Dr Sarath Obeysekera

It is utmost important that Sti Lanka develops vocational training educational revolution to train our youngsters Proposed curriculum will help them students to get into a highly paid employment 

IDMNC ADVANCED WELDING

ACADEMY GALLE 

Proposed Refresher Training Program for Overseas Employment

7-Day Intensive Refresher Course in MMAW & FCAW

1. Program Title

Intensive Refresher Training Program in Manual Metal Arc Welding (MMAW) and Flux

Cored Arc Welding (FCAW)

2. Program Objective

This short-term refresher program is designed to upgrade and standardize the practical welding

skills of experienced welders prior to screening and trade testing by foreign employers.

The program focuses on:

• Improving quality and consistency

• Enhancing positional welding skills

• Familiarizing candidates with international trade-test conditions

• Reducing common causes of rejection during overseas screening

The syllabus is benchmarked against internationally accepted welding training references,

including the AWS Welding Handbook (Volumes 1 & 2) and Welding Principles and

Applications.

3. Target Group

• Experienced welders (local or returnee)

• NVQ Level 3 / 4 welders or equivalent industry experience

• Candidates nominated by foreign employment agencies4. Course Duration

07 Days (Intensive)

Daily training duration: 6–7 hours per day

Mode: Theory + Hands-on Practical Training

5. Welding Processes Covered

• Manual Metal Arc Welding (MMAW / SMAW)

• Flux Cored Arc Welding (FCAW)

6. Detailed Course Syllabus

DAY 1 – Welding Safety, Fundamentals & Trade-Test Orientation

Theory

• Welding safety and health hazards (electrical, arc radiation, fumes, fire)

• Personal Protective Equipment (PPE) requirements for overseas worksites

• Welding symbols and basic fabrication drawing interpretation

• Overview of overseas welder trade tests:

o Plate vs pipe tests

o Welding positions (PA, PB, PC, PF / 1G–3G–5G)

o Typical acceptance and rejection criteria

Practical

• Familiarization with MMAW and FCAW equipment

• Machine setting verification

• Arc striking techniques and bead appearance standards

DAY 2 – MMAW Fundamentals & Fillet Welding

Theory

• Principles of MMAW

• Welding current, polarity, and heat input control

• Electrode classification and applications:

o Rutile electrodes (E6013)

o Basic electrodes (E7018)

• Electrode storage, handling, and moisture control

Practical

• Fillet welds in:

o PA (Flat) positiono PB (Horizontal-Vertical) position

• Slag removal and bead profile improvement

DAY 3 – MMAW Groove Welds & Positional Welding

Theory

• Joint preparation and root gap control

• Causes of common MMAW welding defects

Practical

• Butt welds in:

o PC (Horizontal) position

o PF (Vertical Up) position

• Multi-pass welding techniques

• Identification and correction of defects:

o Lack of fusion

o Undercut

o Slag inclusion

DAY 4 – FCAW Fundamentals & Fillet Welding

Theory

• Principles of Flux Cored Arc Welding

• Differences between FCAW and GMAW

• Flux-cored wire classifications

• Gas-shielded vs self-shielded FCAW

• Parameter selection:

o Voltage

o Wire feed speed

o Travel speed

Practical

• FCAW fillet welds in:

o PA (Flat) position

o PB (Horizontal-Vertical) position

• Spatter control and bead shape optimisation

DAY 5 – FCAW Groove Welds & Vertical Welding

Practical

• FCAW butt welds in:o PC (Horizontal) position

o PF (Vertical Up) position

• Heat input and inter-pass temperature control

• Inter-pass cleaning discipline

• Productivity vs quality balance for trade tests

DAY 6 – Weld Quality, Inspection & Repair

Theory

• Visual inspection criteria for weld acceptance

• Common causes of overseas trade-test rejection

• Introduction to Non-Destructive Testing (NDT):

o Radiographic Testing (RT) – awareness

o Ultrasonic Testing (UT) – awareness

o Magnetic Particle Inspection (MPI) – awareness

Practical

• Weld defect repair techniques

• Time-controlled welding practice under inspection conditions

DAY 7 – Mock Trade Test & Performance Assessment

Assessment

• Simulated foreign employer trade test:

o One MMAW test coupon

o One FCAW test coupon

• Welding performed under strict time limits

• Visual inspection and quality evaluation

Feedback

• Individual performance feedback

• Assessment of readiness for overseas screening

7. Training Methodology

• Short classroom lectures

• Demonstrations by instructors

• Intensive hands-on practical welding

• Continuous supervision and feedback

• Mock trade testing under realistic conditions

8. OutcomeUpon completion of the program, participants will:

• Demonstrate improved weld quality and positional welding skills

• Be familiar with overseas trade-test expectations

• Be better prepared for foreign employer screening

A training completion letter may be issued upon request (this is not a certification or

qualification).

9. Reference & Benchmarking

• AWS Welding Handbook, Volume 1 – Fundamentals

• AWS Welding Handbook, Volume 2 – Welding Processes

• Larry Jeffus, Welding Principles and Applications

10. Fees & Cost Breakdown

10.1 Course Fee (Per Participant)

The indicative course fee for the 7-Day Intensive Refresher Course in MMAW & FCAW is:

LKR 50,000 – 55,000 per participant

(Final fee may be adjusted based on batch size, welding process mix, and material usage.)

10.2 Fee Includes

The course fee covers the following components:

• Instructor and assessor fees

• Use of welding machines and workshop facilities

• Welding consumables:

o MMAW electrodes (E6013 / E7018)

o FCAW wires and shielding gas

• Steel plates and test coupons for practice and assessment

• Power, utilities, and workshop safety provisions

• Mock trade test and performance assessment

• Training coordination and supervision

10.3 Fee Excludes

The course fee does not include:

• Accommodation and meals

• Personal Protective Equipment (PPE)• Transport to and from the training venue

• Medical tests or foreign employer screening charges

(Accommodation can be arranged separately at nearby hotel at a reasonable negotiated rate.)

10.4 Cost Structure (Indicative Internal Breakdown)

Cost Component Approx. Share

Welding consumables & test materials 35–40%

Instructor & assessor remuneration 30–35%

Workshop usage, power & utilities 15–20%

Administration & coordination 10–15%

10.5 Batch Size Assumptions

• Recommended batch size: 10–15 trainees per batch

• Instructor-to-trainee ratio maintained to ensure quality supervision

• Multiple batches can be conducted subject to demand

10.6 Commercial Notes

• The above fee structure is designed for short-term refresher training and pre-

screening preparation, not for long-duration certification programs.

• Fees are benchmarked against similar short-term welding refresher programs conducted

locally and internationally.

• Final pricing can be confirmed after agreement on:

o Batch size

o Welding process emphasis (MMAW / FCAW split)

o Any additional client-specific requirements

This syllabus is indicative and subject to refinement based on client requirements and

Regards

Dr Sarath Obeysekera