Lesson 1Documentation and simple QA checks to show work readiness (weld logs, electrode batch tracking)Introduces basic documentation and quality checks for work readiness in Eritrean shops. Learners fill weld logs, track electrode batches, and record inspections to ensure traceability and maintain high standards in boilermaking tasks.
Essential items in a weld logRecording joint and parameter dataElectrode batch and oven trackingSimple visual inspection recordsHandling nonconformance findingsStoring records for later reviewLesson 2Common welding defects, visual acceptance criteria, and basic corrective actions (porosity, slag inclusion, overlap, undercut)Reviews common SMAW defects, acceptance criteria, and fixes in Eritrea. Learners spot porosity, slag inclusions, overlap, and undercut, then adjust techniques and settings to avoid them in practical boilermaking applications.
Recognizing porosity and gas entrapmentIdentifying slag inclusions in groovesDetecting overlap and cold lapSpotting undercut along toesParameter changes to prevent defectsSafe methods for defect removalLesson 3Tack welding best practices: spacing, number of tacks, sequence to control distortionPresents tack welding methods to control distortion and secure fit-up in Eritrean frames. Learners select tack size, spacing, sequence, and decide on removing or integrating tacks into final welds for stable structures.
Determining tack size and lengthTack spacing for various plate widthsSequencing tacks to balance shrinkageBridging gaps and closing high-lowIncorporating tacks into root passesRemoving defective or misplaced tacksLesson 4Weld pass plan: root pass techniques, fill passes, capping technique, interpass cleaning and temperature controlGuides weld pass planning from root to cap in Eritrea. Learners apply root techniques, sequence fills, manage interpass heat, and clean between passes to produce strong, even welds in boilermaking projects.
Root pass techniques and keyhole controlStringer versus weave bead choicesLayering and sequencing fill passesCapping bead profile and tie-inInterpass slag removal and brushingMonitoring and controlling interpass heatLesson 5Welding positions and their effect on electrode choice and technique (flat, horizontal, vertical, overhead)Explains position effects on electrode and technique in Eritrean SMAW. Learners adjust amperage, speed, and handling for flat, horizontal, vertical, and overhead welds on plates in workshop and field conditions.
Flat position settings and travelHorizontal fillet and groove controlVertical up versus vertical downOverhead weld body and rod controlPosition-rated electrode selectionAdjusting amperage for each positionLesson 6Edge preparation methods (square butt, single V, bevel angle, root face, root gap) with when to use eachCovers edge prep for butt joints in Eritrean plates. Learners compare square butt, single V, bevels, and choose based on thickness, access, distortion control, and penetration needs for effective boilermaking.
Square butt prep for thin plateSingle V prep for medium thicknessBevel angle selection guidelinesRoot face and root gap sizingBacking bars and open root optionsEdge prep tools and safety checksLesson 7Electrode selection rationale: E6010, E6011, E6013, E7018 — applications, penetration, cleaning action, deposition characteristicsExplains choosing E6010, E6011, E6013, E7018 in Eritrea. Compares penetration, cleaning, deposition, and applications to justify selections for specific welds in local carbon steel fabrication tasks.
Key features of E6010 electrodesKey features of E6011 electrodesKey features of E6013 electrodesKey features of E7018 electrodesMatching electrodes to joint conditionStorage and reconditioning needsLesson 8Electrode diameter, polarity, and current selection for common plate thicknesses (1/8", 3/16", 1/4") with typical amperage rangesLinks plate thickness to electrode diameter, polarity, current in Eritrean SMAW. Matches common sizes with electrodes, amperage, and settings for safe, stable arcs in boilermaking on carbon steel plates.
Selecting diameter for 1/8 in plateSelecting diameter for 3/16 in plateSelecting diameter for 1/4 in plateTypical amperage ranges by diameterPolarity choice for each electrode typeAdjusting current for position and fit-upLesson 9Weld metallurgy and joint design basics for carbon steel (fillet vs butt, plate thickness influence)Introduces weld metallurgy and joint design for carbon steel in Eritrea. Compares fillet and butt joints, plate thickness effects on prep, and heat input impacts on microstructure and strength in assemblies.
Heat affected zone in carbon steelCooling rate and hardness relationshipFillet joint geometry and throat sizeButt joint design and root supportPlate thickness and joint selectionBalancing strength, cost, and accessLesson 10Cleaning and fit-up checks before welding (removing scale, oil, rust; using straightedges, squares, feeler gauges)Details cleaning and fit-up checks pre-welding in Eritrean shops. Removes rust, scale, paint, oil, verifies alignment and gaps with tools to minimize defects and rework in boilermaking processes.
Mechanical and chemical cleaning methodsChecking bevels and land dimensionsUsing straightedges for alignmentUsing squares for joint squarenessUsing feeler gauges for root gapMarking and documenting fit-up issues
