M.E.

Part- I (Welding Technology)

EXPERIMENTAL TECHNIQUES

L4 Theory 100 Marks

OBJECTIVE: To expose the students to the concepts and practice of material

characterisation.

1 METALLOGRAPHIC TECHNIQUES ( Part 1) : Numerical aperture, limit of resolution, depth of

field and depth of focus - lens defects and correction- bright field and dark field illumination
–

2. METALLOGRAPHIC TECHNIQUES ( Part 2) : polarised light, phase contrast, interference

contrast and fringe mode, opaque stop, hot stage, in-situ techniques, quantitative
metallography, specimen preparation techniques
.
3. X-RAY DIFFRACTION TECHNIQUES:Powder, rotating crystal and Laue methods,
stereographic projections and reciprocal lattice; X-ray residual stress measurement.

4. ELECTRON MICROSCOPY (Part 1): Construction and operation of TEM - diffraction effects
and image formation, specimen preparation techniques; elemental analysis by wavelength
dispersive and energy dispersive systems

5. ELECTRON MICROSCOPY (Part2): Construction and operation of SEM - analysis of fractured

surfaces.

6. ADVANCED CHEMICAL AND THERMAL ANALYSIS METHODS:X-ray fluoroscopy, spectrometry,

Auger spectroscopy, DTA, DSC and TGA.

7. EXPERIMENTAL STRESS ANALYSIS:Stress analysis by strain gauging, high temperature

strain gauge technique, photoelasticity and holography.
TEXT BOOKS:
1. Smallman R. E., ‘Modern Physical Metallurgy’, 4th Edition, Butterworths, 1985
2. Philips V. A., ‘Modern Metallographic Techniques and their Applications’, Wiley Interscience,
1971
3. Cullity B. D., ‘Elements of X-ray Diffraction’, 4th Edition, Addison Wiley, 1978
4. Loretto M. H., ‘Electron Beam Analysis of Materials’, Chapman and Hall, 1984

REFERENCES :
1. Thomas G., ‘Transmission Electron Microscopy of Metals’, John Wiley, 1961
2. Thomas G., Michael J.G, ‘Transmission Electron Microscopy of Materials’, John Wiley, 1979
3. Amdinckx S., ‘Modern Diffraction and Imaging Techniques in Materials Science’, North
Holland, 1970

PHYSICAL METALLURGY

METW ; 102 Theory : 100 Marks

L 4 TW/Viva : 50
Total : 150

OBJECTIVE : To understand the basic concepts in physical metallurgy including phase

transformations and strengthening mechanisms

1 CRYSTALLOGRAPHY( Part 1):Crystallography - space lattice - unit cell - classification of

space lattices by crystal system - packing factor - indexing of crystal planes and directions
in cubic and hexagonal system

2. CRYSTALLOGRAPHY( Part 2): Defects in crystals - dislocation concepts - slip and twin
crystal orientation.

3 PHASE TRANSFORMATIONS (Part 1): Nucleation and crystal growth during solidification,
important features of pearlitic
4. PHASE TRANSFORMATIONS (Part 2): Martensitic transformations - significance of TTT and
CCT diagrams - basics of ternary diagram, diffusion kinetics

5. HEAT TREATMENT:Heat treatments based on iron-iron carbide diagram, case hardening,

hardenability, its measurement and its significance

6. STRENGTHENING MECHANISMS: Work hardening, solid solution strengthening,

strengthening by heat treatment, precipitation hardening, grain refinement techniques

7. OVERVIEW OF METALLIC MATERIALS: Plain carbon steels, low alloy and Q-T steels, dual
phase steels, HSLA steels,

8. Physical Metallurgy of Hadfield steel, stainless steels, tool steels, ultra-high strength
steelsmaraging steels, high strength aluminium alloys, titanium base alloys, nickel base
super alloys.

Notes : Experiments based on above syllabus

TEXT BOOKS :
1 Leslie W. C., ‘Physical Metallurgy of Steels’, McGraw Hill, 1982
2 Raghavan V., ‘Physical Metallurgy (Principles and Practice)’, Prentice-Hall, 1983
3. Clark D. S. and Varney W. R., ‘Physical Metallurgy for Engineers’, CBS, 1987

REFERENCES :
1. Flemings M. C., ‘Solidification Processing’, McGraw Hill, 1974
2. Smith W. F., ‘Structure and Properties of Engineering Alloys’, McGraw Hill, 1993
3. Pickering F. B., ‘Physical Metallurgy and Design of Steels’, Applied Science, 1978
4. Reed-Hill R. E., ‘Physical Metallurgy Principle’, Affiliated East-West Press, 1973
 ELECTRICAL & CONTROL ASPECTS OF WELDING
METW 103
L4 Theory : 100 Marks

OBJECTIVE : To become familiar with the electrical equipment used in welding and to
understand the role of electrical characteristics on welding processes

1 ELECTRICAL CHARACTERISTICS OF WELDING ARC: Physical phenomenon occurring in the arc,

potential distribution, static and dynamic arc characteristics; brief ideas on heat generation,
types of forces and metal transfer in the arc; arc blow,

2. POWER SOURCE CHARCTERSISTES: volt-ampere relationship and its measurement,

operation point of the arc, variation of current and voltage with arc length, arc length
control.

3. WELDING TRANSFORMERS : Basic principles, different methods of control of volt-ampere

characteristics, operation, volt control, slope control, dual control, use of chokes and
saturable reactors; resistance welding transformers,

4. RECTIFIERS : welding rectifiers, choice of diode material; various types of control output
characteristics, use of thyristors, inverters.

5. ROTATING MACHINES:Alternators and D.C. generators for welding, three brush generator,
setting of power source, characteristics of D.C. motors, synchronous motors.

6 CONTROLS IN WELDING MACHINES :Wire-feed system, carriage movement control,

craterfilling devices, up and down slopes, seam tracking devices, magnetic control of arcs,
pulsing techniques, sequence of control of welding machines, NC and computer controlled
welding machines, controls in resistance welding machines.

7 ELECTRICAL MEASUREMENT IN WELDING:Measurements of welding current, voltage,

temperature, load and displacement, X-Y and strip chart recorders. CRO, LVDT, arc welding
analyzer, resistance welding monitor.
TEXT BOOKS :
1. Welding Handbook, Volume 2, 7th Edition, American Welding Society
2. Richardson V. D., ‘ Rotating Electric Machinery and Transformer Technology’, Prentice Hall
of India,
1978

REFERENCES :
1. Say M. G. Ed., Electrical Engineering Reference Book, 1973
2. Siemens Aklengesel, Chart Electrical Engineering Hand Book, 1987

WELDING PROCESSES

MET/W/104 Theory : 100 Marks

L – 4 T.W./Viva: 50 Marks
Total : 150 Marks

OBJECTIVE : To learn the principles, practice and applications involved in various fusion
welding processes.

1 BASIC WELDING PROCESSES ( Part 1):Classification of welding processes: heat sources,

power sources, arc phenomena, arc blow, power source characteristics, V-I, relationship,
arc length control;

2. BASIC WELDING PROCESSES ( Part 2):manual metal arc welding, ingredients and function
of flux covering, different types of electrodes and their applications, handling and storage of
consumables; gas welding and cutting, flame characteristics, different kinds of flames and
their areas of applications.

3 GAS TUNGESTEN ARC WELDING: electrode polarity, shielding gas, use of DC suppressers,
arc starting and stopping, choice of filler metal composition, use of pulsed arc and GTA spot
welding, other recent developments, applications;
4. GAS METAL ARC WELDING : Considerations of electrode polarity, shielding gas and filler
composition, nature and conditions of spray transfer, difficulties for thin sheet, dip transfer
and CO2 welding, flux cored and pulsed and synergic MIG welding.

5 SUBMERGED ARC WELDING: Advantages and limitations, process variables and their effects,
significance of flux-metal combination, modern developments, narrow gap submerged arc
welding, applications.

6 PLASMA ARC WELDING:Special features of plasma-arc, transferred and nontransferred

arc, keyhole and puddle-in mode of operation, low current and high current plasma arc
welding and their applications, plasma cutting, surfacing and applications.

7 RESISTANCE WELDING: Principle of contact resistance, surface preparation, calculation of

current, voltage and time for spot welding, temperature distribution, spot welding cycle,
inter-relationship between process variables; choice of electrode materials. Welding of
dissimilar combinations; spot, seam and projection welding, stud welding, upset and flash
butt welding; electro slag and electro gas welding.

Note : Experiments based on above syllabus

TEXT BOOKS :

1. Nadkarni S.V., ‘Modern Arc Welding Technology’, Oxford and IBH Publishing,
1996
2. Kearns W. H, ‘Welding Hand Book (Welding Processes)’, Volume II and III, 7th
Edition, AWS,1984
3. Parmer R. S., ‘Welding Engineering and Technology’, Khanna Publishers, 1997
4. Houldcroft P.T, ‘Submerged Arc Welding’, Abington, 1989
5. Lancaster J.F, ‘The Physics of Welding’, Pergamon Press, 1984
REFERENCES : (1) O’Brien R. L,‘Welding Hand Book (Welding Processes)’,Volume
II, 8th Reprint, AWS, 1992 (2)Metals Hand Book (Welding and Brazing), Volume VI,
9th Edition, American Society for Metals, 1989
 NDT AND FAILURE ANALYSIS

METW 105 Theory : 100Marks

L 4 TW/Viva : 50 Marks
Total : 150

OBJECTIVE : To become familiar with NDT techniques and to get exposed to the
concept and procedure associated with failure analysis.

1 LPT, MPT:Visual examination; liquid penetrant testing – procedure; penetrant testing

materials, penetrant testing method – sensitivity; application and limitations; magnetic
particle testing; definition and principle; magnetizing technique, procedure,
equipmentensitivity and limitation;

2. RADIOGRAPHY – basic principle, electromagnetic radiation in film, radiographic imaging,

inspection techniques, applications, limitations, real time radiography, safety in industrial
radiography.

3 EDDY CURRENT:Eddy current testing – principle, instrument techniques, sensitivity

application, limitation; ultrasonic testing – basic properties of sound beam,

4. ULTRASONIC TECHNIQUES: ultrasonic transducers, inspection methods,

technique for normal beam inspection, flaw characterization technique, ultrasonic flaw
detection equipment modes of display, immersion testing, advantage, limitations;
acoustic emission testing – principles of AET and techniques.
5. APPLICATION OF NDT TO FINISHED PRODUCTS :Comparison and selection of NDT methods –
defects like casting defects, forging and rolling defect, extrusion defect, drawing defect,
grinding cracks, heat treating cracks, service defects;

6. SELECTION OF NDT METHODS- VE, LPT, MPT, ECT, RT, UT, AET and thermography; selection of
instrumentation for various NDT methods; reliability in NDT.

7 FAILURE ANALYSIS – I :Failure analysis – methodology; approaches, tools and techniques of

failure analysis; modes of failure; failure data retrieval; procedural steps for investigation of
a failure for failure analysis.

8. FAILURE ANALYSIS – II :Improvements (design, material) derived from failureanalysis; two

case studies; application of fracture mechanics concepts to design forsafety.

Note : Experiments base on above syllabus

TEXT BOOKS :
1. Baldev Raj, Jayakumar T., Thavasimuthu M., ‘Practical Non-Destructive
Testing’, Narosa Publishing, 1997.
2. Das A.K., ‘Metallurgy of Failure Analysis’, TMH, 1992.
3. Hull., ‘Non-Destructive Testing’, ELBS Edition, 1991
4. Halmshaw R., - ‘Non-Destructive Testing’, Edward Arnold, 1989
5. Rolfe T., Barsom J., ‘Fracture and Fatigue Control and Structure – Application of
Fracture Mechanics’, Prentice Hall, 1977
 MECHANICAL BEHAVIOUR OF MATERIALS

METW 106 Theory 100 Marks

L-4

OBJECTIVE : To expose the students to the basic aspects of mechanical behaviour of

materials.

1 MECHANICS OF DEFORMATION( Part 1) :Strength of materials- basic assumptions, elastic and

plastic behaviour, stress–strain relationship for elastic behaviour, elements of plastic
deformation of metallic materials.

2. MECHANICS OF DEFORMATION( Part 2) :Mohr’s circle, yielding theories –Von mises yielding
criterion and maximum-shear-stress/ Tresca criterion, failure criteria under combined
stresses.

3. THEORY OF DISLOCATIONS: Elements of theory of plasticity, dislocation theory properties

of dislocation, stress fields around dislocations, elementary dislocation interactions.
Application of dislocation theory to work hardening,

4. STRENGTHING MECHANISAM : Solid solution strengthening, grain boundary strengthening,

dispersion hardening.

5. FRACTURE AND FRACTURE MECHANICS ( Part 1): Features of ductile and brittle fracture -
ductile to brittle transition temperature- Charpy and Izod testing, significance of DBTT, ECT,
NDT and FATT;

6. FRACTURE AND FRACTURE MECHANICS ( Part 2): elements of fractography - Griffith’s

theory and brittle fracture - Irwin - Orowan modification - stress intensity factor and
fracture toughness - linear elastic and yielding fracture mechanics – crack opening
displacement and J integral - experimental determination of KIC critical COD and J integral.

7. FATIGUE:Characteristics of fatigue failure, initiation and propagation of fatigue cracks,

mechanisms of fatigue failure, factors affecting fatigue strength and methods of improving
fatigue behaviour - fatigue testing - Wohlers test, results of the fatigue test, statistical
analysis of fatigue data, fracture mechanics of fatigue crack propagation, corrosion fatigue.

8 CREEP :Introdcution to creep - creep mechanisms, creep curve, variables affecting

creep, presentation and practical application of creep data, accelerated creep testing, and
time-temperature parameters for conversion of creep data, development of creep resistant
alloys, creep testing - high temperature material problem, stress rapture test, parametric
approaches in presenting creep data - Larsen Miller parameter - Manson Hafred parameter.
TEXT BOOKS :

1.Dieter G. E., ‘Mechanical Metallurgy’, 3rd Edition, McGraw Hill, 1988

2.Suryanarayana, ‘Testing of Metallic Materials’, Prentice Hall India, 1979.
3. Rose R. M., Shepard L. A., Wulff J., ‘Structure and Properties of Materials’, Volume III,4th
Edition, John Wiley, 1984

REFERENCES :

1.Hayden H.A., Motfatt W.G., Wulff J., ‘The Structure and Properties of Materials’,
Volume - III, Wiley, 1986.
2. Kodgire V.D., ‘Material Science and Metallurgy’, 3rd Edition, Everest Publishers
House, 1994.
3.Honeycombe R. W. K., ‘Plastic Deformation of Materials’, Edward Arnold, 1984
 M.E. Part – II (Welding Technology)

WELDING METALLURGY

METW 201
L :4 Hours Theory 100 Marks

OBJECTIVE :To study the principles of welding metallurgy of ferrous and non-ferrous
materials .

1 THERMAL CYCLES Heat flow - temperature distribution-cooling rates - influence of heat

input, joint geometry, plate thickness, preheat, significance of thermal severity number.

2 SOLIDIFICATIONE pit axial growth - weld metal solidification - columnar structures and
growth morphology- effect of welding parameters - absorption of gases - gas/metal and
slag/metal reactions.

3 WELDING METALLURGY OF FERROUS MATERIALS Phase transformationsweld CCT diagrams -

carbon equivalent-preheating and post heating- weldability of low alloy steels, welding
monograms

4 welding of stainless steels (austenitic, ferritic, martensity, duplex and PH stainless steels),
use of Schaffler and Delong diagrams, welding of cast irons – microstructures, defects and
remedial measures.

5 WELDING METALLURGY NON FERROUS MATERIALS: Welding of Cu, Al, Ti and Ni alloys –
processes, difficulties, microstructures, defects and remedial measures.

6 WELD DEFECTS : Origin - types - process induced defects, - significance – remedial

measures, Hot cracking - cold cracking -lamellar tearing - reheat cracking –

7 weldability tests - effect of metallurgical parameters.

Note : Experiment based of above syllabus

TEXT BOOKS :
1. Linnert G. E.,‘Welding Metallurgy’, Volume I and II, 4th Edition, AWS, 1994
2. Granjon H., ‘Fundamentals of Welding Metallurgy’, Jaico Publishing House,
1994
3. Kenneth Easterling, ‘Introduction to Physical Metallurgy of Welding’, 2nd
Edition, Butterworth Heinmann, 1992
4. Saferian D., ‘The Metallurgy of Welding’, Chapman and Hall, 1985
5. Jackson M. D., ‘Welding Methods and Metallurgy’, Grffin, London, 1967

REFERENCES :
1. Norman Bailey, ‘Weldability of Ferritic Steels’, Jaico Publishing House, 1997
2. Kou S., ‘Welding Metallurgy’, John Wiley, 1987

DESIGN OF WELDMENTS

METW 202
L :4 Hours Theory 100 Mark

OBJECTIVE : To discuss general principles of structural design and applying the same to the
design of welded structures.

1 DESIGN BASICS :Type of joints, joint efficiency, factor of safety, symbols, selection of edge
preparation, design considerations, types of loading .

2 STATIC LOADING:Permissible stress, allowable defects, computation of stresses in welds,

weld size calculation, code requirement for statically loaded structures.

3 DYNAMIC LOADINGDesign for fluctuating and impact loading - dynamic behavior of joints -
stress concentrations
4 FATIGUE ANALYSIS fatigue improvement techniques - permissible stress – life prediction.

5FRACTURE MECHANICS :Concept of stress intensity factors - LEFM and EPFM Concepts

5 BRITTLE FRACTURE- Mechanism, transition temperature approach – fracture toughness

testing, application of fracture mechanics to fatigue.

6 RESIDUAL STRESSES: Welding residual stresses - causes, occurrence, effects and

measurements - thermal and mechanical relieving; origin and causes

7 DISTORTION: Types of distortion - factors affecting distortion - distortion control methods

- prediction - correction, jigs, fixtures and positioners.

TEXT BOOKS :
1 Omer W. B., ‘Design of Weldments’, James.F. Lincoln Arc Welding Foundation,
1991
2 Gray T. G. E. ‘Rational Welding Design’, Butterworths, 1982
3 Hertzberg R.W., ‘Deformation and Fracture of Mechanics of Engineering
Materials’, John Wiley, 1996
4 Dieter G.,‘Mechanical Metallurgy’, Tata McGraw Hill, 1988

REFERENCES :

1 Guerey T.R., ‘Fatigue of Welded Structure’, Cambridge University Press, 1979

2 David Broek, ‘Elementary Engineering Fracture Mechanics’, Sujthoff Noordhoof,
1978
3 Rolfe T., Barsom J., ‘Fracture and Fatigue Control of Structure - Applications of
Fracture Mechanics’, Prentice Hall, 1977
 WELDING CODES AND STANDARDS

METW 203
L :4 Hours Theory 100 Mark

OBJECTIVE: To orient the students to the prevailing codes and standards pertaining to
welding and fabrication.

1 STRUCTURAL WELDING CODES : Design requirements, allowable stress values, workmanship

and inspection.

2 PETROLEUM PIPING FABRICATION: Process and product standards for manufacturing of

pipe - welding procedure and welder qualification, field welding and inspection.

3 PRESSURE VESSEL FABRICATION: Design requirements, fabrication methods, joint

categories, welding and inspection, post weld heat treatment and hydrotesting.

4 WELDING PROCEDURE : Welding procedure specification, procedure qualification Records

5 WELDER QUALIFICATION :performance qualification, variables

6 MATERIALS: Introduction to materials standards and testing of materials, consumables

testing and qualification as per ASME/AWS requirements.

7 CONSUMABLES: Types of consumables, Consumable testing and qualification as per

ASME/AWS requirements.
Note : Tutorials based of above syllabus

REFERENCES :
1. AWS D1.1 Structural Welding Code 2. API 5L
3. API 1104 4. ASME Section VIII - Division 1
5. ASME Section IX 6. ASME Section II Part A and C
 ADVANCED WELDING AND ALLIED PROCESSES

METW 204
L4 Theory 100 Mark

OBJECTIVE : The course aims at imparting comprehensive knowledge on advanced welding

and allied processes.

1 SOLID STATE WELDING PROCESSES – I : Fundamental principles of friction, friction stir and
induction pressure welding, process characteristics and applications.

2 SOLID STATE WELDING PROCESSES – II:Explosive, diffusion and ultrasonic welding,

principles of operation, process characteristics and applications.

3 ELECTRON BEAM WELDING (EBW)- Heat generation and regulation, equipment details in
typical set up, electron beam welding in different degrees of vacuum, advantages and
disadvantages, applications

4 LASER BEAM WELDING (LBW) - Physics of lasers, types of lasers, operation of laser welding
setup, advantages and limitations, applications.

5 BRAZING : Wetting and spreading characteristics, surface tension and contact angle
concepts, filling of horizontal and vertical capillary joints, joint design and fixturing, brazing
fillers, role of flux and characteristics, constituents of flux, grouping and applications, fluxes
used for specific braze metal, flux removal and related corrosion problems, atmosphere for
brazing, torch brazing, furnace brazing, induction brazing, dip brazing and resistance
brazing.

6 Soldering : Hand soldering, flame soldering, furnace soldering, hot gas blanket soldering,
wave soldering, fabrication of PCB and ICS; joint design and fixturing, solders,phase diagram,
typical composition and applications .
7 SURFACING,: Thermal spraying, plasma spraying, laser surface alloying and modification,
spraying to improve wear resistance and corrosion resistance, CVD, PVD and ion
implantation, Cladding and its applications.
8. CUTTING AND ADHESIVE BONDING: Oxygen cutting, powder cutting, arc and plasma cutting,
water jet cutting and under water cutting. Adhesive bonding, techniques and applications,
joining of non-metallic materials.

TEXT BOOKS :

1.Schwartz M.,‘ Materials and Applications - Metal Joining Manual’, McGraw-Hill, 1979
2 Nadkarni S.V., ‘Modern Arc Welding Technology’, Oxford IBH Publishers, 1996
3. Christopher Davis, ‘Laser Welding - A Practical Guide’, Jaico Publishing House, 1994
4 Parmar R S, Welding Engineering and Technology, Khanna Publishers, 1997

REFERENCES :

1. Jean Cornu, ‘Advanced Welding Systems’, Volume II and III, Jaico Publishing House, 1994
2. Welding Hand Book, Volume I and IV , 7th Edition , American Welding Society, 1980 Vill V.
I., ‘Friction Welding of Metals’, American Welding Society, 1989
3. Schwartz M., ‘Brazing - for the Engineering Technologists’, Chapman and Hall, 1995
4. Manko H.H., ‘Solders and Soldering’, 2nd edition, McGraw Hill, 1979
5. Thwaites C.J., ‘Capillary Joining - Brazing and Soldering’, Research Studies Press, 1982
6. ‘Brazing Hand Book’, 4th Edition, American Welding Society, 1991
7. Ray Skipp, ‘Soldering Hand Book’, BSP Professional Books, 1988
8. Armin Rahn, ‘The basics of soldering’, John Wiley, 1993
9. Michael G.Pecht, ‘Soldering Processes and equipment’, John Wiley, 1993
10. .S.Sudharshan, ‘Surface Modification Technologies’, Marcel Dekker, Inc
 MANUFACTURING TECHNOLOGY

METW 205
L4 Theory ; 100 Marks
TW/Viva : 50
Total : 150

1. Cutting (Flame & Plasma) Rolling (Hot, Warm, Cold): Theory and practice, different types of
machine and accessories. Rolling of blooms, slabs, rails and structures, flat products and
wheel. Theory of cold and hot rolling. Defects rolled products
2 Forging: Classification of forging, drop and press forging, forging equipments, calculation
of forging pressure & loads, Metallurgical Variables associates with forging. Forging defects
3 Pressing (Die-Punch, Spinning) Drawing L : Tube drawing, wire drawing, Dry and wet wire
drawing, wire drawing equipment & Pipe / Tube Bending
4 Extrusion : Direct and indirect extrusion, variables in extrusion, flow patterns in direct and
indirect extrusion, hydrostatic extrusion
5 Fabrication: Various fabrication operations,Circular seam set ups,Nozzle cut-outs and set
ups,Elevations, orientations, etc. Quality aspects – preheat, visual, arc, strikes,Welder trace
ability, documentation ,Good engineering practices (General and SS fabrication)
Weld repairs – defects marking and repairs Machining
Tube to tube sheet joints, expansion and welding
Material Handling: Concepts ,Tools & Tackles ,Safety
Surface Treatment & Painting: Blasting & Painting ,Passivation
Logistics: Road Transportation Marine / Sea Transportation

Note: Experiments based on above syllabus

References:

William F. Hosford & Robert M. Caddell, “Metal forming mechanics & metallurgy”,
Prentice Hall, N. Y. 1993.
Welding handbook, Section 3: Special welding processes and cutting / American
Welding Society.
Welding and welding technology, Little R.L.
 WELDING ECONOMICS AND MANAGEMENT

METW 206 Theory: 100 Marks

L4

OBJECTIVE : Course discusses techno economic aspects and technology management of

welding.

1 FACTORS INFLUENCING WELDING COST: Welding design, selection of electrodes, size, type
and metal recovery, electrode efficiency, stub thrown away, overwelding and joint, fit - up
welding position operation factor, jigs, fixtures, positioners, operator efficiency.
2 ESTIMATION OF WELDING TIME :Need for time standards, definition of standard time, various
methods of computing standard time, analytical calculation, computerisation of time
standards.
3 COSTING FOR WELDING:Definition of terms, composition of welding costs, cost of
consumables, labour cost, cost overheads, formulae for total cost, cost curves for different
processes like CO2 , SAW, ESW, etc., mechanisation in welding, job shop operation.
4 PLANT LAY OUT(Part 1): Process vs product layout, construction, service consideration,
employees, services, process services, etc., welding shop equipment, oxyacetylene stations,
arc welding stations, inert gas welding stations,
5. PLANT LAY OUT (Part 2): Resistance welding stations, crane, forks, jigs and fixtures, power
tools, blast, cleaning supplies, the welding equipment repair shop, proper arrangement of
the above in the welding shop for maximum convenience and ease of production.
6 SAFE PRACTICES IN WELDING (Part 1) : Selection and installation of equipment, safe handling
of equipment, fire prevention, eye and face protection, respiratory protection, ventilation,
protective extra clothing, electric shock, safety analysis;
7. SAFE PRACTICES IN WELDING (Part 2) : planning for welding operations , production
control, planning for welding processes, pre-production control., planning for welding
processes, pre-production planning routing, scheduling; activating, monitoring, materials
management in welding, inventory control; basic aspects of financial management and man
power planning.
REFERENCES :

1.Bathy J., ‘Industrial Administration and Management’, 1984

2. Pendar J. A., ‘Welding Projects - A Design Approach’, 1977
3.Welding Institute U.K., ‘Standard Data for Arc Welding’, 1994