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.
The course 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 process, 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.
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.
Non-destructive 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.
By taking this course, the student is expected to understand and learn:
The welding safety, welding symbols, welding parameters, weld joint types and designs and welding metallurgy, how to minimize defects during fabrication and operational life
The how to select filler material and 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
To perform welding cost calculations with special focus on filler metal & shielding gas selection vs. penetration increase & spatter minimization.
- 6th September 2021 – start at 9.00 a.m. (4-5 hrs)
- 13th September 2021 – start at 9.00 a.m. (4-5 hrs)
- 20th September 2021 – start at 9.00 a.m. (4-5 hrs)
- 27th September 2021 – start at 9.00 a.m. (4-5 hrs)
- 4th October 2021 – start at 9.00 a.m. (4-5 hrs)
- 11rd October 2021 – start at 9.00 a.m. (4-5 hrs)
Participants will have mandatory assignments (prior requirement to sit exam, 6 out of 8 assignments need to be submitted and approved).
Evaluation by exam as this is a course with 5 ECTSs.
Bachelor degree in engineering
If the course is fully subscribed, we practice first come, first served among those who are qualified.