Welding Inspection, Radiography and Metallurgy

COURSE OUTLINE

Introduction, welding terminology, codes and standards, welding failure and case studies.
Introduction to quality, meeting requirements, customer satisfaction, quality control, how can quality be achieved?
Weld joint design, load performance, types of joints, butt joint, square, grooved butt joint, single V, Double V butt Joint, bevel and double bevel butt, U, J and T, flush.
Welding techniques, positional welding, backing, examples, butt welds without backing.
Welding processes, process options, benefits, problems and applications, oxyacetylene process, fusion welding processes, shielded metal arc welding (SMAW), submerged arc welding, TIG welding, solid wire MIG welding, types of flux/electrodes, metal transfer mode, power source and welding current, arc starting, shielding gas, operating characteristics, applications.

Arc welding electrodes, US standard electrodes, electrode identification, electrode size and currents, common electrode types, extended electrode classification examples, BS classification of electrodes.
Welding defects, introduction, heat affected zone, HAZ, weld defects and imperfections, porosity, solidification cracking, hydrogen cracking, incomplete root fusion or penetration, residual stresses and cracking, reheat cracking, lamellar tearing, liquation cracking, slag inclusion.
Geometric shape imperfections – types and causes, excess weld metal, undercut, overlap (cold lapping), linear misalignment, incomplete filled groove, trouble shooting.
Welding drawings (symbols), introduction, types of projection, welding joints, symbols for welds, parts of the welding symbols, placement of welding symbols, special welds, weld all around, field weld symbols and multiple reference lines.
Basic metallurgy crystalline structure of metals, crystal growth an overall bulk solidification of metals, solid solution, inter-metallic compounds, diffusion, micro-structure of carbon steel, heat treatment of steel, critical cooling rate and mass effect, heat affected zone (HAZ) in Welding, HAZ of carbon and alloy steels, HAZ of stainless steel
Materials for welded sections, weldability of steel groups, stainless steels, cast irons, aluminium alloys, filler alloys, avoiding weld imperfections.

Materials testing and failure, tensile testing, properties obtained from the tensile test, ductility and fracture in metals, impact testing (Izod and Charpy), transition temperature, hardness tests (Vickers and Rockwell), failure due to fracture, stress concentration, fracture toughness, fatigue failure, improving fatigue resistance, creep failure, destructive testing of welds, bend tests, bead-on-plate test, controlled thermal severity (C.T.S.) test, the test and assessment hierarch.
Non destructive testing (NDT), definition and purpose of non-destructive testing, engineering demands for sounder materials, ensuring the integrity and reliability, maintaining uniform quality level of a product, dye penetrant , magnetic methods, X-ray methods, g – ray methods, ultra-sonic methods, eddy current testing, selection of N. D. T. methods, ISO standards for NDT Inspection.

Radiography

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