Introduction : Evolution of welding; classification of welding processes; heat sources and shielding methods.
Physics of Welding Arc : Welding arc; voltage distribution along the arc; thermionic and non-thermionic cathodes; theories of cathode and anode mechanism; arc characteristics and its relationship with power source; arc efficiency; heat generation; effect of type of shielding gas on arc; isotherms of arcs.

Welding Power Sources : Conventional welding power sources; constructional features; static and dynamic characteristics; duty cycle; influence of inductance on arc and power source characteristics; internal and external regulation; specific power source requirements; special welding power sources.
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; Electroslag welding: heat generation; principle; Gas tungsten arc welding; selection of polarity, Plasma arc welding; transferred and nontransferred plasma arc welding; selection of gases; welding parameters; keyhole technique.

Heat flow in welding : Effect of welding parameter on heat distribution; calculation of peak temperatures; thermal cycles; cooling rate and solidification; Residual stresses and their distribution in welds; influence of residual stresses in static and dynamic loading, distortion
Design of weld joints : Introduction to design; engineering properties of steels; Type of welds and weld joints; description of welds: terminology, definitions and weld symbols; edge preparation; sizing of welds in structure; Design for Static loading, Weld Calculations in lap, butt and fillet welds; design for fatigue loading, Introduction to Fatigue; nature of the fatigue process; fatigue strength; factors affecting fatigue life; improvement methods for fatigue strength; reliability analysis and safety factors applied to fatigue design.

Testing and inspection of weld joints : Chemical tests; Metallographic tests; 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: N.D.T. Standard procedure for specification and qualification of welding procedure; WPS and PQR, WPQ

Weldability of metals : Solidification of weld metal; heat affected zone (HAZ), factors affecting properties of HAZ; gas-metal, slag-metal and solid state reactions in welding and their influence on soundness of weld joint; lamellar tearing and hydrogen damage; weldability; definition, factor affecting the weldability of steel Carbon equivalent. weldablity of steel, cast iron and aluminium alloys of commercial importance, failure analysis of welded joints.

Other Resources

Course Curriculum

Mod-01 Lec-01 Introduction to Welding Engineering Details 1:27:44
Mod-01 Lec-02 Classification of Welding Processes- I Details 1:2:31
Mod-01 Lec-03 Classification of Welding Processes- II Details 56:44
Mod-01 Lec-04 Sources of Heat and Protection of Weld pool Details 58:7
Mod-01 Lec-05 Protection of Weld Pool Details 49:15
Mod-02 Lec-01 Introduction Details 47:19
Mod-02 Lec-02 Fundamentals of Arc Initiation Details 45:30
Mod-02 Lec-03 Arc Maintenance & Arc Characteristics Details 46:46
Mod-02 Lec-04 Arc Forces Details 50:4
Mod-02 Lec-05 Arc Efficiency Details 56:52
Mod-02 Lec-06 Metal Transfer and Melting Rate Details 50:18
Mod-03 Lec-01 Types of power sources and their characteristics- I Details 51:47
Mod-03 Lec-02 Types of power sources and their characteristics- II Details 47:34
Mod-04 Lec-01 SMAW- I Details 0:51
Mod-04 Lec-02 SMAW- II Details 52:22
Mod-04 Lec-03 GTAW- I Details 52:55
Mod-04 Lec-04 GTAW- II Details 51:6
Mod-04 Lec-05 PAW & SAW Details 58:4
Mod-04 Lec-06 SAW Details 48:49
Mod-04 Lec-07 GMAW Details 51:42
Mod-05 Lec-01 Weld Thermal Cycle Details 52:32
Mod-05 Lec-02 Effect of WTC and Cooling rate in welding Details 51:50
Mod-05 Lec-03 Cooling rate Details 49:38
Mod-05 Lec-04 Peak temperature & Solidification rate Details 50:46
Mod-05 Lec-05 Residual stress- I Details 49:7
Mod-05 Lec-06 Residual stress- II Details 46:47
Mod-06 Lec-01 Introduction Details 0:48
Mod-06 Lec-02 Type of joints and welds Details 55:57
Mod-06 Lec-03 Edge preparation Details 52:20
Mod-06 Lec-04 Design for static and fatigue loading Details 1:7:24
Mod-06 Lec-05 Fatigue fracture of weld joints- I Details 54:13
Mod-06 Lec-06 Fatigue fracture of weld joints- II Details 58:40
Mod-07 Lec-01 Introduction Details 57:55
Mod-07 Lec-02 DT & NDT Details 55:22
Mod-08 Lec-01 Understanding Weldability Details 51:50
Mod-08 Lec-02 Reactions in weldment Details 54:28
Mod-08 Lec-03 Weldability of Al alloys Details 49:50
Mod-08 Lec-04 Failure analysis and prevention Details 1:33
Mod-06 Lec-03 Edge preparation Details 52:20
Mod-04 Lec-03 GTAW- I Details 52:55

This course & lessons are delivered by IIT Roorkee as part of NPTEL elearning program.

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