Domain Syllabus:

1.Joining Processes and Technology (85 hrs)

1.1            Physics of arc welding

1.2            SMAW Principle and Equipment

1.3            Types of Electrodes, Functions of Coatings

1.4            TIG (GTAW), MIG (GMAW) & Flux-Cored Arc Welding

1.5            Submerged Arc Welding

1.6            Welding Positions, types of Joints

1.7             Residual Stress

1.8             Oxy-Acetylene Welding

1.9             Flux and Filler

1.10           Types of Gas Flames, Gas Welding Techniques

1.11            Difference between Gas Welding and Cutting Torch

1.12            Spot and Seam Welding Parameter, Projection Welding

1.13            Different types of Resistance Welding Electrodes

1.14           Newer welding processes-Flash Butt Welding, Friction Welding, Explosive Welding, Thermit welding of Rails, Electro-Slag Welding, Electro-Gas Welding, Stud Welding, Plasma Arc, Laser Beam, Electron Beam, Ultrasonic, Explosive Welding, Under Water Welding, High-Frequency Resistance and Induction Welding.

1.15           Electricity in Welding: Power Source and Equipment used for AC, DC Welding.

1.16           Selection of Filler Metals, Selection of a Welding Process, Procedures for Welding Stainless Steels.

1.17           AC Welding Machine Fundamentals, Shielding Gases (Purging), Filler Wire/Electrode Selection. Material Preparation, Weld Faults (Causes and Cures).

Practices:

Experiment 1.1           Welding Safety Practice: Welding Fumes, Eye Protection, Personal Protective Equipment, Electrical Safety.

Experiment 1.2           Brazing Practice: Types and Equipment required, Preparation of Joints for Brazing, Cleaning, making of two types of Brazed Parts- Cu and Brass, A/C Tubes.

Experiment 1.3           Soldering Practice: Types of Solders, Equipment details, Preparation for Different Joints, making of two components through Soldering, viz. Electrical Elements, Electronics.

Experiment 1.4           Gas welding Practice: Gas Welding Equipment- Torch, Gas Cylinder, Hose, Three Types of Flames, Welding of M.S. Sheet and Pipe by Gas Welding process.

Experiment 1.5           Gas Cutting Practice: Oxy-acetylene cutting process Straight, Bevel & Circular Cutting on MS. Plate.

Experiment 1.6           Shielded Metal Arc Welding–Manual Metal Arc Practice: Welding of M.S. Plate in all position by SMAW process, Repair & Maintenance works.

Experiment 1.7           GTAW Welding Practice: GTAW Welding of M.S, SS & Aluminium Plate & Pipes.

Experiment 1.8           GMAW Practice: Welding Torch, Electrode, Shielding Gas, GMAW Welding on M.S Sheet & M.S plate.

Experiment 1.9           Resistance Welding Practice: Operating skills of SPOT Welding machine, Resistance Welding Machine Operation and Parameters.

Experiment 1.10          AC, DC Welding, joint configuration and edge preparations familiarization for AC, DC Welding power source.

Experiment 1.11           Identifying Defects and Remedial Measures for Welded Joints.

Experiment 1.12           PUG Cutting Machine, SAW and PAW Demonstration.

Experiment 1.13           Faults in welding and methods to solve them

Experiment 1.14           Selection of Electrode and its effect

2. Metal Transfer and Weld Metallurgy (47 hrs)

2.1           Metal Transfer in AC and DC Arc Welding, Metal Transfer in TIG, MIG and MAG Welding

2.2           Study of different modes of Metal Transfer in MIG welding.

2.3           Theory and Principle of Process, Key Variables, Intermediate Materials.

2.4           Fe-C Equilibrium Diagram, Cooling Curve

2.5           HAZ, Microstructure

2.6           Pre Heat & Post Heat, Stress Relieving and Normalizing. Concept and significance

2.7           Percentage equivalence of Carbon in Weldability, Weldability of Carbon Steels.

2.8           Welding Defects due to improper Metal Transfer and improper Filler Material, Hot Cracks and Cold Cracks, Porosity, Embrittlement, Lamellar Tearing, Distortion etc.

2.9           Weldability of stainless steels, Weldability of Titanium and Alloys, Weldability of High Strength Low Alloy Steels.

2.10          Shot Pinning, Stress Reliving through Vibration.

2.11          Ultra-sonic Welding for Dissimilar Metals.

2.12          Stainless Steel-Types, properties of Stainless steels; Use in Industry,

2.13          Type of Welds and Weld Joints; Stainless Steels - Austenitic, Martensitic Ferritic Stainless Steels,

2.14          Sensitization, Hot Cracking, Precipitation Hardening Stainless Steels,

2.15          Duplex Stainless Steels, Physical Properties, Mechanical Properties.

2.16          Selection of a Stainless Steel, Design for Welding Stainless Steels,

2.17          Properties of Aluminum

2.18          GTAW (TIG) Theory Fundamentals on Aluminum, GTAW (TIG) Welding Techniques on Aluminum

2.19          SMAW Electrode for Aluminum.

2.20         Use of SMAW Electrode in Hard Facing

2.21          Flux Cored Wire Surfacing.

Practice:

Experiment 2.1           Metal transfer in TIG welding

Experiment 2.2           Different modes of Metal transfer in MIG welding

Experiment 2.3           Welding defects in TIG welding

Experiment 2.4           Welding defects in MIG welding

Experiment 2.5           Practice on Stress Relieving and Normalizing in Welding

Experiment 2.6           Experiments for demonstrating Weld-ability

Experiment 2.7           Identification of general Welding Defects

Experiment 2.8           Heat treatment of Welded Structures

Experiment 2.9           Weldability of stainless steel

Experiment 2.10         Practice for Hot Cracking

Experiment 2.11          Faults in Welding and methods to solve them

Experiment 2.12         Repair methods for Cast Iron Welded Parts

Experiment 2.13          Surface Coating Procedure

3. Design of Welded Joints (Design and Validation, 3D Experience- CATIA) (38 hrs)

3.1           Introduction to Design

3.2           Engineering Properties of Steels

3.3           Type of Welds and Weld Joints.

3.4           Description of Welds: Terminology, Definitions and Weld Symbols;

3.5           Edge Preparation; Sizing of Welds in Structure.

3.6           Design for Static Loading,

3.7           Weld Calculations in Lap, Butt and Fillet Welds;

3.8           How to Design Various Kinds of Welding Joints.

3.9           Design of a Butt Joint, the main Failure Mechanism of Welded Butt Joint.

3.10         Design of Transverse Fillet Joint,

3.11          Shear Mechanism in Fillet Weld,

3.12         Design Stresses of Welds.

3.13         Use of CATIA Weld Design Module.

3.14         ASME & IBR Evaluation,

3.15         All Weld Tensile, Transverse Tensile, Bend Test 180° and 90°.

3.16         Evaluation of Test Plate (Practice).

Practice:

Experiment 3.1           Design of Lap Joint

Experiment 3.2           Design of Butt Joint

Experiment 3.3           Tensile Testing of Welded Joints

Experiment 3.4           Bend Test of Welded Joints

4. Testing of Welded Joints (DT, NDT and Microstructure) (40 hrs)

4.1           Weld Defects and NDT Welded Joints.

4.2           ASME Section IX

4.3           WPS and PQR

4.4           ASNT course for 3 days

Practice:

Destructive Tests:

Experiment 4.1           Tensile test using Standard Equipment.

Experiment 4.2           Impact test using Standard Equipment

Experiment 4.3           Bend test using Standard Equipment

Experiment 4.4           Hardness test using Standard Equipment

Non Destructive Tests:

Experiment 4.5           Visual Inspection

Experiment 4.6           Liquid Penetrant Test

Experiment 4.7           Magnetic Particle Inspection

Microstructure:

Experiment 4.8           Analysis of Microstructure by Image Analyzer

Experiment 4.9           Analysis of Microstructure by SEM

5.PROJECT: 6credits
6.INTERNSHIP:4 credits