Course Book · 1. Contribute student to recognition different welding process, how they applied in respect to different materials (steel and non-steels) as base metal 2. To working

Ministry of Higher Education and Scientific research

Directorate of Quality Assurance and Accreditation خشین‌به‌تی‌دڵنیایی‌جۆری‌و‌متمانه‌رایه‌به‌ڕێوه‌به

Department of: Mechanical and Energy Tech. Eng. dept.

College: Erbil Technical engineering college

Erbil Polytechnic University

Subject: Manufacturing Methods & Welding Technology

Course Book – Year 2

Lecturer's name: Assist. Prof. Dr. Gailan Ismail Hassan

Academic Year: 2019/2020

Course Book

1. Course name Manufacturing process & welding technology

2. Lecturer in charge Assist. Prof. Dr. Gailan Ismail Hassan

3. Department/ College Mechanical & Energy tech. Eng. Dept.

4. Contact e-mail: [email protected] or [email protected] Tel: (optional)

5. Time (in hours) per week Theory: 2 Practical: 2

6. Office hours Sunday and Monday

mailto:[email protected]

mailto:[email protected]



7. Course code ME 209

8. Teacher's academic profile B.Sc. in production and metallurgy engineering, University of Technology in Baghdad, 1980. MSc in production engineering in University of Technology in

Baghdad, 1983. MSc Thesis (Application study of rivets instead

of screws in metal joints), University of Technology, Baghdad,

1983. In Arabic language.

PhD in production engineering in Salahaddin University in Erbil,

2005. PhD thesis (Surface finish improvement in metal hard

turning and burnishing operation), College of

Engineering, University of Salahaddin, Erbil, 2005. In English

language.

From 1985 -1990 assistant lecturer.

From 1990-1994 lecturer.

From 1994 assistant professor till now.

From 1987-1988 responsible of Mechanical workshop.

From 1989-2003 head of mechanical dept. in Erbil Technical Institute.

From 2008-2011 director of curriculum development in foundation of technical education-Erbil.

From 2011-2015 Dean of Erbil Technical Engineering College

1. Head of committee of technology sector in foundation of technical education (FTE) from 1996-2009 and from 2011-2013 and from 2014-2015.

2. Head of committee of scientific promotion in FTE from 1998-2004 and Member from 1992-1996, 2010-2013 and 2017-2019.

3. Head of committee of technical curriculum development in FTE for first scientific conference of higher education council at 21-23/4/2001 in Erbil. And first scientific conference of ministry of higher education at 7-8/10/2006 in Erbil.

4. Head of committee of scientific title awarding in FTE from 2010-2013. And member from 1996-2000.



My Publications and research:

1. Scientific book "Machine element Technology” Published by FTE. In English language2012

2. Scientific Dictionary about welding and foundry terms published by Acadimiai Kurdi. Kurdish, Arabic and English language.2011

3. papers (research): 11 papers

9. Keywords Fusion, SMAW, TIG, MIG/MAG, Resistance welding, spot, seam, flash, gas welding, brazing, soldering

10. Course overview: Welding is process of materials joining two pieces by partially melting their surfaces and allowing

them to flow together. Welding is important subject to student in air-conditioning & refrigeration specialization when they deal as engineer with maintenance and repairing different air-conditioning & refrigeration apparatus. Due to all parts and elements of air-conditioning & refrigeration apparatus made from different metals (steel, stainless steel, cast iron, aluminum, copper, brass, bronze, etc) and to joining these metals we need some time permanent joint like welding. Welding performance go one with all parts and elements of air-conditioning & refrigeration apparatus which is general repair work so they must learning and training on different types of welding process and understanding the different welding application methods.

Theoretical hours will be enough to the student to learn different welding process and their principles, equipment, application, limitation, how they work….etc.

Practical hours will be helpful to the students to get good training on different welding processes. All these types of welding which student training on it available in local market and workshops

Principle of welding process is producing coalescence of materials by heating them to intense localized suitable temperatures with or without application of pressure or by the application of pressure alone, and with or without the use of filler material.

11. Course objective: The main objectives:

1. Contribute student to recognition different welding process, how they applied in respect to different materials (steel and non-steels) as base metal

2. To working on different welding equipments. 3. To realizing different welding electrodes and fluxes. 4. To working in mechanical workshops especially welding operations. 5. Preparing mechanical path to execute different welding types. 6. Applying special instruction of occupational safety

12. Student's obligation: Class attendance, preparing yearly report on each chapter by each student using power point not less than 16 slides with the video shot and at the end of every chapter they must be ready to show it as presentation. Quiz for each chapter.(more than 6 quiz at the end) Attendance at practical hours in welding workshop, training on different types of welding to writing



report at the end weekly, also practical examination on each test.

13. Forms of teaching Data show, power point, white board, seminar, pictures and video, training on different types of welding in workshop.

14. Assessment scheme 1. Overall assessment (one seasonal examination, 6 quizzing, data show presentations, report,

practical testing in workshop, also attendance in class). 2. One Seasonal theory examination: (25 %) degree 3. One seasonal practical examination: (10%) degree 4. Two seasonal trainings with weekly report: (5% + 5% ) degree 5. Yearly assessment : 5% degree divided as (2% degree on report and presentation + 2% degree on

quizzing + 1% degree on class attendance) 6. Final theory examination: 40% degree

7. Final Practical examination: 10% degree‌

15. Student learning outcome: The main outcome: 1. Welding is most efficient way to joint metals, and more flexible design provider. 2. Training on different lowest cost joining methods like manual arc welding, gas welding, spot

welding…etc in different welding positions (flat, vertical, horizontal and overhead) to get high labour cost.

3. Identifying different commercial materials like different steels, aluminium, copper, brass, bronze…etc

4. Learning how selecting different electrodes, filler metals. 5. Preparing different work pieces to design different welding joints. 6. Learning how select different welding process in respect to economical factors. 7. Learning how cutting materials by oxy-fuel gas cutting process.

16. Course Reading List and References :

▪ Key references:

1. H. B. Cary; "Modern welding technology" 5th edition, 2002 2. Kalpakjian; "Manufacturing Engineering and Technology", 2002. 3. Md. Ibrahim khan," Welding Science and Technology" 2007

▪ Useful references:

4. M. G. Nicholas;" Introduction to diffusion bonding", 1998. 5. P. J. Harris; "Manufacturing technology 3", 1981. 6. D. Brandon and W. Kaplan;" Joining processes; an Introduction", 1997.

▪ Magazines and review (internet):

1. www.thefabricator.com

2. www.fmametalfab.com

3. www.iteawww.org

http://www.thefabricator.com/

http://www.fmametalfab.com/

http://www.iteawww.org/



17. The Topics: theoretical Lecturer's name

1. Welding technology, manufacturing process, welding process types 2. Definition (fusion, welding, weld and welder), electrical arc welding,

its principles, advantages and limitation of welding in general, Equipment, variables of arc welding (current setting, arc voltage, rate of travel and angle of electrode), it’s general rule.

3. Arc welding electricity, open circuit voltage, welding power source (generator, transformer, rectifier, inverter welding machine), duty cycle, comparisons of alternating and directing current, constant current system, constant voltage system and its principle and differences. Comparison of penetration contours.

4. Manual arc welding, shielded metal arc welding SMAW, striking and maintaining the arc, It’s principles, HAZ, SMAW equipment, filler metal, weldability, deposition rates, electrode coating and its composition, SMAW advantages and limitation.

5. Welding position capabilities, base metal thickness tae, designed of weld joint and welds, types of welding joints, welding types, it;s specification, tips for using the welding process.

6. TIG welding, notes, advantages and major uses, Equipment, welding circuit, tungsten electrode materials and sizes, shielded gas,

7. Types of filler materials (covered electrode, electrode rod or wire, tubular or cord electrode, flux, non-consumable electrode), deposition rates and TIG quality, TIG variables, safety consideration, limitation and application, sticking out variable, polarities In SMAW,TIG,MIG, comparing between them.

8. MIG/MAG welding, it’s principle, Inert gases, advantages and disadvantages, metal transfer mode, equipments, welding circuit.

9. Electrode and shielded gas, specific metal recommendation, deposition rates and MIG quality, application and limitations, purpose of shielding gas. Insufficient shielding gas coverage.

10. Gases for shielding (argon, helium and co2), gas mixtures. Properties of gases, arc spot welding in MIG/MAG, its principle and advantage. Welding position and joints. Advantages of and spot over resistance welding how stopping the MIG/MAG welds. Comparing between gases and TIG with MIG/MAG, comparing between metal transfer.

11. Electrical resistance welding, its principles, factors involved in making resistance welding, total resistance, its application, weld-able metal.

12. Resistance spot welding, spot welding machine, electrodes, its shape welding controllers, welding joints, types of spot welding.

13. Resistance seam welding, notes, types of seam welding joints, flash welding, its principle, projection welding, its principles and advantages.



14. Stud welding, its principles, advantage and methods of application, joint designs, equipment, materials, welding variables and tips for use.

15. Stud limitation, safety consideration, variations of the process (capacitor discharge, drawn arc capacitor discharge, stud friction welding).

16. Stud friction welding, its principle, its advantage and disadvantage. 17. Gas welding, pressure gas welding, oxyacetylene welding, flame

types, advantage and major uses. Gas equipments, types of torch, regulators, flashback arresters, gas hose, gas supply.

18. Fuel gas for welding, factors of selecting gas (acetylene, hydrogen, methane, liquefied petroleum gas, oxygen). Acetylene generator.

19. Gas welding technique, welding joint design, welding rod or filler metal, welding flux, Limitation and variation of the process.

20. Metal cutting by gas (oxyfuel gas cutting), fuel gas types, general concept, chemical formula for oxidation reaction, principle of oxygen cutting, metals condition, types of material can be cut or cannot be cut, types of flame cutting, welding equipment.

21. Types of torch, metal powder cutting, its principle, air carbon arc cutting, circuit diagram, electrode holder.

22. Seminar presentation by students 23. Brazing, its principles, surface preparation, materials used, types of

filler metals and its uses, advantages, and disadvantages. 24. Brazing steps, heat sources of brazing (brazing equipment), cleaning

of brazed joint. 25. Soldering, soft soldering, soldering steps, material used (base metal,

flux, solder, lead), soldering defect, the operator’s effect on the process, disadvantages.

26. Seminar presentation by students

18. Practical Topics: (according to available machines)

Lecturer's name: ex: (2 hrs)

Training on Arc welding (manual, mechanical) Training on TIG welding Training on MIG welding Spot welding techniques with different thickness and metals. Gas welding and cutting Brazing techniques, torch brazing, furnace brazing. Soldering, preparation of surfaces, soldering techniques with different of filling materials.

Lecturer's name Zhian Faiq ex: (2 hrs)

19. Examinations: (Each student has been taken examination samples for five years 2014-2015, 2015-2016- 2016-2017, 2017-2018 and 2018-2019)

1. Compositional:



- Why the deposition rates of gas metal arc welding (MAG) are higher for the same current than shielded metal arc welding (SMAW). Answer: These higher rates occur because there is no electrode coating that must be melted. - Give reason why the excessive Oxygen is not preferred in Oxyacetylene Welding.

Answer: oxygen combines with iron to form inclusions and remain in weld metal, also combines with carbon of steel to form carbon monoxide. The gases collect into pockets that cause pores or hollow space.

2. True or false type of exams: non

3. Multiple choices:

- Choose clearly the purpose of using shielded gas in gas metal arc welding process: (MIG/MAG)

a- to protect the arc area from the atmosphere.. b- to establish the metal transfer mode and deposited weld characteristics. c- to form a protective envelope around the weld area. d- all of them. e- not each of them.

Answer: (d) all of them

Type of question Example

Drawing

Comparing

Choosing

Analysis

Explanation

1. Draw with referring to the main parts TIG welding process diagram. Summarize two advantages of using this type of welding.

2. Compare between shielded metal arc welding (SMAW) and gas tungsten arc welding‌(TIG).

3. Suppliers provide a thin copper coating on the solid electrode wire to

improve: A) deposition rate. B) current pickup between contact tip and

electrode. C) slag coverage. D) mechanical properties.

4. Explain why Application of argon with small amount 5% of hydrogen in

(MIG/MAG) process.

5. Give the benefits or usage using stud gun with special design in arc

stud welding.

20. Extra notes: non

21. Peer review ڵ‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌‌ی‌هاوه‌وه‌پێداچوونه

This course book has reviewed and signed by Dr. Youns Khalid Khdr



Documents

Course Book · 1. Contribute student to recognition different welding process, how they applied in respect to different materials (steel and non-steels) as base metal 2. To working