Course Objectives

• Identifying the right welding methodology and process.
• Understanding the safety practices for welding.
• Identifying various materials used in welding & their key properties.
• Understanding the activities for MIG welding.
• Understanding the activities for TIG welding.
• Understanding the quality checks and inspection of the finished products.

Learning Outcomes

Students will be able to:

• Identify welding requirements and the related processes
• Prepare the welding machine for the welding process.
• Perform various Welding activities.
• Conduct quality checks and inspection of the finished products.
• Perform various Welding activities at different welding positions.

Course Syllabus

MODULE I

Introduction: Evolution of welding. Welding terms and definitions. Uses of welding. Introduction & Importance of Welding in Industry. Occupational Opportunities in Welding.

Welding Processes: Shielded metal arc welding, Gas tungsten arc welding, Gas metal arc welding and Flux cored arc welding. Advantages and Limitation of Welding as a Fabrication Technique. Applications of welding

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.

Preparation of the welding machine for the welding process: Identifying the right welding methodology and process to be adopted for completing the work. Electrodes and its types. Describe various materials used in welding & their key properties. Explain the basic principles of geometry and drawing. 

PRACTICE:

• Use of measuring instruments like vernier calipers, micrometer.
• Reading and interpretation of sketches and engineering drawings.
• Presentations of preparation of welding machine for the welding process.
• Presentation of codes and use of it.

MODULE II

Arc Welding Processes: Consumable electrode welding processes. Manual metal arc (MMA) welding. Gas metal arc welding. Pulsed MIG welding. Submerged arc welding. Significance of flux-metal combination. Gas tungsten arc welding: selection of polarity.  

PRACTICE:

• Practice of Gas Metal Arc Welding(MIG).
• Practice of Gas Tungsten Arc Welding(TIG).
• Practice of Submerged Arc Welding(SAW).
• Practice of Shielded Metal Arc Welding(SMAW).

MODULE III

Testing and inspection of weld joints: Destructive Testing. Hardness tests. Mechanical test for groove and fillet welds-full section, reduced section and all-weld- metal tensile tests, root, face and side bend tests, fillet weld break tests, creep & fatigue testing. Non-Destructive Testing of Weldments. Visual inspection. Dye-penetrant inspection. Magnetic particle inspection. Ultrasonic inspection- principle of ultrasonic testing. Radiographic inspection –principle of radiography, X-ray tubes, gamma-ray sources, defect discernibility. Eddy current inspection. Leak tests.

PRACTICE:

• Practice of Hardness Testing.
• Practice of Tensile Testing.
• Practice of Bending Test.
• Practice to do Dye penetrant inspection and make a inference.
• Practice to do Ultrasonic inspection and make a inference.
• Practice to read Radiographic inspection

MODULE IV

Welding positions: Flat Position – Butt, Lap & Tee Welds. Vertical Position – Butt, Lap & Tee Welds. Horizontal Position – Butt, Lap & Tee Welds. Overhead Position – Butt, Lap & Tee Welds. Brazing and Soldering.

PRACTICE:

• Practice of flat position lap welding.
• Practice of vertical position butt welding.
• Practice of horizontal position tee welding.
• Practice of overhead position lap welding.
• Practice of Brazing operation.
• Practice of Soldering operation.

MODULE V

PROJECTS:

• Projects based on TIG welding.
• Projects based on MIG welding.
• Projects based on Destructive Testing of welded pieces.
• Projects based on Non Destructive Testing of welded pieces.

Session Plan

Session 1

LECTURE:

Introduction: Evolution of welding. Welding terms and definitions. Uses of welding. Introduction & Importance of Welding in Industry. Occupational Opportunities in Welding.

Welding Processes: Shielded metal arc welding, Gas tungsten arc welding, Gas metal arc welding and Flux cored arc welding. Advantages and Limitation of Welding as a Fabrication Technique. Applications of welding

WEB LINKS:

What is Welding?

Welding Introduction and Advantages

Welding Processes, Advantages and Defects

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.

Preparation of the welding machine for the welding process: Identifying the right welding methodology and process to be adopted for completing the work. Electrodes and its types. Describe various materials used in welding & their key properties.

WEB LINKS:

Welding Safety Tips

Session 3

PRACTICE:

Presentations of preparation of welding machine for the welding process.

WEB LINKS:

How to Setup a TIG Welder 

Session 4

LECTURE:

Explain the basic principles of geometry and drawing.

PRACTICE:

Reading and interpretation of sketches and engineering drawings.

Session 5

PRACTICE:

Use of measuring instruments like vernier calipers, micrometer.

WEB LINKS:

Vernier Callipers principle and description

Working of Micrometer  

Session 6

PRACTICE:

Presentation of codes and use of it.

Session 7

LECTURE:

Consumable electrode welding processes. Manual metal arc (MMA) welding. Gas metal arc welding. Pulsed MIG welding.

PRACTICE:

Practice of Gas Metal Arc Welding(MIG).

WEB LINKS:

MIG Welding Animation 

Session 8

LECTURE:

Submerged arc welding

PRACTICE:

Practice of Submerged Arc Welding(SAW).

WEB LINKS:

Submerged Arc Welding - SAW

Session 9

LECTURE:

Gas tungsten arc welding: selection of polarity.

PRACTICE:

Practice of Gas Tungsten Arc Welding(TIG).

WEB LINKS:

TIG Welding Animation 

Session 10

LECTURE:

Significance of flux-metal combination.

PRACTICE:

Practice of Shielded Metal Arc Welding(SMAW).

WEB LINKS:

Shielded metal arc welding 

Session 11

LECTURE:

Destructive Testing. Hardness tests. Mechanical test for groove and fillet welds-full section, reduced section and all-weld- metal tensile tests, root, face and side bend tests, fillet weld break tests, creep & fatigue testing.

WEB LINKS:

Destructive Testing and Types of Destructive Testing 

Session 12

PRACTICE:

Practice of Hardness Testing.

WEB LINKS:

Brinell Hardness Test

Rockwell Hardness Test 

Session 13

PRACTICE:

Practice of Tensile Testing.

WEB LINKS:

Tensile Test 

Session 14

PRACTICE:

Practice of Bending Test.

WEB LINKS:

Bend and Re-bend Testing 

Session 15

LECTURE:

Non-Destructive Testing of Weldments. Visual inspection. Dye-penetrant inspection. Magnetic particle inspection. Ultrasonic inspection- principle of ultrasonic testing. Radiographic inspection –principle of radiography, X-ray tubes, gamma-ray sources, defect discernibility. Eddy current inspection. Leak tests.

WEB LINKS:

Non Destructive Testing Methods 

Session 16

PRACTICE:

Practice to do Dye penetrant inspection and make a inference.

WEB LINKS:

Liquid Penetrant Testing (NDT) 

Session 17

PRACTICE:

Practice to do Ultrasonic inspection and make a inference.

WEB LINKS:

Ultrasonic Testing 

Session 18

PRACTICE:

Practice to read Radiographic inspection report.

WEB LINKS:
Radiographic Testing (NDT)

Session 19

LECTURE:

Welding positions: Flat Position – Butt, Lap & Tee Welds. Vertical Position – Butt, Lap & Tee Welds. Horizontal Position – Butt, Lap & Tee Welds. Overhead Position – Butt, Lap & Tee Welds.

WEB LINKS:

Welding positions 

Session 20

PRACTICE:

Practice of flat position lap welding.

WEB LINKS:

Flat position lap welding 

Session 21

PRACTICE:

Practice of vertical position butt welding.

WEB LINKS:

Vertical butt joint arc welding 

Session 22

PRACTICE:

Practice of horizontal position tee welding.

WEB LINKS:
Horizontal Tee Welding

Session 23

PRACTICE:

Practice of overhead position lap welding.

WEB LINKS:

Overhead Welding 

Session 24

LECTURE:

Brazing

PRACTICE:

Practice of Brazing operation.

WEB LINKS:

Brazing Thin Sheets

Brazing Procedure 

Session 25

LECTURE:

Soldering

PRACTICE:

Practice of Soldering operation.

WEB LINKS:

Beginner how to Solder

Basic Soldering Technique 

Session 26

PROJECT:

Projects based on TIG welding.

WEB LINKS:

TIG WELDING ART MIXTAPE - MY TIG WELDING PROJECTS

TIG WELDING ART - TIG WELDING ALUMINUM XMAS PRESENT!

Affordable Tig Welder Project 

Session 27

PROJECT:

Projects based on MIG welding.

WEB LINKS:

Quick Mig Welding Project for Students

MIG Welding Project - Steel Work Bench 

Session 28

PROJECT:

Projects based on Destructive Testing of welded pieces

Session 29

PROJECT:

Projects based on Non Destructive Testing of welded pieces.

Case Studies

Case Studies