Syllabus : Summary of Information on each course

1. Name of Course: Metal Fabrication Activities

2. Course Code: MTK 8033
3. Names of academic staff: 1. ZAINAL BIN HUSIN
2. AHMAD FAHMI BIN MOHD ADNI
4. Rationale for the inclusion of the course in the programme:
The course helps students to acquire skills, knowledge and the right attitude to select standard jigs and
fixtures, design jigs and fixtures for welding fabrication, decide predictive & corrective action method
related to pre-preparation of fabrication work, prepare corrective action report, monitor heat treatment
process on welded material (pre-heat & PWHT), monitor heat treatment process on welded material
(pre-heat & PWHT), and prepare work report for other activities related to fabrication project
5. Semester and Year offered: Year 2 Semester IV
6. Total Student Learning Time (SLT):
Category of Total Hours/
Learning Activity
Activities Semester
Lecture 25
Guided learning Tutorial/Practical 28
Student centered learning activities 3
Preparation for assignments/projects 19
Self-learning Independent study/revision 25
Preparation for assessment 10
Formal Continuous assessments 6
assessments Final examination sitting 4
Total SLT 120

7. Credit Value: 3 credits

8. Prerequisite (if any): None

9. Course Learning Outcomes (CLO):

CLO1 Determine metal fabrication design and specification related to work requirement (C4,
PLO3)

CLO2 Assemble jigs and fixture for metal fabrication according to BS/AWS standards (P3, PLO2)

CLO3 Prepare work report of non-conformance in accordance to corrective action report

specification standard (A3, PLO5)

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10. Transferable Skills (Skills and how they are developed and assessed, project and practical experience
and internship):
Related PLO Transferable Skills Skills Development Skills of Assessment
Problem Solving And Case Study, Project,
PLO3 Presentation, Essay
Scientific Skills Tutorial, Group Work
PLO2 Practical skills Practical, demonstration Practical test
Social Skills, Team Skills Case Study, Project,
PLO5 Presentation, Project
And Responsibilities Tutorial, Group Work
11. Teaching-learning and assessment strategies:

CLO Method of delivery Method of assessment KPI

CLO1 Determine metal
fabrication design and Lectures & Student Marks
specification related to Centered Learning Quiz, Test 50% and
work requirement Activities above
(C4, PLO3)

CLO2 Assemble jigs and fixture

for metal fabrication Marks
according to BS/AWS Lectures & Practical Practical Work 50% and
standards (P3, PLO2) above

CLO3 Prepare work report in

non-conformance in Marks
accordance to corrective Guided Project Practical Work 50% and
action report specification above
standard (A3, PLO5)

12. Course Synopsis:

This course identifies the competence required for selecting standard jigs and fixture, design jigs and
fixtures for welding fabrication, deciding predictive & corrective action method related to pre-
preparation of fabrication work, preparing corrective action report, conducting stress relief process on
material, monitoring heat treatment process on welded material (pre-heat & PWHT),verifying marking
& development (design), verifying suitable of corrosion protection method, determining appropriate
corrosion protection method, determining appropriate work process for joint preparation and preparing
work report for other activities related to fabrication project in accordance to BS/AWS standards.
13. Mode of Delivery (e.g. Lecture, Tutorial, Workshop, Seminar etc):
Lecture, Practical, Student Centred Learning, and Guided Project

14. Assessment Methods and Types:

Quiz, Test, Practical Work, Final Examination ( Theory and Practical)

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15. Mapping of the course to the Programme Educational Objectives (PEO):

PEO1 PEO2 PEO3 PEO4

X X
16. Mapping of the course to the Programme Learning Outcomes (PLO):

PLO1 PLO2 PLO3 PLO4 PLO5 PLO6 PLO7 PLO8 PLO9

X X X

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17. Content outline of the course and the SLT (lecture hours) per topic:

SLT (hrs)

Non F2F
Face to Face (F2F)

Total (hours)

Assessment
Week Topic

Test & Exam

Self-Study
Practical
Tutorial
Theory
1 1.0 Standard Jigs And Fixtures
1.1 types of jigs and fixtures for
related welding fabrication 2 - 2 1 3 8 Quiz, Test,
work Practical test,
1.2 function of jigs and fixtures Individual
Assignment
for related welding and
fabrication work
1.3 basic heat transfer due to
welding

2-4 2.0 Jigs And Fixtures Design For

Welding Fabrication
2.1 design for jigs & fixtures in
accordance to the jig and
fixtures design and
specification.
2.2 engineering drawing of jig
21
and fixtures design
6 - 6 2 7 Quiz, Test,
specification.
Practical test,
2.3 tolerance and joint fit-up in Individual
accordance to work Assignment
requirement.
2.3 technical drawing for jigs &
fixtures design in
accordance to product
specification.
2.4 jigs & fixtures installation

5 3.0 Predictive & Corrective Action

Method Related To Pre-
Preparation Of Fabrication Work

4
 3.1 non-conformance work of
engineering practice
requirement for pre-
3.2 preparation of fabrication
work
3.3 corrective action to
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overcome previous non-
conformance work
3.4 methods of making 2 - 2 1 3 Quiz, Test,
predictive projection Practical test,
Individual
3.5 non-conformance of fit-up,
Assignment
orientation, dimension,
profile etc.
3.6 preventive actions methods
3.7 economic approach
assessment for predictive
& corrective action.

6 4.0 Corrective Action Report

4.1 non-conformance and
characteristics of defects in 2 - 2 1 3 8 Quiz, Test,
accordance to the Practical test,
corrective action report Individual
Assignment
specification standard.
4.2 tolerance of acceptability of
defect according to
BS/AWS
4.3 causes of imperfection
according to BS/ AWS.
4.4 imperfection evaluation
and acceptance or
rejection based on code &
standard according to
BS/AWS

7-8 5.0 Stress Relief Process On Material

5.1 Identify material
mechanical properties in 4 - 4 2 7 21 Quiz, Test,
accordance to stress relief Practical test,
5.2 work requirement standard. Individual
stresses in welding – Assignment
5.3 caused, prevention and
rectification; effect on
weldment
Iron carbon phase
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 5.4 diagram.
Stress relief technique and
5.5 procedure –oven, coil,
flame & mechanical
Techniques in accordance
5.6 to stress relief work
requirement standard.
Chart configuration, unit
5.7 Heat, range and time
5.8 duration.
stress relief operation in
accordance to standard
procedures.
stress relief chart.
design stress from mill
certificate.

9 6.0 Heat Treatment Process On

Welded Material (Pre-Heat & 2 - 2 1 3 8 Quiz, Test,
PWHT) Practical test,
Individual
6.1 type and purpose of heat
Assignment
treatment – annealing,
tampering, hardening,
quenching, case hardening
etc.

6.2 material mechanical

properties.
6.3 stress relief techniques and
procedure using – oven,
coil and flame.
6.4 chart configuration, unit
heat range and time
duration.
6.5 carbon equivalence.
6.6 heat treatment process
procedure and operation

10 7.0 Marking And Development

(Design)
7.1 Engineering drawing and 2 - 2 1 3 8 Quiz, Test,
symbols Practical test,
7.2 Fitting and tolerances Individual

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 7.3 Joints and configuration in Assignment
accordance to marking and
development design
standard interpreting
requirements.
7.4 Fabrication processes in
accordance to marking and
development design
standard interpreting
requirements.
7.5 process of marking, fit-up
work and development.

11 8.0 Suitability Of Corrosion Protection

Method 2 - 2 1 3 8 Quiz, Test,
8.1 type of corrosion in Practical test,
Individual
accordance to code &
Assignment
practice
8.2 material properties in
accordance to standard
corrosion protection
method requirement.
8.3 type of corrosion protection
methods – current, anodic
& cathodic protection &
surface
8.4 various causes and form of
corrosion in accordance to
standard corrosion
protection method
requirement
8.5 surface preparation,
surface protection
treatment in accordance
to standard corrosion
protection method
8.6 requirement
statutory requirement on
handling, using and
disposal of toxic-based
8.7 paint and solvent
8.8 type of corrosion
various types of
instrument/equipment to
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 measure thickness and
profile of surface coating

12 9.0 Corrosion Protection Method

Quiz, Test,
2 - 2 1 3 Practical test,
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9.1 material properties in Individual
accordance to code and Assignment
standard specific
requirement.
9.2 type of corrosion protection
methods : electroplating,
natural oxidation, blasting
painting, fusion bond-up,
galvanizing, metal spray
and dissimilar metal
cladding of corrosion
9.3 surface protection
9.4 treatment statutory
requirement on handling,
using and disposal of toxic-
based and solvent
9.5 method and techniques of
corrosion protection
9.6 measure thickness and
profile of surface coating

13 10.0 Work Processes For Joint

Preparation 2 - 2 1 3 8 Quiz, Test,
10.1 machining processes – Practical test,
milling, turning, grinding, Individual
Assignment
drilling/boring, bevel
cutting, sawing, guillotine
10.2 etc.
cutting processes – flame
cutting, plasma cutting,
hydro jet cutting laser
10.3 cutting etc.
methods and techniques of
10.4 gouging process
joint configuration and
10.5 symbols
10.6 joint tolerances
engineering drawing
8
 interpretation

14 11.0 Work Report Preparation For

Other Activities Related To
Fabrication Project 2 - 2 1 3 Quiz, Test,
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11.1 progress of work Practical test,
11.2 manpower utilization in Individual
accordance to quality Assignment
assurance requirement
11.3 costing involved in
fabrication project
11.4 work scheduling
11.5 safety reporting procedure
in accordance to OSHA
11.6 contract administration
related to fabrication work
in accordance to quality
assurance requirement
11.7 personnel qualification
(welding) in accordance to
quality assurance
requirement
11.8 facility requirement
11.9 progress of work and
contract requirement
related to fabrication work

15 Study week
16 Final exam (Teori) 2 2

17 Final exam (Amali) 2 2

TOTAL 28 - 28 13 51 120
Notional hours 40
Credit Value 3

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18. Main and additional references supporting the course:

1. MODERN WELDING
Author : Andrew D. Althouse, Carl H.Turnquist, William A. Bowditch, Kevin E. Bowditch, Mark
A.Bowditch
2. AUDEL WELDING POCKET REFERENCE
3. READY, SET, WELD BEGINNER-FRIENDLY
PROJECTS FOR THE HOME & GARDEN
Author : Kimberli Matin
4. WELDERS HANDBOOK, REVISED HP1513
A GUIDE TO PLASMA CUTTING, OXYACETYLENE,ARC,MIG AND TIG WELDING
Author : Richard Finch
5. MODUL PEMBELAJARAN MTK8033

19. Other additional information: -

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