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