SEMESTER I

12WT101

PROBABILITY AND STATISTICS

31 04

Note: (Use of Std tables and Charts are permitted in the examination)

PROBABILITY AND RANDOM VARIABLES

9+3

Random variables Moments Moment generating function Standard distributions

Binomial, Poisson , Normal and Uniform distributions-Functions of random variables.
TWO DIMENSIONAL RANDOM VARIABLES
9+3
Joint distributions Marginal and conditional distributions Covariance Correlation and
regression Transformation of random variables Central l limit theorem.
ESTIMATION THEORY
9+3
Principle of least squares Regression Multiple and partial correlations Estimation of
Parameters Maximum likelihood estimates Method of moments.
TESTING OF HYPOTHESIS
9+3
Sampling distributions Large Sample Tests: Normal test for Single and differences of Mean(s)
and Proportion(s)-Small Sample Tests: t-test for Single and differences of Mean(s), Chi-square
test for goodness of fit and independence of attributes and F-test for equality of variances.
ANALYSIS OF VARIANCE AND DESIGN OF EXPERIMENTS
9+3
Analysis of variance -One way and Two way classifications- Completely Randomized Design
Randomized Block design Latin square design .
L +T: 45+15 = 60
REFERENCES:
1. Gupta, S.C. and Kapur , V.K. Fundamentals of Mathematical Statistics, Sultan
Chand and Sons, New Delhi, 1999.
2. Grewal, B.S., Higher Engineering Mathematics, 41st edition, Khanna Publishers,
New Delhi 2007.
3. Kapan .J..N & Sexana H.C., Mathematical statistics, S.Chand & Co., 2003
4. Fruend John, E. and Miller, Irwin, Probability and Statistics for Engineering, 5th
Edition , Prentice Hall, 1994.
5. Jay , L. Devore, Probability and Statistics for Engineering and Sciences,
Brooks/Cole Publishing Company Monterey, California, 1982.

12WT102

JOINING PROCESSES - I

3003

INTRODUCTION TO JOINING PROCESSES AND GAS WELDING

(9)

Classification of welding processes Heat sources and welding methods. Gas Welding: Gases
setup of equipment Flame characteristics, different kinds of flame and their areas of
application, Weld quality applications- variants of oxy-gas welding.
SHIELDED METAL ARC WELDING
(9)
The process, power sources, function of flux covering, different type of electrodes and their
applications, electrode designations- defects in welding.
GAS TUNGSTEN ARC WELDING & GAS METAL ARC WELDING
(9)
Gas Tungsten Arc Welding - Electrode 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.
Gas Metal Arc Welding - Considerations of electrodes polarity, shield gas and filler composition.
Nature of conditions of spray transfer, difficulties for thin sheet. Dip transfer and CO 2 welding.
Flux cored and pulsed MIG welding other recent developments applications defects.
SUBMERGED ARC WELDING AND ECONOMICS OF WELDING
(9)
The process, power sources, advantages and limitations, process variables and their effects, SAW
consumables significance of flux-metal combination, modern developments-applicationsdefects. Economics of welding-introduction, welding costs, productivity, post welding
operations,scrap allowance,standard time and cost calculations.
RESISTANCE WELDING , BRAZING & SOLDERING
(9)
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,. Spot seam, and Projection welding. Upset butt weld,
flash butt welding, percussion welding - defects. Brazing and Soldering Fundamentals of
Brazing and Soldering and their types.

Total : 45
TEXT BOOKS:
1. Parmar R.S. Welding Processes and Technology, Khanna Publishers. 1992
2. Nadkarni. S.V. Modern Arc Welding Technology. Oxford IBH Publishing Co. 1996.

REFERENCES:
1. A.W.S. Welding Handbook. 8th edition. Volume 1 Welding Technology. 1991
2. A.W.S. Welding Handbook. 8th edition. Volume 2 Welding Processes. 1991
3. Lancaster J.F. The Phyiscs of Welding. Pergamon Press. 1984.
4. Metals Handbook (Welding, Brazing and Soldering) Vol. 6, 10th Edition. ASM 1995.

12WT103

ELECTRICAL ASPECTS OF WELDING

30 03

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 characteristicselection 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
TEXT BOOKS:
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
REFERENCES:
1. Howard B.Cary Arc Welding Automations, Marcel Dekker inc, Newyork 1995.
2. Md.Ibrahim Khan Welding Science and Technology, Newage International New
Delhi 2007.
3. Pan Jiluan Arc Welding control CRC Press Washington D.C. 2003.
4. The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973.

12WT104

MATERIALS TECHNOLOGY

3003

CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS

(9)
Phases, solid solutions, compounds - Concept of phase diagram phases and microconstituents
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.
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 steels for magnetic and
electrical applications, 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)
Brasses, bronzes, Cu-Ni alloys High Strength Al Alloys, Ti alloys, Ni alloys and Mg alloys Physical metallurgy, composition, properties and applications.
Total: 45
TEXT BOOKS:
1.
2.
3.

Raghavan V. Physical Metallurgy Principles and Practice, Prentice Hall of India,

1993.
Brick Gardon Philips. Structure and Properties of Alloys, McGraw Hill, 1976.
Flinn. R.A. and Trojan. P.K. Engineering Materials and their Applications, 4 th Edition,
Jaico, 1999.

REFERENCES:
1.
2.
3.
4.

Leslie. W.C., The Physical Metallurgy of Steels. McGraw Hill. 1983.

Metals Hand book. 10th edition. Volume 2. ASM. 1995.
Askeland. D.R. The Science and Engineering of Materials. PWT Kent Publishing
Company, Boston, 1989
Pickering F.B. Physical Metallurgy and Design of Steels. Applied Science Publishers
Limited. London. 1978.

12WT105

METALLURGY & WELDING LAB

0 0 3 2

LIST OF EXPERIMENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.

Specimen preparation for microscopic observation

Microstructure of plain carbon steels
Microstructure of cast irons
Macro and Microstructure of welded specimens
Study of weld bead characteristics
Grain size determination
Microhardness survey of welded specimens
Preparation of WPS, PQR and Welder qualification test
Arc Welding Practices

REFERENCES:
1 ASM Metals Hand Book, Vol. 9, 10th edition 1995.
2 ASM International, Metallography Principles & Practice, ASM 1999.
3 Vander voort. G.F., Metallography: Principles & Practice, McGraw Hill, 1984.
EQUIPMENTS AND FACILITIES NEEDED:
1 Microscope
2 Belt grinders
3 Disc polishers
4 Electro polishing and etching unit
5 Grain size comparison eye pieces and micrometer eye pieces

12WT201

MECHANICAL BEHAVIOUR OF MATERIALS

31 04

DISLOCATIONS AND STRENGTHENING MECHANISMS

(9+3)
Dislocations Burgers 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+3)
Tensile test- Engineering stress-strain curve, True Stress-strain curve, Plastic Instability, Testing
mechanics and procedures. Impact test- Izod and Charpy impact test, Ductile Brittle Transition
Temperature, determination of DBTT, Drop Weight tests and other large scale tests. Hardness
test- Introduction, Brinell, Vickers and Rockwell hardness tests. Bend tests for weldments.
FRACTURE AND FRACTURE MECHANICS
(9+3)
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.
Toughness of materials.
FATIGUE
(9+3)
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+3)
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.
L+T:45+15=60
TEXT BOOKS:

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.
REFERENCES:

1 Courtney T. H. Mechanical Behavior of Materials_, 2nd edition, McGraw Hill. 2000.

2 Rose. R.M. Shepard L.A. Wulff. J. Structure and Properties of Materials, Vol. 3,
Mechanical Behavior. 4t h edition. John Wiley. 1984.
3 Smallman R.E. Modern Physical Metallurgy_, Butterworths, 4th edition, 1985.
4 Meyers M.A. Chawla. K.K . Mechanical Behaviour of Materials, Prentice-Hall
International Inc. 1999.

12WT202

WELDING METALLURGY

30 03

THERMAL CYCLES IN 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.
PHYSICAL METALLURGY OF WELDING
(9)
Welding of ferrous materials: Iron - carbon diagram, TTT and CCT diagrams, effects of steel
composition, formation of different microstructural zones in welded plain-carbon steels, C-Mn and lowalloy steels. Phase transformations in weld metal and heat affected zones. Typical weld metal CCT
diagrams, formation of acicular ferrite and factors affecting formation of acicular ferrite, effect on weld
metal toughness.
WELDABILITY AND TESTING
(9)
Concept of weldability, carbon equivalent, concept of preheat and post weld heat treatment, cold cracking,
role of hydrogen. Phenomenon and mechanisms of hot cracking, reheat cracking and lamellar tearing.
Weldability tests cold cracking, hot cracking, reheat cracking and lamellar tearing tests.
WELDABILITY OF STEELS AND CAST IRONS
(9)
Weldability of low alloy steels, steels for low and high temperature applications problems encountered
and solutions Welding process, procedure and filler metal selection. Weldability of different types of
stainless steels ferritic, martensitic, austenitic, precipitation hardenable and duplex types, overview of
joining ferritic and martensitic types, welding of austenitic stainless steels - hot cracking Schaeffler, DeLong and WRC diagrams, sigma phase embrittlement and weld decay - ways of overcoming these
difficulties Welding process, procedure and filler metal selection. Welding of cast irons Process,
procedure and filler metal selection, weldability problems encountered and solutions.
WELDABILITY OF NON-FERROUS ALLOYS AND DISSIMILAR WELDING

(9)

Weldability of aluminum and its alloys, copper and its alloys, Titanium and its alloys Ni and its alloys and
Mg and its 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: 45
TEXT BOOKS:
1 Parmar R.S. Welding Engineering and Technology, Khanna Publishers. 1997.
2 Lancaster J.F. Metallurgy of Welding, George Allen & Unwin. Boston. 1980.
REFERENCES:
1
2
3
4

Kou. S. Welding Metallurgy, John Wiley & Sons. 1987.

Granjon. H. Fundamentals of Welding Metallurgy, Jaico Publishing House. New Delhi 1994.
Norman Bailey. Weldability of Ferritic Steels, Jaico Publishing House. 1997
AWS Welding Hand book. 8th edition. Vol-1. Welding Technology. 1998

12WT203

QUALITY CONTROL OF WELDMENTS

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, comparison with X ray radiography 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. Acoustic Emission
Techniques, holography, leak and pressure testing.
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, phased array Ultrasonic Testing.
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
TEXT BOOKS:
1. Nadkarni. S. V . Modern Arc Welding Technology_, Oxford IBH. 1996.
2. Baldevraj., Jayakumar.T., Thavasimuthu. M., Practical Non-destructive Testing,
Narosa Publishers. 1997.
3. AWS Welding Handbook, vol.5,Engineering Costs, Quality and Safety, seventh
edition,AWS, 1997
REFERENCES:
1 .Hull, Non Destructive Testing, ELBS Edition, 1991.
2. McGonnagle. W.T. Non-Destructive Testing_, McGraw Hill. 1961.
3 .ASM Metals Hand Book. Vol. 9. Non-destructive Testing and Inspection_, 1988.
4. Codes And Standards- ASNT,AWS D1.1,API1104, ASME- Boiler & Pressure vessel

Code Section II, V, VIII, IX.

12WT204

JOINING PROCESSES - II

30 03

SOLID STATE WELDING PROCESSES

(9)
Fundamental principles, survey of the various pressure welding processes and their applications.
Cold pressure welding, explosive welding, diffusion welding and Ultrasonic welding Principles
of operation, process characteristics and application.
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 in FSW, Important welding parameters, tool rotation and traverse speeds, tool tilt
and plunge depth, tool design, Generation and flow of heat in FSW, Applications, advantages and
limitations, Flaws and defects in FSW.

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:
Principles of operation, advantages, and limitations, applications.
ELECTRO SLAG WELDING AND PLASMA ARC WELDING
(9)
Heat generation, principles of operations, wire and consumable guide techniques, selection of
current, voltage and other process variables, nature of fluxes and their choice. Electro-gas
welding: Principle and applications. Special features of plasma arc- transferred and non
transferred arc, key hole and puddle-in mode of operation, micro low and high current plasma
arc welding and their applications.
OTHER WELDING PROCESSES AND WELDING SAFETY
(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,
High Frequency Welding, Stud Welding, Underwater Welding. welding safety-various hazards,
confined spaces, under water, radio-active zones and other processes.
Total: 45
TEXT BOOKS:
1 AWS- Welding Hand Book. 8th Edition. Vol- 2. W elding Process, 1998.
2 Schwartz M.M. Metals Joining Manual. McGraw Hill Books. 1979.
REFERENCES:
1 Tylecote R.F. The Solid Phase Welding of Metals. Edward Arnold Publishers
Ltd. London. 1968.
2 Nadkarni S.V. Modern Arc Welding Technology, Oxford IBH Publishers. 1996.
3 Christopher Davis. Laser Welding - Practical Guide, Jaico Publishing House.
1994.

4 Parmar R.S. Welding Processes and Technology, Khanna Publishers, New Delhi,
LIST OF ELECTIVES

1998

12WTE01 SPECIAL EXPERIMENTAL TECHNIQUES IN METALLURGY 3 0 0 3

METALLOGRAPHIC TECHNIQUES
(9)
Resolution, depth of focus and components of microscope, polarized light, phase contrast, interference,
hot stage and quantitative metallographic techniques in situ techniques, specimen preparation
techniques.
X-RAY DIFFRACTION TECHNIQUES
(9)
Characteristic spectrum Braggs 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, Atomic Emission
Spectroscopy, Auger spectroscopy. Differential Thermal Analysis, Differential Scanning Calorimetry and
Thermo Gravimetry Analysis, Stress analysis.
Total: 45
TEXT BOOKS:
1 Philips V.A. Modern Metallographic Techniques and their Applications, Wiley
Interscience, 1971.
2 Cullity B.D. Elements of X- ray Diffraction_, 4th Edition, Addison Wiley, 1978.
REFERENCES:
1
2
3
4

Thomas. G. Transmission Electron Microscopy of Metals_. John Wiley. 1961.

Smallman R.E. Modern Physical Metallurgy_, 4th Edition, Butterworths. 1985.
Loretto. M.H. Electron Beam Analysis of Materials_, Chapman and Hall, 1984.
ASM Metals Handbook, Vol.10, Material Characterization, ASM, New York, 1998.

12WTE02

WELDING PROCEDURES FOR SPECIFIC APPLICATIONS

3003

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, inspection and testing.
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,
Pipe production by welding, gravity welding, welding of coated and clad steels, welding of composites
and ceramics

Total: 45
TEXT BOOKS:
1
2

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

1996
R.S.Parmar Welding Engineering and Technology, Khanna Publishers, New
Delhi, 1st edition 1997

REFERENCES:
1
2

AWS Welding Handbook, Sec.5 Applications of Welding, 5 th Edition, 1967.

AWS Welding Handbook, Vol.4, 7th Edition, 1991.

3
4

ASM Metals Handbook, Vol.6, Welding, Brazing and Soldering, ASM, New York, 1998.
Howard B. Cary, "Modern Welding Technology", Prentice Hall, New Jersey, USA, 1989.

12WTE03 AUTOMATION AND APPLICATION OF ROBOTS IN WELDING 3 0 0 3

INTRODUCTORY TO 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. Robatic 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
TEXT BOOKS:
1
Howard B.Cary-Arc welding Automation- Marcel Dekker ,New York 1995
2
Welding Handbook, Vol. 3, 7th edition., A W S., 1991.
REFERENCES:
1. AWS Welding Handbook, vol.5,Engineering Costs, Quality and Safety, 7th edition,AWS, 1997
2. The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973.
3. Proceedings of the International Conference on Assembly Automation,

4.

British Welding Institute, 1981.

Kozyrev, Industrial Robots Handbook_, Mir Publishers, Moscow,1975

12WTE04

WELDING ECONOMICS AND MANAGEMENT

3 0 0 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
TEXT BOOKS:
1
2

ASM Metals Handbook, Vol.6, Welding, Brazing and Soldering, ASM, New York, 1998.
AWS Welding Handbook, vol.5,Engineering Costs, Quality and Safety,
edition,AWS, 1997.

REFERENCES:
1 John Norrish, Arc welding processes - Institue of Physics Publishing Bristol 1992.
2 Standard Data for Arc Welding The Welding Institute, U.K., 1994.
3 Bathy. J., Industrial Administration and Management, 1984.
4 The Procedure Handbook of Arc Welding, twelfth Edition, Lincoln Electric, USA, 1973

7th

12WTE05

FRACTURE MECHANICS

3 0 0 3

TYPES OF FRACTURE
(9)
Ductile and brittle fracture, features of fracture surface for ductile, brittle and mixed modes, fractrography
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
Concepts of tolerable defects, use of fracture mechanics in design and material selection.

(9)
Total: 45

TEXT BOOKS:
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.
REFERENCES:
1. Rolfe T., Bassom J., Fracture and Fatigue Control of Structures Applications of Fracture
Mechanics, Prentice Hall, 1977.
2. Tetelmen A.S. and McEvily. A.J. Fracture of Structural Materials_. John Wiley & Sons, 1967.
3. Gurney T.R., Fatigue of Welded Structures, Cambridge University Press, 1979.

12WTE06

BRAZING,SOLDERING, SURFACING AND CUTTING

3003

FUNDAMENTALS OF BRAZING AND SOLDERING

(9)
Wetting and spreading characteristics, surface tension and contact angle concepts. Filling of
horizontal and vertical capillary joints. Capillary dams.
FLUXES AND ATMOSPHERES FOR BRAZING AND SOLDERING
(9)
Role of flux and characteristics constituents of flux, grouping and applications Fluxes used for
specific braze metal flux removal and related corrosion problem. Atmosphere for brazing and
atmosphere for brazing specific base metal Metallurgy of filler metal for brazing and soldering.
Joint design and fixturing for brazing.
SOLDERING AND BRAZING PROCESSES
(9)
Hand soldering, flame soldering furnace soldering, hot gas blanket soldering, wave soldering,
etc., torch brazing furnace brazing, induction brazing, dip brazing resistance brazing, vaccum
brazing, etc., applications of brazing soldering-brazing and soldering defects.
SURFACING
(9)
Thermal spraying, plasma spraying, laser surface alloying and modification. Surfacing spraying
to improve wear resistance and corrosion resistance. CVD, PVD and ion implantation. Cladding
and its applications.
THERMAL CUTTING PROCESSES
(9)
Oxygen cutting-oxy fuel gas ,metal powder , chemical flux and oxygen arc cutting. Arc cutting
processes- carbon arc, air carbon arc cutting. Metal and plasma arc cutting ,High energy beam
cutting, laser beam cutting, water jet cutting and under water cutting.
Total: 45
REFERENCES
1. Schwartz. M., Brazing for the Engineering Technologies, Champan and Hall, 1995.
2. Manko. H.H., Solders and Soldering.2nd Edition, McGraw Hill 1979..
3. Udin, Funk, and Wulf ., Welding for ENGINEERS.
4. ASM Metals Hand Book Vol. 6 Welding and Brazing, 1988.
5. Lancaster . J . F . Metallurgy of Welding, Brazing and Soldering. 3rd edition. George
Allen & Unwin. 1980.
6. Brooke, Indusrial Brazing, Bcton. 1975.

12WTE07

WELDING CODES AND STANDARDS

30 03

Note: (Use of relevant welding codes and Stds are permitted in the examination)
WELDING PROCEDURE AND WELDER QUALIFICATION
Welder procedure specification, procedure qualification records performance qualification,

(9)

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
Design requirements, allowable stress values, workmanship and inspection

(9)

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

TEXT BOOKS/REFERENCES:
1. AWS D1.1 Structural Welding Code
2. API 5L
3. API 1104
4. ASME Section VIII Division 1
5. ASME Section IX
6. ASME Section II Part A and C
7. API 6A
8. IBR 1950

12WTE08

LIFE ASSESSMENT OF WELDED STRUCTURES

30 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
Toughness, DBTT, LEFM, EPFM, temper embrittlement, hydrogen embrittlement.

(9)

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), thermalmechanical 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
TEXT BOOKS:
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.
REFERENCES:
1 Hertzberg. R.W. Deformation and Fracture Mechanics of Engineering Materials,
John Wiley, New York,1989
2 Karl Hauffe, Oxidation of Metals, Plenum Press, 1981.
3 Alan F.Liu, Structural Life Assessment methods, ASM International, 1999.
4 Smallman R.E. Modern Physical Metallurgy, Butterworths, 4th edition, 1985.

12WTE09

REPAIR WELDING AND RECLAMATION

30 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

TEXT BOOKS:
1 Weld Surfacing and Hardfacing_, The Welding Institute, 1987.
2 Nagendra Reddy A., Maintenance Welding Made Easy_, Jaico Publishing,
New Delhi.2004
REFERENCES:
1 Recommended Practice for Repair W elding and Fabrication Welding of Steel
Casting_, Steel Foundry Research Foundation, 1981.
2 Lim Cottrel C., Welding Cast Irons_, The Welding Institute, 1991.
3 Nadkarni. S.V. Modern Arc Welding Technology. Oxford IBH Publishing Co. 1996.

12WTE10

PROCESS MODELING AND APPLICATIONS

30 03

INTRODUCTION TO MODELING AND PROCESS CONTROL

(9)
Mathematical modeling, physical simulation advantages and limitations, process control and
instrumentation use of converters, gauges, thermocouples and other sensors.
MATHEMATICAL CONCEPTS
(9)
Review of differential equations and numerical methods introduction to FEM, FDM, CFD and heat
transfer analysis.
SOFTWARE PACKAGES AND EXPERT SYSTEMS
(9)
Introduction to standard software packages like ANSYS, IDEAS, DEFORM. Introduction to expert
systems, applications of expert systems in metallurgical processes, use of artificial intelligence.
COMPUTER APPLICATIONS IN PHYSICAL METALLURGY
(9)
Modeling and use of computer for the construction of phase diagrams, alloy design and crystallography.
COMPUTER APPLICATIONS IN PROCESS METALLURGY
Modeling of solidification, heat transfer, fluid flow, casting, welding and liquid metal treatment.

(9)

Total: 45
TEXT BOOKS:
1. Piwonka T.S., Vollen V., Katgerman L., Modeling of Castings, Welding and
Advanced Solidification Processes_, 4th edition. TMS-AMIE., 1993.
2. Cerjak H., Mathematical Modeling of Weld Phenomena_. 2, The Institute of
Materials, 1995.
REFERENCES:
1. Stocks G.M., Turchi P.E.A., Alloy Modeling and Design, The Metals Society
AMIE, 1994.
2. Trivedi R., Sekhar J.A., Majumdar J., Principles of Solidification and Materials
Processing_, Vol. 1 and 2., Oxford and IBH, 1989.

12WTE11

CORROSION AND SURFACE ENGINEERING

30 03

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 - 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
TEXT BOOKS:
1. Fontana. G., Corrosion Engineering, McGraw Hill, 1985.
2. Kenneth G.Budinski, Surface Engineering for Wear Resistance, Prentice hall,1992.
REFERENCES:
1. ASM Metals Hand Book Vol. 5, Surface Engineering, 1996.
2. Denny A Jones, Principles and prevention of corrosion, 2 nd edition, Prentice Hall,
New Jersey, 1995.
3. ASM International, Surface Engineering for Corrosion and Wear Resistance, 2005.
4. Schweitzer. P.A., Corrosion Engineering Hand Book, 3rd Edition, Marcel
Decker, 1996.
WEB REFERENCES:
1. www.hw.ac.uk/mecwww/research/an/coserg-2.htm

12WTE12

TOTAL QUALITY SYSTEM AND ENGINEERING

3 0 0 3

Note: (Use of Std tables and Charts are permitted in the examination)
INTRODUCTION
(9)
Principles of Quality Management Pioneers of TQM Quality Cost-Quality System-Customer
Orientation Bench marking Re-engineering - Concurrent Engineering.
PRACTICE OF TQM
(9)
Leadership Organizational Structure- Team Building- Information Systems and Documentation
Quality Auditing - ISO 9001:2008, ISO/TS16949:2009.
TECHNIQUES OF TQM
(9)
Single vendor Concept, J.I.T, Quality Function Deployment, Quality Circles, KAIZEN, POKA YOKE,
Taguchi Methods, 5S, TPM.
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 Six Sigma accuracy.
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
TEXT BOOKS:
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.
REFERENCES:
1. Fiegenbaum.A.V, Total Quality Control, Mc Graw Hill Inc., New Delhi, 1991.
2. Eugene Grant et al, Statistical Quality Control, 7 th edition, Mc Graw Hill, New
Delhi, 2000.
WEB REFERENCES:
1. www.ahepr.golv/research/feb00/02000RA15.htm
2. www.mcb.co.uk/tam.htm

12WTE13

DESIGN OF WELDMENTS AND FAILURE ANALYSIS

3003

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
TEXT BOOKS:
1
2

Bladgett. O. W. Design of Weldments, James F. Lincoln Arc Welding Foundation, 1991

R.S.Parmar Welding Engineering and Technology 1st edition,1997.

REFERENCES:
1. Gurney T.R. Fatigue of W elded Structures_. Cambridge University Press, 1979.
2. Rolfe. T., Barsom. J., Fracture and Fatigue Control of Structures Applications
of Fracture Mechanics, Prentice Hall, 1977.
3. Metals Hand Book. Failure Analysis and Prevention_. Vol. 10. ASM 1995.
4. Das, A.K., Metallurgy of Failure Analysis, Tata McGraw Hill, New Delhi, 1992.

12WTE14

METALLURGICAL FAILURE ANALYSIS

3003

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
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.