It starts with providing an awareness of accidents case histories and current challenges in welding. Then, it presents welding physics, welding techniques and welding metallurgy. The welding metallurgy has been focused on steel and stainless steel.
The course enables to acquire a better understanding about role of welding in design, construction, and operations (inspection & maintenance) phases. It also provides an overview of risk of welding failures and methods to minimize the risk of potential welding failures.
The course describes the key characteristics of welding quality management and use of statistical principles and role of non-destructive testing (NDT). Finally, it presents the role of the skill of welders on welding quality, related parameters, and welding cost comparisons & calculations.
Featuring industry case-studies and practical examples – the course covers the entire asset life cycle and addresses key stage issues with a view to optimize welded joints’ performance and quality. This course is considered not only for the engineers or project managers but for anyone who is working on onshore or offshore systems and who needs to be a professional player during the overall life cycle of a structural/mechanical system.
Course Agenda (Day 1 – 3)
The lectures will be on Zoom following dates:
From 09.00 to 15.00
- Industrial challenges in welding: case histories and current issues.
- Fundamental of Welding and Welding physics
- Welding safety
- Types of welds
- Weld joints
- Welding physics
- Power density and calculations
- Heat balance in fusion welding
- Heat transfer and melting factors
- Weld interface and HAZ
- Welding methods (resistance welding, Oxyfuel welding, shielded metal arc welding, gas metal arc welding, plasma arc welding and gas tungsten arc welding)
- Common welding elements and welding positions
- Pipe Welding positions, Plug and slot welds, Electrode orientations, Shielding
- Work lead connections and welding hand tools
- Distortion in welding and methods of distortion minimization, Robotics in welding
- Welding Metallurgy
- Mild steel and steel welding
- Classification systems for steel
- Microstructures and iron carbon diagram
- Time temperature transformation curve and cooling rates
- Heat treatment of welds
- Residual stresses in Welding and theoretical analogy
- Residual stress measurement methods
- Welding stainless steel
- Stainless steels (austenitic, martensitic, ferritic grades and duplex stainless steel)
- Dilution and calculations
- Filler metal and final weld microstructure (Schaeffler diagram and De Long diagrams) related analysis
- Welding quality
- hierarchy of different disciplines related to welding activities
- Main factors related to welding discontinuities
- Welding quality
- Welding procedure specification (WPS) and Qualification (WPQ)
- Weld Testing and Inspection Methods
- NDT techniques
- DT Techniques
- Economics of Arc welding process: combining all the knowledge gained in day 1 and day 2 to make cost benefit analysis in industrial applications:
- Skills of welding and operating factor
- Deposition efficiency
- Operator factor vs. Cost variation
- Equations for the welding cost calculations and welding cost comparisons
- Classroom case study calculations.
Who should attend?
This course is applicable to those who currently work or will start to work on onshore/offshore construction projects as well plants operations, inspection, modification, maintenance and repair tasks. The course will be of benefit to QA/QC, piping, structural/mechanical/process, integrity, static rotating equipment engineers and technicians.
The course is held by Professor R. M. Chandima Ratnayake.
Read more about him here.