Welding and In-service Inspection Technologies (MSK580)

The course focuses on increasing the understanding of the principles of welding and related quality assurance/ in-service inspection technologies in the field of mechanical/structural engineering. It starts with a description of welding safety, welding physics and its principles, welding metallurgy, types of fusion and solid state welding methods, Merits and Limitations of welding processes, and weld quality control. It covers introduction to various types of welded joints, details of welded connections, the life cycle perspective of a welded fabrication: different weld geometries, welding symbols, filler metal selection, shielding gas selection, residual stress estimation, welds acceptance criteria, types of weld defects and quality control approaches, life extension approaches, use of robotics in welding, welding inspection program development and welding cost calculations. Welding robotics and programming.


Course description for study year 2024-2025

Facts

Course code

MSK580

Version

1

Credits (ECTS)

10

Semester tution start

Autumn

Number of semesters

1

Exam semester

Autumn

Language of instruction

English

Content

NB! This is an elective course and may be cancelled if fewer than 10 students are enrolled by August 20th for the autumn semester.

The course aims at fundamentals of various Welding processes (fusion and solid state welding), welding metallurgy (carbon and stainless steel), weld metal requirements like matching filler metals, Electrodes selection for welding processes, Shielding methods, weld joints types, design of welded connections, residual stress evaluation, welding symbols and safety precautions as per internationally accepted codes (AWS, ASME, NORSOK).

Pre-qualification of Welding procedure specifications (WPSs) and its qualifications for various type of joints, PART-A-General requirement for preparations of Welding procedure specification (WPS) and Procedure Qualification record (PQR), PART-B- Welding procedure specification (WPS), Essential variable limitations, Number of tests, testing methods and acceptance standards for WPS qualification, Qualification test requirements, test assemblies, qualification ranges and validity of qualifications for various joint types. PART-C Welder Performance qualification (WPQ), essential variables, Number of tests and methods for WPQ and duration of qualifications.

Welding Fabrication covers preparation of materials assembly, welding positions and various destructive and Nondestructive Inspection techniques. The risk/reliability based weld integrity assessment and control are explained. Welding quality control approaches in fabrication yards and welding fabrication projects’ roles explained. Geometrical aspects of welded joint performance improvement and life extension approaches explained. Robotics in welding, wire arc addtive manufacuting (WAAM).

Nondestructive testing methods of examination covers general requirements, equipment, procedural calibration, examinations and Inspections, evaluation, documentation as per internationally accepted codes (ASME SEC IX). Fundamentals for Nondestructive examinations like Ultrasonic (introduction to Phase array UT, TOFD), Radiography, Penetration testing, Magnetic particle, Eddy current testing. Probability of weld defect detection (PoD) calculations supported by CIVA non-destructive testing (NDT) simulation.

Learning outcome

By taking this course, the student is expected to understand and learn:

  • the welding safety, welding symbols, welding parameters, weld joint types and welding design considerations.
  • welding metallurgy, how to minimize defects during fabrication and operational life.
  • the how to select filler material & shielding and the need for pre- and post-weld heat treatment.
  • the influence of residual stress in welded joints during operational life, residual stress minimization& estimation techniques.
  • the geometric sources of local stress concentrations and sources to eccentricities.
  • the life extension approaches of a welded connection and minimization of stress concentration.
  • the influence of welding parameters on final joint performance and role & preparation of welding documentation.
  • the role of national and international standards/codes relevant for weld fabrication and inspection of existing welds and to develop mechanical and structural welded joints’ inspection programs
  • the role of reliability and risk based approaches in welded joints’ integrity assessment
  • pros and cons of existing NDT methods in weld integrity assurance and selection of NDT approach for inspection of a selected weld geometry.
  • Perform welding cost calculations with special focus on filler metal & shielding gas selection vs. penetration increase & spatter minimization.
  • Welding robotics programming.

Required prerequisite knowledge

None

Recommended prerequisites

BYG200 Steel Structures, BYG530 Plastic Analysis of Structures, MSK200 Materials Technology, MSK205 Mechanics of Materials, MSK210 Mechanical Design

Exam

Written exam and a project

Form of assessment Weight Duration Marks Aid
Project 2/5 1 Semesters Letter grades
Written exam 3/5 4 Hours Letter grades Standard calculator

The course has a continous assessment. All parts must be passed to obtain overall pass grade in the subject.The project assignment is individual. Written exam on paper. There is no resit possibilities for the project assignment. Students who wish to re-take this part may do so the next time the course is lectured.

Coursework requirements

Mandatory assignments
Mandatory assignments. In order to take the written exam for this course, the students must have at least 6 of 8 compulsory exercises approved. Mandatory welding lab class.

Course teacher(s)

Coordinator laboratory exercises:

Jan-Tore Jakobsen

Head of Department:

Mona Wetrhus Minde

Method of work

Lectures (5 hrs/week), exercises (2 hrs/week) and project work. Mandatory welding lab class.

Open for

Master studies at the Faculty of Science and Technology. For students with background in Mechanical and Structural and Petroleum Engineering.

Course assessment

There must be an early dialogue between the course supervisor, the student union representative and the students. The purpose is feedback from the students for changes and adjustments in the course for the current semester.In addition, a digital subject evaluation must be carried out at least every three years. Its purpose is to gather the students experiences with the course.

Literature

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