ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

1. Explain the definition in welding according to AWS or British Standard Institution

(BSI)!
o The AWS (American Welding Society) definition for a welding process is "a
materials joining process which produces coalescence of materials by heating them
to suitable temperatures with or without the application of pressure or by the
application of pressure alone and with or without the use of filler material".
In another definition by AWS, welding is the process of joining two pieces of
metal by creating a strong metallurgical bond between them by heating or pressure
or both. The filler metal with the same melting point can be used or not. (American
Welding Society 1989 Welding Handbook Volume I 8th ed.)
o The BSI (British Standard Institution) definition of welding is joining between
two or more material in a plastic or liquid state using thermal (heat) or pressure or
both. Filler metal with a melting temperature equal to the melting temperature of
parent metal can be used or not. (British Standard Institution 1983; BS 499; Part
1)

2. Give the main difference among Welding, Brazing, and Soldering in general!
o Welding involves the process of fusion which takes place along with the melting
of base metal and a filler metal.
o Brazing has been defined as a group of joining processes specially arranged in a
manner to produce coalescence of materials. The process involves heating of these
materials at a brazing temperature by using a filler metal which has a liquidus above
840F (450C), and below the solidus of the base metals. Also, the filler metal is
distributed in the joint by capillary action.
o Soldering has the same definition as brazing except for the fact that the filler metal
pastes used has a liquidus below 840F (450C) and below the solidus of the base
metals.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

3. Explain the difference between welding and casting process in general!

Welding

Casting

Bond with mold

There must be a bond

There should be no bond

Heat input

Continuously

Un-continuously

Structure

Columnar

Dendritic

Solidification time

Fast

Slow

Surface shape

Constant

Have an ability to change

4. Looking at the engineering side and economic side, how do you think for a selection
process of joining on steel plates using process among: Welding, Nut and Bolt
(Screwing), Adhesive Bonding and Brazing or Soldering? Which join process gives
the stress which is axial direction (not shear stress)? Explain what you choose!
Welding

Screwing

Adhesive Bond.

Brazing - Soldering

Joint strength

Strongest

Weakest

Quiet strong

Strong

Stress

Almost

Biggest

Big

Quiet big

Concentration

nothing

Joint dimension

Parallel

Overlap

Overlap

Overlap

Price

Most

Most cheap

Quiet cheap

Quiet cheap

expensive

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ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

5. As a metallurgist, how do you explain the use of metallurgical science to control the
quality of welds to be free from defects? It is due to the fact that the welding heat
resulting the changes in material structure.
There are several explanations by using metallurgical science to control the quality of
welds to be free from defects:
o Controlling the chemical composition in order to avoid cracking clotting, such as
reducing the sulfur and phosphorus content, do grain refinement, reducing the strain
of the heat source, and improve weld geometry.
o Perform a surface preparation in order to avoid from contamination, e.g. in the form
of hydrogen ions H2O which can cause HE (hydrogen embrittlement) or HIC
(hydrogen induced cracking).
o Controlling the cooling rate in order to avoid the formation of martensite at HAZ
and residual stress.
o Perform a heat treatment process in the form of pre-heating after the welding
process in order to make the hydrogen diffuses out, thus to prevent the presence of
HE (hydrogen embrittlement) or HIC (hydrogen induced cracking).

6. Briefly describe the level qualification of welding personnel in the world based on the
International Institute of Welding (IIW) scheme and American Welding Society
(AWS) scheme. Explain the duty of responsibility each welding personnel in related
to Welding Job in general!
o Qualification of welding personnel based on IIW:

International Welding Specialist (IWS)

Personnel with basic technical knowledge where the level of technical
knowledge needs to be sufficient for the planning, executing, supervising
and testing of the tasks and responsibilities within a limited technical field
involving only simple welded constructions.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

International Welding Technologist (IWT)

Personnel with specific technical knowledge where the level of technical
knowledge needs to be sufficient for the planning, executing, supervising
and testing of the tasks and responsibilities in welding fabrication within a
selective or limited technical field.

International Welding Engineer (IWE)

Personnel with comprehensive technical knowledge where full technical
knowledge is required for the planning, executing, supervising and testing
of all tasks and responsibilities in welding fabrication.

o Qualification of welding personnel based on AWS:

Inspectors
Personnel who responsible for overseeing and make a drawing that make
sure each welded area has been inspected with the acceptance criteria code
in specifically.

Educators
Personnel who directed professionally in the field of welding education that
has the ability, talent, and knowledge directly and can perform welding
training or instruction in the classroom.

Radiographic Interpreters
Personnel with the ability to assess the indications welding resulting in
radiographic films and other similar matters.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Supervisors
Personnel with the ability to increase productivity and maintain the welding
quality.

Sales Reps
Sales professionals in the welding industry that offers solutions and
recommendations of the welding problems, such as improving quality and
productivity.

Engineers
Personnel with the ability to direct the operation of welding and other
joining methods according to the documents, codes, and other standards to
produce a satisfactory product.

Robotics
Personnel with the ability to work with a variety of codes, standards, and
specifications welding.

Fabricators
Personnel who have the resources, procedures, and personnel to create a
quality management system for welding fabrication activities.

Welders
Personnel with the ability to weld quality. Qualification of welding
personnel consist of qualifying stages and specific qualifications.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-1 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

o Stages Qualification
SMAW (Shielded Metal Arc Welding)

GMAW (Gas Metal Arc Welding)

GTAW (Gas Tungsten Arc Welding)

SAW (Submerged Arc Welding)

Brazing & Braze Welding

OAW (Oxyacetylene Welding)

o Specific Qualification

Welding Supervisor
In charge of improving the productivity of welding and maintain the quality
welding and perform internal and external quality control.

Welding Inspector
In charge to overseeing projects that concentrate on the quality of welding
and welding structure and ensure all have inspected with code specific
acceptance criteria.

Welder (SMAW/Non SMAW)

In charge of do welding operation which is suitable with standard criteria.

References:
o http://www.engineershandbook.com/Tables/welding%20processes.htm
o http://ewi.org/technologies/soldering-and-brazing-main/
o http://www.aws.org/certification/
o http://www.wim.org.my/training/iiw_diploma.php

METALLURGY AND MATERIALS ENGINEERING