ITI/NCVT Welder (Fab & Fit) (AITT Theory) study plan

Map the SMAW power-source types (transformer, rectifier, inverter, engine-driven) to their duty cycles and open-circuit voltage limits, writing a one-page comparison from memory.

Calculate heat input and current setting for three plate thicknesses using electrode diameter and deposition-rate rules of thumb, showing every step.

Classify the four electrode groupings by covering type (rutile, cellulosic, basic, iron-powder) and state the current polarity and re-drying regime each demands.

Apply workshop safety controls: identify the five hazard classes in a welding bay and match each to a specific control measure (fume extraction, screens, earth leakage protection, PPE, hot-work permit).

Diagnose ten defect scenarios (porosity, slag inclusion, lack of fusion, undercut, arc blow) and trace each to its root cause in current, arc length, travel angle or joint preparation.

Select the correct non-destructive test for five given weld situations, justifying choice by defect type, thickness and accessibility.

Describe the sequence of a visual inspection and a destructive bend test, listing acceptance criteria you would check.

Explain how arc blow arises and list four corrective actions with the condition under which each works.

Set oxy-acetylene flame types (neutral, oxidising, carburising) against the metal being joined and state the gas ratio and flame appearance for each.

Sequence the full lighting, adjusting and shutting-down procedure for a gas welding set, including flashback arrestor and backfire response.

Distinguish braze welding from bronze surfacing and silver brazing by filler, temperature range and joint strength.

Relate carbon equivalent and preheat requirement to cracking risk for three steel compositions, and describe the heat-affected-zone changes in each.

Compare short-circuiting, globular and spray transfer in MIG/MAG by current density, shielding gas and positional suitability, and pick a transfer mode for three given jobs.

Match shielding gas mixtures to ferrous and non-ferrous metals and explain the effect of CO2, argon and helium fractions on penetration and arc stability.

Set TIG parameters (polarity, current type, electrode type and size, gas flow) for aluminium, stainless steel and carbon steel, and justify each choice.

Explain the role of flux-cored wire types (self-shielded versus gas-shielded, rutile versus basic) in outdoor and high-deposition work.

Decode ten weld symbol strings into full joint descriptions, including arrow side, other side, tail instructions, size, length and pitch.

Sketch the five basic joints in all four positions and label each with the correct position designation.

Predict the distortion mode (longitudinal shrinkage, transverse shrinkage, angular, bowing) for four given weld sequences and propose a control method for each.

Explain residual stress formation and compare stress-relief, peening, pre-setting and balanced sequencing as remedies.

Calculate blank length for three bent components using bend allowance and neutral-axis rules, showing the formula and substitution.

Work out cut lengths, marking allowances and pipe template development for a mitred and a branch intersection.

Describe the shearing, bending and rolling operations in order, naming the machine and the safety interlock for each.

Solve five workshop calculation problems covering weld metal volume, deposition time, taper and simple triangulation.

Interpret radiograph and ultrasonic indications described in text, deciding defect type and severity against a stated acceptance level.

Assemble a weld procedure qualification outline naming the essential variables that would require re-qualification.

Draft a job hazard analysis for a confined-space weld repair, listing atmospheric testing, ventilation and rescue provisions.

Prepare answers on employability topics: interview conduct, teamwork in a fabrication shop, and the responsibilities of a welder under quality and safety systems.

Complete two full-length timed mock papers under exam conditions and record a score per domain.

Re-teach the three weakest domains from the mock results using only your own notes, then re-attempt the missed items.

Recite from memory the key parameter tables for SMAW, MIG/MAG, TIG and gas welding without reference.

Consolidate all reference sheets into one revision pack indexed by domain.