Description

There is demand for welders in fabrication across the globe. The opportunities are available for all type of welders. But each welder need to know about the welding specifications, welding process and to do defect free welding products. All welders need to qualify for welder certification to take up various type of welding tasks. So there is a need to get trained in welding trade with a professional approach to land in a appropriate job.

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: 1

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

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

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

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

Submerged arc welding

PRACTICE:

Practice of Submerged Arc Welding(SAW).

WEB LINKS:

Submerged Arc Welding - SAW

Session 9

Gas tungsten arc welding: selection of polarity.

PRACTICE:

Practice of Gas Tungsten Arc Welding(TIG).

WEB LINKS:

TIG Welding Animation

Session 10

Significance of flux-metal combination.

PRACTICE:

Practice of Shielded Metal Arc Welding(SMAW).

WEB LINKS:

Shielded metal arc welding

Session 11

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