WELDING TECHNOLOGY

Prof. Dr. Ir. Winarto, M.Sc.

Metallurgy & Materials Engineering Department

Universitas Indonesia

For manufacturing…
WELDING TECHNOLOGY

Materials Productions

Dr. Ir. Winarto, M.Sc. 1

 For manufacturing…
WELDING TECHNOLOGY

Materials Joining & Welding Productions

Most of productions need

joining & welding in manufacturing
634 m

56 m
72 m

Titanic
10

H2B Tokyo Sky Tree;

Rocket broadcasting

73 m
269 m

345 m
Open cover…
0.1 m

0.001 m
iPhone

Dr. Ir. Winarto, M.Sc. 2

 Joining & Welding in Manufacturing in Japan
～From International Conference “8WS” by Japan Welding Society ～

How to welding of a metal to a metal

Local melting of metals is necessary.

Fe Al

specific gravity 7.9 2.7

Melting point (℃) 1536 660

Tensile strength 23 11
(kgf/mm2)

Dr. Ir. Winarto, M.Sc. 3

 Definisi dari Pengelasan
WELDING TECHNOLOGY

 Penyambungan antara dua/lebih material dalam keadaan

plastis atau cair dengan menggunakan panas (heat) atau
tekanan (pressure) atau keduanya. Logam pengisi (filler
metal) dengan temperatur lebur yang sama dengan TL dari
logam induk dapat atau tanpa digunakan dalam proses
penyambungan tsb. (British Standards Institution 1983 : BS 449: Part 1)

 Penyambungan dari logam atau non-logam yang dihasilkan

dengan memanaskan material hingga temperatur las,
dengan atau tanpa menggunakan tekanan (pressure), atau
hanya tekanan, dengan atau tanpa menggunakan logam
pengisi. (American Welding Society 1989 Welding Handbook Vol.I 8th ed.)

Schematic Welding
WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 4

 Welding Application
WELDING TECHNOLOGY

 STRUCTURAL (bridge, ship

building, etc)
 ENGINIRING COMPONENTS
(Turbine, Otomotive, etc)
 SEMI-FINISHED PRODUCTS

Welding Classification (AWS)

WELDING TECHNOLOGY

JOINING METHODS

Welding Mechanical Fastening Adhesive Bonding

Brazing
Fusion Solid State and
Soldering

Dr. Ir. Winarto, M.Sc. 5

 Electric Arc Welding
Las Busur Listrik

SMAW TIG
WELDING TECHNOLOGY

Shielded-metal arc welding

Gas-tungsten arc welding
MIG

Gas-metal arc welding Submerged arc welding SAW

Mechanical Joining
 All types of materials can be joined
WELDING TECHNOLOGY

 joining can be removed, but not for rivets

 more cheaper when the number of joint is small
 Problems: strength, seal, loosening

Dr. Ir. Winarto, M.Sc. 6

 Brazing/Soldering vs. Welding
WELDING TECHNOLOGY

 Welding is a joining process wherein metallic components

are joined through fusion (melting) or recrystallization of
the base metal by applying heat, pressure or both. This
process differs from brazing, where only the filler metal
melts during processing.

 Soldering is a joining process wherein metals are bonded

together using a non-ferrous filler metal with a melting
(liquidus) temperature lower than 450 °C (840°F).
Whenever the filler metal liquidus is greater than 450 °C
(840 °F), the joining process is considered to be a brazing
process rather than a soldering process.

Microstructure Brazing
WELDING TECHNOLOGY

Filler metal can be

partly soluble with
the parent metal

Dr. Ir. Winarto, M.Sc. 7

 Components produced by
Furnace Brazing
WELDING TECHNOLOGY

Soldered Wire Joints

WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 8

 WELDING TECHNOLOGY

Stress distribution
among the joining
process

Welding Classification
(in general)
WELDING TECHNOLOGY

Welding Process

Oxyfuel Arc Resistance Solid State Unique

Oxyacetylene Shielded Metal Resistance Friction Thermit

(OAW) (SMAW) Spot (RSW) (FRW) (TW)

Gas Metal Arc Ultrasonic Laser Beam

(GMAW) (USW) (LBW)

Gas Tungsten Cold Pressure

(GTAW) Welding

Dr. Ir. Winarto, M.Sc. 9

 STAGE OF MANUFACTURING
PROCESS IN WELDING
WELDING TECHNOLOGY

 DESIGN
 PRODUCTION
 INSPECTION

THE DEVELOPMENT OF
WELDING
WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 10

 WELDING TECHNOLOGY

EXAMPLES
WELDING APPLICATION
ON MOTOR-CYCLE INDUSTRY

MAG (GMAW) SWING ARM

. .
WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 11

 SPOT WELD – FUEL TANKS
. .
WELDING TECHNOLOGY

R/L 5
Braket Fuel Unit
Patch fuel cock (2)

(8)

R.L
(2)

Clip Wire throttle ( 7 ~ 12 ) R.L

(1) (2)

GMAW ROBOT – FUEL TANKS

. .
P ± 620 mm
WELDING TECHNOLOGY

Half
Outer R

Half
Outer L

Dr. Ir. Winarto, M.Sc. 12

 SEAM WELD – FUEL TANKS
. .
WELDING TECHNOLOGY

Plate tank Bottom

Comp

Star Awal

Fuel Tank Assy

SOLDERING - FUEL TANKS

. .
WELDING TECHNOLOGY

Solder Gas
Timah Patri

half outer comp

Tambal ( solder )
brusshing

Dr. Ir. Winarto, M.Sc. 13

 BRAZING – FUEL TANKS
. .
WELDING TECHNOLOGY

Patch Fuel Cock

Brazing with Oxy-Acetylene welding p ± 60

mm

WELDING PERSONEL
TEACHING HOURS

 WELDING MANPOWER

1) INTERNATIONAL WELDING ENGINEER (IWE)

– Curriculum = 438 Hours

2) INTERNATIONAL WELDING TECHNOLOGIST (IWT)

– Curriculum = 338 Hours

3) INTERNATIONAL WELDING SPECIALIST (IWS)

– Curriculum = 227 Hours

4) INTERNATIONAL WELDING PRACTITIONER

– Curriculum = 140 Hours

5) INTERNATIONAL WELDER (IW)

– The time needed may vary individually according to the capability of the student

6) INTERNATIONAL WELDING INSPECTION PERSONNEL (IWIP)

– Curriculum = 257 Hours

Dr. Ir. Winarto, M.Sc. 14

 AUTHORIZED TRAINING BODY (ATB) IWS ANB
1. ATB B4T, IWS-ATB – 001 (IWE, IWT, IWS, IWP, IWIP)
2. ATB PUSDIKLAT MIGAS CEPU, IWS-ATB – 002 (IW)
3. ATB WTC-POLBAN, IWS-ATB – 003 (IW)

Dr. Ir. Winarto, M.Sc. 15

 International Welding Engineering (IWE) & International Welder (IW) Certificate

IWS-JWES Training Course Certification

Training Hours Contents of Training

Level
Basic Application ( Fields of technical knowledge)

Senior 30
WE 24 Hours 1. Welding Process and Equipment
Hours 2. Materials and their behavior during welding
3. Construction and design
WE -
4. Fabrication, application engineering
5. Practical Design of Frame Structure
18 - 6. Practical Design of Vessel Structure
AWE
Hours

Remarks
Contents of training from No.1 to No.4 are applied to both WE and AWE level, and No. 1
to No. 6 are applied to only Senior WE

Dr. Ir. Winarto, M.Sc. 16

 IWS-JWES Training Course Certification
(total 1st - 15th = 500 certificates)

Batch Location
WELDING TECHNOLOGY

1st – Feb 2008 UI – Depok

2nd – Dec 2008 UI - Depok

3rd – Feb 2009 POLTEK – ITS Surabaya

4th – July 2009 POLTEK – ITS Surabaya

5th – Nov 2009 POLTEK - Batam

6th – Feb 2010 MIDC – Bandung

7th – Feb 2011 UI - Jakarta

8th – Oct 2011 POLTEK – ITS Surabaya

9th – Oct 2011 Depok, Banten, Surabaya & Batam

10th – Oct 2011 POLTEK Negeri Jakarta (PNJ) – Depok

11th – Nov 2013 UI - Depok & Banten

12th – June 2014 UI - Depok & Banten

13th – Dec 2014 UI - Depok & UMS Solo

14th – Nov 2015 UI - Depok & JIM - Semarang

15th – Nov 2016 UI - Depok & PPNS Surabaya

Dual Certificates IWS-JWES

WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 17

 WELDING TECHNOLOGY

What is Welding Inspector ?

Departemen Metalurgi & Material

Fakultas Teknik Universitas Indonesia

Definition of Welding Inspectors

WELDING TECHNOLOGY

 The welding inspector is a composite person – a specialist,

highly qualified in the field of welding.
 The functions of welding inspector is as the quality
representative of an organization, which may be
manufacturer, the purchaser, an insurance company, or a
government agency.
 As an inspector, it is responsibility to judge the quality of
the product in relation to some form of written specification
and also must be able to interpret this specification both as
to its limitation and intent.

Dr. Ir. Winarto, M.Sc. 18

 QUALIFICATIONS FOR BECOMING
WELDING TECHNOLOGY

A WELDING INSPECTOR

1. Knowledge of drawings and

specializations
2. Knowledge of welding terms
3. Knowledge of welding processes
4. Knowledge of testing methods
5. Ability to maintain records
6. Good physical condition
7. Good vision
8. Professional attitude
9. Training in engineering and
metallurgy
10.Inspection experience
11.Welding experience

Responsibility of
A WELDING INSPECTOR
1. Interpret all welding drawings and specification
WELDING TECHNOLOGY

2. Check purchase order to assure that welding materials and consumables have
been properly specified
3. Check and identify materials as they are received against the purchase
specification
4. Check the chemical compositions and mechanical properties shown on mill test
reports against specified requirements
5. Investigate base material imperfections and deviation
6. Check storage of filler materials
7. Check equipment to be used
8. Check weld join preparations
9. Check joint fit-up
10. Verify the application of the approved welding procedure
11. Verify the qualifications of the welders or welding operators
12. Select production test samples
13. Evaluate the test results
14. Maintain the record
15. Prepare report

Dr. Ir. Winarto, M.Sc. 19

 WELDING TECHNOLOGY

Guidance for
The Code of Ethics

AWS Certification in Welding

WELDING TECHNOLOGY

 Certified Welding Engineer (CWEng)

 Certified Welding Fabricator (CWFab)
 Certified Welding Supervisor (CWS)
 Certified Robotic Arc Welding (CRAW)
 Certified Welder (CW)
 Certified Welding Educator (CWE)
 Certified Associate Welding Inspector (CAWI)
 Certified Welding Inspector (CWI)
 Senior Certified Welding Inspector (SCWI)

Dr. Ir. Winarto, M.Sc. 20

 International Certification
in Welding
WELDING TECHNOLOGY

 International Welding Engineer (IWE)

 International Welding Technologist (IWT)
 International Welding Inspection Personnel (IWIP)
 International Welding Specialist (EWS)
 International Welding Practitioner (EWP)
 International Welder (IW)
The Certification Scheme for Welding and Inspection Personnel (CSWIP) - UK
• Visual Welding Inspectors - CSWIP - 3.0
• Welding Inspectors - CSWIP - 3.1
• Senior Welding Inspectors - CSWIP - 3.2

A welding Inspector –
A communicator
WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 21

 A welding Inspector –
As a team work
WELDING TECHNOLOGY

THANK YOU
.
WELDING TECHNOLOGY

Dr. Ir. Winarto, M.Sc. 22