Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Welding and Fabrication Engineers
• Mechanical and Design Engineers
• Maintenance and Inspection Personnel
• Quality Control and Assurance Engineers
• Project and Construction Supervisors
• Anyone involved in welding design, fabrication, or inspection

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the principles and metallurgy of welding processes
• Identify suitable materials, electrodes, and consumables for specific applications
• Interpret welding symbols, codes, and standards accurately
• Evaluate weld design and joint configurations
• Recognize and prevent common welding defects and discontinuities
• Apply inspection and testing techniques to ensure weld quality and safety

DAY 1

Introduction to Welding Engineering

• Welcome and Introduction
• Pre-Test
• Overview of Welding in Engineering and Industry
• Basic Welding Processes: SMAW, GTAW, GMAW, FCAW, SAW
• Welding Terminology and Symbols
• Heat Flow, Cooling Rates, and Weld Thermal Cycles
• Effects of Welding on Material Properties
• Safety Considerations in Welding Operations

DAY 2

Welding Metallurgy and Material Behavior

• Metallurgical Principles in Welding
• Structure and Properties of Weld Metals and HAZ
• Preheating, Post-Weld Heat Treatment (PWHT), and Stress Relief
• Influence of Alloying Elements on Weldability
• Cracking Mechanisms: Hot Cracking, Cold Cracking, and Lamellar Tearing
• Selection of Filler Materials and Electrodes
• Case Studies on Material Failures and Metallurgical Defects

DAY 3

Weld Design and Procedures

• Principles of Weld Joint Design and Strength Analysis
• Welding Positions and Joint Configurations
• Edge Preparation and Fit-Up
• Development and Qualification of Welding Procedures (WPS/PQR)
• Control of Welding Parameters (Voltage, Current, Speed)
• Residual Stress and Distortion Control Methods
• Applicable Codes and Standards (AWS, ASME Section IX, ISO, API)

DAY 4

Weld Inspection, Testing and Quality Assurance

• Visual Inspection and Dimensional Control
• Non-Destructive Testing (NDT) Techniques – RT, UT, PT, MT, VT
• Destructive Testing Methods – Tensile, Bend, and Impact Tests
• Acceptance Criteria and Defect Classification
• Welding Documentation and Traceability Requirements
• Welding Quality Management Systems (ISO 3834)
• Failure Analysis and Root Cause Investigation

DAY 5

Welding Applications, Troubleshooting and Course Wrap-up

• Welding of Different Materials: Carbon Steel, Stainless Steel, Aluminum, and Alloys
• Common Welding Problems and Their Solutions
• Repair Welding Techniques and Procedures
• Automation and Advanced Welding Technologies (Laser, Friction Stir, etc.)Review of Key Learning Points
• Post-Test
• Certificate Ceremony