonstrate how to determine the shaping speed to include
- stroke length
- number of strokes per minute
- ratio between return stroke time and cutting stroke time
- material of the cutting tool
- amount of material to be removed
Machining to the required dimensions

 Demonstrate how to machine to the required dimensions to include
- feed
- depth of cut
- taking measurements
Observing safety precautions to be observed when machining on the shaper

 Demonstrate safe working habits when machining on the shaper to include
- personal safety and workmates
- machine safety
 cleaning
 oiling/greasing
 proper storage of equipment
The trainee should

 select work holding device and cutting tools to be used for a given operation
 mount work holding device on the shaping machine
 set the tool for machining
 calculate the cutting speed to machine a selected piece of work
 perform shaping machine operation to the required dimensions
 demonstrate safe working habits when machining on the shaper
282
 shaping machine
 shaping machine accessories
 cutting tools
 charts/diagram
 measuring tools
Assessment Methods
 Oral quiz on how to read and interpret a working drawing, selecting work
holding and cutting tools
 Written test on mounting work holding device on the shaping machine, setting
the work for machining, setting the tool for machining and speed calculations
 Observation – on attitude on personal and equipment safety
 Project work on shaping operations
References
1. Workshop Technology bk 2 by J. Chapman
2. Workshop Technology by Pritchard
3. Workshop Technology by G.H. Thomas
283

Metal Processing Instructor's Guide Level I and Ii

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Metal Processing Instructor's Guide Level I and Ii

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REPUBLIC OF KENYA

NATIONAL VOCATIONAL CERTIFICATE OF EDUCATION

METAL PROCESSING TECHNOLOGY

Hon. (Prof) Hellen Sambili EGH,

JAMES M. WAWERU, EBS

D.C. Mwinzi (Ph.D)

INTRODUCTION TO THE INSTRUCTORS’ GUIDE..................................................................................8

METAL PROCESSING TECHNOLOGY LEVEL I.....................................................................................17

14.1.1.1 MODULE UNIT: ETHICS AND INTEGRITY.....................................................................17

The instructors’ guide has been developed so as to:-

The guide lays emphasis on the following:

3.0 OVERVIEW OF COURSE SYLLABUS

The syllabus is modeled on modular approach and is trainee - centered.

The syllabus covers the following:-

Level 1 - 1980 hours

The trainees will be allowed to select either option 1 or option 2

4.0 TARGET GROUP AND COURSE OUTLINE

The course outline will be as follows:

The course outline will be as follows:-

5.1 Instructor Preparedness

5.2 Learning Environment

5.2.2 Supervision of class activity

It is of utmost importance that the instructor supervises trainees to see

5.3 Resources Management

5.4 Quality products and services

6.0 MODE OF DELIVERY

6.1 Demonstration method

For a demonstration to be effective, the instructor should:

6.2 Discussion method

6.3 Lecture method

6.4 Visit / Field Trip

6.7 Project Method

6.10 Case Study

This is an account depicting a real life situation, a scenario or problem.

6.11.1 The Concept of Infusion

Some of the common assessment methods included in the guide are

6.11.3 Use of questions

6.11.4 Self assessment

6.11.5 Peer assessment

6.11.6 Follow up Activities

6.11.7 Continuous Assessment

6.11.8 Final assessment Test

7.1 Guest Speakers/Resources Persons

Sometimes it may be useful to invite a speaker such as an engineer or an

7.2 Picture Code

14.1.1.1T MODULE UNIT: ETHICS AND INTEGRITY

Defining of Ethics and Integrity

Explaining importance of Ethics and Integrity

Discussing the significance of values, development and Sustainability

Discussing significance of values in Society

The trainee should

Key learning Resources

14.1.1.2T MODULE UNIT: SAFETY

14.1.1.2T1 Specific Objectives

14.1.1.2 P1 Specific Objectives

Identifying causes of accidents in the workshop

Practicing safety in the workshop

Identifying fire fighting equipment

The trainee should

Key Learning resources

14.1.1.3T MODULE UNIT: QUALITY CONTROL

14.1.1.3P1 Specific Objectives

Controlling the work pieces