CRC WELDED STRUCTURES - MATERIALS WELDING AND JOINING
DISTANCE EDUCATION PROGRAM : SYLLABUS

The syllabus of the Graduate Diploma and Master of Engineering Practice follows the IIW guidelines but additional material appropriate to Australian national requirements is included. In addition some of the most recent developments from the CRC-WS research program are included in the material. The most recent information and regular updates will be conveyed to the students via the web based support package (WebCT).



ENGG901 - Introduction to Materials Welding and Joining Processes
Author: John Norrish

  1. An introduction to materials welding and joining.
  2. Health and safety in welding and cutting operations.
  3. Introduction to physics of welding arcs.
  4. Electrotechnology for welding.
  5. The effect of joining on materials.
  6. Weldability of carbon and alloy steels.
  7. Weldability of non-ferrous materials.
  8. Mechanical testing and non-destructive testing.
  9. Introduction to fracture mechanics and behaviour of welds under load.
  10. Joint design and terminology.
  11. Welding economics.
  12. Quality assurance and AS/NZS ISO 9000/1/2/3.
  13. Control of welding.
  14. Repair and reclamation by welding.
  15. Advanced joining techniques.

Introduction to welding and joining technology. Classification of welding processes, applications; typical problems, health and safety issues. Introduction to fusion and pressure welding processes; adhesive bonding, soldering and brazing; joining process physics. Review of basic electrics and electronics; arc characteristics and control. Introduction to behaviour of metals during welding. Introduction to mechanical testing and NDT. Basic joint design and testing. Quality assurance of joining techniques. Introduction to reclamation repair by welding. Introduction to advanced welding technology. Introduction to Fracture Mechanics.

ENGG902 - Fusion Welding Processes (Part 1)
Author: John Norrish

  1. The Arc.
  2. Process principles GTAW.
  3. Advanced GTAW.
  4. Power sources and equipment GTAW.
  5. Plasma arc welding and cutting.
  6. Electron beam welding.
  7. Laser welding and cutting.

Introduction to gas shielded welding; process principles of GTAW welding; shielding gases; effect of gases on arc characteristics; filler metals; standards; typical problems; health and safety issues. Tungsten inert gas (TIG) welding; power sources; process factors; joint design; specifications; applications and typical problems; health and safety factors. Plasma, electron beam, laser welding and cutting. Advanced TIG welding.

ENGG903 - Other Joining Processes
Author: Ian Squires

  1. Cold pressure, ultrasonic and explosive welding and diffusion bonding.
  2. Stud welding and mechanical fasteners.
  3. Resistance welding; weld-bonding; ERW and flash butt welding.
  4. Oxy-fuel welding.
  5. Cutting and other edge preparation processes.
  6. Friction welding; friction stir welding.
  7. MIAB welding.
  8. Brazing.
  9. Soldering.
  10. Pre-heating; fuel gas, electric equipment and techniques.

ENGG904 - Fusion Welding Processes (Part 2)
Author: John Norrish

  1. Metal transfer principles.
  2. Manual metal arc welding (shielded metal arc welding - SMAW).
  3. Gas metal arc welding (GMAW) - principles, operation and applications.
  4. Advanced GMAW.
  5. Submerged arc welding (SAW) - principles, operation and applications.
  6. Advanced submerged arc welding (SAW).
  7. Power sources, GMAW, MMA, SAW, FCAW.
  8. Flux cored arc welding (FCAW).
  9. Electroslag welding.

Gas metal arc welding (GMAW); metal inert gas (MIG) welding; metal active gas (MAG) welding; power sources; process factors; special techniques; joint design; specifications; applications; typical problems; health and safety issued. Metal transfer. Manual metal arc (MMA) welding; (SMAW, MMAW); power sources; process factors; electrode coatings; joint design; specifications; applications and typical problems; health and safety factors. Submerged arc welding (SAW); power sources; process factors; joint design; specifications; applications; typical problems; health and safety issues. Advanced GMAW, FCAW. Electroslag welding; process factors; applications and limitations.

ENGG905 - Introduction to Behaviour of Metals During Welding (Part 1)
Author: Druce Dunne

  1. Structure and properties of pure metals.
  2. Alloys and phase equilibrium diagrams.
  3. Structure of the welded joint.
  4. Iron-carbon alloys.
  5. Manufacture and designation of steels.
  6. Plain carbon and carbon-maganese steels.
  7. Heat treatment of base metals and welded joints.
  8. Cracking phenomena in steels.
  9. Fine grained (HSLA) steels - development.
  10. Thermomechanically treated steels.
  11. Application of structural and high strength steels.

Structures and properties of metals; alloys and phase diagrams; iron-carbon alloys; heat treatment of steels; microstructures of welded joints; embrittlement and cracking in steels. Structural steels; fine grained steels; thermomechanically processed steels.

ENGG906 -Behaviour of Metals During Welding (Part 2)
Author: Noel Herbst

  1. Introduction to corrosion.
  2. Nickel and nickel alloys.
  3. Low alloy steels for low temperature (cryogenic) use.
  4. Low alloy creep resistant steels.
  5. High-alloyed (stainless) steels.
  6. Creep resist and heat resistant steels.
  7. Welding of castings - cast steel and cast iron.
  8. Joining dissimilar metals.

High temperature creep resistant steels; high alloy stainless steels; cryogenic steels; low temperature steels; stainless steels; H/R steels; creep resistant steels; nickel-based alloys; other metals and alloys; welding of ferrous and non-ferrous castings; introduction to corrosion and wear; welding of castings.

ENGG907 - Welding of Non-Ferrous Metals and Joining of Non-Metals
Author: Stephen Yeomans

  1. Copper and copper alloys.
  2. Aluminium and aluminium alloys.
  3. Other metals and alloys.
  4. Joining processes for plastics.
  5. Joining processes for advanced materials - composites & ceramics.
  6. Microstructures of welded joints.
  7. Joining of coated steels.

Copper and copper-based alloys; aluminium and aluminium-based alloys; joining dissimilar alloys; structures and properties of non-metallic materials and composites; joining of polymers; joinng ofpolymers to metals; joining of ceramics; ceramic-metal joints; methods used for joining of composites and composites to other materials.

ENGG908 - Construction and Design (Part 1)
Author: Lewis Schmidt

  1. Strength of materials (Part 1) - Concepts and theories.
  2. Strength of materials (Part 2) - Failure concepts & Fracture mechanisms.
  3. Basics of weld design (Part 1) - Design principles - avoiding failure.
  4. Basics of weld design (Part 2) - Viewpoint of fracture mechanics.
  5. Design principles of welded structures - basic methods.
  6. Design principles Rules and standards - examples.
  7. Economic weld design.
  8. Joint design - welded connections.
  9. Joint design - tolerances, welding symbols and standards.
  10. Introduction to fracture mechanics.
  11. Fundamentals of fatigue.
  12. Overview of design.

Fundamentals of the strength of materials; basics of weld design; design principles for welded structures; joint design; fracture mechanics.

ENGG909 - Construction and Design (Part 2)
Author: Lewis Schmidt

  1. Behaviour of welded structures under different types of loading.
  2. Design of welded structures with predominately static loading.
  3. Behaviour of welded structures under dynamic loading.
  4. Fatigue strength of welded structures - complex stress history.
  5. Design for dynamic loading - worked examples.
  6. Design for thermodynamic loading - pressure vessels, etc.
  7. Thermodynamic loading - worked examples.
  8. Design of lightweight structures - aluminium and its alloys.
  9. Aluminium welded structures - case studies.
  10. Reinforcing-steel welded joints.

Behaviour of welded structures under load; design of welded structures for static loading; effects of dynamic loading; thermodynamically loaded welded structures; reinforced steel welded joints; design of welded aluminium alloy structures.

ENGG910 - Fabrication/Applications Engineering (Part 1)
Author: Max Conyngham

  1. Health and safety issues.
  2. Introduction to quality assurance in welded construction basics.
  3. Weld quality standards - ISO 9000 vx ISO 3834.
  4. Quality control - weld procedure specification and qualification.
  5. Welder qualification.
  6. Fitness for purpose considerations.
  7. Economic aspects of weld fabrication.

Cutting and other edge preparation processes. Quality assurance in welded structures; quality control during manufacture; total quality management. Plant facilities; welding jigs and fixtures. Fume and radiation hazards from welding; health and safety issues.

ENGG911 - Fabrication/Applications Engineering (Part 2)
Author: Max Conyngham

  1. Welding stresses and distortion.
  2. Effects of residual stresses on structures.
  3. Control of welding restraint.
  4. Stress relieving of weldments.
  5. Plant facilities.
  6. Welding jigs and fixtures, heat treatment.
  7. Repair welding.

Welding stresses and distortion; control of welding restraint; stress relieving of weldments. Fepair welding; fitness for purpose considerations; economic aspects of weld fabrication; economic considerations of high productivity welding; automatic and robotic welding.

ENGG914 - Fabrication/Applications Engineering (Part 3)
Author: Max Conyngham

  1. Non-destructive testing applied to welding & materials (Part 1).
  2. Non-destructive testing applied to welding & materials (Part 2).
  3. Non-destructive testing codes and standards.
  4. Measurement control and recording.

Non-destructive testing; measurement control and recording.

ENGG919 - Dissertation (For Masters Students Only)

A thesis is required based on project work and/or an interpretive literature review on a topic in materials welding and joining. The thesis can be oriented towards mechanical, materials, civil, or mining engineering.

SUMMER SCHOOL 1: ENGG917

The theme of this summer school will be to reinforce the process and equipment subjects and consists of:

  • Laboratory exercises
  • Case Studies - process selection
  • Lectures from visiting experts on welding process applications and equipment
  • Mechanisation and automation laboratory
  • Tutorial

SUMMER SCHOOL 2: ENGG918

This summer school will reinforce the materials weldability subjects and give hands-on experience of metallography and it will consist of:

  • Metallography of welded joints-practical
  • Mechanical testing practicals
  • Wear and surfacing case studies
  • Lectures of surfacing and weld metallurgy
  • Tutorial

SUMMER SCHOOL 3: ENGG915

The summer school will address welded construction and design. It will include:

  • Design case studies
  • Lecture from visiting experts on design of welded structures
  • Tutorial

SUMMER SCHOOL 4: ENGG916

This summer school will consolidate the previous sections of the course and concentrate on fabrication application. It will include:

  • NDT practicals
  • Welding procedure case studies
  • Lecture from guest welding engineer
  • Tutorial

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