Welding Activities, Procedures and Standards

Introduction

Welding is a metallurgical process. Welds are to be produced in a range of metals and alloys, the personnel involved must have a thorough understanding of the behavior of materials during welding. Participants will learn how to analyze the metallurgical changes that take place in a material during welding and investigate the influence of these changes on the properties of the weld and the surrounding material of a number of different metals and alloys.

The course also highlights all of the activities related to the design, production, performance, and maintenance of welded products. Interest is primarily in the manufactured product, including material selection, manufacturing methods, tooling, operator training, quality control, performance evaluation, sales, and service. The broad range of welded products with which welding engineers deal includes structures, pressure vessels and heat exchangers, chemical processing equipment, storage vessels, and transmission and distribution piping

Objectives

Upon successful completion of this course, participants will be able to:

• Acquire important knowledge on welding metallurgy
• Discover practical solutions to overcome problems in welding
• Select a suitable welding process and formulate a simple welding procedure
• Understand the most important soldering and brazing processes
• Understand the development of solidification microstructure
• Understand the microstructures typically present in carbon steel welds and surrounding material
• Acquire knowledge of the fundamental theory of the process, design, materials and testing aspects of welding
• Apply fundamental welding engineering knowledge in an integrated fashion to solve diverse practical problems in the welding and joining the field
• Acquire important knowledge on the welding metallurgy of the different types of cast iron
• Understand typical problems that may be experienced during the welding of cast iron and propose ways of avoiding such problems and producing successful welds
• Identify weld defects and avoid them by choosing the proper welding methods and procedure

Target Audience

• Personnel who deal with welding and welding-related industries
• Welding engineers
• Welding inspectors
• Quality Assurance/Control personnel
• Fabrication personnel
• Plant maintenance engineers
• Welding inspectors and technicians

Welding Outline

The course covers the following topics:

Welding standards

• CSA W59
• AWS D1.1
• AWS D1.3
• AWS D1.6

Welding processes

• SMAW
• FCAW
• MCAW
• SAW
• GMAW

Welding activities

Weld types

• FILLET
• COMPLETE
• PARTIAL

Manual welding

Machine welding

Automatic welding

Welding Procedure Specification (WPS for the CSA code)

Welding Procedure Data Sheet (WPDS)

Prequalified Welding Procedure Data Sheet (PWPDS)

Understanding Metals

Arc Welding

• Power sources and electrode identification
• Weldability of metals
• Joint design
• Air arc
• Oxyacetylene cutting
• Vertical and overhead welding
• Weld symbols
• Joint preparation
• Weld codes
• AWS standards and weld alloy

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

• Light gauge steel, aluminum, and stainless steel
• Ferrous and nonferrous metal identification and welding characteristics
• MIG welding applications and variable
• Inert shielding gases and mixtures
• Troubleshooting MIG equipment
• Welds and spot welding
• Vertical and overhead welding
• Out-of-position GMAW (MIG) welding

Flux Cored Arc Welding (FCAW)

• Out-of-position FCAW (flux-cored) welding

Gas Tungsten Arc Welding (GTAW)

• Vertical and overhead welding
• Out-of-position GTAW (TIG) welding
• Applying welding techniques to ferrous and nonferrous pipe, sheet and tube materials

Structural Steel and flux Corded Arc Welding

• Structural steel and FCAW practices
• Ferrous metal identification and welding characteristics
• FCAW welding applications and variable
• Dual shield inert shielding gases and mixtures
• Troubleshoot FCAW equipment

Metal Arc, Oxy and Flux Core Welding

• Shielded metal arc welding on carbon steel plate welding

Welding and Cutting Safety

• Protective Clothing
  • All-natural fibers garments
  • Proper eye protection (safety glasses)
  • Hood or shield
  • Nuisance level respirators

Protective Equipment

• Suitable fire extinguishers
• Pails of water and buckets of sand
• Hose or portable extinguishers
• Welding curtains

Protective Measures

• Fire hazards removal
• Fire watch
• Securing gas cylinders
• Dilution ventilation

Oxy-Acetylene Flame Cutting and Gouging

Oxy-Acetylene Fusion Welding, Braze Welding,

Brazing and Soldering

Air Carbon-Arc Gouging and Plasma Arc

Cutting and Gouging

Controlling Weld Quality

Welding Principles and Practices