Course Objectives

• Understanding the classification of welding processes.
• Understanding the welding safety.
• Understanding the processes of  TIG welding.
• Understanding the processes of MIG welding.
• Understanding the processes of Pipe welding.
• Understanding the processes of Sheet Metal welding.

Learning Outcomes

Students will be able to:

• Identify the requirements of different types of welding.
• Monitor the defects of the welded product.
• Perform the TIG welding.
• Perform the MIG welding.
• Perform the Pipe welding.
• Perform the Sheet metal welding.

Course Syllabus

MODULE I

Classifications of Welding: Plastic Welding, Fusion Welding. Gas welding i. Oxyacetylene ii. Air-acetylene iii. Oxy-hydrogen. Arc Welding i. Carbon Arc ii. Metal Arc iii. Gas Metal Arc ( MIG) iv. Gas Tungsten Arc(TIG) v. Atomic-hydrogen arc vi. Plasma Arc vii. Submerged Arc weldingviii. Flux-cored arc ix. Electro-slag. Resistance welding i. Butt welding ii. Spot welding iii. Seam welding iv. Projection welding v. Percussion welding. Solid State welding i. Friction ii. Ultrasonic iii. Diffusion iv. Explosive. Newer Welding Processes i. Electron Beam ii. Laser. Thermit welding. Related processes i. Oxyacetylene cutting ii. Arc cutting iii. Hard facing iv. Brazing v. Soldering.

Safety in Welding: Introduction of Occupational Safety and Health Administration(OSHA), Material Safety and Data Sheet(MSDC), face, eye, and ear protection, respiratory protection ,special protection clothing, fire protection and electricity safety.

PRACTICE:

• Practice on Welding Safety.

MODULE II

TIG Welding: Definition, TIG Arc, materials for TIG welding, equipment, TIG Torch, cooling of the TIG Torch, the gas nozzle, the power source, electrodes for TIG welding and dimensions, shielding gases, welding fumes and gases, hygienic limit values, filler materials, welding defects, the heat-affected zone(HAZ). Applications, advantages and limitations.

PRACTICE:

• Practice of  butt joint using TIG welding.
• Practice of  lap joint using TIG welding.
• Practice of  tee joint using TIG welding.
• Practice of flat position welding using TIG welding.
• Practice on TIG welding defects identification from welded piece.

MODULE III

MIG Welding: Definition, power source, equipment, the wire-feed unit, the MIG torch, shielding gas, metal transfer across the arc, welding process variables: welding current, welding voltage, travel speed, wire electrode size, electrode extension, electrode angle, weld joint position. Joint types and joint preparation. MIG welding Troubleshooting: causes and remedies. Applications, advantages and limitations.

PRACTICE:

• Practice of  butt joint using MIG welding.
• Practice of vertical position butt joint using MIG welding.
• Practice of horizontal position lap joint using MIG welding.
• Practice of over head position tee joint using MIG welding.
• Practice on MIG welding defects identification from welded piece.

MODULE IV

Pipe Welding: Introduction, welding process & method, base material, filler metal classification & size, joint geometry, position & direction of welding, preheating, inter pass temperature & controlled cooling, post weld heat treatment, shielding gas, electrical characteristics, removal and repair of defects.

PRACTICE:

• Pipe welding - elbow joint on ms pipe (TIG welding).
• Pipe welding "T" Joint on ms pipe (TIG welding).
• Pipe welding 45 ° angle joint on ms pipe(MIG welding).
• Pipe butt joint.(MIG welding).

MODULE V

Joining of Sheet Metals and Stainless steels Using Welding: Introduction, Basics of welding thin sheets and stainless steel, welding method used.

PRACTICE:

• Square Butt joint on S.S. sheet. of 2 mm thick(GTAW).
• Square Butt joint on Brass sheet of 2 mm thick(GTAW). 
• Square Butt & Lap joint on M.S. sheet of 2 mm thick by brazing. 
• Practice on Aluminium sheet welding.

MODULE VI

PROJECTS:

• Projects based on TIG welding.
• Projects based on MIG welding.
• Project on pipe joint using TIG welding.
• Project on stainless steel welding.

Session Plan

Session 1

LECTURE:

Classifications of Welding: Plastic Welding, Fusion Welding. Gas welding i. Oxyacetylene ii. Air-acetylene iii. Oxy-hydrogen. Arc Welding i. Carbon Arc ii. Metal Arc iii. Gas Metal Arc ( MIG) iv. Gas Tungsten Arc(TIG) v. Atomic-hydrogen arc vi. Plasma Arc vii. Submerged Arc welding viii. Flux-cored arc ix. Electro-slag. Resistance welding i. Butt welding ii. Spot welding iii. Seam welding iv. Projection welding v. Percussion welding. Solid State welding i. Friction ii. Ultrasonic iii. Diffusion iv. Explosive. Newer Welding Processes i. Electron Beam ii. Laser. Thermit welding. Related processes i. Oxyacetylene cutting ii. Arc cutting iii. Hard facing iv. Brazing v. Soldering.

WEB LINKS:

Welding and its Classificaton

Session 2

LECTURE:

Safety in Welding: Introduction of Occupational Safety and Health Administration(OSHA), Material Safety and Data Sheet(MSDC), face, eye, and ear protection, respiratory protection ,special protection clothing, fire protection and electricity safety.

WEB LINKS:

Welding Safety

Session 3

PRACTICE:

Practice on Welding Safety.

WEB LINKS:

Welding Safety Tips 

Session 4

LECTURE:

TIG Welding: Definition, TIG Arc, materials for TIG welding, equipment, TIG Torch, cooling of the TIG Torch, the gas nozzle, the power source, electrodes for TIG welding and dimensions, shielding gases, welding fumes and gases, hygienic limit values, filler materials, welding defects, the heat-affected zone(HAZ). Applications, advantages and limitations.

WEB LINKS:

TIG Welding

Session 5

PRACTICE:

Practice of  butt joint using TIG welding.

WEB LINKS:

TIG-Butt Weld Practice 

Session 6

PRACTICE:

Practice of  lap joint using TIG welding.

WEB LINKS:

TIG Welding - Lap Joint

Session 7

PRACTICE:

Practice of  tee joint using TIG welding.

WEB LINKS:

Tee or Fillet Welding

Session 8

PRACTICE:

Practice of flat position welding using TIG welding.

Session 9

LECTURE:

Practice on TIG welding defects identification from welded piece.

WEB LINKS:

TIG Welding Troubleshooting 

Session 10

LECTURE:

MIG Welding: Definition, power source, equipment, the wire-feed unit, the MIG torch, shielding gas, metal transfer across the arc, welding process variables: welding current, welding voltage, travel speed, wire electrode size, electrode extension, electrode angle, weld joint position. Joint types and joint preparation. MIG welding Troubleshooting: causes and remedies. Applications, advantages and limitations.

WEB LINKS:

Intro_MIG_Welding

Session 11

PRACTICE:

Practice of  butt joint using MIG welding.

WEB LINKS:

BUTT JOINT MIG WELDING

Session 12

PRACTICE:

Practice of vertical position butt joint using MIG welding.

WEB LINKS:

MIG Welding Downhill Butt

Session 13

PRACTICE:

Practice of horizontal position lap joint using MIG welding.

Session 14

PRACTICE:

Practice of over head position tee joint using MIG welding.

WEB LINKS:

MIG Welding Overhead T joint 

Session 15

PRACTICE:

Practice on MIG welding defects identification from welded piece.

WEB LINKS:

Welding Defects

Session 16

LECTURE:

Pipe Welding: Introduction, welding process & method, base material, filler metal classification & size, joint geometry, position & direction of welding, preheating, inter pass temperature & controlled cooling, post weld heat treatment, shielding gas, electrical characteristics, removal and repair of defects.

WEB LINKS:

Pipeline Welding 

Session 17

PRACTICE:

Pipe welding - elbow joint on ms pipe (TIG welding).

WEB LINKS:

How-To Weld Elbow Joints Easily

Session 18

PRACTICE:

Pipe welding "T" Joint on ms pipe (TIG welding).

WEB LINKS:

TIG Welding T-Joint 

Session 19

PRACTICE:

Pipe welding 45 ° angle joint on ms pipe (MIG welding).

WEB LINKS:

MIG Pipe Welding

Session 20

PRACTICE:

Pipe butt joint.(MIG welding).

WEB LINKS:

Butt welding of Pipes 

Session 21

LECTURE:

Joining of Sheet Metals and Stainless steels Using Welding: Introduction, Basics of welding thin sheets and stainless steel, welding method used.

PRACTICE:

Square Butt joint on S.S. sheet. of 2 mm thick (GTAW).

WEB LINKS:

Stainless Steel Butt Joint 

Session 22

PRACTICE:

Square Butt joint on Brass sheet of 2 mm thick (GTAW).

WEB LINKS:

TIG Welding Brass 

Session 23

PRACTICE:

Square Butt & Lap joint on M.S. sheet of 2 mm thick by brazing.

WEB LINKS:
Brazing Thin Materials

Session 24

PRACTICE:

Practice on Aluminium sheet welding.

WEB LINKS:

Aluminum Sheet Metal Welding

Session 25

PROJECT:

Projects based on TIG welding.

Session 26

PROJECT:

Projects based on MIG welding.

Session 27

PROJECT:

Project on pipe joint using TIG welding.

Session 28

PROJECT:

Project on stainless steel welding.

Session 29

PROJECT:

Project on sheet welding.

Case Studies

Case Studies