| Course Unit Title | Course Unit Code | Type of Course Unit | Level of Course Unit | Year of Study | Semester | ECTS Credits |
|---|---|---|---|---|---|---|
| Welding Metallurgy | KMP237 | Elective | Associate degree | 2 | Fall | 4 |
Name of Lecturer(s)
Lecturer Ahmet Sefa ATALAY
Lecturer Ahmet ÇALIŞKAN
Learning Outcomes of the Course Unit
1) Explain the temperature distribution in welds and the microstructure formed as a result for a single pass weld versus a multi-pass weld.
2) Comment of the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the microstructure formed for a single pass weld versus a multi-pass weld.
3) Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on it properties for a single pass weld versus a multi-pass weld.
4) Explain areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties for a single pass weld versus a multi-pass weld.
5) Discuss the various aspects of weldability.
6) Deduce the microstructural and weldability changes induced by dilution.
7) Explain the concept and use of carbon equivalent.
8) Explain the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding).
9) Recognize the structure of welds and HAZ for given thermal cycles and composition.
10) Explain in detail the effects of a multi pass welding on the structure, the mechanical properties.
11) Discuss the factors affecting cold cracking.
12) Identify optimal heat input and appropriate pre-heat for given materials, conditions and applications utilising Codes and standards as required.
Program Competencies-Learning Outcomes Relation
| Program Competencies | ||||||||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | ||
| Learning Outcomes | ||||||||||||
| 1 | No relation | High | High | High | High | High | High | High | High | High | High | |
| 2 | High | High | High | High | High | High | High | High | High | High | High | |
| 3 | Middle | Middle | High | High | High | High | High | High | High | High | High | |
| 4 | High | High | High | High | High | High | High | High | High | High | High | |
| 5 | High | High | High | High | High | High | No relation | No relation | No relation | No relation | No relation | |
| 6 | High | High | High | High | High | High | High | High | High | High | High | |
| 7 | No relation | No relation | No relation | No relation | No relation | No relation | No relation | No relation | No relation | No relation | No relation | |
| 8 | High | High | High | High | High | High | High | High | High | High | High | |
| 9 | High | High | High | High | High | High | High | High | High | High | High | |
| 10 | High | High | High | High | High | High | High | High | High | High | High | |
| 11 | High | High | High | High | High | High | High | No relation | High | High | High | |
| 12 | High | High | High | High | High | High | High | High | High | High | High | |
Mode of Delivery
Face to Face
Prerequisites and Co-Requisites
None
Recommended Optional Programme Components
Material Technology-1
Course Contents
1. Thermal field 2. Equations for the heat distribution 3. Heat input and efficiency of heat input 4. Peak temperature 5. Cooling rate and thermal cycle 6. Dilution 7. Weld metal 8. Solidification of weld pool 9. Structure of the weld 10. Fusion line 11. Heat-affected zone (HAZ) 12. Microstructure of HAZ 13. Grain growth and grain refinement 14. Relationship grain size – toughness 15. Transition temperature 16. Weldability (definitions) 17. Application of TTT diagrams 18. Hardening effects 19. Carbon equivalent 20. Standards 21. Effects of multi-pass welding 22. Structure of the weld and the HAZ 23. Factors influencing cracking 24. Relationship C% max – hardness 25. Relationship Ceq – hardenability 26. Determination of preheat and interpass temperature (diagrams) 27. Weld – simulation (Weld thermal cycle simulation) 28. Determination of the optimal heat input 29. Influence of restraint
Weekly Schedule
1) Introduction to resource capability, definition of resource capability and influencing factors2) What is the ideal source attachment, what should be done to achieve the ideal source attachment
3) Mass and heat transfer in fusion welding
4) Metallurgical effect of welding thermal cycle
5) Chemical reactions in the welding zone
6) Residual stresses in the source, distortion
7) Solidification of weld metal and phase transformation in the weld zone
8) Parts of the heat affected zone
9) Effect of alloying elements on weld metal properties
10) Causes of welding errors and prevention solutions
11) Heat treatments applied to welded joints
12) Destructive and non-destructive testing methods of welded joints
13) Welding metallurgy of stainless steels and Welding metallurgy of non-ferrous metals
14) Welding metallurgy of stainless steels and Welding metallurgy of non-ferrous metals
15) General Review
16) Final Exam
Recommended or Required Reading
1- Çeliklerin kaynak kabiliyeti, Cilt 3, Prof . Dr. Selahattin Anık, İTÜ, Makine Fakültesi 1981.
2- Kou, S. Welding Metallurgy , Willey Interscience Publisher, pp. 56-69, (2002).
3- Metallurgy of Welding, Fifth edition, Chapman&Hall publication, England.
Planned Learning Activities and Teaching Methods
1) Lecture
2) Question-Answer
3) Discussion
4) Demonstration
5) Brain Storming
6) Case Study
7) Problem Solving
Assessment Methods and Criteria
Contribution of Midterm Examination to Course Grade |
50% |
|---|---|
Contribution of Final Examination to Course Grade |
50% |
Total |
100% |
Language of Instruction
Turkish
Work Placement(s)
Not Required