Course Objectives

• Understanding the role and responsibilities of the welding supervisor.
• Understanding of knowledge of drawing in welding.
• Understanding of modelling of welded parts.
• Understanding of large scale production units.
• Understanding of advanced welding processes.
• Understanding of different methods of inspection.

Learning Outcomes

Students will be able to:

• Interpret the complex drawings.
• Manage the material and manpower effectively.
• Perform the design and analysis of different parts to be joined and welded pieces.
• Explain the end to end process of large scale production line.
• Perform the advanced welding processes.
• Perform the destructive testings.
• Perform the non-destructive testings and inspections.

Course Syllabus

MODULE I

Complex Drawings, Sectional Views and its interpretation: Role and responsibilities of welding supervisors. Basic Principles of geometry and drawing. Analysis of complex drawings, sectional views. Interpretation of complex drawings into suitable designs. Materials used for various welding processes and their properties. Material calculation for specific welding methods. Shop floor operation management. Different initiatives and their implementation.

PRACTICE:

• Practice on Engineering drawing from the given data.
• Practice on analysis of Complex drawings.
• Practice on Engineering drawing of sectional views.

MODULE II

Design, Modelling and Analysis of Welding Parts: Definition, designing automobile parts: steel body, fuel tank, half axle and piston rod. Designing transformer parts: tank/body, conservator, cooling tubes. Designing Boilers and Pressure Vessels. Design of pipes.

PRACTICE:

• Design and analysis of an Automobile body using CATIA/ ANSYS.
• Design and analysis of an Automobile fuel tank using CATIA/ ANSYS.
• Design and analysis of Transformer tank/body using CATIA/ ANSYS.
• Design and analysis of Transformer conservator using CATIA/ ANSYS.
• Design and analysis of Pressure vessel using CATIA/ ANSYS.

MODULE III

Large Scale Production Unit Management: Definition, Transformer Manufacturing unit: End to end observation of welding products of transformer unit, quality control, material management and manpower management. Fabrication Unit: End to end observation of welding products: automobile body parts, storage tanks, bulk containers, Data sheet analysis and management.

FIELD STUDY:

• Transformer Manufacturing Unit Visit and Analysis
• Fabrication Unit Visit and Analysis

PRACTICE:

• Practice on producing transformer body by TIG welding.
• Practice on producing automobile body by TIG welding.
• Practice on producing storage tank by TIG welding.
• Practice on material and manpower management.

MODULE IV

Advanced Welding Processes: Definition, Laser beam welding, Electron beam welding, Ultrasonic welding and Explosive welding.

PRACTICE:

• Practice using Laser beam welding.
• Practice using Electron beam welding.
• Practice using Explosive welding.

MODULE V

Testing and Inspection: Introduction, Non-Destructive testing: Visual Inspection, Magnetic Particle Inspection, Liquid Penetrant Inspection, Radiographic Inspection, Ultrasonic Inspection, Eddy Current Testing. Destructive testing: Free-Bend Test, Impact Test, Hardness Test, Tensile Strength Test, Etching Test.

PRACTICE:

• Practice of Bending test of welded piece.
• Practice of Impact test of welded piece.
• Practice of Tensile test of welded piece.
• Practice of Hardness test of welded piece.
• Practice of Etching test of welded piece.
• Practice of Liquid penetrant inspection of welded piece.
• Practice of Ultrasonic inspection of welded piece.
• Practice of Radiographic inspection of welded piece.
• Practice of Magnetic particle inspection of welded piece.

MODULE VI

PROJECTS:

• Projects based on Transformer Manufacturing using welding.
• Projects based on Automobile body Manufacturing using welding.
• Projects based on Pressure vessel Manufacturing using welding.
• Projects based on Casting of alloys, its application for welding.
• Projects based upon the advanced welding processes.
• Projects based on Destructive testings of newly manufactured alloy used in welding.
• Projects based on Non-Destructive testings of newly manufactured alloy used in welding.
• Project based on Laser beam welding.
• Project based on Electron beam welding.
• Project based on Explosive welding.

Session Plan

Session 1

LECTURE:

Role and responsibilities of welding supervisors. Basic Principles of geometry and drawing. Analysis of complex drawings, sectional views. Interpretation of complex drawings into suitable designs.

WEB LINKS:

The Basics of Reading Engineering Drawings 

Session 2

PRACTICE:

Practice on Engineering drawing from the given data.

Session 3

PRACTICE:

Practice on analysis of Complex drawings.

Session 4

PRACTICE:

Practice on Engineering drawing of sectional views.

WEB LINKS:

Sectional Views 

Session 5

LECTURE:

Materials used for various welding processes and their properties. Material calculation for specific welding methods. Shop floor operation management. Different initiatives and their implementation.

WEB LINKS:

Welding Materials 

Session 6

LECTURE:

Designing automobile parts: steel body, fuel tank, half axle and piston rod.

PRACTICE:

Design and analysis of an Automobile body using CATIA/ ANSYS.

WEB LINKS:

HOW TO DESIGN CAR BODY USING CATIA 

Session 7

PRACTICE:

Design and analysis of an Automobile fuel tank using CATIA/ ANSYS.

WEB LINKS:

Fuel Tank Design By CATIA

Session 8

LECTURE:

Designing transformer parts: tank/body, conservator, cooling tubes.

PRACTICE:

Design and analysis of Transformer tank/body using CATIA/ ANSYS.

Session 9

PRACTICE:

Design and analysis of Transformer conservator using CATIA/ ANSYS.

Session 10

LECTURE:

Designing Boilers and Pressure Vessels.

Design of pipes.

WEB LINKS:

Pressure Vessel Design 

Session 11

PRACTICE:

Design and analysis of Pressure vessel using CATIA/ ANSYS.

WEB LINKS:

Pressure vessel in catia 

Session 12

LECTURE:

Transformer Manufacturing unit: End to end observation of welding products of transformer unit, quality control, material management and manpower management.

FIELD STUDY:

Transformer Manufacturing Unit Visit and Analysis

Session 13

PRACTICE:

Practice on producing transformer body by TIG welding.

Session 14

LECTURE:

Fabrication Unit: End to end observation of welding products: automobile body parts, storage tanks, bulk containers, Data sheet analysis and management.

FIELD STUDY:
Fabrication Unit Visit and Analysis

Session 15

PRACTICE:

Practice on producing automobile body by TIG welding.

WEB LINKS:

BMW Spartanburg Welding Body Shop

Session 16

PRACTICE:

Practice on producing storage tank by TIG welding.

WEB LINKS:

Making Simple Steel Storage while Learning to Weld 

Session 17

PRACTICE:

Practice on material and manpower management.

Session 18

LECTURE:

Advanced Welding Processes: Definition, Laser beam welding, Electron beam welding, Ultrasonic welding and Explosive welding.

WEB LINKS:

Electron Beam Welding

Laser Beam Welding

Ultrasonic Welding Process 

Session 19

PRACTICE:

Practice using Laser beam welding.

WEB LINKS:

Laser Beam Welding

hand held laser welding machine 

Session 20

PRACTICE:

Practice using Electron beam welding.

WEB LINKS:

Electron beam welding 

Session 21

PRACTICE:

Practice using Explosive welding.

WEB LINKS:

The Process of Explosion Welding

Session 22

LECTURE:

Non-Destructive testing: Visual Inspection, Magnetic Particle Inspection, Liquid Penetrant Inspection, Radiographic Inspection, Ultrasonic Inspection, Eddy Current Testing.

WEB LINKS:

Non Destructive Testing Methods 

Session 23

LECTURE:

Destructive testing: Free-Bend Test, Impact Test, Hardness Test, Tensile Strength Test, Etching Test.

WEB LINKS:

Destructive Testing 

Session 24

PRACTICE:

Practice of Bending test of welded piece.

WEB LINKS:

Bending Test 

Session 25

PRACTICE:

Practice of Impact test of welded piece.

WEB LINKS:

Charpy Impact Test 

Session 26

PRACTICE:

Practice of Tensile test of welded piece.

WEB LINKS:

Tensile Testing a Stainless Steel  

Session 27

PRACTICE:

Practice of Hardness test of welded piece.

WEB LINKS:

Brinell Hardness Test

Rockwell Hardness Test 

Session 28

PRACTICE:

Practice of Etching test of welded piece.

WEB LINKS:

Weld Etching Test 

Session 29

PRACTICE:

Practice of Liquid penetrant inspection of welded piece.

WEB LINKS:

Liquid Penetrant Testing, Welding Inspection

Session 30

PRACTICE:

Practice of Ultrasonic inspection of welded piece.

WEB LINKS:

Ultrasonic Testing on Pipe Welding 

Session 31

PRACTICE:

Practice of Radiographic inspection of welded piece.

WEB LINKS:

Radiographic Testing (NDT) 

Session 32

PRACTICE:

Practice of Magnetic particle inspection of welded piece.

WEB LINKS:

Magnetic Particle testing (NDT) 

Session 33

PROJECTS:

Projects based on Transformer Manufacturing using welding.

Session 34

PROJECTS:

Projects based on Automobile body Manufacturing using welding.

Session 35

PROJECT:

Projects based on Pressure vessel Manufacturing using welding.

Session 36

PROJECT:

Projects based on Casting of alloys, its application for welding.

Session 37

PROJECT:

Projects based upon the Ultrasonic welding inspection.

Session 38

PROJECT:

Projects based on Destructive testings of newly manufactured alloy used in welding.

Session 39

PROJECT:

Projects based on Non-Destructive testings of newly manufactured alloy used in welding.

Session 40

PROJECT:

Project based on Laser beam welding.

Session 41

PROJECT:

Project based on Electron beam welding.

Session 42

PROJECT:

Project based on Explosive welding.

Case Studies

Case Studies