HW-07_1206291992

ASSIGNMENT-7 ENMT610029 WELDING ANDARADHI NARARYA/1206291992

METALLURGY AND MATERIALS ENGINEERING 1

1. Explain the concept welding design and fabrication in manufacturing steel structure.

What should you do when you act as:

a) Welding Engineer

1) Develops welding techniques, procedures, and application of welding equipment

to problems involving fabrication of metals, utilizing knowledge of production

specifications, properties and characteristics of metals and metal alloys, and

engineering principles: Conducts research and development investigations to

develop and test new fabrication processes and procedures, improve existing or

develop new welding equipment, develop new or modify current welding methods,

techniques, and procedures, discover new patterns of welding phenomena, or to

correlate and substantiate hypotheses.

2) Prepares technical reports as result of research and development and preventive

maintenance investigations.

3) Establishes welding procedures to guide production and welding personnel

relating to specification restrictions, material processes, pre- and post-heating

requirements which involve use of complex alloys, unusual fabrication methods,

welding of critical joints, and complex postheating requirements.

4) Evaluates new developments in welding field for possible application to current

welding problems or production processes.

5) Directs and coordinates technical personnel in performing inspections to ensure

workers' compliance with established welding procedures, restrictions, and

standards; in testing welds for conformance with national code requirements; or

testing welding personnel for certification.

6) Contacts personnel of other agencies, engineering personnel, or clients to

exchange ideas, information, or offer technical advice concerning welding matters.



7) May perform experimental welding to evaluate new equipment, techniques, and

materials.

b) Welding Supervisor

1) Supervises and coordinates activities of workers engaged in welding and cutting

of products and structures, such as auto, aircraft, and ship components, pipes,

boilers, and mobile homes, applying knowledge of welding and cutting techniques,

materials, and equipment, and fabrication requirements: Analyzes work orders and

blueprints to determine need for supplies and sequence of operations required.

2) Requisitions supplies, such as weld rods, gas, flux, and fixtures.

3) Inspects work or confers with WELD INSPECTOR I and WELD INSPECTOR

II to maintain specified standards and quality.

4) Trains workers in operation of equipment.

5) May set up machines or make trial welds to make test runs and experimental

products.

6) May supervise brazing and soldering operations.

7) May supervise fitting and assembly of structural frames.

8) May supervise workers engaged in making tubing from flat steel strips by

electric-weld process and be designated Welding Supervisor, Electric-Weld Pipe

Mill.

9) Important variations include location of workers supervised, such as in-plant,

job-shop, construction site, or shipyard.

10) Performs other duties as described under SUPERVISOR Master Title.



c) Welding inspector

(1) Codes, standards and specifications: Interpretation of the intent and ensuring

the requirements of codes, standards and specifications are met.

(2) Welding procedures: Ensuring that a procedure is available, has been approved

and is being employed in production.

(3) Witnessing of welder and procedure approval tests: Witnessing the

preparation of test plates and destructive tests and verifying compliance with

appropriate standards and specifications.

(4) Welder approvals: Verifying that adequate and valid welder approvals are

available, and that only approved welders are used in production.

(5) Parent material: Verifying parent material against documentation and

markings.

(6) Welding consumables identity: Verification of correctness of welding

consumables (electrodes, filler wires, consumable inserts, gases, fluxes etc.)

(7) Pre-weld inspection: Verification that dimensions, fit-up and weld

preparations are in accordance with specifications.

(8) Preheating: Verification that any required preheat is in accordance with the

specified procedure.

(9) In-process welding inspection and surveillance: Surveillance during welding

to verify compliance with specified procedures including any preheat, interpass

temperature control and post heat requirements.

(10) Inspection and Test Plans: Assistance and agreement with the preparation of

Inspection and Test Plans (ITPs)

(11) Post-weld heat treatment: Verification, when required that post weld heat

treatment has been conducted in accordance with specification requirements.

(12) Post-weld visual inspection: Visual inspection and dimensional check of

completed weldment against specification requirements and drawings.

(13) NDT reports: The study and cognisance of NDT results on any welding work

for which the welding inspector is responsible. Where the duties of the welding

inspector include using NDT methods such as liquid penetrant, magnetic particle,



radiography or ultrasonic inspection then it is suggested that he/she obtains

certification in accordance with the related approval schemes.

(14) Reports: Evaluation of and preparation of inspection reports for the employer

or the client.

(15) Records: Maintenance of records of inspections carried out

2. Sketch drawing welded construction with reference to welding symbol below.

(a)

(b)



3. Calculate the minimum fillet weld size on a welded construction as shown in the

picture below, the known shear stress (T) which is parallel to the load of 20 MPa or

N/mm2, while the load (P) which is 20000 N (2.5 Tons) with the length of each side of

the weld joint (W) is 100 mm. Use the formula: T = P/(2.w.a)

=

2. w. a

20 =20000

2.100. a

200 =20000

20

=500

200

=500

200

= 2.5



4. Welding symbols

HW-07_1206291992

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