Theory of Welding Processes

Description: Within the framework of this discipline, the physical and chemical processes occurring during welding, the features of welding equipment, types of welding seams, welding process technologies and much more are studied. Knowledge of the theory of welding processes is essential for effective welding operations and ensuring high-quality welding.

Amount of credits: 8

Course Workload:

Component: Component by selection

Cycle: Base disciplines

Goal

• The purpose of studying this discipline is to familiarize students with the basics of physico-chemical, metallurgical, thermal processes and structural-phase transformations occurring during welding, the influence of these processes on the quality of formation of welded joints.

Objective

• Tasks of the discipline: - to give students a fundamental understanding of the welding processes taking place with various welding methods; - to prepare students for the study of subsequent welding disciplines; - to teach students to navigate welding technologies.

Learning outcome: knowledge and understanding

• Students should know: the goals and objectives of the theory of welding processes − practical rational application of the theory of welding processes −fundamentals of metallurgical processes in welding, the mechanism of formation of welded joints and the formation of primary and secondary structures, seam metal and weldability.

Learning outcome: applying knowledge and understanding

• to acquire practical skills: in assessing the weldability of various metals and alloys, the main sources of energy during welding, about physico-chemical and thermal deformation processes occurring during welding.

Learning outcome: formation of judgments

• - have an idea about the main sources of energy during welding, about physico-chemical and metallurgical processes;

Learning outcome: communicative abilities

• fundamentals of metallurgical processes in welding, the mechanism of formation of welded joints and the formation of primary and secondary structures, seam metal and weldability.

Learning outcome: learning skills or learning abilities

• Discipline exam

Teaching methods

In the conditions of credit technology of training, classes should be conducted mainly in active and creative forms. Among the effective pedagogical techniques and technologies that contribute to the involvement of students in the search and management of knowledge, the acquisition of experience in solving problems independently, it should be highlighted:  technology of problem- and project-oriented learning;  technologies of educational and research activities; communication technologies (discussion, press conference, brainstorming, educational debates and other active forms and methods);  case study method (situation analysis); game technologies in which students participate in business, role-playing, simulation games;  information and communication (including distance education) technologies.

Assessment of the student's knowledge

Teacher oversees various tasks related to ongoing assessment and determines students' current performance twice during each academic period. Ratings 1 and 2 are formulated based on the outcomes of this ongoing assessment. The student's learning achievements are assessed using a 100-point scale, and the final grades P1 and P2 are calculated as the average of their ongoing performance evaluations. The teacher evaluates the student's work throughout the academic period in alignment with the assignment submission schedule for the discipline. The assessment system may incorporate a mix of written and oral, group and individual formats.

The evaluating policy of learning outcomes by work type

Evaluation form

The student's final grade in the course is calculated on a 100 point grading scale, it includes:

• 40% of the examination result;
• 60% of current control result.

The final grade is calculated by the formula:

 

Where Midterm 1, Midterm 2are digital equivalents of the grades of Midterm 1 and 2;

E is a digital equivalent of the exam grade.

Final alphabetical grade and its equivalent in points:

The letter grading system for students' academic achievements, corresponding to the numerical equivalent on a four-point scale:

Topics of lectures

• Electrode (auxiliary, melting) welding materials for fusion welding
• Welding with a non-melting electrode
• GOST 2246, name, brand, classification and designation
• GOST 10543, wire brands, classification and designation
• material requirements, designations and brands
• Wire design, core components, manufacturing
• Powder Wire for baking
• Self-protection wires
• Purpose and classification of modern fluxes
• Kyshkyl, beitarap Zhane negizgi fluster
• Manganese-free and manganese fluxes
• General information
• Protective functions of the coating
• Types of coated electrodes for welding high-alloy steels with special properties
• Coated electrodes for welding cast iron and non-ferrous metals

Key reading

• Advancements in Intelligent Gas Metal Arc Welding Systems Paul Kah/ISBN: 9780128239056 Publication Date: 2021-06-25
• Welding and Joining of Aerospace Materials Mahesh Chaturvedi (Editor) ISBN: 9780128191408 Publication Date: 2020-10-20
• Welding: Principles & Practices Edward R. Bohnart ISBN: 9780073373713 Publication Date: 2011-07-08

Further reading

• Arc Welding John R. Walker; W. Richard Polanin ISBN: 9781605251899 Publication Date: 2009-10-02
• Performance Welding Handbook Richard Finch ISBN: 9780760321720 Publication Date: 2005-03-04