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TNPSC ITI Trade: Welder (Gas and Electric) (Code 440) Syllabus: A Comprehensive Guide

TNPSC ITI Trade: Welder (Gas and Electric) (Code 440) Syllabus: A Comprehensive Guide

"For aspirants preparing for the Tamil Nadu Public Service Commission (TNPSC) examinations for Trade: Welder (Gas and Electric) (ITI Standard, Subject Code 440), a precise understanding of the official syllabus is paramount. This trade encompasses fundamental welding processes, equipment, safety, and advanced techniques. This guide meticulously details each unit, outlining critical areas for effective preparation for the Combined Technical Services Examination (Diploma / ITI Level), as outlined in Notification No. 10/2025. The question paper for this subject will be available in both English and Tamil."

"Associated Post and Language"

  • "Post Name: Junior Training Officer (Welder)"
  • "Post Code: 3647"
  • "Number of Vacancies: 4"
  • "Question Paper Language: English and Tamil"

"Key Examination Details"

  • "Notification Issue Date: June 13, 2025"
  • "Online Application Last Date: July 12, 2025, at 11:59 PM."
  • "Application Correction Window: July 16, 2025, 12:01 AM to July 18, 2025, 11:59 PM (three days)."
  • "Paper I Examination: August 31, 2025, Forenoon (Tamil Eligibility Test, General Studies, Aptitude and Mental Ability, Subject Code 501)."
  • "Paper II Examination (Subject Paper 440): Broadly scheduled between September 7, 2025, and September 15, 2025. Exact date and time to be announced on the Commission's website."

"Examination Structure and Evaluation"

  • "Mandatory Appearance: Compulsory to appear for both Paper I and Paper II. Failure to do so will lead to disqualification."
  • "Paper I (SSLC Standard, OMR-based):
    • "Total: 100 objective questions, 150 marks."
    • "Part A: Tamil Eligibility Test (minimum 40% or 60 marks required to qualify)."
    • "Part B: General Studies (75 questions, Degree Standard)."
    • "Part C: Aptitude and Mental Ability (25 questions, SSLC Standard)."
    "
  • "Paper II (Subject Paper - Trade: Welder (Gas and Electric), ITI Standard, CBT):
    • "200 objective questions."
    • "Duration: 3 hours."
    • "Maximum Marks: 300."
    "
  • "Total Marks for Final Selection: 450 marks (Part B + Part C of Paper I + Paper II)."
  • "Evaluation Criteria: Paper II and Parts B and C of Paper I will be evaluated only if minimum qualifying marks in Part A of Paper I are secured."

"Eligibility Criteria for Junior Training Officer (Welder) - Post Code: 3647"

  • "Age Limit (as of July 1, 2025):
    • "Others: Maximum 32 years."
    • "Reserved Categories (BC, BCM, MBC/DC, SC, SCA, ST): No Maximum Age Limit."
    "
  • "Educational Qualification: Must have passed SSLC or its equivalent AND possess any one of the following:
    • "A Degree in Engineering / Technology in Mechanical / Metallurgy / Mechatronics / Production / Manufacturing from any institution / university recognized by AICTE / UGC."
    • "A Diploma in Mechanical and allied / Production / Manufacturing Engineering from any institution / university recognized by AICTE / UGC."
    • "A National Trade Certificate / National Apprenticeship Certificate in Welder."
    "
  • "Physical Standards: Vision Standard III or better. The post is identified as suitable for persons with benchmark disabilities of all categories."

"Official Syllabus Breakdown: TNPSC Trade - Welder (Gas and Electric) (Code 440)"

"The syllabus for Trade - Welder (Gas and Electric) at the I.T.I. Standard is structured into the following units. Aspirants should systematically cover these units for comprehensive preparation, noting that question distribution is indicative. This trade also integrates concepts from Workshop Calculation Science and Engineering Drawing."

"Unit I: Introduction and Definition of Welding (10 Questions)"

  • "Introduction to Welding: Historical overview, importance of welding in various industries."
  • "Definition of Welding: Principles of fusion welding, types of bonding."
  • "Welding Processes Overview: Brief introduction to gas welding, arc welding, resistance welding, and other common processes."
  • "Roles and Responsibilities of a Welder: Basic duties, safety considerations, and required skills."
  • "Welding Terms and Definitions: Basic terminology used in welding technology."

"Unit II: Welding Processes and Applications (10 Questions)"

  • "Classification of Welding Processes: Fusion welding, pressure welding."
  • "Specific Processes and Applications:
    • "Oxy-Acetylene Welding (OAW): Principles and common applications."
    • "Shielded Metal Arc Welding (SMAW): Basics, advantages, and typical uses."
    • "Gas Metal Arc Welding (GMAW / MIG/MAG): Introduction and applications."
    • "Gas Tungsten Arc Welding (GTAW / TIG): Introduction and applications."
    • "Resistance welding: Principles and types (spot, seam)."
    "
  • "Other Joining Methods: Bolting, riveting, soldering, brazing, seaming – their principles and differences from welding."

"Unit III: Set the Oxygen - Acetylene Gas Cutting Plant (OAGC) and Oxygen - Acetylene Welding (OAW) (10 Questions)"

  • "Oxy-Acetylene Gas Cutting (OAGC):
    • "Principles of gas cutting."
    • "Setting up the OAGC plant: Gas cylinders (oxygen, acetylene), regulators, hoses, cutting torch, nozzles."
    • "Safety precautions during gas cutting operations."
    • "Techniques for straight line and profile cutting."
    "
  • "Oxygen-Acetylene Welding (OAW):
    • "Setting up the OAW plant: Welding torch, filler rods, fluxes."
    • "Types of oxy-acetylene flames (neutral, oxidising, carburising) and their applications."
    • "Welding techniques: Rightward and leftward welding."
    • "Fusion runs with and without filler rod on different materials (e.g., Mild Steel - MS)."
    "

"Unit IV: Arc Welding Power Sources (20 Questions)"

  • "Types of Arc Welding Power Sources:
    • "Welding Transformers (AC welding machines)."
    • "Welding Rectifiers (DC welding machines)."
    • "Inverter type welding machines."
    "
  • "Characteristics of Power Sources: V-I characteristics, constant current (CC) vs. constant voltage (CV)."
  • "Advantages and Disadvantages: Comparison of AC and DC welding machines."
  • "Polarity: Direct Current Electrode Negative (DCEN) / Straight Polarity and Direct Current Electrode Positive (DCEP) / Reverse Polarity – their applications."
  • "Maintenance: Care and maintenance of arc welding power sources."

"Unit V: Arc Welding Positions (30 Questions)"

  • "Standard Welding Positions (as per AWS/ISO):
    • "Flat (1G/1F)."
    • "Horizontal (2G/2F)."
    • "Vertical (3G/3F)."
    • "Overhead (4G/4F)."
    "
  • "Joint Types: Butt joints (square, single V, double V) and Fillet joints (lap, T-joint, corner joint)."
  • "Techniques for Various Positions: Demonstrating and performing welding in all standard positions for both butt and fillet joints on Mild Steel (MS) plates."
  • "Weaving and Beading: Techniques for depositing straight line beads and weaved beads."
  • "Edge Preparation and Fit-up: Importance of proper edge preparation and fit-up for different material thicknesses."

"Unit VI: Gas Cylinders and Regulators (20 Questions)"

  • "Gas Cylinders:
    • "Types of gas cylinders used in welding (Oxygen, Acetylene, Argon, CO₂)."
    • "Colour coding for different gas cylinders (as per BIS/international standards)."
    • "Charging process of oxygen and acetylene gases."
    • "Safe handling, storage, and transportation of gas cylinders."
    • "Manifold systems for gas supply."
    "
  • "Gas Regulators:
    • "Types of regulators (single stage, double stage) and their working principles."
    • "Uses of gas regulators for controlling gas pressure and flow."
    "
  • "Flashback Arrestors and Hydraulic Back Pressure Valves: Their function and importance in safety."

"Unit VII: SMAW Defects (20 Questions)"

  • "Welding Defects: Understanding common defects in Shielded Metal Arc Welding (SMAW)."
  • "Types of Defects:
    • "Porosity and blowholes (causes and remedies)."
    • "Cracks (hot cracks, cold cracks, crater cracks – causes and prevention)."
    • "Incomplete fusion, incomplete penetration."
    • "Undercut, overlap, excessive reinforcement."
    • "Slag inclusions, spatter, arc blow."
    • "Distortion in welding and methods to minimise distortion."
    "
  • "Causes and Remedies: Identifying the causes of defects and implementing corrective measures."
  • "Good vs. Defective Welds: Visual inspection for distinguishing between good quality welds and defective welds."

"Unit VIII: Arc Welding Electrode (20 Questions)"

  • "Arc Welding Electrodes:
    • "Types of electrodes (e.g., cellulose, rutile, basic) and their composition."
    • "Functions of flux coating: Arc stabilisation, shielding, slag formation, deoxidation."
    • "Coating factor."
    • "Sizes of electrodes."
    "
  • "Electrode Coding: Classification and coding of electrodes as per BIS, AWS (American Welding Society), and BS (British Standard) standards."
  • "Moisture Pick-up: Effects of moisture pick-up on electrodes and baking/drying procedures for electrodes."
  • "Storage and Handling: Proper methods for storage and handling of welding electrodes."
  • "Filler Rods: Gas welding filler rods, specifications, and sizes."

"Unit IX: Testing Welded Joints by Different Method of Testing (10 Questions)"

  • "Purpose of Weld Testing: Ensuring weld quality and structural integrity."
  • "Destructive Testing Methods:
    • "Tensile test."
    • "Bend test (face bend, root bend)."
    • "Impact test (Charpy, Izod)."
    • "Hardness test."
    • "Fracture toughness test."
    "
  • "Non-Destructive Testing (NDT) Methods:
    • "Visual Inspection: Weld gauges and their uses."
    • "Dye Penetrant Testing (DPT)."
    • "Magnetic Particle Testing (MPT)."
    • "Ultrasonic Testing (UT)."
    • "Radiographic Testing (RT)."
    "
  • "Weld Quality Inspection: General principles and importance."

"Unit X: Gas Tungsten Arc Welding (GTAW) & Gas Metal Arc Welding (GMAW) (CO₂) Welding Process (40 Questions)"

  • "Gas Tungsten Arc Welding (GTAW / TIG):
    • "Principle of operation (non-consumable electrode)."
    • "Equipment: GTAW torch, tungsten electrodes (types, grinding), shielding gases (argon, helium), power sources."
    • "Applications (e.g., stainless steel, aluminium, thin sheets, root pass)."
    • "Purging techniques for GTAW."
    "
  • "Gas Metal Arc Welding (GMAW / MIG/MAG / CO₂ welding):
    • "Principle of operation (consumable electrode)."
    • "Equipment: GMAW torch, wire feeder, wire electrodes (types, sizes), shielding gases (CO₂, Argon-CO₂ mixtures, Argon), contact tip, gas nozzle."
    • "Process variables and modes of metal transfer (short-circuit, globular, spray)."
    • "Applications (e.g., mild steel, stainless steel, high deposition rates)."
    • "Pre-heater usage for CO₂ as shielding gas."
    "
  • "Comparison of GTAW and GMAW: Advantages and disadvantages of each process."
  • "Related Core Skills: This unit also includes concepts from Workshop Calculation Science (e.g., material calculations, heat transfer in welding) and Engineering Drawing (e.g., reading welding symbols, interpreting fabrication drawings, sketching weld joints) relevant to these advanced processes."
"Important Note for Aspirants: This comprehensive syllabus for Trade: Welder (Gas and Electric) (Code 440) at the ITI Standard provides a robust framework for examination preparation for the Junior Training Officer (Welder) role. Aspirants are strongly advised to meticulously cover all topics, focusing on both theoretical understanding and practical applications of various welding processes, safety procedures, and quality control. Consistent revision and hands-on practice are essential for success in this competitive examination."

"Success in the TNPSC Trade: Welder (Gas and Electric) (Code 440) examination requires a disciplined and strategic approach. By gaining a strong command of welding fundamentals, mastering different welding processes, understanding equipment operation and maintenance, and adhering to strict safety protocols, aspirants can significantly enhance their performance and achieve their career objectives in the fabrication and welding industry."

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