the indian institute of welding41
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3/11/2014 The Indian Institute of Welding
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Eligibility Criteria
Course Structure
Course Curriculam & Syllabi
Reference Books
Examination Schedules
Course Fees
Result
Download Forms
General Info
AM - IIW Degree
National Welders’ Training &
Certification Scheme
Modular Employable Skills -
Skill Development Initiative
Other Courses
The Indian Institute of Welding
(A Member Society of The International Institute of Welding)
“MAYUR APARTMENT”, Flat No. 4 B/ N,
3A, Dr. U. N. Brahmachari Street, Kolkata - 700 017, INDIA
Phone: 91 33 2281 3208 | Telefax: 91 33 2287 1350
E-mail: [email protected] | Website: http://www.iiwindia.com
Welding for Nation Building ... A World of Joining Experience
Education, Training &
Certification
AM - IIW Degree - Course Curriculam & Syllabi for Associate Membership (AMIIW)Examination
AMIIW EXAMINATION(w.e.f. December 2007)
REVISED CURRICULUM & SYLLABI
PART ‘A’ PREPARATORY COURSE Marks
AME-1: Elementary Mathematics 100
AME-2: Physics 100
AME-3: Chemistry 100
AME-4: General English 100
AME-5: Applied Mechanics 100
AME-6: Industrial Sociology 100
PART ‘B’ INTERMEDIATE COURSE Marks
AME-7: Strength of Materials 100
AME-8: Electrical Engineering and Electronics 100
AME-9: Material Science 100
AME-10: Production Engineering 100
AME-11: Engineering Drawing 100
AME-12: Engineering Mathematics 100
AME-13: Welding Metallurgy-I 100
AME-14: Heat & Mass Transfer 100
AME-15: Welding & Allied Processes-I 100
PART ‘C’ FINAL EXAMINATION
Part I: Welding Engineering Course Marks
AME-16: Engineering Economics 100
AME-17: Computation Methods and Computer Programming 100
AME-18: Weldment Design & Weld Procedure 100
AME-19: Testing and Quality Assurance 100
Part II: Welding Technology Course Marks
AME-20: Welding Metallurgy – II 100
AME-21: Welding Applications 100
AME-22: Welding & Allied Processes – II 100
AME-23: Welding Equipment & Consumables 100
AME-24: Advanced Welding Technology 100
PART ‘D’ ELECTIVE PROJECT & VIVA VOCE
I. Elective Project on an approved topic
II. Viva Voce: shall be comprehensive and include the Project Work.
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1. AME-1: ELEMENTARY MATHEMATICS
Vector Algebra: Vectors and scalars, vector addition, resolution of vectors, scalar
components, unit vectors, vector representation in three dimensions, scalar and vector product of
two vectors.
Determinants: Determinants; properties, solution of a system of linear equations by
Cramer’s rule.
Complex numbers: Complex Numbers, De Moiver’s theorem, exponential values of sines
and cosines, hyperbolic functions.
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Differential Calculus: Differentiation and integration of hyperbolic functions. Rolle’s
theorem, mean Value theorem, Taylor’s and Maclaurin’s series. Maxima and Minima of function of
one variable.
Integral Calculus: Properties of Definite Integrals. Fundamental theorem of integral
calculus. Arc length and surface areas of plane curves. Volume and Surface Area of Solids of
revolution. Centre of gravity.
Recommended Text Books:
Differential Calculus, Dhami H.S., 1998, New Age International (P) Ltd.
Integral Calculus, Dhami H.S., 2001, New Age International (P) Ltd.
Textbook of Engineering Mathematics, Debashis Datta, 2002, New Age International (P) Ltd.
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2. AME-2: PHYSICS
Geometrical Optics: Lens aberrations; longitudinal chromatic aberration, lateral chromatic
aberration, two lenses in contact, two lenses separated by a distance; Monochromatic aberration;
spherical aberration, coma, oblique astigmatism, curvature and field of distortion.
Interference: Relation between phase and path difference; coherent sources; Young’s Double
slit, Fresnel’s Biprism, Lloyd’s single mirror; position of Bright and Dark fringes, fringe width.
Displacement of fringes; Newton’s rings.
Diffraction: Fresnel and Fraunhofer diffraction, single slit and double slit diffraction, diffraction
grating; introduction to reflection and transmission, resolution and Raleigh criterion, resolving
power of grating.
Polarisation: Concepts, Brewester’s law, double refraction, optic axis; Nicol prism. Laurent’s
and Bi-quartz’s polarimeter.
Fibre Optics: Basic principle and application of optical fibres.
Introduction to Lasers: Stimulated absorption, spontaneous emission and stimulated
emission. Characteristics of Laser light. Einstein’s A and B coefficients. Population inversion’ Ruby
laser, helium-neon laser, argon ion laser, CO2 laser, semi conductor lasers.
Acoustics: Simple harmonic motion, free and damped vibration, analogy with electric circuits,
forced vibration, Resonance; amplitude resonance and velocity resonance and energy intake,
absorption of sound; Sabine’s formula (statement only), acoustic properties of buildings,
production and application of ultrasonics.
Magnetism & Electricity: Biot-Savart law; magnetic fields due to a long straight conductor,
a narrow circular coil, on the axis of a solenoid. Magnetic circuits, magnetomotive force, reluctance.
Alternative current; r.m.s. value, mean value of an a.c. current. Applications of a.c. to (i) a pure
resistance, (ii) a pure inductance, (iii) a capacitor, (iv) an L-R circuit. Impedence triangle and power
triangle. Application of a.c. to (i) a C-R circuit and (ii) an L-C-R circuit in series.
Recommended Text Books:
Engineering Physics, by Srivastava S.K., and Yadav R.A., New Age International (P) Ltd., Fourth
Edition, 2006.
Physics for Engineers, by Srinivasan M.R., New Age International (P) Ltd., 1996.
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3. AME-3: CHEMISTRY
Chemical Bonds: Types of chemical bonds; ionic, covalent, coordination bonds. Theory of
bonding in metals; free electron theory, valence bond theory, molecular orbital theory. Hydrogen
bonding; intermolecular and intramolecular hydrogen bonding. Solid state chemistry; laws of
crystallography, laws of constancy of interfacial angle, law of rationality of indices, Weiss and Miller
indices, law of symmetry; plane of symmetry, axis of symmetry, centre of symmetry. Crystal lattice
and unit cell. Examples of cubic, tetragonal, orthorhombic, monoclinic, triclinic, hexagonal and
rhombohedral crystals. Body centered and face centred lattices.
Polymer Chemistry: Natural and synthetic polymers, Organic and inorganic polymers,
thermoplastic and thermosetting polymers, plastics, elastones, fibres and liquid resins. Addition
and condensation polymers. Structure of polymers.
Chemical Kinetics: Reaction rate and rate laws, rate constant, order of a chemical reaction;
zero, first and second order reaction.
Corrosion: Types of corrosion, theories of corrosion, factors affecting corrosion, protection
from corrosion.
Water Treatment: Types and degrees of hardness, softening of water; lime soda process,
treatment of boiler feed water.
Fuel and Combustion: Calorific value, determination of calorific value, analysis of coal.
Environmental protection: Types and sources of air pollutants, pollution control
techniques. Smog formation, acid rain, depletion of ozone layer.
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techniques. Smog formation, acid rain, depletion of ozone layer.
Recommended Text Books:
Fundamentals of Engineering Chemistry, Singh S.K., New Age International (P) Ltd., Third
Edition, 2005.
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4. AME-4: GENERAL ENGLISH
Grammar. Usage, essays on current topics, précis, letter and technical presentation and technical
report writing.
Selected pieces of prose and poetry from English literature.
5. AME-5: APPLIED MECHANICS
Statics: Composition ad resolution of forces, equilibrium, Lami’s theorem; Coplanar Non-
concurrent forces, moment, Varignon’s theorem, couple, resultant of force systems. Reactions at
supports of beams. Analysis of pinjointed plane frames; method of joints, method of section.
Friction: Laws of friction; angle of friction, angle of repose and cone of friction, simple
applications to wedges, ropes.
Centroid and Moment of Inertia: Determination of centroids of simple figures,theorems
of moments of inertia, determination of moments of inertia of simple shapes.
Dynamics: Kinematics; Linear motion with uniform velocity and uniform acceleration.
Projectiles; inclined projections on level ground, projections on inclined plane, Relative velocity.
Kinetics: D’Alembert’s principle, Impulse momentum, simple applications to motion of
connected bodies.
Circular motion of rigid bodies: acceleration, motion on level ground, banking of roads
and super elevation of rails, designed speed, skidding and overturning on banked roads.
Recommended Text Books:
Engineering Mechanics, Bhavikatti S.S., and Rajasjekarappa K.G., New Age International (P)
Ltd.
Engineering Mechanics, Irving H. Sharnes, Prentice Hall of India Pvt. Ltd., 1998.
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6. AME-6: INDUSTRIAL SOCIOLOGY
Basic concepts of sociological perspective.
Society, groups and sub groups, group formation and dynamics.
Stratification, status and role. Functionalist conflict and elitist perspectives on social
stratification.
Culture; elements of culture, cultural systems and sub-systems. Social changes in modern
India.
Impact of science and technology on culture and civilization. The post industrial society.
Urban sociology and industrial sociology. Sociological problems of economic development
and social change.
Development; the role of state and the role of the market.
Technology Transfer; Technology Assessment.
Sociological perspectives on environment.
Labour in India: Wage regulation; contract labour, women workers, bonded labour, child
labour. Workers’ adjustment and maladjustment. Incentives and disincentives.
Industrial Relations: Workers’ participation in management. Grievance redressal. Industrial
disputes, trade unionism in India, arbitration.
Recommended Text Books:
Industrial Sociology; Dr. Kumar Narain’s series, Lakshmi Narain Agrawal, Agra.
Industrial Sociology; Dr. Vatsyayan Sirth & enlarged Edition; Kedarnath Nath Ram Nath, Meerut
& Delhi.
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7. AME-7: STRNGTH OF MATERIALS
Stress-strain diagram, Hooke’s law, Poisson’s ratio, principal stresses, Mohr circle in two
dimensions. Thermal stresses.
Flexure formulae, bending moment and shear force diagram of cantilever, simply supported and
overhanging beams with concentrated, uniformly distributed and uniformly varying loads. Deflection
in simply supported and cantilever beams; double integration method.
Thin cylinder under internal pressure.
Recommended Text Books:
Elements of Strength of Materials – Timoshenko.
Strength of Materials – G. H. Rhyder.
Strength of Materials – Basavarajaiah B.S., and Mahadevappa P.
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8. AME-8: ELECTRICAL ENGINEERING AND ELECTRONICS
Applied Electricity and magnetism: Electrical charge; potential, flux density, magnetic
field; Direct current – emf, Current and Ohm’s law; resistivity; Kirchhoff’s law. Wheatstone bridge,
potentiometer; Elements of Network Analysis; delta-star transformation. Magnetomotive force,
magnetic reluctance, Ampere turns; hysterisis; self and mutual inductance, eddy currents.
Alternating current; instantaneous, average and r.m.s. values; Vector representation; simple circuit
calculations; response of resistance, inductance and capacitance to D.C. and A.C. voltage
sources. Series and parallel resonance of LRC Circuits. Power factor.
Electrical Machines: Elements of construction, operation and characteristics of D.C. and
A.C. Generators and motors; starters. Transformers, Introduction to variable speed drives.
Electrical Measuring Instruments: Ammeter, Voltmeter, Wattmeter, energy meter,
recorders.
Electronics: Semi Conductors: P and N type, P-N diodes, P-N-P and N-P-N transistors.
Diodes and transistor circuits; single phase, half wave and full wave rectifier, bridge rectifiers and
filtering circuits. Transistor biasing and stabilisation.
Transistor as an amplifier. Common emitter amplifier, the emitter follower. Feedback amplifier;
positive and negative feedback. The operational amplifier (TC). Use of operators of amplifier as
Invertor. Adder, integrator, differentiator.
Push-Pull inverter circuits.
Recommended Text Books:
Electrical Engineering and Electronics, Theraja B.L., 1998, S. Chand & Co. Ltd.
Basic Electronic Principles, Millman and Halkias
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9. AME-9: MATERIAL SCIENCE
Atomic structure and types of bonding between atoms: Bohr’s atomic model
– electronic configuration of atoms, periodic classification of elements. Binding energy; ionic
bonds, covalent bonds, material properties having these bonds. Electro negativity. Metallic bond –
materials properties having this bond. Intermolecular forces.
Concepts of crystal geometry: space lattice – cubic, tetragonal, orthorhombic,
rhombohedral, hexagonal, monoclinic and triclinic. Unit cell parameters to specify each crystal
system. Crystal directions and planes, Miller indices.
Binding in solids: covalent, ionic, metallic and molecular bonding. Crystal symmetry and
structure. Crystalline imperfections. Point imperfections and line imperfections or dislocations,
edge and screw dislocations, slip planes. Surface imperfections. Structure in silica and silicates;
polymorphism in metals and ceramics; Amorphous materials – glass and polymer.
Alloys: binary phase diagrams of important alloy systems, dendrite structure, lever rule, solid
solutions, eutectic, peritectic, eutectoid and peritectoid reactions. Intermetallic compounds, sigma
& other phases.
Mechanical deformation of materials: elastic and anealstic; plastic deformation and
creep, slip and twin, dislocation theory, critical resolved sheer stress, deformation in polycrystalline
material. Bauschinge’s effect and elastic after effect. Work hardening; recovery, recrystalisation and
grain growth, preferred orientation.
Fracture in metals and alloys: ductile and brittle fracture, Griffith’s theory, fracture
toughness, ductile-brittle transition, fatigue fracture. Mechanical testing of metals.
Ceramic Materials: the structure of silica and silicates, polymorphism, fracture in glass,
electrical properties of ceramic phases, refractories.
Polymers: classification, degree of polymerization. Formability; addition polymerization,
copolymerization, condensation polymerization. Molecular structure; linear, branched, cross linked
polymers. Thermoplastic and thermosettling polymers. Structure-property correlation, crystallinity,
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polymers. Thermoplastic and thermosettling polymers. Structure-property correlation, crystallinity,
mechanical properties, applications.
Composites: General characteristics, dispersion / particulate strengthened composites, fibre
reinforced composites, fabrication.
Recommended Text Books:
Material Science, S. L. Kakani and Amit Kakani, First Edition, New Age International (P) Ltd.
Principles of Engineering Metallurgy, L. Krishna Reddy, 1996, New Age International (P) Ltd.
Material Science and Engineering, 7th Edition, by William D. Callister Jr., John Willey & Sons Inc
(2006).
Material Science and Engineering – a First Course, by V. Raghavan, 4th Edition, Prentice Hall of
India Pvt. Ltd., New delhi (2004)
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10. AME-10: PRODUCTION ENGINEERING
Foundry Practice: Types of pattern and core boxes; metal flow in a mould; gating & risering;
Casting processes; green and dry sand, other sand casting processes, metal mould casting
processes, precision casting processes. Melting furnaces. Casting defects, inspection and
rectification.
Forging Practice: Plastic flow of metals; open die, machine and drop forging; forging
machines, hammers & presses.
Cold Working: Blanking and piercing; elements of die design. Deep drawing; Cold working
presses.
Metal Cutting: Geometry of single point tools, chip formation, cutting force, tool life. Cutting
fluids, speed feed, depth of cut and power requirements. Various machining operations; turning,
milling, shaping, planing, screw thread and gear cutting, grinding. Machine tools.
Metrology: Line & end standards, comparators, measurement of flatness and surface finish,
measurement of screw threads and gears; limits & fits, limit gauging, elements of design of limit
gauges.
Process and Production Planning and Control: Production planning, Gantt
Chart, inventory control; inventory policies, economic batch quantities; Method and Work Study, time
study, systems of rating, time standards. Introduction to linear programming; scheduling, PERT
and CPM.
Recommended Text Books:
Production Technology, Jain, R.
A Text Book of Production Engineering, Pandey P.C., Singh C.K., and Balbir Singh
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11. AME-11: ENGINEERING DRAWING
Introduction to IS Code of drawing.
Conics and Curves used in engineering practice: ellipse, parabola, hyperbola,
cycloid, involute and helix.
Orthogonal projection: First and third angle projection of points, lines, planes and solid
objects – cube, prism, pyramid, cylinder, cone and sphere.
Isometric, oblique and perspective projection: Section and auxiliary views.
Introduction to development and intersection of surfaces.
Machine elements: Conventional representation. Assembly and working drawings with
limits, fits and finish.
Welding Symbols: Standard welding symbols used on drawings.
Recommended Text Books:
Engineering Drawing, Bhatt N.D., Panchal V.M., 1998, Charbotar Publishing House.
Machine Drawing, Bhatt N.D., Panchal V.M., Charbotar Publishing House.
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12. AME-12: ENGINEERING MATHEMATICS
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Matrices: Addition and multiplication of matrices. Adjoint and inverse matrix. Matrix method of
solution of a system of linear equations.
Functions of several variables: Limit and continuity, partial derivatives, total differential,
Jacobean and problems of two variables. Tangent planes and normals. Maxima, minima and
saddle points; Lagrange multipliers, problems related to three variables.
Integral Calculus: Double and triple Integrals; simple applications.
Differential Equations: Review of Ordinary Differential Equations. Linear and non-linear
first order equations. Second and higher order equations with constant coefficients. Method of
variation of parameters. Euler-Cauchy equation. Fourier series. Partial differential equations.
Solution of one dimensional wave and diffusion equations. Two dimensional LaPlace equation.
Infinite Series: Convergence and divergence; Comparison test, D’Alembert’s ratio test,
Cauchy’s root test and integral test. Alternating series; tests for convergence and divergence.
Recommended Text Books:
Textbook of Engineering Mathematics, Debashis Datta, 2002, New Age International (P) Ltd.
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13. AME-13: WELDING METALLURGY – I
Solidification of pure metals; micro and macro structure, elastic / plastic deformation,
recrystallisation, work hardening.
Equilibrium diagrams of common binary alloy systems; non, fully and partially mixable
components, their construction and use.
Fe-C diagram; diffusion; equilibrium and non-equilibrium transformation in Fe-C system. C-curves,
solidification, undercooling, ingot structure and coring. Phase transformation in steel; pearlitic,
Bainitic, martensitic reactions and related properties; hardenablity. Heat treatment of steels;
austenitising, annealing, normalising, spherodising, stress relieving; T-T-T & C-C-T diagrams.
Effect of micro-alloying elements on structure and mechanical properties of steels.
Structure of welds; fusion, thermal field, heat distribution, heat input, peak temperature, cooling
rate, solidification of weld pool, fusion line, HAZ, single and multi pass welding.
Recommended Text Books:
Welding Handbook, American Welding Society, Part I: Fundamentals of Welding
Metallurgy of Welding – J. L. Lancaster, Woodhead Publishing Ltd. (Website:
www.woodheadpublishing.com)
Metals and their Weldability, Welding Handbook, Part-4, American Welding Society
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14. AME-14: HEAT AND MASS TRANSFER
Steady state conduction (without heat generation) through a single and composite walls, steady
radial flow through hollow cyllinder, critical thickness of insulation. Cooling by fins and fin
performance.
Unsteady heat flow in a semi infinite solid, long cylinder and sphere, dimensionless numbers,
Heisler charts.
Heat transfer in forced and free convection. Overall heat transfer coefficient. Dimensional analysis
and dimensionless numbers. Natural convection. Heat exchangers, parallel flow and counter flow
heat exchangers, log mean temperature difference. Heat transfer by radiation; law, radiation
properties of gases, heat exchange by radiation between black and gray surfaces.
Intrduction to mass transfer. Fick’s law.
Recommended Text Books:
Heat and Mass Transfer by Nag P.K., Tata McGraw Hill & Co., Second Edition, 2007.
Fundamentals of Heat and Mass Transfer by Kothandaraman C.P., New Age International (P)
Ltd., Third Edition, 2006.
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15. AME-15: WELDING AND ALLIED PROCESSES – I
Metal joining processes used in welded fabrication.
Classification of welded processes – Fusion and solid phase.
Oxy-gas and related welding processes – oxy-gas combustion, different fuel gases, equipment,
safety and applications, Gas cutting and flame hardening processes – equipment and
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safety and applications, Gas cutting and flame hardening processes – equipment and
accessories.
Soldering methods, equipment, applications area and quality standards.
Inert gas shielded non-consumable arc welding (TIG) process – principles, equipment and
accessories, application area, quality standards.
Manual Metal Arc (MMA) welding process – principles, equipment and accessories, electrode type,
arc characteristics, the main arc areas, arc stability, voltage distribution across the arc, heat
generation at the cathode and anode. Polarity and arc characteristics in A.C. and D.C. and its
control. Temperature distribution in the arc and effects. Influence of the magnetic fields on the arc.
Magnetic defection problems. Transfer of metal modes – dip, globular, spray, pulsed.
Gas Shielded Metal Arc Welding (MIG/MAG) and Flux cored welding processes – principles, metal
transfer characteristics; dip, globular spray; power source, wire feeder, welding gun and
accessories, application area and quality standards.
Recommended Text Books:
Welding Engineering and Technology – R. S. Parmar, M/s. Khanna Publishers, 2-B Nath
Market, Nai Sarak, Delhi – 110006
A Textbook of Welding Technology – O. P. Khanna
Welding Handbook, American Welding Society, Section-II: Gas Arc and Resistance.
The Science and Practice of Welding, Vol-1: Welding Science and Technology.
The Science and Practice of Welding, Vol-2: The Practice of Welding: A. C. Davies, Cambridge
University Press (Website: www.cambridge.org).
Messler R.W., Principles of Welding, John Wiley & Sons, 1999
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16. AME-16: ENGINEERING ECONOMICS
Consumer behaviour and demand: Concept and definition of demand; types of
demand; demand schedule, demand curve and demand function; Laws of demand, elasticity of
demand – price elasticity, income elasticity, cross elasticity; demand forecasting, methods of
demand forecasting.
Production functions: product function, period in production; total, average and marginal
product, types of production function; laws of increasing, constant and diminishing returns,
economies of scale.
Cost analysis: opportunity cost, past and future cost, avoidable and unavoidable cost,
replacement cost, historical cost, incremental and sunk cost, controllable cost, production and
short run cost, relationship between various costs.
Break even analysis: limitations, formulae for break even analysis.
Markets: classification on the basis of competition, perfect competition, monopoly, bilateral
monopoly, forms of price discrimination, imperfect competition, monopolistic competition,
oligopoly, duopoly; determination of equilibrium price, price control, price support and minimum
price fixation, pricing strategy.
Sources of finance: financial accounts and management of finance; cost of capital, working
capital management, capital market and money market.
Recommended Text Books:
Managerial Economics and Financial Analysis, Siddiqui S. A., and Siddiqui A.S., 2005, new Age
International (P) Ltd.
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17. AME-17: COMPUTATIONAL METHODS AND COMPUTER PROGRAMMING
Basic components of a Computer System: Primary and secondary memory,
processing unit, input and output devices.
Representation of numbers: Representation of numbers to various bases and their
conversion; representation of signed and unsigned integers in binary form, representation of
floating point numbers.
Languages: Assembly language, high level language, compiler and assembler. Operating
systems like DOS, WINDOWS, UNIX.
The C Language: The C character set, identifiers and keywords, data types and sizes,
variable names, declaration, statements.
Arithmetic, relational and logical operators, increment and decrement operators, assignment
operators and expressions, bitwise operators. Precedence and order of evaluation. Input and
output. Conditionals and branching. Iteration. Functions, recursion.
One dimensional arrays, introduction to pointers, Multi dimensional arrays.
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One dimensional arrays, introduction to pointers, Multi dimensional arrays.
Structures, Unions and files.
Writing Simple Programmes: Writing programmes to solve simple problems using C.
Recommended Text Books:
Programming in C, Balaguruswamy.
The C Programming Language, Kernighan B.W., and Ritchie D.M.
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18. AME-18: WELDMENT DESIGN AND WELD PROCEDURE
Welding Design: Structural elements, cables, bars, beams, plates, slabs, shells, columns.
Stresses and strains, normal stress, shear stress, hot spot stress, notch stress; axial strain, shear
strain. Stress strain relationship; elastic and plastic deformation; Young’s modulus, shear
modulus, transversal contraction coefficient.
Welded joint design, types of joints, classification of groove shapes; welding symbols on drawings,
symbols for groove shapes. Standard representation of welded, brazed and soldered joints.
Behaviour of welded structures under different types of loading – static strength, elevated
temperature strength, low temperature strength, creep resistance, impact behaviour. Design for
torsional loading.
Design of welded joints for column base, plate girders, cylindrical shells and pressure vessels,
pipelines. Design for flanged connections. Joint design for minimising fatigue failures.
Control of distortion and shrinkage, residual stresses in welding.
Welding Procedure: Welding Procedure; definition, significance, Welding Procedure
Specification, Welding Procedure Qualification. Welder qualification, Welding Operator
qualification.
Weldign procedures for manual, semi-automatic and automatic welding by MMAW, TIG, MIG, SAW
processes for materials such as carbon steel, cast iron, low alloy steels, stainless steel,
aluminium.
Introduction to ASME Section IX. Procedures for cutting by gas and plasma. Procedure for pre-
heating and post weld heat treatment of weldments.
Recommended Text Books:
Welding Technology and Design – V. M. Radhakrishnan, Revised Second Ed., New Age
International Publishers.
A Guide to Designing Welds – J. G. Hicks, Woodhead Publishing Ltd. (Website:
www.woodheadpublishing.com)
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19. AME-19: TESTING AND QUALITY ASSURANCE
Mechanical testing; hardness test techniques; static tension testing – stress and strain,
toughness, deviation from elasticity, strain hardening, fracture. Dislocation and Plasticity,
dislocation and strength, yield point phenomenon.
Modulii of elasticity, anelasticity, visco-elasticity. Bauschinger effect.
Impact toughness – measurement techniques.
Cyclic stress – low and high cyclic fatigue, fatigue limit.
Creep stress – stress rupture.
Fracture toughness – measurement techniques
Non-destructive testing; NDT methods; visual, dye penetrant, magnetic particle, eddy
current, acoustic emission, radiographic, ultrasonic testing.
Weld defects; identification, origin, classification.
Statistical Quality Control; X and R charts, p and c charts; sampling plans, single and
double sampling, O.C. curves.
Quality assurance and quality control in welded fabrication; quality manual, quality plan,
personnel and equipment.
Documentation to national, regional and international standards.
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20. AME-20: WELDING METALLURGY – II
Alloy systems of industrial importance and their properties; structural and high strength steels, Cr-
Mo steels, stainless steel, heat resisting steels and alloys, cryogenic steels. Cast irons; types,
microstructure and properties. Titanium and its alloys; magnesium and its alloys; Cermets and
hard facing alloys; Copper base and aluminium base alloys; nickel and its alloys.
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Absorption of gases by weld; O2, N2, H2 and their effects on weld properties. Gas metal and Slag
metal reaction in relation to welding.
Cracking in welds; mechanism of cracking in welded joints and the HAZ, the effect of variables on
the incidence of cracking; effect of elements, heat input, bead shape, hot cracking, reheat cracking,
cracking during heat treatment and multi-pass welding, lamellar tearing, tests for susceptibility of
cracking. Effect of preheating, C.E. values, post weld heat treatment.
Residual Stress; definition, effects on the welded fabrication; measurement and control of residual
stress.
Distortion in welding; transverse, longitudinal and angular. Factors responsible for distortion.
Distortion control.
Corrosion and oxidation of weldments; electro-chemistry of corrosion, redox potential, pickling and
passivation, aeration, cathodic and anodic protection. Types of corrosion; intercrystelline,
transcrystalline, knife-line attack, pitting, crevice and stress-corrosion. Protective coating – oxidation
mechanisms.
Weldability; testing methods; weldability of different engineering alloys; C-Mn steels, stainless
steels, creep resistant steels, cast irons, Ni based, Cu based and Al based alloys.
Joining dissimilar metals; use of Schaeffler / De Long diagram, formation of intermetallic
compound, carbon migration.
Protective layers and cladding; processes for cladding, joining clad steels; corrosion resistance
and wear resistance layers, surface coated and galvanised steels.
Recommended Text Books:
Metallurgy of Welding, J. F. Lancaster, Woodhead Publishing Ltd. (Website:
www.woodheadpublishing.com)
Metals and their Weldability, Welding Handbook, Part-4, American Welding Society.
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21. AME-21: WELDING APPLICATIONS
Application of welding in (a) Building Structures, (b) Bridges, (c) Pressure Vessels (fired and
unfired), (d) Pipelines including Cross Country, (e) Chemicals and Petro-Chemical Plants, (f)
Surfacing and hardfacing in Mining and Steel Plants, (g) Transportation – marine, surface, and
aerospace, (h) power generation plants; thermal, hydel, nuclear.
The following aspects are to be covered in each application areas: (a) governing Codes &
Specification (if any), (b) Base Material, (c) Design Considerations & Details, (d) Welding Process,
Equipments and Consumables, (e) Workmanship Standards to be attained, (f) Inspection
requirements, (g) Computation of welding costs and factors involved eg. deposition rate, cost of
labour, consumables, equipment, return on investment, cost of energy, welder’s duty cycle.
Repair Welding: Problems of repair and maintenance welding both for in-manufacture and
in-service situations. Welding repair procedure specification. Welding repair plan. Welding repair
procedure qualification. NDT of weld repair. Operator qualification to be applied to repair welds.
Fitness for purpose: Principles for fitness for purpose. Effect of imperfection size,
morphology and position on structural integrity. Typical methods of conducting an engineering
critical assessment of a welded structure.
Recommended Text Books:
Welding Technology and Design, Revised 2nd Ed., V. M. Radhakrishnan; New Age International
Publishers (Website: www.newagepublishers.com)
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22. AME-22: WELDING AND ALLIED PROCESSES – II
Submerged Arc Welding (SAW) Process: principles, equipment and accessories, application area,
common problems and quality standards.
Resistance Welding Processes: Spot, seam, projection, butt and flash welding processes.
Temperature distribution. Effect of welding parameters, deformation, surface films, equipment and
accessories, application area and quality standards.
Alumino-thermit welding process – principles, heat source, filler metal, equipment, application
area and quality standards.
Cutting and other edge preparation processes; arc cutting, carbon and metal arc, oxy-arc cutting;
plasma and laser cutting; principles, equipment and application using air and gas mixtures.
Brazing: fundamentals, MIG/MAG pulsed brazing, braze welding; applications and special
problems.
Recommended Text Books:
Welding Engineering and Technology – R. S. Parmar, M/s. Khanna Publishers, 2-B Nath
Market, Nai Sarak, Delhi – 110006.
3/11/2014 The Indian Institute of Welding
http://www.iiwindia.com/education/course_curriculam.html 10/10
Market, Nai Sarak, Delhi – 110006.
A Textbook of Welding Technology – O. P. Khanna
Welding Handbook, American Welding Society, Section-II: Gas Arc and Resistance.
The Science and Practice of Welding, Vol-1: Welding Science and Technology.
The Science and Practice of Welding, Vol-2: The Practice of Welding: A. C. Davies, Cambridge
University Press (Website: www.cambridge.org).
Messler R.W., Principles of Welding, John Wiley & Sons, 1999.
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23. AME-23: WELDING EQUIPMENT AND CONSUMABLES
Welding Equipment Welding power sources and auxiliary equipment system for various welding
processes such as MMAW, TIG, MIG & MAG, SAW.
Selection criteria for welding power source and auxiliary requipment.
Welding Automation including positioners & manipulators and robots etc.
Metal cutting equipment – flame & plasma; profile-following systems- magnetic, optical, NC.
Welding Consumables Welding Consumables for various welding processes, e.g. (a) Gas
Welding & Brazing, (b) Manual Metal Arc Welding, (c) Inert gas, (d) Shielded Tungsten Arc Welding
(MIG & MAG), (e) Submerged Arc Welding, (f) Surfacing, Cladding and Hardfacing Purposes.
Assessment of quality of welding consumables, e.g. Wire Products – Solid, Flux Cored, Metal
Spraying Powder Products, Wire-flux Combinations, Wire-gas Combinations, Flux-Coated
Products – Solid & Tubular. Introduction to relevant national and international standards.
Selection criteria for welding consumables for (a) Welding Dissimilar Metals – Processwise &
Applicationwise, (b) Surfacing & Hardfacing – Processwise & Applicationwise, (c) Aluminium Alloys
– Processwise & Applicationwise, (d) Welding of Constructional Steels – Processwise &
Applicationwise.
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24. AME-24: ADVANCED WELDING TECHNOLOGY
Surfacing and Spraying: Fundamentals of cladding techniques; flame spraying, arc spraying,
plasma spraying; surface preparation, spraying materials; structure of spray layer and substrate.
Advanced Welding Processes: plasma, electron beam, laser, electro-slag, friction, friction stir,
magnetic pulse, ultrasonic, explosive, diffusion, stud, and cold pressure welding processes;
principles, equipment and accessories, wire and shielding media, application areas and quality
standards.
Advances in welding consumables and techniques in welding low weldable metals and high
alloyed weld metals; Inconel, titanium alloys, Cr-Ni-Mn steels.
Welding of polymers; hot plate, butt fusion, hot gas welding, extrusion welding, induction welding,
resistance welding, implant welding, high frequency, friction, electro-fusion, ultrasonic and vibration
welding, adhesive bonding.
Joining processes for ceramics and composites.
Computer application in welding technology; CAD, N.C. Machines, Robotics.
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