Course: Welding and Inspection
Total Credits: (8-8-6) 22
1. Joining Processes and Technology (2-2-2)
2. Metal Transfer and Weld Metallurgy (2-2-0)
3. Design of Welded Joints (Design and Validation, 3D Experience- CATIA) (2-2-2)
4. Testing of Welded Joints (DT, NDT and Microstructure) (2-2-2)
1.To develop understanding and skill of students for Welding Technology
2. students pursuing this domain will be ready for industrial employment
3. The students develop a passion for higher education and research in Welding Engineering
1.Welding certification will make the candidate recognized at national and international levels in the industry
2. He/she can be self-employed by opening a small scale welding shop to a medium scale industry
3. Can produce Welding Design as per requirement using Dassault Welding Design module
4. Suggest suitable Welds, based on Strength, Failure, and Reliability
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).
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 positions 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.
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).
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
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
Experiment 4.8 Analysis of Microstructure by Image Analyzer
Experiment 4.9 Analysis of Microstructure by SEM
1: Joining Processes and Technology 85 hours
Session 2:Personal safety and welding safety
Session 3:Intro to Welding Technology
Session 4:Welding, Brazing, Soldering
Session 5:Soldering And Brazing (Difference)
Session 6:Intro to Oxy-Acetylene Welding
Session 7:What is STICK Welding? (SMAW)
Session 8:Introduction to Resistance Welding
2: Metal Transfer and Weld Metallurgy 47 hours
Session 1:Laser Welding
Session 2:Modes of Metal Transfer | Short Circuit vs Spray vs Globular
Session 3:Welding defects|| Animation || 7 different types of defect
Session 4:Heat treatment of metals | Types. Process, Applications
Session 5:What is WELDABILITY?
3: Design of Welded Joints (Design and Validation, 3D Experience- CATIA) 38 hours
Session 1:design of welding
Session 2:catia single u-butt joint weld
Session 3:Weld Design, CATIA
Session 4:Welding Analysis in CATIA
Session 5:Tutorial Catia Welding Analysis of Component
Session 6:catia FEA seam weld
4: Testing of Welded Joints (DT, NDT, and Microstructure) 40 hours
Session 1:welding defects, causes and correction
Session 2:Welding Defects
Session 3:Mechanical Testing - Bend tests
Session 4:Tensile Test on ASME Welded Sample
Session 5:Mechanical Testing-charpy impact test
Session 6:Hardness testing- Welding inspector-Welding inspection
Session 7:Visual Weld Inspection
Session 8:Liquid Penetrant Testing (Non Destructive Testing)
Session 9:Magnetic Particle Testing
List of Projects/ papers/jobs/products:
1.Box Jig (Design and Manufacturing)
2. Fixture for MIG Gun (Design and Manufacturing)
3. Ergonomically designed welding table with compartment for power source and tools tray (Design and Manufacturing)
4. Welding slag cleaning machine (Design and Manufacturing)
5. Ergonomically designed motorised wheelchair (Design and Manufacturing)