RRB ALP Welder Trade Syllabus

The RRB ALP CBT 2 Part B -- Welder trade syllabus covers the core technical knowledge tested in the 75-question, 60-minute trade-specific section of the RRB ALP 2027 examination. Part B is qualifying in nature only: candidates must score a minimum of 35% (26.25 marks out of 75) to clear Part B. The marks scored in Part B are NOT added to the final merit list. Merit is determined entirely by CBT 2 Part A scores. The syllabus for Part B is based on the NCVT (National Council for Vocational Training) ITI curriculum for the Welder trade at the ITI certificate level.

Quick Facts: ALP Welder Trade

Important Note on Part B

CBT 2 Part B is qualifying only. A candidate who scores below 35% in Part B is eliminated regardless of their Part A score. However, a candidate who clears the 35% threshold in Part B is ranked exclusively on their CBT 2 Part A score. This makes Part B preparation essential for elimination prevention, while Part A preparation determines the final rank. Candidates should ensure they are thoroughly familiar with the Welder trade theory and practical knowledge at the ITI level before the examination.

Detailed Welder Trade Syllabus (Part B)

The Welder trade syllabus for RRB ALP CBT 2 Part B is drawn from the NCVT ITI curriculum and tests trade theory, applied knowledge, and practical understanding across the following topic areas:

1. Engineering Drawing for Welders

•        Drawing Reading: orthographic views; sectional views; isometric drawing; dimensioning

•        Weld Symbols: AWS A2.4 and ISO 2553; weld symbol components (reference line, arrow, weld symbol, tail, supplementary symbols); reading weld symbols on drawings

•        Joint Preparation Symbols: bevel angle; root gap; root face; root radius; groove dimensions

2. Metallurgy for Welders

•        Crystal Structure of Metals: BCC; FCC; HCP; grain structure; grain boundary; grain growth

•        Iron-Carbon Phase Diagram: phases (ferrite, austenite, cementite, pearlite, martensite); eutectic and eutectoid reactions; classification of steel by carbon content

•        Heat Treatment: annealing; normalising; hardening; tempering; case hardening; effects on weldability

•        Weldability of Metals: mild steel; medium and high carbon steel (preheat requirements); stainless steel (sensitisation, intergranular corrosion); aluminium; copper; cast iron -- weldability factors and precautions

•        Preheating and Interpass Temperature: purpose; calculation of preheat (carbon equivalent); measurement; maintenance

•        Post Weld Heat Treatment (PWHT): purpose; temperature range; soaking time; cooling rate; effect on residual stresses

•        Heat Affected Zone (HAZ): formation; grain growth; hardening; softening; width; control measures

3. Shielded Metal Arc Welding (SMAW / Manual Metal Arc Welding)

•        SMAW Equipment: AC and DC welding machines (transformer, rectifier, generator, inverter); OCV and arc voltage; duty cycle; rating; polarity (DCEP, DCEN, AC)

•        Electrodes: composition (core wire, flux coating); types of coating (cellulosic, rutile, basic, iron powder); IS 814 classification; AWS A5.1 classification; selection criteria (base metal, position, strength, impact); storage (drying for basic electrodes)

•        Arc Striking and Arc Length: scratch and tapping methods; optimum arc length; effect of long and short arc; arc blow

•        Welding Positions: flat (1G, 1F); horizontal (2G, 2F); vertical (3G, 3F -- upward and downward); overhead (4G, 4F); position qualification

•        Joint Types: butt; tee; corner; lap; edge; joint preparation for different thicknesses

•        Welding Technique: angle of electrode; angle of travel; weaving patterns (zig-zag, C, J, triangular); weld pass sequence (root, fill, cap)

•        Common SMAW Defects: porosity; undercut; overlap; incomplete penetration; incomplete fusion; cracks (hot, cold, crater); slag inclusion; arc strike -- causes and prevention

4. Gas Welding and Cutting

•        Oxygen-Acetylene Welding: equipment (cylinders, regulators, hoses, blowpipe, nozzles); flame types (neutral, oxidising, carburising); applications

•        Welding Technique: leftward and rightward welding; filler rod selection; joint preparation

•        Gas Cutting (Oxy-Fuel Cutting): principle; equipment; cutting nozzle; preheat; cutting speed; cutting oxygen pressure; kerf; cut quality; plasma cutting basics

•        Brazing and Soldering: definition; filler materials; fluxes; types (torch, furnace, dip, induction); joint clearance; capillary action; applications; silver brazing; soft soldering

•        Gas Welding Safety: cylinder handling; storage; manifold systems; flashback and backfire; safe working distance; PPE

5. MIG/MAG Welding (GMAW)

•        GMAW Equipment: welding machine (constant voltage); wire feeder; welding gun; contact tip; liner; drive rolls; gas cylinder and regulator

•        Shielding Gases: argon (MIG); CO2 (MAG); argon-CO2 mixtures; argon-O2 mixtures; effect on arc, bead shape, spatter, penetration

•        Wire Electrodes: solid wire; flux-cored wire; classification (AWS A5.18, AWS A5.20); selection

•        Process Variables: wire feed speed (controls current); arc voltage; travel speed; shielding gas flow rate; stick-out; contact-to-work distance

•        Transfer Modes: short circuit (dip transfer); globular; spray; pulsed spray -- conditions and applications

•        Common GMAW Defects: porosity; spatter; burnthrough; lack of fusion; undercut; causes and remedies

6. TIG Welding (GTAW)

•        GTAW Equipment: TIG welding machine; HF arc starter; torches (air-cooled, water-cooled); tungsten electrodes (classifications -- EWP, EWTH-2, EWLA-2; diameter selection; tip preparation); filler rods

•        Shielding Gases: argon; helium; argon-helium; argon-hydrogen; selection based on material

•        Polarity: DCEN (DC electrode negative) for steel and stainless; DCEP (DC electrode positive); AC for aluminium (cleaning action)

•        GTAW Technique: torch angle; travel speed; filler rod addition; hand position; contamination avoidance; back purging for stainless steel

•        Applications: precision welding of thin materials; aerospace; stainless steel; aluminium; titanium

7. Welding Inspection and Quality Control

•        Visual Inspection: criteria per IS/ASME/AWS; inspection tools (fillet weld gauge, pit gauge, undercut gauge, weld ruler)

•        Non-Destructive Testing: Dye Penetrant Testing (DPT/PT) -- procedure, developer, indications; Magnetic Particle Testing (MPT) -- yoke, coil, indications; Ultrasonic Testing (UT) -- A-scan, probe types; Radiographic Testing (RT) -- X-ray, gamma ray, film density, IQI; Eddy Current Testing (ET) basics

•        Destructive Testing: tensile test; bend test (face, root, side); impact test (Charpy, Izod); macro examination; hardness test; nick break test

•        Weld Defects (Classification): volumetric defects (porosity, inclusions); planar defects (cracks, lack of fusion, lack of penetration); dimensional defects (undercut, overlap, excess reinforcement); acceptance criteria

•        WPS and PQR: Welding Procedure Specification (WPS); Procedure Qualification Record (PQR); Welder Qualification Test (WQT) per ASME IX / IS 7307

8. Safety in Welding

•        Electrical Safety: earthing of welding equipment; insulated electrode holders; protection from electric shock; safe voltage

•        Fire and Explosion Hazards: hot work permit; fire watch; flammable gas cylinder safety; fire prevention in welding area

•        Fume and Gas Hazards: welding fumes composition; OEL (Occupational Exposure Limits); LEV (Local Exhaust Ventilation); RPE (respirator types -- half-face, full-face)

•        PPE for Welding: auto-darkening helmet; welding gloves; leather apron; spats; safety shoes; hearing protection; UV burn prevention

•        Working at Heights: scaffolding safety; welding safety harness; fire protection on elevated platforms

•        Confined Space Welding: hazards; oxygen deficiency and enrichment; purging and testing; attendant; rescue plan

Weightage Analysis and Preparation Strategy

The 75 Part B questions are drawn proportionally from across all major topic areas of the Welder trade curriculum. Questions test both theoretical knowledge (principles, formulae, definitions, standards, safety rules) and applied understanding (fault diagnosis, calculations, material selection, tool usage, quality checks). The following approach maximises Part B preparation efficiency:

•        Revise systematically from NCVT ITI Welder trade theory textbooks for Semester 1 and Semester 2

•        Focus on definitions, formulae, standards (BIS/IS codes), safety regulations, and technical specifications -- these are directly testable as MCQs

•        Practise numerical calculations relevant to the trade (e.g., circuit calculations for Electrician, speed/feed calculations for Fitter/Turner/Machinist)

•        Study common faults, their causes, symptoms, and remedies for all major equipment in the trade

•        Revise tools, instruments, and equipment used in the trade: their names, specifications, uses, and maintenance

•        Solve previous years' RRB ALP Part B question banks for your specific trade

•        Allocate 60 minutes of daily trade-specific study alongside Part A preparation throughout the preparation period

Frequently Asked Questions

Q1. Is CBT 2 Part B merit-based or qualifying?

CBT 2 Part B is qualifying only. A minimum score of 35% is required to pass Part B. The marks scored in Part B are not added to the merit list. Only Part A marks determine the final ranking.

Q2. What happens if a candidate fails Part B?

Candidates who score below 35% in Part B are disqualified regardless of their Part A performance. They will not be considered for Document Verification or further selection stages.

Q3. How should I divide study time between Part A and Part B?

Since Part A determines the final merit and Part B is qualifying, prioritise Part A in your preparation. However, allocate at least 30 to 40% of study time to Part B to ensure you comfortably clear the 35% qualifying threshold. Aiming for 50 to 55 marks (about 70%) in Part B provides a safe buffer.

Q4. Is the Part B syllabus the same as the ITI exam syllabus?

Yes. The RRB ALP Part B syllabus is directly based on the NCVT ITI curriculum for the relevant trade. Candidates who have completed their ITI in the relevant trade and revised their course material systematically are well positioned for Part B.