GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11

(An Autonomous Institution, Affiliated to Anna University, Chennai)

M.E., WELDING TECHNOLOGY

(FULL TIME & PART TIME)

REGULATIONS - 2016

CURRICULUM AND SYLLABUS

DEPARTMENT OF METALLURGICAL ENGINEERING

GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11
JULY 2016
 DEPARTMENT OF METALLURGICAL ENGINEERING
GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11

M.E., WELDING TECHNOLOGY (FULL TIME)

REGULATIONS - 2016
AUTONOMOUS CURRICULUM STARTING FROM JULY 2016 ONWARDS

I SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
THEORY
1 16WT101 Applied Mathematics and 4 4 0 0 4
Statistics
2 16WT102 Welding and Allied PC 3 3 0 0 3
Processes-I
3 16WT103 Nondestructive Testing PC 3 3 0 0 3
4 Elective I PE 3 3 0 0 3
5 Elective II PE 3 3 0 0 3
6 Elective III PE 3 3 0 0 3
PRACTICAL
7 16WT104 Metallurgy & Welding Lab PC 4 0 0 4 2
Total 23 19 0 4 21

II SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
THEORY
1 16WT201 Welding and Allied PC 3 3 0 0 3
Processes-II
2 16WT202 Mechanical Behaviour of PC 3 3 0 0 3
Materials
3 16WT203 Welding Metallurgy PC 3 3 0 0 3
4 Elective IV PE 3 3 0 0 3
5 Elective V PE 3 3 0 0 3
6 Elective VI PE 3 3 0 0 3
Total 18 18 0 0 18
 III SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
THEORY
1 Elective VII PE 3 3 0 0 3
2 Elective VIII PE 3 3 0 0 3
3 Elective IX PE 3 3 0 0 3
PRACTICAL
4 16WT301 Project Work Phase-I EEC 14 0 0 14 7
Total 23 9 0 14 16

IV SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
PRACTICAL
1 16WT401 Project Work Phase-II EEC 30 0 0 30 15

Total 30 0 0 30 15

Minimum No. of total credits to be earned: 70

 PROFESSIONAL ELECTIVES (PE)
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
1 16WTE01 Corrosion and Surface PE 3 3 0 0 3
Engineering
2 16WTE02 Structure and Properties of PE 3 3 0 0 3
Alloys
3 16WTE03 Material Characterization PE 3 3 0 0 3
4 16WTE04 Welding Application PE 3 3 0 0 3
Technology
5 16WTE05 Electrical Aspects of Welding PE 3 3 0 0 3
6 16WTE06 Automation and Robots in PE 3 3
3 0 0
Welding
7 16WTE07 Welding Economics, PE 3 3
3 0 0
Management and Safety
8 16WTE08 Welding Procedures and PE 3 3
3 0 0
Qualification
9 16WTE09 Fracture Mechanics PE 3 3 0 0 3
10 16WTE10 Welding Codes and Standards PE 3 3 0 0 3
11 16WTE11 Welding Metallurgy of Non- PE 3 3
3 0 0
ferrous Alloys
12 16WTE12 Welding consumables PE 3 3 0 0 3
13 16WTE13 Metal forming Technology PE 3 3 0 0 3
14 16WTE14 Metal Casting PE 3 3 0 0 3
15 16WTE15 Life Assessment of Welded PE 3 3 0 0 3
Structures
16 16WTE16 Repair Welding and PE 3 3
3 0 0
Reclamation
17 16WTE17 Total Quality System and PE 3 3 0 0 3
Engineering
18 16WTE18 Design of Weldments and PE 3 3
3 0 0
Failure Analysis
19 16WTE19 Metallurgical Failure Analysis PE 3 3 0 0 3
20 16WTE20 Optimization Techniques in PE 3
3 0 0 3
Engineering
21 16WTE21 Advanced Finite Element PE 3 3
3 0 0
Analysis
22 16WTE22 Reliability and Quality PE 3 3
3 0 0
Engineering
23 16WTE23 Non-metallic Materials PE 3 3 0 0 3
; PC–Professional Courses; PE - Professional Electives; EEC - Employability
Enhancement Courses; L - Lecture; T - Tutorial; P - Practical; C - Credits;

HOD / METALLURGICAL ENGINEERING

 DEPARTMENT OF METALLURGICAL ENGINEERING
GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11

M.E., WELDING TECHNOLOGY (PART TIME)

REGULATIONS - 2016
AUTONOMOUS CURRICULUM STARTING FROM JULY 2016 ONWARDS

I SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
THEORY
1 16WT101 Applied Mathematics and 4 4 0 0 4
Statistics
2 16WT102 Welding and Allied PC 3 3 0 0 3
Processes-I
3 Elective I PE 3 3 0 0 3
PRACTICAL
4 16WT104 Metallurgy & Welding Lab PC 4 0 0 4 2
Total 14 10 0 4 12

II SEMESTER
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
THEORY
1 16WT201 Welding and Allied PC 3 3 0 0 3
Processes-II
2 16WT202 Mechanical Behaviour of PC 3 3 0 0 3
Materials
3 Elective II PE 3 3 0 0 3
Total 9 9 0 0 9

III SEMESTER

S. COURSE COURSE TITLE CATEGORY CONTACT L T P C

No CODE PERIODS
THEORY
1 16WT103 Nondestructive Testing PC 3 3 0 0 3
2 Elective III PE 3 3 0 0 3
3 Elective IV PE 3 3 0 0 3
Total 9 9 0 0 9
 IV SEMESTER

S. COURSE COURSE TITLE CATEGORY CONTACT L T P C

No CODE PERIODS
THEORY
1 16WT203 Welding Metallurgy PC 3 3 0 0 3
2 Elective V PE 3 3 0 0 3
3 Elective VI PE 3 3 0 0 3
Total 9 9 0 0 9

V SEMESTER

S. COURSE COURSE TITLE CATEGORY CONTACT L T P C

No CODE PERIODS
THEORY
1 Elective VII PE 3 3 0 0 3
2 Elective VIII PE 3 3 0 0 3
3 Elective IX PE 3 3 0 0 3
PRACTICAL
4 16WT301 Project Work Phase-I EEC 14 0 0 14 7
Total 23 9 0 14 16

VI SEMESTER

S. COURSE COURSE TITLE CATEGORY CONTACT L T P C

No CODE PERIODS
PRACTICAL
1 16WT401 Project Work Phase-II EEC 30 0 0 30 15

Total 30 0 0 30 15

Minimum No. of total credits to be earned: 70

 PROFESSIONAL ELECTIVES (PE)
S. COURSE COURSE TITLE CATEGORY CONTACT L T P C
No CODE PERIODS
1 16WTE01 Corrosion and Surface PE 3 3 0 0 3
Engineering
2 16WTE02 Structure and Properties of PE 3 3 0 0 3
Alloys
3 16WTE03 Material Characterization PE 3 3 0 0 3
4 16WTE04 Welding Application PE 3 3 0 0 3
Technology
5 16WTE05 Electrical Aspects of Welding PE 3 3 0 0 3
6 16WTE06 Automation and Robots in PE 3 3
3 0 0
Welding
7 16WTE07 Welding Economics, PE 3 3
3 0 0
Management and Safety
8 16WTE08 Welding Procedures and PE 3 3
3 0 0
Qualification
9 16WTE09 Fracture Mechanics PE 3 3 0 0 3
10 16WTE10 Welding Codes and Standards PE 3 3 0 0 3
11 16WTE11 Welding Metallurgy of Non- PE 3 3
3 0 0
ferrous Alloys
12 16WTE12 Welding consumables PE 3 3 0 0 3
13 16WTE13 Metal forming Technology PE 3 3 0 0 3
14 16WTE14 Metal Casting PE 3 3 0 0 3
15 16WTE15 Life Assessment of Welded PE 3 3 0 0 3
Structures
16 16WTE16 Repair Welding and PE 3 3
3 0 0
Reclamation
17 16WTE17 Total Quality System and PE 3 3 0 0 3
Engineering
18 16WTE18 Design of Weldments and PE 3 3
3 0 0
Failure Analysis
19 16WTE19 Metallurgical Failure Analysis PE 3 3 0 0 3
20 16WTE20 Optimization Techniques in PE 3
3 0 0 3
Engineering
21 16WTE21 Advanced Finite Element PE 3 3
3 0 0
Analysis
22 16WTE22 Reliability and Quality PE 3 3
3 0 0
Engineering
23 16WTE23 Non-metallic Materials PE 3 3 0 0 3
; PC – Professional Courses; PE - Professional Electives; EEC - Employability
Enhancement Courses; L - Lecture; T - Tutorial; P - Practical; C - Credits;

HOD / METALLURGICAL ENGINEERING

 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

SEMESTER – I

16WT101 APPLIED MATHEMATICS AND STATISTICS LTPC

4 0 04

CALCULUS OF VARIATIONS (9)

Concept of variation and its properties – Euler’s equation – Functionals dependent on first
and higher order derivatives –Functionals dependent on functions of several independent
variables – Direct methods: Rayley-Ritz and Galerkin methods.

SOLUTION OF LINEAR SYSTEMS OF EQUATIONS (9)

Direct method: Gaussian Elimination, Gauss–Jordan and Factorisation methods – Iterative
method: Gauss-Jacobi, Gauss- Seidel Methods- Eigen value problems: Power and Gauss
Jacobi Methods.

PROBABILITY DISTRIBUTIONS AND RANDOM VARIABLES (9)

Random variables- Moments – Moment generating function – Standard distributions-
Binomial, Poisson, Uniform and Normal Distributions- Joint distributions- Marginal and
Conditional distributions- Covariance- Correlation and Regression.

TESTING OF HYPOTHESIS (9)

Sampling distributions – Large Sample Tests: Normal test for Single and difference of
Mean(s) and Proportion(s)-Small Sample Tests: t-test for Single and difference of Mean(s),
F-test for equality of variances and Chi-square test for goodness of fit and independence of
attributes.

ANALYSIS OF VARIANCE AND DESIGN OF EXPERIMENTS (9)

Analysis of variance -One way and Two way classifications- Completely Randomized
Design– Randomized Block design – Latin square design.

Total: 60 periods

REFERENCES:
1. Grewal, B.S., Higher Engineering Mathematics, 43rd edition, Khanna Publishers,
New Delhi 2014.
2. Gupta, A.S., Calculus of Variations with Applications, Prentice Hall of India Pvt.
Ltd., New Delhi 2004.
3. Gupta, S.C. and Kapur, V.K., Fundamentals of Mathematical Statistics, S.Chand
and Sons, New Delhi, 11th Edition 2014
4. Fruend John, E. and Miller Irwin, Probability and Statistics for Engineers,
8thEdition, Prentice Hall India (P) Ltd, 2010.
5. Sankara Rao. K., “Numerical methods for Scientists and Engineers”, Prientice
Hall of India (P) Ltd, 3-rd Edition, New Delhi, 2008

7
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WT102 WELDING AND ALLIED PROCESSES – I LTPC

3 00 3

INTRODUCTION TO JOINING PROCESSES AND GAS WELDING (9)

Classification of welding processes – Heat sources for fusion welding, Shielding methods,
Nature and behavior of fluxes for welding, Shielding gases, Arc physics.
Oxy Fuel Gas Welding: Gases – setup of equipment – Flame characteristics, different kinds
of flame and their applications, Variants of oxy fuel gas welding.

SHIELDED METAL ARC WELDING (9)

Arc Welding Power sources, Polarities, V-I Characteristics of power sources – static and
dynamic, Duty cycle
SMAW Process: Principle of the process, Electrodes, functions of flux coating, types of
electrodes and their applications, AWS Classifications of electrodes, electrode designations,
variants of SMAW, defects, causes and remedies.

GAS TUNGSTEN ARC WELDING & PLASMA ARC WELDING (9)

Gas Tungsten Arc Welding – Equipment, Electrodes, polarity, shielding gas, use of D.C.
suppressors, arc starting and stopping, choice of filler metal composition, use of pulsed arc
and GTA spot welding, other recent developments, applications - defects, causes and
remedies. Plasma arc welding: Equipment, Operating modes – melt-in technique, key-hole
technique, arc- transferred and non-transferred arc, micro low and high current plasma arc
welding and their applications.

GAS METAL ARC WELDING & FLUX CORED ARC WELDING (9)
Gas Metal Arc Welding- Principle of operation, Metal transfer mechanisms, Equipment,
shielding gases, electrodes, Pulsed GMAW, Synergic GMAW, Cold Metal Transfer.
Flux cored arc welding – Process features, Equipment, Electrode manufacture and Electrode
classification.

SUBMERGED ARC WELDING, STUD WELDING & CARBON ARC WELDING (9)
Submerged arc welding – Principle of operation, Equipment, Flux classification, Basicity
index, Electrodes, Variations of Process, Defects, Applications
Stud arc welding - Equipment, operation, Stud arc welding gun, Ferrules
Carbon arc welding – operation, single electrode operation, twin electrode operation,
electrodes, applications.

Total: 45 periods
REFERENCES:

1. Parmar R.S. “Welding Processes and Technology” Khanna Publishers. 1992

2. Nadkarni. S.V. “Modern Arc Welding Technology” Oxford IBH Publishing Co. 1996.
3. AWS Welding Handbook. 8th edition. Volume 1 Welding Technology. 1991
4. AWS Welding Handbook. 8th edition. Volume 2 Welding Processes. 1991
5. Lancaster J.F. “The Phyiscs of Welding”. Pergamon Press. 1984.
6. Metals Handbook (Welding, Brazing and Soldering) Vol. 6, 10th Edition. ASM 1995.

8
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WT103 NONDESTRUCTIVE TESTING LTPC

30 03
SURFACE NDT TECHNIQUES (9)
Relative merits and limitations of NDT vs. Conventional testing –Visual inspection, thermal
inspection methods. Liquid penetrant Inspection: Principles, applications advantages and limitations,
Dyes, developers, and cleaners, fluorescent penetrant test application of liquid penetrant testing to
weldments Magnetic particle Inspection: Principle, application, magnetization methods, magnetic
particles, dry and wet technique, demagnetization. Principles application and Instrumentation of Eddy
current testing.

X-RAY RADIOGRAPHY (9)

Types of radiation, production of X-rays,properties of X-rays relevant to NDE, absorption of X-rays,
scattering, types and use of filters and screens, geometric factors, inverse square Law, film types and
processing, characteristics of films – grain fineness, density, speed contrast characteristic curves,
penetrameters, Exposure charts, radiographic equivalence.

GAMMA RAY RADIOGRAPHY AND OTHER NDT TECHNIQUES (9)

Gamma ray sources, radioactive decay, artificial radioactivity, characteristics of Gamma ray sources,
Gamma ray exposure chart. Measurement of radioactivity, radiation hazards, units of radiation dose
measurement, permissible radiation dose, radiation detection and measurement instruments,
protection against radiation. Fluoroscopy technique, standard radiographs, Interpretation of
radiographs, application of radiographic testing to weldments. Digital radiography. Acoustic Emission
Techniques, Holography, Leak testing – hydrostatic testing, bubble leak test, pneumatic testing,
service leak test

ULTRASONICS (9)
Types of ultrasonic waves, principles of wave propagation characteristics of ultrasonic waves,
attenuation production of ultrasonic waves couplants. Inspection methods – Pulse echo, transmission
and resonance, thickness measurement. Types of scanning., test blocks IIW reference block.
Calibration of ultrasonic equipment application of ultrasonic testing to weldments, Time of flight
diffraction (TOFD), Phased array Ultrasonic Testing.

OVERVIEW OF CODES AND STANDARDS RELATED TO NDT & WELDING (9)

Qualification of inspectors as per ASNT and their authority and responsibility. Elementary
introduction to AWS documents on following subject areas like definition and symbols, filler metals,
Qualification and Testing, welding processes, welding application and safety - API codes on pipelines
and refining equipment and storage tanks for refinery service, ASME – Boiler and Pressure vessel
code Section II, V, VIII & IX, ASME code for pressure pipings - the purpose of respective code only.
Welding Procedure Specifications, Procedure Qualification Records, Welder Performance
Qualification.

Total: 45 periods
REFERENCES:
1. Baldevraj., Jayakumar.T., Thavasimuthu. M., Practical Non-destructive Testing, Narosa
Publishers. 1997.
2. AWS Welding Handbook, vol.5, “Engineering Costs, Quality and Safety”, 7th Ed, AWS, 1997
3. Hull, “Non Destructive Testing”, ELBS Edition, 1991.
4. McGonnagle. W.J. Non-Destructive Testing, Gordon and Breach, 2nd Ed., 1971.
5. ASM Metals Hand Book. Vol. 9. Non-destructive Testing and Inspection_, 1988.
6. Codes And Standards- ASNT, AWS D1.1, API1104, ASME- Boiler & Pressure Vessel Code
– Section II, V, VIII, IX.
7. ASNT Nondestructive Testing Handbooks, Third Edition, American Society for
Nondestructive Testing

9
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WT104 METALLURGY & WELDING LAB LTPC

0 0 4 2
LIST OF EXPERIMENTS

1. Specimen preparation for microscopic observation

2. Microstructure of plain carbon steels
3. Microstructure of cast irons
4. Macro and Microstructure of welded specimens
5. Study of weld bead characteristics
6. Microhardness survey of welded specimens
7. Preparation of WPS, PQR and Welder qualification test
8. Fit-up inspection
9. Arc Welding Practices
10. Visual weld defect inspection
11. Penetrant Testing and Magnetic Testing Examination
12. Radiographic Testing (RT) Interpretation

10
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

SEMESTER – II

16WT201 WELDING AND ALLIED PROCESSES - II LTPC

3 0 0 3
SOLID STATE WELDING PROCESSES (9)
High temperature solid state welding, Low temperature solid state welding, Fundamental
principles, various solid state welding processes and principles of operation, applications.
Cold pressure welding, explosive welding, diffusion welding, Ultrasonic welding, Forge
welding, Roll welding – Principles of operation, Equipment, process characteristics and
applications.
FRICTION AND FRICTION STIR WELDING (9)
Friction Welding- Theoretical considerations, Process characteristics, Friction Welding
machines and equipments, welding variables, weld properties, Joint design, Applications.
Friction Stir Welding - Principles of operation, Important welding parameters, tool rotation
and traverse speeds, tool tilt and plunge depth, tool design, Generation and flow of heat,
Applications, advantages and limitations, Flaws and defects in FSW. Friction surfacing and
friction processing.
ELECTRON AND LASER BEAM WELDING (9)
Heat generation and regulation, equipment details in typical set-up, electron beam welding in
different degrees of vacuum, advantages and disadvantages, applications.
Laser Welding: Laser sources for welding, Principles of operation, advantages, and
limitations, applications.
ELECTRO SLAG WELDING AND RESISTANCE WELDING (9)
Electro slag welding - Heat generation, principles of operations, wire and consumable guide
techniques, selection of current, voltage and other process variables, nature of fluxes and their
choice, applications, variants of electro slag welding, Electro-Gas welding.
Resistance welding - Principles of contact resistance, surface preparation, calculation of
current, time and voltage for spot welding – Temperature distribution, spot welding cycle,
inter-relationship between process variables, choice of electrode material, seam welding,
projection welding. Flash welding, Upset welding, High frequency welding.
OTHER WELDING PROCESSES AND THERMAL CUTTING (9)
Adhesive bonding – Concept, Procedure, Testing of Adhesive bonded joints, types of
adhesive bonded joints, Sandwich Construction, selection and types of adhesives. Welding of
plastics, Underwater Welding. Thermit Welding, Brazing and Soldering -Fundamentals,
Types, brazing and soldering alloys and their classification. Thermal cutting – Oxy-fuel
cutting, arc cutting, plasma arc cutting, laser cutting.

Total: 45 periods
REFERENCES:

1. AWS Welding Hand Book. 8th Edition. Vol- 2. Welding Process, 1998.
2. Schwartz M.M., Metals Joining Manual, McGraw Hill Books. 1979.
3. Tylecote R.F. The Solid Phase Welding of Metals, Edward Arnold Publishers Ltd.
London. 1968.
4. Parmar R.S. “Welding Processes and Technology”, Khanna Publishers, New Delhi,
1998
5. Christopher Davis. Laser Welding - Practical Guide, Jaico Publishing House, 1994.
6. Nadkarni S.V., Modern Arc Welding Technology, Oxford IBH Publishers. 1996.
11
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WT202 MECHANICAL BEHAVIOUR OF MATERIALS LTPC

3 0 0 3

DISLOCATIONS AND STRENGTHENING MECHANISMS (9)

Dislocations –Burger’s circuits– Deformation by slip – dislocation movement –Twinning
systems – cross slip – dislocation reaction – dislocation climb – intersection of dislocation-
jogs – dislocations sources – multiplication of dislocations – dislocation pile-ups. Cold
working, hot working & annealing. Strengthening of Mechanisms- work hardening, cold
worked structure, grain boundary strengthening, yield point phenomena, strain-aging solid
solution strengthening, precipitation hardening, dispersion strengthening, fiber strengthening.

TENSILE IMPACT AND HARDNESS TESTS (9)

Tensile test- Engineering stress-strain curve, True Stress-strain curve, Testing mechanics and
procedures. Impact test- Izod and Charpy impact test, Ductile Brittle Transition Temperature,
determination of DBTT, Nick Break Test, Drop Weight tests and other large scale tests.
Hardness test- Introduction, Brinell, Vicker’s and Rockwell hardness tests. Bend tests.
Nanoindentation.

FRACTURE AND FRACTURE MECHANICS (9)

Types of fracture in metals – Griffith theory of brittle fracture, Introduction to fracture
mechanics, Strain – energy release rate, stress intensity Factor and fracture toughness.
Elementary discussions on linear elastic and Elastic – plastic fracture mechanics and crack
opening displacement. Experimental determination of KIC and critical COD and J integral.
CTOD test, Toughness of materials.

FATIGUE (9)
Fatigue testing, factors affecting fatigue, structural changes accompanying fatigue, formation
of fatigue cracks and fatigue failure. Cumulative damage. Low cycle fatigue. Application of
fracture mechanics to fatigue crack propagation.

CREEP (9)
Introduction to creep – creep curve, variables affecting creep, accelerated creep testing, and
time – temperature parameters for conversion of creep data, development of creep resistant
alloys, stress rupture test, parametric approaches in presenting creep data – Larsen Miller
parameter, Manson Hafred parameter.

Total: 45 periods

REFERENCES:
1. Dieter G. E. Mechanical Metallurgy_, SI metric Edition, McGraw Hill Books, 1988.
2. Hertzberg. R.W. Deformation and Fracture Mechanics of Engineering Materials, John
Wiley, New York,1989.
3. Courtney T. H. Mechanical Behavior of Materials_, 2nd edition, McGraw Hill. 2000.
4. Rose. R.M. Shepard L.A. Wulff. J. Structure and Properties of Materials, Vol. 3,
Mechanical Behavior. 4th edition. John Wiley. 1984.
5. Smallman R.E. Modern Physical Metallurgy_, Butterworths, 4th edition, 1985.
6. Meyers M.A. Chawla. K.K . Mechanical Behaviour of Materials, Prentice-Hall International
Inc. 1999.

12
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WT203 WELDING METALLURGY LTPC

3 0 03

HEAT FLOW IN ARC WELDING (9)

Heat flow-Basic heat transfer equations, temperature distributions and cooling curves-
Influence of heat input, Joint Geometry, plate thickness, preheating and other factors.
Comparison of welding processes based on these considerations. Solidification – Epitaxial
growth – weld metal solidification – cellular and columnar structures – effect of welding
parameters – absorption of gases – gas/metal and slag/metal reactions.

WELDABILITY AND WELDABILITY TESTING (9)

Concept of Weldability, Factors affecting Weldability, Welding Defects, Causes and
remedies, Cracking phenomena in welding, Characterization of weldments, Weldability tests
– cold cracking tests, hot cracking tests, Internal restraint tests, External restraint tests,
Mechanical tests for weldments-Tension tests and Bend tests.

WELDABILITY OF CARBON STEELS AND LOW ALLOY STEELS (9)

Formation of different microstructural zones in welded plain-carbon steels, C-Mn and low
alloy steels. Phase transformation in weld metal and heat affected zones. Hydrogen induced
cracking, Carbon equivalent, preheating, Post heating and post weld heat treatment, Hot
cracking – compositional features – Effect of S and P, Reheat cracking and Lamellar
cracking.

WELDABILITY OF STAINLESS STEEL (9)

Introduction to stainless steel classification, effect of alloying elements, Austenitising
elements, Ferritising elements, Weldability of austenitic stainless steels – Hot cracking –
constitution diagrams – Schaffler, Delong, WRC diagrams, Mode of solidification,
Sensitisation, Sigma embrittlement. Metallurgical difficulties in welding of ferritic,
martensitic and duplex stainless steels, selection of filler metals.

WELDABILITY OF OTHER ALLOYS AND DISSIMILAR WELDING (9)

Welding of cast irons, High Cr steels, Maraging Steels – Process, procedure and filler metal
selection, weldability problems encountered and solutions.
Weldability of Al alloys, Cu Alloys, Ti Alloys and Ni Alloys – Selection of welding process
and procedure appropriate for each material.
Dissimilar welding: Metallurgical problems in dissimilar welding- calculation of dilution-
methods of controlling dilution - techniques of dissimilar welding.

Total: 45periods
REFERENCES:

1. Parmar R.S. Welding Engineering and Technology, Khanna Publishers. 1997.

2. Lancaster J.F. Metallurgy of Welding, George Allen & Unwin. Boston. 1980.
3. Kou. S. Welding Metallurgy, John Wiley & Sons. 1987.
4. Granjon. H. Fundamentals of Welding Metallurgy, Jaico Publishing House. New
Delhi 1994.
5. Norman Bailey. Weldability of Ferritic Steels, Jaico Publishing House. 1997
6. AWS Welding Hand book. 8th edition. Vol-1. Welding Technology. 1998

13
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

LIST OF ELECTIVES

16WTE01 CORROSION AND SURFACE ENGINEERING LTPC

30 0 3

MECHANISMS AND TYPES OF CORROSION (9)

Principles of direct and Electro chemical Corrosion, Hydrogen evolution and Oxygen absorption
mechanisms – Galvanic corrosion, Galvanic series-specific types of corrosion such as uniform,
Pitting, Intergranular, Cavitations, Crevice Fretting, Erosion and Stress Corrosion –Factors
influencing corrosion

TESTING AND PREVENTION OF CORROSION (9)

Corrosion testing techniques and procedures- Corrosion Testing ASTM Standards, Pitting Corrosion
Test, Hydrogen Induced Cracking (HIC) Test, Sulphide Stress Corrosion Cracking (SSCC) Test-
Prevention of Corrosion-Design against corrosion –Modifications of corrosive environment –
Inhibitors – Cathodic Protection –Protective surface coatings.

CORROSION BEHAVIOR OF MATERIALS (9)

Corrosion of steels, stainless steel, Aluminum alloys, copper alloys, Nickel and Titanium alloys-
corrosion of Polymers, Ceramics and Composite materials.

SURFACE ENGINEERING FOR WEAR & CORROSION RESISTANCE (9)

Diffusion coatings –Electro and Electroless Plating –Hot dip coating –Hard facing-Metal spraying,
Flame and Arc processes- Conversion coating –Selection of coating for wear and Corrosion
resistance.

THIN LAYER ENGINEERING PROCESSES (9)

Laser and Electron Beam hardening –Effect of process variables such as power and scan speed -
Physical vapor deposition, Thermal evaporation, Arc vaporization, Sputtering, Ion plating - Chemical
vapor deposition – Coating of tools, TiC, TiN, Al2O3 and Diamond coating – Properties and
applications of thin coatings.

Total: 45 periods

REFERENCES:

1. Fontana. G., Corrosion Engineering, McGraw Hill, 1985.

2. Kenneth G.Budinski, Surface Engineering for Wear Resistance, Prentice hall,1992.
3. ASM Metals Hand Book –Vol. 5, Surface Engineering, 1996.
4. Denny A Jones, “Principles and prevention of corrosion”, 2nd edition, Prentice Hall, New
Jersey, 1995.
5. ASM International, Surface Engineering for Corrosion and Wear Resistance, 2005.
6. Schweitzer. P.A., Corrosion Engineering Hand Book, 3rd Edition, Marcel Decker, 1996.

14
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE02 STRUCTURE AND PROPERTIES OF ALLOYS LTPC

3 0 0 3

CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS (9)

Phases, solid solutions, compounds - Concept of phase diagram – types and examples. Phases
and micro-constituents in steels and cast irons – equilibrium and non-equilibrium cooling of
various Fe-C alloys – Fe-C Equilibrium diagram - effects of alloying elements and cooling
rate on structure and properties of steels and cast irons.

HEAT TREATMENT (9)

Introduction to heat treatment; TTT diagram and CCT diagram – hardenability measurement,
annealing – normalizing – hardening and tempering – heat treatment atmospheres –
quenching media – case hardening techniques, precipitation hardening.

STEELS (9)
Introduction to specifications – plain carbon steels – low alloy and Q and T steels dual phase
steels – Ultra high strength steels – maraging steels – HSLA steels – High Cr steels -
processing, properties & applications.

STAINLESS STEELS AND CAST IRONS (9)

Stainless steels – phase diagrams – effects of chromium and nickel – ferritic and Austenitic,
martensitic, duplex and precipitation hardened stainless steels. Types of Cast Irons- Gray
Cast iron, white iron, malleable iron, S.G. Iron and alloy cast irons – physical metallurgy,
composition of cast irons, properties and applications. Heat treatment of cast irons.

NON-FERROUS ALLOYS (9)

Physical metallurgy, composition, properties and applications of Cu alloys, Al Alloys, Ti
alloys, Ni alloys and Mg alloys.

Total: 45 periods
REFERENCES:

1. Raghavan V. “Physical Metallurgy – Principles and Practice”, Prentice Hall of India,

1993.
2. Brick Gardon Philips. “Structure and Properties of Alloys”, McGraw Hill, 1976.
3. Flinn. R.A. and Trojan. P.K. “Engineering Materials and their Applications”, 4th
Edition, Jaico, 1999.
4. Leslie. W.C., “The Physical Metallurgy of Steels”. McGraw Hill. 1983.
5. Metals Hand book. 10th edition. Volume 2. ASM. 1995.
6. Askeland. D.R. “The Science and Engineering of Materials”. PWT Kent Publishing
Company, Boston, 1989
7. Pickering F.B. “Physical Metallurgy and Design of Steels”. Applied Science
Publishers Limited. London. 1978.

15
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE03 MATERIAL CHARACTERIZATION LTPC

30 0 3

METALLOGRAPHIC TECHNIQUES (9)

Resolution, depth of focus and components of microscope, polarized light, phase contrast,
interference, hot stage and quantitative metallographic techniques-grain size, volume fraction, etc., In-
situ metallography, specimen preparation techniques.

X-RAY DIFFRACTION TECHNIQUES (9)

Continuous and Characteristic spectrum – Bragg’s law – Diffraction methods – Laue, rotating crystal
and powder methods. Intensity of diffracted beams – structure factor calculations.

APPILICATIONS OF X-RAY DIFFARACTION (9)

Diffractometer – general feature and optics – proportional scintillating and Geiger counters. X-ray
diffraction application in determination of crystal structure, lattice parameter and residual stress –
quantitative phase estimation.

ELECTRON MICROSCOPY (9)

Construction and operation of Transmission Electron Microscopy – Diffraction effects and image
formation, specimen preparation techniques, elemental analysis by wavelength dispersive and energy
dispersive systems. Construction and operation of Scanning Electron Microscopy. Atomic force
microscopy. Analysis of fractured surfaces.

ADVANCED CHEMICAL AND THERMAL ANALYSIS METHODS (9)

X-ray fluoroscopy, Spectroscopy- principles, Atomic Absorption Spectroscopy, Optical Emission
Spectroscopy, Auger spectroscopy. Differential Thermal Analysis, Differential Scanning Calorimetry
and Thermo Gravimetry Analysis, Stress analysis.

Total: 45 periods
REFERENCES:

1. Philips V.A. Modern Metallographic Techniques and their Applications, Wiley Interscience,
1971.
2. Cullity B.D., Elements of X- ray Diffraction, 2nd Edition, Addison Wiley, 1978.
3. ASM Metals Handbook, Vol.10, Material Characterization, ASM, New York, 1998.
4. Thomas. G. Transmission Electron Microscopy of Metals_. John Wiley. 1961.
5. Smallman R.E. Modern Physical Metallurgy_, 4th Edition, Butterworths. 1985.
6. Loretto. M.H. Electron Beam Analysis of Materials_, Chapman and Hall, 1984.

16
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE04 WELDING APPLICATION TECHNOLOGY LTPC

3 0 03

WELDING OF STRUCTURALS & PRESSURE VESSELS (9)

STRUCTURALS: Types of structural elements and their welding, materials used in bridges and
welding of bridges.
VESSELS: Material selection and factors affecting it, fabrication of conventional pressure vessels –
welding processes used, nozzle welding, tube to tube plate welds, flanges, vessel ends, fabrication of
clad pressure vessels. Weldability aspects of pressure vessel steels.

WELDING OF STORAGE TANKS & PIPINGS (9)

Welding of vertical storage tanks and Hortonsphere.
WELDING OF PIPING & PIPELINES: pipe steels and electrodes, types of joints and weldings,
backing welds rings, fittings, alloys used for piping, pipe welding procedures, preheating and PWHT,
offshore pipework, pipelines and pipeline welding, under water pipeline welding.

WELDING APPLICATIONS IN SHIP STRUCTURE AND RAILWAYS (9)

SHIP STRUCTURE:Main parts of ship structure , materials for ship building, unit and block method
of ship construction , welding of submarine steels, welding of offshore structures.
RAILWAYS: Materials used for locomotive subassemblies, rail coaches, wagons& its
subassemblies, rails and welding process used

WELDING APPLICATIONS IN CHEMICAL PLANTS, CRYOGENICS AND MICRO

JOINING TECHNIQUES: (9)
CHEMICAL PLANTS: Welding of oil-refinery components and fertilizer plant components.
CRYOGENICS: Materials used for cryogenic applications, problems of welding. Welding processes
and procedures used for welding cryogenic materials.
MICRO JOINING TECHNIQUES: Various techniques used for joining of electronic circuits and
other micro joining applications.

WELDING ECONOMICS AND OTHER SPECIFIC APPLICATIONS (9)

ECONOMIC CONSIDERATION: Weldment deposition rates for different welding processes-
welding cost estimation, standard data for cost estimation, comparative cost study for various welding
procedures. Gravity welding, welding of coated and clad steels, welding of composites and ceramics.
In-service welding (Hot Tapping) in live lines-Types, preparation, testing requirements, flow
considerations and Temper bead technique.

Total: 45 periods

REFERENCES:

1. S.V.Nadkarni -Modern Arc Welding Technology,Oxford-IBH Publishers,New Delhi ,7th

edition 1996.
2. R.S.Parmar – Welding Engineering and Technology, Khanna Publishers, New Delhi, 1 st
edition 1997.
3. AWS Welding Handbook, Sec.5 – Applications of Welding, 5th Edition, 1967.
4. AWS Welding Handbook, Vol.4, 7th Edition, 1991.
5. ASM Metals Handbook, Vol.6, Welding, Brazing and Soldering, ASM, New York, 1998.
6. Howard B. Cary, "Modern Welding Technology", Prentice Hall, New Jersey, USA, 1989.

17
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE05 ELECTRICAL ASPECTS OF WELDING LTPC

3 0 0 3

ELECTRICAL CHARACTERISTICS OF WELDING ARC AND POWER SOURCES (9)

Physical phenomena occurring in arc-potential distribution-static and dynamic arc characteristics-
types of forces in arc-arc blow-causes of arc blow-(steps to reduce arc blow)-methods of arc
initiation- methods of arc maintenance - requirements for an welding power source-V-I characteristic
of a welding power source-external static V-I characteristic-constant current characteristic- constant
voltage characteristic-selection of V-I characteristic for an welding process – dynamic V-I
characteristic - simple problems On static V-I characteristic- arc lengths control.

WELDING TRANSFORMERS AND ROTATING MACHINES (9)

Requirements of welding transformer – types of welding transformer-high reactance- external reactor
– integral reactor – saturable reactor – all characteristic- rotating machine – series generator –
separately excited- self excited – split pole dc welding generator – out put characteristic – multi
operator dc welding generator – duty cycle and simple problems.

SOLID STATE WELDING POWER SOURCES (9)

Rectification principles – uncontrolled, controlled – basic inverter principles – solid state electronic
power regulation systems – SCR phase control, transistor series regulator – secondary switched
transistor (PWM technique)- primary rectification – inverter control – hybrid designs –features of
solid state electronic power source design – advantages of solid state power sources.

CONTROLS IN ARC WELDING (9)

Open loop control and close loop control- electric wire feed-automatic control techniques-monitoring
of process- resistance spot welding monitoring and control-seam tracking devices- sensors for seam
tracking devices- robotic arc welding system- adaptive control in automated welding system- data
acquisition in welding- expert system in welding.

ELECTRICAL MEASUREMENTS IN WELDING AND SPECIAL POWER SOURCES (9)

Measurements of welding current, voltage, temperature, load and displacement in welding process-
digital storage oscilloscope, LVDT, thermocouples, Hall Effect current sensors, DC shunt- pulsed
welding power sources- synergetic welding power sources

Total: 45 periods

REFERENCES:

1. John Norrish, “Arc Welding processes” - Institute of Physics Publishing Bristol 1992
2. R.S. Parmar, “Welding Process and Technology” Khanna Publishers 2nd edition 2003
3. Howard B.Cary “Arc Welding Automations”, Marcel Dekker inc, Newyork 1995.
4. Md.Ibrahim Khan “Welding Science and Technology, Newage International New Delhi 2007.
5. Pan Jiluan “Arc Welding control” CRC Press Washington D.C. 2003.
6. The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973.

18
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE06 AUTOMATION AND ROBOTS IN WELDING LTPC

3 0 0 3

AUTOMATION OF ARC WELDING PROCESSES (9)

Need for automation in welding, introduction to semi-automatic mechanized, automatic, robotic and
adaptive control welding. Automatic welding system – factors affecting welding productivity–
advantages and disadvantages of welding automation. Arc welding processes suitable for automation
and degree of automation possible in different welding processes like GMAW, FCAW, SAW,
GTAW, PAW and Stud welding.

AUTOMATION OF OTHER RELATED PROCESSES (9)

Automation of Resistance welding, EBW, Laser beam Welding, Solid State welding. Automation of
oxygen cutting, Arc and Plasma cutting, Laser beam cutting, thermal spraying.

AUTOMATED WELDING EQUIPMENT, ARC AND WORK MOTION DEVICES (9)

Welding power sources, type of electrode wire feeders and electrode wire dispersing system – spools,
coils, rods, drums, pay off packs, typical adaptors and spiders. Types of welding torches used in
automated welding and functions of torches. Types of standardized arc motion devices – Tractor,
carriages, side beam carriages, manipulators and Gantry carriages. Work motion devices – Universal
positioners, turning rolls, head and tail stock positioners. Combination of arc and work motion
devices.

STANDARDIZED ARC WELDING MACHINES, CONTROLS AND SENSORS (9)

Standardized arc welding equipment, types of standardized welding machines – seamers, welding
lathes, weld – around machines, nozzle welders and bore welders. I beam welders and strip welders.
Standardized welding machines for maintenance work. Automatic welding of pipes and tubes
Introduction to some dedicated arc welding machines. Temporary portable automated tooling for
welding control functions involved in a mechanized total welding system sensor systems –
introduction and classification.

ROBOTIC ARC WELDING (9)

Introduction to flexible automatic welding. Robotic arc welding system, types of welding Robots –
Revolute, Cartesian, Spherical, Cylindrical and Scara – Hybrid robots far welding, features of welding
robot, robotic part – holding positioners, Teaching the robot, some case studies of robotic application
in welding.
Total: 45 periods

REFERENCES:
1. Howard B.Cary-“Arc welding Automation”- Marcel Dekker ,New York 1995
2. AWS Welding Handbook, Vol. 3, 7th edition., A W S., 1991.
3. AWS Welding Handbook, vol.5, “Engineering Costs, Quality and Safety”, 7th edition,AWS,
1997
4. The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973.
5. Proceedings of the International Conference on Assembly Automation, British Welding
Institute, 1981.
6. Kozyrev, Industrial Robots Handbook, Mir Publishers, Moscow,1975

19
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE07 WELDING ECONOMICS, MANAGEMENT AND SAFETY LTPC

3 00 3

FACTORS INFLUENCING WELDING COST (9)

Welding design- selection of electrodes, size, type and metal recovery – electrode efficiency, sub,
thrown away electrodes – over welding and joint fit – up welding position - operation factor – jigs,
fixtures, positioners, Operator efficiency.

ESTIMATION OF WELDING TIME (9)

Need for time standard – definition of standard time- various methods of computing standard time –
analytical calculation – computerisation of time standards.

COSTING FOR WELDING (9)

Definition of terms – composition of welding costs, cost of consumables – labour cost – cost over
heads - formulae for total cost – cost curves for different processes like GMAW, SAW, ESW,
Mechanisation in welding – job shop operation.

PLANT LAY OUT (9)

Process Vs product lay out – construction – service consideration – employees- services, welding
shop equipment, oxy acetylene stations- resistance welding stations – inert gas welding stations – arc
welding stations – crane forges - jigs and fixtures; power tools - blast cleaning supplies- welding
equipment repair shop - proper arrangement of the above in the welding shop for maximum
convenience and ease of production.

SAFE PRACTICES IN WELDING (9)

Selection and installation of equipments, safe handling equipment - fire prevention- eye and face
protection - respiratory protection - ventilation -protective extra clothing -electric shock- safety
analysis.
Planning for welding operations, 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.

Total: 45 periods

REFERENCES:

1. ASM Metals Handbook, Vol.6, Welding, Brazing and Soldering, ASM, New York, 1998.
2. AWS Welding Handbook, vol.5, “Engineering Costs, Quality and Safety”, 7th edition,AWS,
1997.
3. John Norrish, “Arc welding processes” – Institute of Physics Publishing Bristol 1992.
4. Standard Data for Arc Welding – The Welding Institute, U.K., 1994.
5. Bathy. J., Industrial Administration and Management, 1984.
6. The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973

20
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE08 WELDING PROCEDURES AND QUALIFICATION LTPC

30 0 3

PROCESSES & WELDING METALLURGY (9)

Overview of selected processes: SMAW, GTAW, GMAW, FCAW, SAW: AWS: Fundamentals,
Equipments, Electrodes / Filler metals Classifications as per AWS.
Review of welding metallurgy of selected metals – Carbon steels, low alloy steels, stainless steels, Ni
alloys, Cu alloys, Al alloys, ASME B&PV Code – Sections IIC and IX
CODE PRACTICE (9)
Familiarization of codes: Section IIC, Section IX of ASME B&PV Code, API 1100 and AWS D1.1;
Essential variables, non-essential variables, Supplementary essential variables
WPS formats, PQR formats and WPQ formats
Test requirements; Range qualified for varying values of essential values.
Preparation of WPSs, PQRs and Range Qualified tables; Preparation of WPQs.
WELDING PROCEDURE SPECIFICATIONS (WPS) – FERRITIC STEELS (9)
Preparation of WPS’s for metal joining for Process variation:
SMAW, GTAW, GTAW+SMAW, GMAW, SAW, SMAW+SAW, GTAW+SAW
Material variation: Carbon steels, Low Alloy Steels, Cr-Mo Steels
Post Weld Heat Treatment: No PWHT, Stress Relieving, Other Heat Treatments
Thickness: 2 to 200 mm.
Model WPSs of all the above categories and combinations to be prepared.
WELDING PROCEDURE SPECIFICATIONS (WPS) – STAINLESS STEELS AND NON-
FERROUS ALLOYS (9)
Preparation of WPS’s for metal joining for Process variation:
SMAW, GTAW, GTAW+SMAW, GMAW, SAW, SMAW+SAW, GTAW+SAW
Material variation: Stainless steels, Nickel alloys, Copper alloys, Titanium alloys, Al Alloys.
Preparation of WPS’s for dissimilar metal joining for Process variation:
SMAW, GTAW+SMAW
Material combination: Carbon steel to low alloy steels, Stainless steels to carbon steels, Copper alloys
to carbon steels, Low alloy steels to another low alloy steel.
Preparation of WPS’s for weld overlaying of Stainless steels over carbon steel, Nickel alloys over
carbon steels, Cu alloys over carbon steels, Stellite over carbon steels / stainless steels
Model WPSs of all the above categories and combinations to be prepared.
PQRs AND WPQs (9)
Preparation of PQRs for selected WPSs
Preparation of WPQs for selected WPSs for various processes, material thicknesses, positions for butt
welding, fillet welding and weld overlay.
Model PQRs to be prepared for WPSs for butt welding, fillet welding and weld overlay.

Total: 45 periods

REFERENCES:
1. ASM Metals Handbook, Vol 6,"Welding Brazing and Soldering", ASM International, 2003.
2. ASME B&PV Code Section IX and Section IIC
3. API Code 1100
4. AWS D1.1 Code

21
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE09 FRACTURE MECHANICS LTPC

3 00 3

TYPES OF FRACTURE (9)

Ductile and brittle fracture, features of fracture surface for ductile, brittle and mixed modes,
fractography Transition temperature approach: Notched bar impact tests. Ductile to brittle transition,
influence of temperature, strain rate and multi-axial loading, limitations of charpy testing. Drop-
weight test and other large scale tests – fracture analysis diagram.

FRACTURE MECHANICS APPROACH (9)

Stress distributions around discontinuities, stress analysis in simple cracked bodies, plane strain and
plane stress conditions, stress intensity factor and fracture toughness.

YIELDING FRACTURE MECHANICS (9)

Concept of crack opening displacement, calculation of COD. The J contour integral- derivation of J
from load – displacement diagram. The relationship between J and COD

EXPERIMENTAL MEASUREMENT OF FRACTURE TOUGHNESS (9)

KIC testing – test piece requirements and types, fatigue pre-cracking, determination of COD,
estimation of critical COD from the test data. Measurement of J integral and R curve.

APPLICATIONS OF FRACTURE MECHANICS (9)

Concepts of tolerable defects, use of fracture mechanics in design and material selection.

Total: 45 periods

REFERENCES:

1. David Broek, Elementary Engineering Fracture Mechanics, Sujthoff Noordhoof, 1978.

2. Hertzberg R.W. Deformation and Fracture Mechanics of Engineering Materials, 3rd edition,
John Wiley 1989.
3. Rolfe T., Bassom J., Fracture and Fatigue Control of Structures – Applications of Fracture
Mechanics, Prentice Hall, 1977.
4. Tetelmen A.S. and McEvily. A.J. Fracture of Structural Materials_. John Wiley & Sons,
1967.
5. Gurney T.R., Fatigue of Welded Structures, Cambridge University Press, 1979.

22
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE10 WELDING CODES AND STANDARDS LTPC

3 0 03

WELDING PROCEDURE AND WELDER QUALIFICATION (9)

Welder procedure specification, procedure qualification records performance qualification,

MATERIALS AND CONSUMABLES (9)

Introduction to materials standards and testing of materials, consumables testing and qualification as
per ASME/AW S requirements

STRUCTURAL WELDING CODES (9)

Design requirements, allowable stress values, workmanship and inspection

PETROLEUM PIPING FABRICATION (9)

Process and product standards for manufacturing of pipe – welding procedure and welder
qualifications, field welding and inspection.

PRESSURE VESSEL FABRICATION (9)

Design requirements fabrication methods, joint categories, welding and inspection, post weld heat
treatment and hydrotesting.

Total: 45 periods

REFERENCES:

1. AWS D1.1 Structural Welding Code

2. API 1104
3. ASME Section VIII – Division 1
4. ASME Section IX
5. ASME Section II Part A and C
6. API 6A

23
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE11 WELDING METALLURGY OF NON-FERROUS ALLOYS LTPC

3 0 03

WELDING OF ALUMINIUM ALLOYS (9)

Heat treatable and non-heat treatable Al alloys, Hot cracking, Crack sensitivity curves, filler
metal selection for avoiding cracking, effect of heat input / thermal cycles, Porosity, Effect of
hydrogen and heat input / travel speed, Distortion control, control of oxide formation. Soft
zone formation, Post weld heat treatments, Process selection, Filler metal selection,
Dissimilar welding with other metals.

WELDING OF NICKEL ALLOYS (9)

Pure nickel, solid solution Ni alloys, Precipitation hardenable alloys, Ni-Cu alloys, Ni-Cr
alloys, Ni-Cr-Fe alloys, Ni-Cr-Mo alloys, Welding Problems – Grain boundary precipitation,
Grain growth, Hot cracking, Porosity formation, Post weld heat treatments, Process selection,
Filler metal selection,

WELDING OF COPPER ALLOYS AND MAGNESIUM ALLOYS (9)

Copper alloys: Pure Cu, Cu-Zn alloys, Cu-Sn alloys, Cu-Al alloys, Cu-Si alloys, Cu-Ni
alloys, Cu-Be alloys, Welding problems – Hot cracking, Porosity, Surface condition,
Preheating, Dissimilar welding with other alloys.
Magnesium alloys: Welding problems – Reactivity, Cracking, Porosity formation, surface
condition. Post weld heat treatments, Profess selection, Filler metal selection.

WELDING OF TITANIUM ALLOYS (9)

Pure Titanium, Alpha Titanium, Alpha Beta Titanium, Beta Titanium alloys, Welding
Problems – Reactivity and Embrittlement cracking, Porosity formation, Soft zone formation
in heat treatable alloys, Hydrogen embrittlement, Process selection, Filler metal selection.

WELDING OF OTHER ALLOYS (9)

Welding of Zirconium alloys, Weld overlay – Cladding and Hard facing – Overlaying of
Stainless steels, Nickel alloys, Copper alloys, High chromium steels and Cobalt alloys /
Stellites over carbon steels, low alloy steels and martensitic steels.

Total: 45 periods

REFERENCES:
1. Kou. S. Welding Metallurgy, John Wiley & Sons. 1987.
2. Granjon. H. Fundamentals of Welding Metallurgy, Jaico Publishing House. New
Delhi 1994.
3. AWS Welding Hand book. Volume 4, 9th edition, Materials and Applications, Part 1
4. AWS Welding Hand book. Volume 5, 9th edition, Materials and Applications, Part 2
5. ASM Handbook, Volume 6, Welding, Brazing and Soldering, 10th edition, 1993

24
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE12 WELDING CONSUMABLES LTPC

3 0 03

FLUX COATED ELECTRODES (9)

SMAW electrodes for carbon steels, low alloy steels, stainless steels, Al alloys, Cu alloys, Ni
alloys – Classification as per AWS, Requirements of mechanical properties, chemical
composition, testing requirements, intended use of important electrodes

BARE WELDING ELECTRODES AND RODS (9)

Bare welding electrodes and rods for carbon steels, low alloy steels, stainless steels, Al
alloys, Ni alloys, Cu alloys, Ti alloys– Classification as per AWS, Requirements of
mechanical properties, chemical composition, testing requirements, intended use of important
electrodes

ELECTRODES AND FLUXES FOR SAW AND FLUX CORED ELECTRODES (9)
SAW electrodes for carbon steels, low alloy steels, Fluxes, manufacturing methods, chemical
nature; FCAW electrodes for Carbon steels, Low alloy steels, Stainless steels, Ni alloys.
Classification as per AWS, Requirements of mechanical properties, chemical composition,
testing requirements, intended use of important electrodes

SURFACING ELECTRODES, CAST IRON ELECTRODES AND RODS (9)

Classification as per AWS, Requirements of mechanical properties, chemical composition,
testing requirements, intended use of important electrodes

BRAZING METALS, BRAZING FLUXES, TUNGSTEN ELECTRODES,

SHIELDING GASES (9)
Classification as per AWS, intended use, testing requirements,
Shielding gases - Types, characteristics, physical properties, shielding properties,
applications.

Total: 45 periods

REFERENCE:
ASME Boiler and pressure Vessel Code – Part II C – Specifications for Welding Rods,
Electrodes and Filler metals, 2013

25
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE13 METAL FORMING TECHNOLOGY LTPC

3 0 03

STRESS TENSOR AND YIELD CRITERIA (9)

State of stress, components of stress, symmetry of stress tensor, principal stresses, stress
deviator, Von Mises, Tresca yield criteria, comparison of yield criteria, Octahedral shear
stress and shear strain, Forming load calculations.
FUNDAMENTALS OF METAL FORMING (9)
Classification of forming processes, Mechanics of metal working, Flow stress determination,
Effect of temperature, strain rate and metallurgical structure on metal working, Friction and
lubrication. Deformation zone geometry, Workability, Residual stresses.
FORGING AND ROLLING (9)
Forging-types of presses and hammers. Classification. Open die forging and Closed die
forging, die design, forging in plane strain, calculation of forging loads, forging defects-
causes and remedies, residual stresses in forging. Rolling: Classification of rolling processes,
types of rolling mills, hot and cold rolling, rolling of bars and shapes, forces and geometrical
relationship in rolling, analysis of rolling load, torque and power, rolling mill control, rolling
defects - causes and remedies.
EXTRUSION AND DRAWING (9)
Direct and indirect extrusion, variables affecting extrusion, deformation pattern, equipments,
Port-hole extrusion die, hydrostatic extrusion, defects and remedies, simple analysis of
extrusion, tube extrusion and production of seamless pipe and tube. Drawing of rods, wires
and tubes.
SHEET METAL FORMING AND OTHER PROCESSES (9)
Forming methods - Shearing, blanking, bending, stretch forming, deep drawing. Types of
dies used in press working, defects in formed part, sheet metal formability, formability limit
diagram. High velocity forming: Comparison with conventional forming. Explosive
forming, Electro hydraulic, Electro Magnetic forming, Dynapak and Petro-forge forming.

Total: 45 periods

REFERENCES:
1. Dieter.G.E ., “Mechanical Metallurgy”, McGraw-Hill Co., SI Edition, 1995.
2. Nagpal.G.R., “Metal Forming Processes”, Khanna Pub., New Delhi, 2000.
3. Kurt Lange “Handbook of Metal Forming”, Society of Manufacturing Engineers.
Michigan, USA, 1988
4. Avitzur, “Metal Forming - Processes and Analysis”, Tata McGraw-Hill Co., New
Delhi, 1977.
5. ASM Metals Handbook. Vol.14, “Forming and Forging”, Metals Park, Ohio, USA,
1990.
6. Taylor Altan, Soo I.K. Oh, Harold. L.Gegel. “Metal Forming: Fundamentals and
Applications” ASM, Metals Park, Ohio, USA, 1983.

26
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE14 METAL CASTING LTPC

3 0 03

PATTERN PREPARATION AND MOULDING (9)

Introduction to foundry operations, patterns - functions, types, allowances, selection of
pattern materials, colour codes, core boxes, moulding practice, ingredients of moulding sand
and core sand, Testing of Moulding sands. Sand preparation, Sand moulding: green sand
moulding, dry sand moulding, skin dry sand moulding, core sand moulding, loam moulding,
fluid sand process, shell moulding, carbon-di-oxide process.
MELTING PRACTICE (9)
Melting practice and special precautions for steels, alloy steels, cast irons, aluminium alloys,
copper alloys and magnesium alloys, safety considerations, fluxing, degassing and
inoculation

CASTING TECHNIQUES (9)

Sand casting, permanent mould casting, die casting, centrifugal casting, plaster mould
casting, investment casting, continuous casting, squeeze casting, full mould process.

DESIGN OF CASTINGS (9)

Elements of gating system, types, design of gating system with examples, functions of risers,
types of risers, Chvorinov’s rule, design and positioning of riser with examples, directional
solidification, use of chills, exothermic compounds etc., riser efficiency, yield calculations.

FETTLING, INSPECTION AND AUTOMATION (9)

Cleaning and repair of castings. Casting defects and remedies. Heat treatment of castings.
Inspection of casting. Principles of mechanisation, automation and foundry layout. Pollution
control and safety considerations in foundries. Functional design, simplification of foundry
practices, metallurgical design

Total : 45 periods

REFERENCES:
1. Heine. R.W., Loper. C.R.,Rosenthal, P.C. “Principles of Metal Casting”, Tata
McGraw-Hill Publishing Co., Ltd., New Delhi, 1995.
2. Jain.P.L., “Principles of Foundry Technology”, Tata McGraw-Hill Publishing Co.,
Ltd., New Delhi, 1995.
3. Ramana Rao.T.V. “Metal Casting Principles and Practice”, New Age Pub. Co., New
Delhi,1996.
4. Beeley.P.R., “Foundry Technology”, Butterworths, London, 1982.
5. Srinivasan.N.K, “Foundry Engineering”, Khanna Tech Publications, New Delhi,
1994.
6. ASM Metals hand Book. Vol. 15. “Casting”, ASM International, 10th Edition, 1991.

27
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE15 LIFE ASSESSMENT OF WELDED STRUCTURES LTPC

3 0 03

NEED FOR REMAINING LIFE ASSESSMENT (RLA) IN PLANTS (9)

Historical evolution and operation of power plants and petrochemical plants – general description,
temperature, pressures and materials, failure in plants, definition of zero failure.

MATERIAL PROPERTIES CONSIDERED FOR RLA (9)

Toughness, DBTT, LEFM, EPFM, temper embrittlement, hydrogen embrittlement.

CREEP (9)
Mechanisms, parametric extrapolation techniques – LM, OSD, MII, MB and MCM, design rules,
cumulative damage, crack growth models, RLA methodology for bulk and localized damages.

FATIGUE (9)
High and low cycle fatigue, Coffin-Manson relationship, creep fatigue interaction, effect of hold time,
frequency strain concentration, environment, rupture ductility, damage rules and life prediction,
design rules for creep fatigue (CF), linear damage summation, failure mechanism maps, thermal
fatigue (TF), thermal-mechanical fatigue (TMF), thermal fatigue (TF), thermal-mechanical fatigue
(TMF), thermal-mechanical fatigue life prediction, crack growth in fatigue.

LIFE PREDICTION FOR POWER PLANT COMPONENTS (9)

Materials, damage mechanisms and RLA of boiler tubes, header, steam pipes, roots, steam casings,
valves and steam chests, steam turbines blades, high temperature bolts, Non-destructive assessment
methods for extent of creep damage, replication, creep pipes, principles of micro-thermography,
effective temperature determination by implanting diffusion couples, life prediction of petroleum
pressure vessel- materials for hydrogen service, materials of construction, integrity consideration of
pressure vessel shells and cladding RLA techniques for improved alloys, Arkhausen Noise.

Total: 45 periods

REFERENCES:
1. Viswanathan R. Life Assessment and Improvement of Turbo-generators Rotors for Fossil
Plants, Pergamon Press, 1985.
2. Viswanathan. R, Damage Mechanisms and Life Assessment of High Temperature
Components, American Society for Metals, 1989.
3. Hertzberg. R.W. Deformation and Fracture Mechanics of Engineering Materials, John Wiley,
New York,1989
4. Karl Hauffe, Oxidation of Metals, Plenum Press, 1981.
5. Alan F.Liu, Structural Life Assessment methods, ASM International, 1999.
6. Smallman R.E. Modern Physical Metallurgy, Butterworths, 4th edition, 1985.

28
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE16 REPAIR WELDING AND RECLAMATION LTPC

3 0 03

REPAIR WELDING (9)

Engineering aspects of repair, aspects to be considered for repair welding, techno-economics, repair
welding procedures for components made of steel casting and cast iron, full-mould process, AWA
bath tub test for cast iron repair, special procedures to avoid post-repair stress relief heat treatment,
half bead, temper bead techniques, usage of Ni based filler metals.

REPAIR TECHNIQUES FOLLOWED IN SPECIFIC APPLICATIONS (9)

Damaged bends in gas transmission pipe lines, heat exchanger repair techniques – explosive
expansion, plugging, creep damaged high temperature components, repair of cracked petroleum
pressure vessel/ reactor.

RECLAMATION (9)
Types of wear, wear resistant materials, selection of materials for various wear applications,
reclamation surfacing techniques. Selection of welding processes for reclamation.

MAINTENANCE WELDING IN NUCLEAR POWER PLANTS (9)

Integrating repair/maintenance into on-going operation, radiation protection, steam generators repair,
plugging.

EVALUATION OF SURFACE COATINGS (9)

Various types of hardness tests, NDE of surface coatings, characterization of coatings, photo-thermal
imaging, case studies on selection, application and materials combination.

Total: 45 periods

REFERENCES:
1. Weld Surfacing and Hardfacing, The Welding Institute, 1987.
2. Nagendra Reddy A., Maintenance Welding Made Easy, Jaico Publishing, New Delhi, 2004.
3. Recommended Practice for Repair Welding and Fabrication Welding of Steel Casting, Steel
Foundry Research Foundation, 1981.
4. Lim Cottrel C., Welding Cast Irons, The Welding Institute, 1991.
5. Nadkarni. S.V., Modern Arc Welding Technology, Oxford IBH Publishing Co. 1996.

29
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE17 TOTAL QUALITY SYSTEM AND ENGINEERING LTPC

3 0 0 3

INTRODUCTION (9)
Principles of Quality Management – Pioneers of TQM –Quality Cost-Quality System-Customer
Orientation –Bench marking – Re-engineering - Concurrent Engineering.

MANAGEMENT SYSTEMS (9)

Leadership – Organizational Structure- Team Building- Information Systems and Documentation –
Quality Auditing – Brief overview of ISO 9001:2015, ISO/TS 16949:2014, ISO 14001:2015,
OHSAS 18001:2007, ISO 50001:2011

TECHNIQUES OF TQM (9)

FMEA, Quality Function Deployment, Quality Circles, KAIZEN, POKA YOKE, Taguchi Methods,
5S, Six Sigma, TPM, Single vendor Concept, J.I.T.

STATISTICAL QUALITY CONTROL (9)

Methods and Philosophy of statistical process control –Control Charts for Variables and Attributes –
Cumulative sum and Exponential - weighted moving average control charts- other SPC techniques –
Process Capability Analysis

ACCEPTANCE SAMPLING (9)

Acceptance sampling Problem –Single Sampling Plans for Attributes –Double, Multiple and
sequential sampling, Military standards – The Dodge – Romig Sampling plans.

Total: 45 periods

REFERENCES:

1. Mohamed Zairi, Total Quality Management for Engineers, Woodhead Publishers, 2002.
2. Montgomery Douglas C, “Introduction to Statistical Quality Control”, John Wiley and Sons
Inc., New Delhi, 2001.
3. Fiegenbaum.A.V, “Total Quality Control”, Mc Graw Hill Inc., New Delhi, 1991.
4. Eugene Grant et al, “Statistical Quality Control”, 7th edition, Mc Graw Hill, New Delhi, 2000.

30
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE18 DESIGN OF WELDMENTS AND FAILURE ANALYSIS LTPC

3 0 0 3

DESIGN BASICS (9)

Types of joints, Types of welds, variants of joints, selection of weld type, weld joints for structural
tubular connections, welding symbols, weld dimensions, NDT symbols.
Principles of weld joint design – General and specific design principles.

WELD DESIGN FOR STATIC LOADING (9)

Material or section properties, Weld design stress calculation for welds, design under different types
of loading like tension, compression, bending, shear, torsion and shock

WELD DESIGN FOR DYNAMIC LOADING (9)

Basic details of fatigue and fatigue failure ,S-N curve , Goodman diagram, factors affecting fatigue
life of welded joint , methods of improving fatigue life of welded structures –design for fatigue
loading, weld design using fracture toughness value (K1C).

DISTORTION AND RESIDUAL STRESSES (9)

Welding residual stresses – causes, occurrence, effects – thermal and mechanical relieving. Types
of distortion – factors affecting distortion –distortion control methods – prediction- correction, jigs,
fixtures and positioners.

FAILURE ANALYSIS (9)

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. Case studies in
welding.

Total: 45 periods

REFERENCES:

1. Bladgett. O. W., Design of Weldments, James F. Lincoln Arc Welding Foundation, 1991
2. R.S.Parmar, Welding Engineering and Technology 1st edition,1997.
3. Gurney T.R. Fatigue of Welded Structures. Cambridge University Press, 1979.
4. Rolfe. T., Barsom. J., Fracture and Fatigue Control of Structures – Applications of Fracture
Mechanics, Prentice Hall, 1977.
5. ASM Metals Hand Book. Failure Analysis and Prevention. Vol. 10. ASM 1995.
6. Das, A.K., Metallurgy of Failure Analysis, Tata McGraw Hill, New Delhi, 1992.

31
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE19 METALLURGICAL FAILURE ANALYSIS LTPC

3 00 3

INTRODUCTION TO FAILURE ANALYSIS (9)

Stages of failure analysis, classification and identification of various types of
fracture.Overview of fracture mechanics, characteristics of ductile and brittle fracture.

TYPES OF FAILURES (9)

General concepts, fracture characteristics revealed by microscopy, factors affecting fatigue,
life Creep, stress rupture, elevated temperature fatigue, metallurgical instabilities,
environmental induced failure. Some case studies failures.

SURFACE FAILURES (9)

Types of wear, analyzing wear failure. Corrosion failures- factors influencing corrosion
failures, overview of various types of corrosion stress corrosion cracking, sources,
characteristics of stress corrosion cracking. Procedure for analyzing stress corrosion cracking,
various types of hydrogen damage failures.

FAILURE OF MANUFACTURED PRODUCTS (9)

Causes of failure in forging, failure of iron and steel castings, improper heat treatment, stress
concentration and service conditions. Failure of weldments - reasons for failure procedure for
weld failure analysis.

RELIABILITY (9)
Reliability concept and hazard function, life prediction, condition monitoring, application of
Poisson, exponential and Weibull distribution for reliability, bath tub curve, parallel and
series system, mean time between failures and life testing.

Total: 45 periods

REFERENCES:

1. ASM Metals Handbook “Failure Analysis and Prevention”, ASM Metals Park.
Ohio,Vol.10, 10th Edition, 1995.
2. Colangelo.V.J. and Heiser.F.A., “Analysis of Metallurgical Failures”, John Wiley and
Sons Inc. New York, USA, 1974.
3. Das, A.K., “Metallurgy of Failure Analysis”, Tata McGraw Hill, New Delhi, 1992.

32
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE20 OPTIMIZATION TECHNIQUES IN ENGINEERING LTPC

30 03

CLASSICAL OPTIMIZATION TECHNIQUES - I (9)

Optimization – Historical Development – Engineering applications of optimization –
Statement of an Optimization problem – classification of optimization problems - Linear
programming - Graphical method.

CLASSIC OPTIMIZATION TECHNIQUES - II (9)

Linear programming – simplex method – dual simplex method – revised simplex method –
duality in LP – Parametric Linear programming – Goal Programming.

NON-LINEAR PROGRAMMING (9)

Introduction – Lagrangeon Method – Kuhn-Tucker conditions – Quadratic programming –
Separable programming – Stochastic programming – Geometric programming

INTEGER PROGRAMMING AND DYNAMIC PROGRAMMING (9)

Integer programming - Cutting plane algorithm, Branch and bound technique, Zero-one
implicit enumeration – Dynamic Programming – Formulation, Various applications using
Dynamic Programming.

NETWORK TECHNIQUES AND ADVANCED TECHNIQUES (9)

Network Techniques – Shortest Path Model – Minimum Spanning Tree Problem – Maximal
flow problem. Genetic algorithms – simulated annealing – Neural Network and Fuzzy
systems

Total: 45 periods

REFERENCES:
1. R. Panneerselvam, “Operations Research”, Prentice Hall of India Private Limited,
New Delhi, 2005
2. P.K. Guptha and Man-Mohan, “Problems in Operations Research” – Sultan Chand &
Sons, 1994
3. Ravindran, Philips and Solberg, “Operations Research Principles and Practice”, John
Wiley & Sons, Singapore, 1992
4. J.K.Sharma, “Operations Research – Theory and Applications” – Macmillan India
Ltd., 1997
5. Hamdy A. Taha “Operations Research – An Introduction”, Prentice Hall of India,
1997

33
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE21 ADVANCED FINITE ELEMENT ANALYSIS LTPC

300 3

TWO DIMENSIONAL PROBLEMS (9)

Poisson equation – Laplace equation – Weak form – Element matrices for triangular and
rectangular elements – Evaluation of integrals – Assembly – Axi-symmetric problems –
Applications – Conduction and convection heat transfer – Torsional cylindrical member –
Transient analysis - Theory of elasticity – Plane strain – Plane stress – Axi-symmetric
problems– Principle of virtual displacement

ISOPARAMETRIC ELEMENTS AND ITS APPLICATIONS (9)

Introduction – Bilinear quadrilateral elements – Quadratic quadrilaterals – Hexahedral
elements - Numerical integration – Gauss quadrature – Static condensation – Load
considerations – Stress calculations – Examples of 2D and 3D applications

NON-LINEAR PROBLEMS AND ERROR ESTIMATES (9)

Introduction-Iterative Techniques-Material non-Linearity-Elasto Plasticity-Plasticity-Visco
plasticity-Geometric Non linearity-large displacement Formulation-Application in Metal
Forming Process and contact problems- Error norms and Convergence rates- high refinement
with adaptivity-Adaptive refinement

DYNAMIC PROBLEM (9)

Direct Formulation - Free- Transient and Forced Response - Solution Procedures-Subspace
Iterative Technique -Houbolt- Wilson- Newmark - Methods – Examples

FLUID MECHANICS (9)

Governing Equations of Fluid Mechanics-Inviscid and Incompressible Flow-Potential
Formulations-Slow Non- Newtonian Flow-Navier Stokes Equation-Steady and Transient
Solutions.

Total: 45 periods

REFERENCES:

1. Cook, Robert Davis et al “Concepts and Applications of Finite Element Analysis”,

Wiley, John & Sons, 1981.
2. Zienkiewicz O.C., “The Finite Element Method”, 3rd Edition, Tata McGraw-Hill,
2005.
3. Desai C.S. and Abel J.F., “Introduction to Finite Element Method”, Affiliated East-
West Press, 1972.
4. Chandrupatla, Belagundu, “Finite Elements in Engineering”, Prentice Hall of India
Private Ltd., 2002.

34
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE22 RELIABILITY AND QUALITY ENGINEERING LTPC

30 0 3

QUALITY CONCEPTS (9)

Quality objectives - Quality control - Quality Assurance - Quality systems, economics,
Statistical tolerancing - Quality loss function.

STATISTICAL PROCESS CONTROL (9)

Process variability - Control charts for variables and attributes, Moving average control
charts, multivarichart- Cumulative chart - demerit control chart - process capability studies.

DESIGN OF EXPERIMENTS (9)

Factorial experiments - fractional replication - Taguchi methods - Use of orthogonal arrays –
Response surface methodology- Cases.

RELIABILITY AND QUALITY MANAGEMENT (9)

Reliability function – failure rate – mean time between failures (MTBF) – mean time to
failure (MTTF) – A priori and a posteriori concept - mortality curve – useful life –
availability – maintainability – system effectiveness Reliability prediction and testing -
Quality circles - Zero defects program - ISO 9000 and TQM - Total quality organisation.

RELIABILITY MANAGEMENT AND RISK ASSESSMENT (9)

Reliability testing – Reliability growth monitoring – Non-parametric methods – Reliability
and life cycle costs – Reliability allocation – Replacement model-Definition and
measurement of risk – risk analysis techniques – risk reduction resources – industrial safety
and risk assessment.

Total: 45 periods

REFERENCES:

1. Logothetis.N, “Managing for total quality from Deming to Taguchi and SPC”, PHI,
1997.
2. Fiegenbarum.A.V, “Total Quality Control”, McGraw Hill Inc., 1991.
3. Douglas, C.Montgomery, “Introduction to Statistical quality control”, Second Edition
John Wiley and Sons, 1991.
4. Srinath L.S, “Reliability Engineering”, Affiliated East-West Press Pvt Ltd, New
Delhi, 1998.
5. Modarres, “Reliability and Risk analysis”, Maral Dekker Inc.1993.
6. Dale H.Besterfield, “Quality Improvement”, PHI, 2010.

35
 DEPARTMENT OF METALLURGICAL ENGINEERING
M.E., WELDING TECHNOLOGY

16WTE23 NON-METALLIC MATERIALS LTPC

30 0 3

INTRODUCTION TO POLYMERS (9)

Classification- thermoset, thermoplastics and elastomers. Structure of polymers-crystalline and
amorphous polymers-concept of Glass Transition Temperature (Tg). Polymerization-types and
mechanisms with examples Degree of polymerization -molecular weight of polymers- problems.
Polymer additives. Structure, properties and applications of polyethylene, polypropylene, polyvinyl
chloride, polystyrene, Polymethyl methacrylate, PTFE, polyamides, polyesters, polycarbonates and
polyurethanes. Engineering rubbers, natural rubber. Styrene, butadiene rubber, nitrile rubbers,
PROCESSING AND BEHAVIOUR OF POLYMERS (9)
Brief description of equipments and process details of Extrusion, injection moulding, Reaction and
Reinforced Reaction Injection Moulding, thermoforming, Blow moulding, compression moulding and
calendaring. Viscoelasticity- creep and stress relaxation in polymers. Yielding and fracture of
polymers. Crazing of polymers.
ENGINEERING CERAMICS (9)
Review of bonding types in ceramics – calculation of percentage ionic character. Ceramic crystal
structures: Sodium chloride, cesium chloride, alumina, spinel and fluorite structures - examples. Co-
ordination number and ionic radius ratio - Pauling's Rules. Simple problems involving Packing
Fraction, critical radius ratio and density. Properties and applications of SiC, Cubic Boron Nitride,
PSZ, Barium Titanate, Iron ferrites, etc
PROCESSING OF CERAMICS AND GLASSES (9)
Brief description of slip and slurry casting, applications. Powder processing equipment and process
details of hot pressing. Hot Isostatic Pressing and Cold Isostatic pressing, Liquid Phase sintering.
Types of glasses, structure, properties and applications. Blowing, pressing, drawing, rolling and
casting, Pilkington process for float glass.
COMPOSITES (9)
Polymer Matrix Composites: Polymer matrix resins, Reinforcement fibers – various types of fibers.
PMC processes - Hand lay up processes, Spray up processes, Compression moulding, Resin transfer
moulding, Pultrusion, Injection moulding. Fiber reinforced plastics (FRP), Glass fiber reinforced
plastics (GRP).
Ceramic Matrix composites: Ceramic matrix - oxide ceramics, non-oxide ceramics, alumina, silicon
nitride. Reinforcements – particles, fibers, whiskers. Sintering - Hot pressing, Cold isostatic pressing,
Hot isostatic pressing

Total: 45 periods
REFERENCES:
1. Raymond Seymour, “An Introduction to Polymer Chemistry”, McGraw-Hill Book Co., New
York, USA,1971.
2. Michel Barsoum, “Fundamentals of Ceramics”, McGraw-Hill Publishing Co. Singapore,
1997.
3. Kingery W.D., “Introduction to Ceramics”, John Wiley, USA, 1960.
4. Mathews F.L. and Rawlings R.D., “Composite materials: Engineering and Science”,
Chapman and Hall, London, England, 1st edition, 1994.
5. Chawla K.K., “Composite materials”, Springer – Verlag, 1987.
6. Bhargava., “Engineering Materials- Polymers, Ceramics and Composites”, Prentice Hall of
India Ltd’ New Delhi.
7. Gowariker V R., Viswanathan NV, Jayadev Sreedhar, “Polymer Science”, New Age
International P Ltd., 2005

36