THE TECHNOLOGY OF WELDING &

A CASE FOR THE ACADEMIA TO SERVE THE INDUSTRY NEEDS

An Overview of Welding Practices in Industry- for the Academia to align

its curriculum

TODAYS NEED

• Today's need is for highly trained welding experts

• The fabrication Industry is experiencing skill shortage due to high intakes in IT industry.

• Predictions reveal it may get worse.

TODAYS NEED-2

• The average age of welder is over 45 years.

• Fabrication industry will need more than 200,000 workers each year to replace those leaving the workforce

• & To cater to Infrastructure development a priority sector.

TODAYS NEED-3

• Some leave the industry, some go abroad and they take away much-needed skills with them.

• Estimated that 300- 350,000 new welders will be needed nationwide by 2016-17 .

( Allowing for industry growth of around 6-8% -presently 2013-14, fewer than 3%)

• & May be more.

TODAYS NEED -4

• Welding is a multidisciplinary subject and very rarely understood by common man.

• It is in one form or another, has been an integral part of the fabrication.

• Welding is now used as a tool from small time industry to space craft & parts for Human beings.

TODAYS NEED-5

• Today's welding experts must be proficient in multiple welding processes.

• Must have expertise to weld using SMAW, GTAW, GMAW and SAW processes as a minimum.

• Popularity for GMAW is gaining, being cost effective

• GMAW should supersede age old SMAW.

INDUSTRY NEED

Need for skills are growing

• Skilled welders,

• Trained supervisors

• Certified Engineers

&

• Certified Inspectors

WHAT• Training to include automatic & semi-automatic

welding processes including Robotics.

• Robotics slowly but steadily taking over skilled welders .

• Robotic now, extensively used for welding pipelines, heavy industrial plants, nozzles, forging etc apart from proven automobile industry.

• Training must include simple cost effective automation for higher productivity.

WHAT-2

• Earlier supervision was left to the skill of welders.

• Due to stiff competition & high standard quality requirement , Supervision and Inspection has become an integral part of quality construction.

• Training of welder, welding engineer and welding inspector is need of the hour for any industry engaged in fabrication and competes in world market.

Field Requirement

• Career options may expand for welders with more expertise and education.

• Being educated in the latest technologies is as essential, as is a willingness to relocate.

• Certificate of proficiency in the trade or techniques from a recognized institution, welding society or University of repute.

Field Requirement-2

• Building successful good hand-eye coordination and manual dexterity, communication skills and problem-solving skills for welder

• Possible careers include welding inspector, welding fabricator, welding sales representative, welding instructor, supervisor, welding engineer and foreman.

Welding Processes

• SMAW

• GTAW

• GMAW

• SAW

• RW

• LASER

• HYBRID

• ETC ETC- A big list-TEXT BOOK

http://www.google.co.in/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=5XvnQs_fZg-q6M&tbnid=4R4ypHyuDIeikM:&ved=0CAUQjRw&url=http%3A%2F%2Fbansalwiki.blogspot.com%2F2013%2F02%2Fwelding-shop.html&ei=yRXEUqv_B4ryrQfe-oGgDA&bvm=bv.58187178,d.bmk&psig=AFQjCNHll4zWW4IZQan55rdeFENdzpw9mA&ust=1388668422498266

Share of Welding Process In INDIA

1960 1970 1980 1990 2000 2010 2020

9995 92 90

80

70

60

0 1 2 410

18 15

0 0 1 1 3 510

0 1 1 1 1 2 20 2 3 3 4 48

1 1 1 1 1 1 2

SMAW MIG/MAG FCAW GTAW SAW OTHERS

Added

1960’s 1970’s 1980’s 1990’s 2000’s

Welding Process-

MMAGAS

TIG/SAW/MIG/MAG

T/TS welding,Strip Cladding/ESSC

Pulsed/Plasma/NG welding

Hot wire Tig/Laser

Welding Consumables

E6012/13,E7018E308 small quantity

E6012/13/ 7018/SS/UreaGrade/SAW Fluxes Fused/Agglomerated

Alloy Steel,Mig/Mag / Wire/Fluxes for LT application/LF SS Electrodes

SSFluxes/FCAW wires/

Inconel/Nielectrodes

Welding Equipments

Transformer,MG sets

Rectifiers,Diode based

Thyristor Inverter CompleteProgrammable

Welding Consumable Usage - IndiaPROCESS TYPE / GRADE

SMAW C.STEELS.STEELCr-Mo STEEL

HARDFACINGCAST IRON

GMAW SOLID WIRESC.STEELS.STEELCr-Mo STEEL

FCW – C.STEELFCW – S.STEEL

SAW C.STEELS.STEELOTHER GRADES

GTAW C.STEELS.STEELCr-Mo STEEL

Ni ALLOY WIRES +ELECTRODES

MISC.

Materials Welded in India progressive

Material 1960s 1970s 1980s

1990s 2000s 2010s Future

ADDED CARBONSTEEL/ MS,Steelswith C <0.20

SS, Alloy Steel

2Cr 1Mo,DSS

3Cr1Mo,Ti,Zr

9 Cr 1Mo,12% Cr Mo, Super DSS, Lean DSS,HSLA For better operational efficiency Power Plants

Alloys ofTitanium,Tantalum,Zirconium,supercritical Cr Mo etc

Hybrid,Sandwitch

LATEST SHIPPED OUT EQUIPMENTS

Tube to Tubesheet Welding

Equipment for Aerospace Applications

End Shield for Nuclear Application

End Shield Manufacturing Lattice tube

welding

Tri junction weld

CUTTINGGAS,PLASMA,LASER

• WHY TRAINING

• To provide suitable employment opportunity

Welding Curriculum

FOR WHOM

• The recruitment process as a part of program must examine and reach out to those segments of our country's population which have experienced alarmingly high levels of unemployment that is in rural, adivasis, dalits, SC and many school dropouts across the country.

• Our Government is sponsoring such projects directly and indirectly.

FOR WHOM-2

• This will perhaps bridge gap of need of welders and further training can build up their career.

• There are many youngsters who have not yet found careers that match their talents or meet their needs.

• They look forward to the day when they can find fulfilling employment that will enable them to earn a decent living.

WHO

• Today’s job scenario has created number of unemployed engineers due to mushrooming of institutes

• Additional trade training would fulfill their dream job. Once institutes takes lead in specialization and create job opportunity, the institute would be most sought after.

• It's all a matter of connecting the right people with the right jobs — and the right training.

For the one who seeks Career

• Participating in Welding-education-and-training courses means:

• Obtaining hands-on experience, being exposed to practical welding work under expert supervision and learning techniques to be employed to operate successfully any given process.

For the one who seeks Career-2

• To succeed, the trainee must produce a test piece that will stand the nondestructive, metallographic and mechanical tests established for the level of certification involved.

• Plan to acquire or refresh basics of the trade from a professional source

• ABOVE ALL A COST EFFECTIVE PROGRAM IS DESIRED

For the one who seeks Career-3

• The best preparation for Welding-education-and-training would be

• One that ensures the highest degree of theoretical knowledge together with a good manual ability to perform at least a few of the possible different processes.

For the one who seeks Career-4

• Usually the professionals entering on Welding-education-and-training are divided

• The blue collar experts who are respected and courted for their manual dexterity and skill,

• The white collar experts with their outstanding knowledge and theoretical preparation

Which one of the welding profession?

• Ample space for all kinds of professions promoted by Welding-education-and-training are expected.

• All educational institutes with proper bent of mind can cater to need of Industry as well as aspiring personnel.

Education Requirement:

• Students in a welding program learn the art of shaping metals.

• Formal education programs may take anywhere from a few weeks to a few years to complete depending upon nature of program

Curriculum

• Required classes may include advanced mathematics, metallurgy, blueprint reading, welding symbols, pipe layout ,specification and codes and a welding practice along with sandwiched industrial training

• Hands-on training to include oxyacetylene welding and cutting, shielded metal arc welding, gas tungsten arc welding gas metal arc welding and submerged arc welding.

Certification:

• Welding education programs may culminate in a Welding Certificate of Achievement

• Diploma in welding engineering or Bachelor of Science in Welding Engineering or a Master of Technology in welding Engineering.

• A recognised certificate would help increasing image of the institute and also would offer lucrative jobs to trainees.

• For this purpose it is essential to tie up with best industry or welding society both India and abroad

CERTIFICATION-2

• A Certified person holds a Certificate that exhibits a proof that he/she passed an examination involving certain materials, processes, thickness range and techniques as required by the particular Welding Procedure Specification (WPS) .

• AWS has developed certification program

--welders working on robotic or automatic welding machines called CRAW (Certified Robotic Arc Welder).

CERTIFICATION-3

• Certified Welding Engineer is an individual having the required Welding-education-and-training, experience and knowledge, and who passes the relevant examinations.

• This preparation demonstrates his/her capability of directing all activities required to ensure that welded fabrications entrusted to his/her responsibility meet all requirements of applicable codes and standards.

SOURCE -CERTIFICATION :1• The Indian Welding Society with Annamalai

University conducts Diploma in Welding Engineering.

• IIW conducts AMWE examination, a graduate program

• National certification is available through IBR. Certification may be achieved independently or through Employers (Only for welders)

• May opt AWAcademy for IBR test .

SOURCE -CERTIFICATION :2

• The American Welding Society administers certification program and entrusting the actual examinations to Accredited Testing Facilities.

• In UK certifications are carried out by TWI Certification Ltd.

• Such programs are conducted in India periodically.

SOURCE -CERTIFICATION :3

• Certification for Inspectors is administered according to ANSI/AWS QC1-96, Standard for Certification of Welding Inspectors.

• AWS Certifications for Inspectors are articulated in three levels from the basic one, issued to Certified Associate Welding Inspectors (CAWI).

SOURCE -CERTIFICATION :4

• The Certificate (CAWI) permits one to gain experience by working in close association with an accomplished Certified Welding Inspector (CWI).

SOURCE -CERTIFICATION :6

• To qualify for AWS Certified Welding Inspector (CWI) thorough examination divided in three parts, by participating in Welding-education-and-training seminars conducted to provide the best possible preparation.

• Senior Certified Welding Inspector occupies a supervisory position after having attained an elevated degree of experience.

SOURCE -CERTIFICATION :7

• Certified Welding Educator (CWE) is an individual whose knowledge and experience qualifies him/her to provide Welding-education-and-training trough welder training and classroom instruction.

CERTIFICATION

• Welding-education-and-training is never finished and that there is always room for improvement in a way as Refreshers Program.

• The training Institute shall facilitate proper certification program on regular basis so that it becomes an institute of importance for Industry as well as for prospective learner.

COURSES TO BE OFFERED:

• Add on program to Graduate Engineers who would like to pursue in core engineering

• Add on program to Diploma engineering students for supervisor program.

• Special skill development program to ITI-welding trade or Fresh school dropouts who wish to make career in welding

SUBJECTSLimits to various programs and application

Industrial Sociology & Engg. Economics

Material Science

Welding Metallurgy Welding & Allied Processes Weld Design and Weld ProceduresWelding Applications

Advanced Welding Technology & New Trends

Welding Equipment & Consumables , usage and its application

Electricals and Electronics

National & International Codes ,Standards, & Specifications

Testing Inspection methology & Quality Assurance

Present Status: WHY AWAC

• Besides manpower, AWAC has resources enough to promote Welding Specialisation.

• Its Chairman has ambitious program and appetite for furthering and developing Welding Training.

WHY AWAC-1

• Takes pride in training consulting approach, since its clients have stayed over the years

• The extra personal touch has led to a partnering approach.

• Given tremendous satisfaction to watch partnership bear dividends in the organizations that have partnered.

WHY AWAC-2

• AWAC have been successful in contributing by partnering with organisations, in their learning and development plans:

• Identifying training needs,

• Establishing a plan and a process for the most effective delivery,

• Developing and executing the relevant delivery solutions,

• Evaluating training effectiveness post delivery.

WHY AWAC-3

• In the absence of a training manager, Supplement the efforts of industry training manager with their strengths,

• AWAC takes on that role.

• This requires lot of trust building along with the ability to flex and think differently, as the need of each organization varies from the others.

PERIODICAL AUDIT

After running few program, it needs to be audited and modified to meet need and for further expansion.

CONCLUSION:• In the technical and professional circles an

increasing concern is felt:

“There is a lack of competent people in this trade at ALL LEVELS”.

• AW ACADEMY can play a significant role

• Educational institutes have lot to play a dominating role and try best through contacts & students and alumni base also collaborating with reputed institutes like,WRI,IIW,IWS,AWS, etc and in collaborating with Asian, UK,German, American welding Society.

ACKNOWLEDGMENT

• Author wish to thank Organisors of this program and also to BOG of AWAC to present views at this conference.

• Papers from various Conferences in India & Abroad

• Personal Communications and collection of data

• L&T to share pictures of Fabrication

THANK YOU

Wish You all A

Happy& Prosperous

Year 2014