Course Curriculam

COURSE CURRICULAM

A) Revised Curriculum and Syllabi

1) The Revised of the Curriculum is in keeping with the trends of B.E. Courses in universities and Colleges with a proper balance between science, engineering science, humanities & social science, and professional engineering subjects. Thus, a new subject “Fluid Mechanics” comes in, both because of its intrinsic need and as a prerequisite for “Heat Transfer”.

The revised curriculum and syllabi come into effect for candidates Registering from Winter-2014 Examination. The old curriculum will be valid for existing candidates till 2016.

2) Elements of Safety and Environment Control have been incorporated.

3)Syllabi of all subjects have incorporated latest trends and developments.

4)Syllabi contain full details in keeping with specific requests from candidates.

5) Part ‘A’, ‘B’, and ‘C’ contain 08 Subjects each.

6)All earlier revisions have been carried forward especially, of Part ‘D’ consisting of (i) Project Work, and (ii) Viva Voce.

Part – A

AME – 01 Elementary Mathematics .
I Vector Algebra
Vectors and scalars, vector addition, resolution of vectors, scalar components, unit vectors, vector representation in three dimensions, scalar and vector product of two vectors.
II Determinants
Properties of determinants up to 3 rd order, solution of system of linear equations by Cramer’s rule, with three unknowns.
III Complex Numbers
DeMoivre’s theorem, roots of real and complex numbers, exponential values of sines and cosines, hyperbolic functions.
IV Differential Calculus
Differentiation and integration of hyperbolic functions. Rolle’s theorem and its application, Mean Value theorems – Lagrange & Cauchy and their application. Taylor’s theorem with Lagrange’s and Canchy’s form of remainders, Expansion of functions by Taylor’s and Maclaurin’s theorem, Maclaurin’s infinite series expansion of Standard functions : sinx, cosx, ex, log (1+x).
Maxima and minima of functions of one variable.
V Integral Calculus:
Properties of definite integrals, fundamental theorem of integral calculus and its applications.
Arc length and surface areas of plane curves. Volume and surface area of solids of revolution. Centre of gravity.

Recommended Text Books : .

1) Differential Calculus, Dhami H.S. 1998, New Age International (P) Ltd.
2) Integral Calculus, Dhami H.S. 2001, New Age International (P) Ltd.
3) Textbook of Engineering Mathematics, Debashis Datta, 2002, New Age International (P) Ltd.
4) Engineering Mathematics – Kreszyg.
5) Pal and Das, Engg. Mathematics, vols I & II, U.N. Dhar & Brothers P. Ltd.

 

2. AME – 2 : PHYSICS

 

Geometrical Optics : Lens aberrations; longitudinal chromatic aberration, lateral chromatic aberration, two lenses in contact, two lenses separated by a distance; Monochromatic aberration; spherical aberration, coma, oblique astigmatism, curvature and field of distortion.

Interference : Relation between phase and path difference; coherent sources; Young’s Double slit, Fresnel’s Biprism, Lloyd’s single mirror; position of Bright and Dark fringes, fringe width. Displacement of fringes; Newton’s rings.

Diffraction : Fresnel and Fraunhofer diffraction, single slit and double slit diffraction, diffraction grating; introduction to reflection and transmission, resolution and Raleigh criterion, resolving power of grating.

Polarisation : Concepts, Brewester’s law, double refraction, optic axis; Nicol prism. Laurent’s and Bi-quartz’s polarimeter.

Fibre Optics : Basic principle and application of optical fibres.

Introduction to Lasers : Stimulated absorption, spontaneous emission and stimulated emission. Characteristics of Laser light. Einstein’s A and B coefficients. Population inversion, Ruby laser, helium-neon laser, argon ion laser, CO 2 laser, semi conductor lasers.

Acoustics : Simple harmonic motion, free and damped vibration, analogy with electric circuits, forced vibration, Resonance; amplitude resonance and velocity resonance and energy intake, absorption of sound; Sabine’s formula (statement only), acoustic properties of buildings, production and application of ultrasonics.

Magnetism & Electricity : Biot-Savart law; magnetic fields due to a long straight conductor, a narrow circular coil, on the axis of a solenoid. Magnetic circuits, magnetomotive force, reluctance.

Alternating Current ; r.m.s. value, mean value of an a.c. current. Applications of a.c. to (i) a pure resistance, (ii) a pure inductance, (iii) a capacitor, (iv) an L-R circuit. Impedence triangle and power triangle. Application of a.c. to (i) a C-R circuit and (ii) an L-C-R circuit in series.

Recommended Books :
1) Engineering Physics, by Srivastava S.K., and Yadav R.A., New Age International (P) Ltd., Fourth Edition, 2006.

2) Physics for Engineers, by Srinivasan M.R., New Age International (P) Ltd., 1996.

AME – 3 : CHEMISTRY

Chemical Bonds :
Types of chemical bonds; ionic, covalent, coordination bonds. Theory of bonding in metals; free electron theory, valence bond theory, molecular orbital theory. Hydrogen bonding; intermolecular and intramolecular hydrogen bonding. Solid state chemistry; laws of crystallography, laws of constancy of interfacial angle, law of rationality of indices, Weiss and Miller indices, law of symmetry; plane of symmetry, axis of symmetry, centre of symmetry. Crystal lattice and unit cell. Examples of cubic, tetragonal, orthorhombic, monoclinic, triclinic, hexagonal and rhombohedral crystals. Body centered and face centred lattices.

Polymer Chemistry :
Natural and synthetic polymers, Organic and inorganic polymers, thermoplastic and thermosetting polymers, plastics, elastones, fibres and liquid resins. Addition and condensation polymers. Structure of polymers.

Chemical Kinetics :
Reaction rate and rate laws, rate constant, order of a chemical reaction; zero, first and second order reaction.

Corrosion :
Types of corrosion, theories of corrosion, factors affecting corrosion, protection from corrosion.

Water Treatment :
Types and degrees of hardness, softening of water; lime soda process, treatment of boiler feed water.

Fuel and Combustion :
Calorific value, determination of calorific value, analysis of coal.

Environmental protection :
Types and sources of air pollutants, pollution control techniques. Smog formation, acid rain, depletion of ozone layer.

Recommended Books :
• Fundamentals of Engineering Chemistry, Singh S.K., New Age International (P) Ltd., Third Edition, 2005.

4 . AME – 4 : GENERAL ENGLISH

  Grammar. Usage, essays on current topics, précis, letter and technical presentation and technical report writing.

Selected pieces of prose and poetry from English literature.

 

AME – 05 Applied Mechanics

  I Statics :

Composition and resolution of forces; moment of a force about a point and an axis ; reduction of a force system to a force and a couple, equilibrium; Lami’s theorem ;coplanar non concurrent forces; Varignon’s theorem; resultant of a force system.

II Friction :

Laws of Coulomb friction ; angle of friction, angle of respose and cone of friction. Simple problems applied to wedges, square threaded screws, belt friction, ropes.

III Frames and trusses

Analysis of pin jointed plane frames and trusses; method of joints,method of sections.

IV Properties of Areas and Solids

Centroid, centre of gravity, moment of inertia, polar moment of inertia, principal axes, theorems of moments of inertia, moments of inertia of rigid bodies.

V Kinematics; linear motion with uniform velocity and uniform acceleration. Projectiles; inclined projections on level ground, projections on inclined plane; relative velocity.

VI Kinetics:

D’ Alembert’s principle; Impulse, momentum, simple applications to motion of connected bodies.

VII Circular Motion of Rigid Bodies

Acceleration, motion on level ground, banking of roads, super elevation of rails, designed speed, skidding and overturning on banked roads.

VIII Work and Energy

Principles of work and energy applied to particle and rigid bodies, power and efficiency, simple examples. .

Recommended Books :

•  Engineering Mechanics, Bhavikatti S.S. , and Rajasjekarappa K.G., New Age Intl.(P) Ltd.

•  Engineering Mechanics, Irving H. Sharnes, Prentice Hall of India Pvt. Ltd. 1998.

AME – 06 INDUSTRIAL SOCIOLOGY

•  Defining Sociology, Sociology and other Social Sciences – economics, political science, Psychology, history and social anthropology. The sociological perspective.

•  Culture , geographical background of Indian culture, definition of culture, elements of Culture, values, beliefs, ideologies, norms, convention, etiquette, customs, traditions, fashion. Sub-culture, contra-culture, ethno – centrism, culture and socialization. Social Changes in modern India.

•  Society, rural and urban communities, nature of urbanization in India, regionalism, tribal society, agrarian society, industrial society. Social groups and sub-groups.

•  Impact of science and Technology on culture and civilization; the post industrial society.

•  Social Stratification; social differentiation, stratification, status consistency and Inconsistency, functionalist approach to stratification, social mobility, vertical mobility.

•  Urban and Industrial Sociology; sociological problems of economic development and social change. Functionalist explanation of social change, demography and social change, social factors determining fertility, morality.

•  Traditional Sociology and Modernisation; meaning of modernization, complexities of modernization, Westernisation.

•  Development; the role of the state and the role of the market.

•  Technology Transfer; technology transfer, technology assessment, sociological perspectives on environment, influence of technology on environment.

•  Labour in India; wage regulation, contract labour, women workers, bonded labour, child labour, migrant labour. Worker’s adjustment and maladjustment. Incentives and disincentives.

•  Industrial Relations ; grievance redressal, industrial disputes, trade unionism in India, arbitration, worker’s participation in management.

Recommended Books :

•  Industrial Sociology – Dr.Kumar Narain’s series, Lakshmi Narain Agrawal, Agra.

•  Industrial Sociology – Dr. Vatsyayan, Sixth & enlarged Edition, Kedarnath Ram Nath, Meerut & Delhi.

•  Sociology …………- Parimal Kar, Central Educational Enterprises, Kolkata.

AME – 07 Strength of Materials

I Simple Stress and Strain

Stress – strain Diagram for ductile, brittle and plastic materials, concept of true modulus of elasticity,yield stress ultimate stress, working stress,proof stress, and engg.stress, factor of safety, stress coneentration, simple problems of thermal stresses and statically indeterminate problems.

II Elastic Constants :

Poisson’s ratio; bulk modulus; relation between bulk modulus and Young’s modulus ; modulus of rigidity and shear modulus, relation between modulus of rigidity and Young’s modulus.

III. Plane stress and strain

Basic concepts; principal and principal strains ; Mohr’s circle of stresses.

IV Bending of Beams:

Types of beams, supports and loads; concentrated load, uniformly distributed load, gradually varying load; bending moment and shear force diagrams;

V Stresses in Beams :

Theory of simple bending; neutral axis, moment of resistance, section modulus flexural equations. Bending stress distribution in beams.

Shear stress distribution in beams of rectangular, solid circular, and I – section beams.

VI Deflection of Beams :

Differential equation of the Elastic Curve; relation between deflection, shape, shear force and bending moment; simple problems of deflection of beams.

VII Buckling of Columns

Euler’s theory ; critical loads; short and long columns.

VIII Torsion of Circular Shafts :

Torsional stress and strain, polar moment of inertia, power transmitted by a shaft. Shear stress distribution across solid and hollow shafts.

IX Thin Cylinder under Internal Pressure:

Circumferential and longitudiual stress; change in volume due to internal pressure; simple problems.

Recommended Books :

•  Elements of Strength of Materials – Timoshenko.

•  Strength of Materials – G.H. Rhyder.

•  Strength of Materials – Basavarajaiah B.S., and Mahadevappa P.

•  Strength of Materials – Popar.

 

AME – 08 Electrical Engineering and Basic Electronics

D.C. Circuits :

Node, branch, active and passive elements, linear and non linear circuits, bilateral network, Kirchhoff’s laws, Maxwell’s loop current method, star – delta transformation.

Network theorems – superposition theorem, Thevenin’s theorem, Norton’s theorem, maximum power transfer theorem.

Magnetic Circuits :

Magnetic quantities, B-H curve, calculations on magnetic circuits, analogy with electrical circuits.

A.C. Circuits :

Sinusoidal quantities, phase and phase difference, average and r.m.s. values,form factor and peak factor, phasor diagram, impedence and admittance, power and power factor.

Single phase a.c. circuits; series and parallel combinations of R,L,C; phasor diagram; apparent, active and reactive power; resonance in a.c. series and parallel circuits; application of network theorems to simple A.C. circuits.

Three phase a.c. circuits, balanced system, star and delta connections, phase and line quantities and their relationships, phasor diagram.

Transformers :

Types, emf equation, phasor diagrams,equivalent circuit, no load and short circuit tests, losses and efficiency, voltage regulation.

D.C. Machines :

Types, emf equation; d.c. motors; back emf, torque equation; characteristic curves of different types of motors, starting and speed control methods.

Induction Motor :

Single phase motors; capacitor start and run motors. Classification and applications.

Measuring Instruments :

Classification; torques in indicating instruments; moving iron dynamometer type instruments and their applications as ammeter, voltmeter, wattmeter, energy meter and recorders.

Semiconductors; intrinsic, N – type, P – type; the P – N junction; forward and reverse bias; junction, Zener and avalanche breakdown.

P – N Junction diode; application as rectifier, voltage doublers and waveshaping power supply. Bipolar junction transistors; biasing, characteristic, different modes of operation.

Field effect transistor; types, configuration, characteristics and use as an amplifier. Introduction to optoelectronic devices; LED, LCD,LDR, Photodetectors.Transistor as an amplifier; common emitter amplifier, the emitter follower. Feed back amplifier; positive and negative feedback, the operational amplifier (TC). Use of operators of amplifier as invertor, adder integrator, differentiator .

Push –Pull inverter circuits. Boolean functions and logic gates.

Recommended Text Books :

•  Electrical Engineering and electronics, Theraja B.L., 1998, S. Chand & Co. Ltd.

•  Basic Electronic Principles, Millman and Halkias.

 

 

Part – B

 

AME – 09 Materials Science

Atomic structure and types of bonding between atoms : Bohr’s atomic model – electronic configuration of atoms, periodic classification of elements. Binding energy; ionic bonds, covalent bonds, material properties having these bonds. Electro negativity. Metallic bond – matrials properties having this bond. Intermolecular forces.

Concepts of crystal geometry : Space lattice – cubic, tetragonal, orthorhombic, rhombohedral, hexagonal, monoclinic and triclinic. Unit cell parameters to specify each crystal system. Crystal directions and planes, Miller indices.

Binding in solids : Convalent, ionic, metallic and molecular bonding. Crystal symmetry and structure. Crystalline imperfections. Point imperfections and line imperfections or dislocations, edge and screw dislocations, slip planes. Surface imperfections. Structure in silica and silicates; polymorphism in metal and ceramics; Amorphous materials – glass and polymer.

Alloys : Binary phase diagrams of important alloy systems, dendrite structure, lever rule, solid solutions, eutectic, peritectic, eutectoid and peritectoid reactions. Intermetallic compounds, sigma & other phases.

Mechanical deformation of materials : Elastic and anealstic ; plastic deformation and creep, slip and twin, dislocation theory, critical resolved sheer strees, deformation in polycrystalline material. Bauschinge’s effect and elastic after effect. Work hardening; recovery, recrystalisation and grain growth, preferred orientation.

Fracture in metals and alloys : Ductile and brittle fracture, Griffith’s theory, fracture toughness, ductile-brittle transition, fatigue fracture. Mechanical testing of metals.

Ceramic Materials : The structure of silica and silicates, polymorphism, fracture in glass, electrical properties of ceramic phases, refractories.

Polymers : Classification ; degree of polymerization. Formability; addition polymerization, copolymerization, condensation polymerization. Molecular structure; linear, branched, cross linked polymers. Thermoplastic and thermosetting polymers. Structure-property correlation, crystallinity, mechanical properties, applications.

Composites : General characteristics, dispersion / particulate strengthened composites, fibre reinforced composites, fabrication.

Recommended Text Books :

•  Material Science, S. L. Kakani and Amit Kakani, First Edition, New Age International (P) Ltd.

•  Principles of Engineering Metallurgy, L. Krishna Reddy, 1996, New Age International (P) Ltd.

•  Material Science and Engineering, 7 th Edition, by William D. Callister Jr. John Willey & Sons Inc. (2006).

•  Material Science and Engineering – a First Course, by V. Raghavan, 4 th Edition, Prentice Hall of India Pvt. Ltd., New Delhi (2004).

AME – 10 Production Engineering

I Metal Casting

Types of patterns and core boxes; metal flow in a mould; gating and risering ; casting proceses; green and dry sand, other sand casting processes, metal mould casting proceses, precision casting processes. Melting furnaces; casting defects, inspection and rectification.

II Metal Forming

Cold and hot working processes; various metal forming processes; punching, blanking, coining, drawing, extrusion, rolling, bending.

Hot plastic flow of metals; machine and drop forging, dies for drop forging, forging hammers and presses.

III Machining and Machine Tools

Definition of Machining and Machine Tools. Elements of Mechanics of metal cutting, types of chips, cutting tools, tool geometry, in AsA, ORS and NRS systems shear angle and shear strain, tool materials and there properties, forces on cutting tool, Merchant’s circle diagram, tool failure, tool life, cutting fluids, speed, feed and depth of cut, power requirements. Various machining operations, turning, milling, shaping, planing, screw thread cutting gear cutting, grinding, super finishing, and machine tools used, motions needed for machining on respective machine tools and their structures.

IV Metrology

Use of comparators, measurement of flatness and surface finish, use of gauges; limits fits, and tolerance.

Process and Production Planning and control ;

Production planning Gantt chart, inventory control, inventory policies, economic batch quantity; Method and work study; time study, systems of rating, time standards.

V Surface Modification Technology

Case hardening by flame, case carburizing, nitriding, carbo-nitriding, coating; PVD and CVD techniques, cladding.

Recommended Text Books :

•  Production Technology, Jain R.

•  A Text Book of Production Engineering, Pandey P.C, Singh C.K, and Balbir Singh.

•  Production Technology, O.P. Khanna and G. K. Lal, Vols- I and II.

•  Materials and Manufacturing Processes, Degarro, Kohser and Black.

 

AME – 11 Engineering Drawing

I Introduction to IS code of drawing

Lines lettering and dimensioning

II Method of drawing geometrical curves as used in engineering practice such as parabola, ellipse, hyperbola, involute, cycloid, epicycloids and hypocycloid helix.

III Concept of First and third Angle Projection

Projection of points, lines and surfaces in first and third angle. Sections of solids and their projections.

IV Isometric projection:

Section and auxiliary views, development of srfaces and intersection of solids, Projection of nuts, bolts, rivets and riveted joints, keys, cotters, couplings.

V Machine Drawing:

Drawing of simple machine parts from pictorial views, machine drawing conventions, conventional sectioning.

Conventional representation of machine elements. Assembly and working drawings with limits, fits and finish.

VI Welding symbols:

Standard welding symbols used on drawings

Recommended Text Books :

•  Engineering Drawing, Bhatt N.D., Panchal V.M., 1998, Charbotar Publishing House.

•  Machine Drawing, Bhatt N. D., Panchal V.M., Charbotar Publishing House.

 

AME – 12 Engineering Mathematics

I Matrices : Addition and multiplication of matrices; adjoint and inverse matrix. Matrix method of solution of a system of linear equations upto three unknowns.

II Functions of several variables :

Limit and continuity; partial derivatives ; total differentials; Jacobean and problems of two variables; tangent planes and normals. Maxima, minima and saddle points; Lagrange multipliers; problems related to three variables.

III Integral Calculus :

Mean value theorem of integral calculus ( no proof); Improper integrals; Beta and gamma functions and their relation (no proof) and some applications; Double and triple integrals; simple applications.

IV Infinite series:

Convergence and divergence; comparison test, D Alembert’s ratio test, Gauss test, Cauchy’s root test and integral test. Alternating series; tests for convergence and divergence. Power series (basic concepts).

V Ordinary Differential Equations :

Review of ordinary Differential Equations, linear and non – linear first order equations;

Second and higher order equations with constant coefficients, method of variation of parameters. Euler – Cauchy equations.

VI Fourier Series

Fuler’s formulae for Fourier series (without proof)

Expansion of functions in Fourier Series and in half range series.

VII Partial Differential Equations :

Boundary and initial value problems leading to P.D.E.’s. Method of solution by separation of variables. Application to one dimensional wave and diffusion equations and two dimensional Laplace equation.

Recommended Text Book :

•  Textbook of Engineering Mathematics, Debashis Datta, 2002, New Age Intl. (P) Ltd.

•  Differential Equations, H.T.H. Piagglo, CBS Publishers and Distribution.

•  Engineering Mathematics, Pal and Das, U.N. Dhar and Sons P. Ltd.

•  Engineering Mathematics, Kreyzig.

 

AME – 13 Fluid Mechanics

I Properties of fluids; density, specific gravity, surface tension and capillarity, viscosity.

II Fluid statics; pressure, Pascal’s law, pressure variation for incompressible fluid, absolute and gauge pressure. Hydrostatic pressure on a submerged surface, force on a horizontal submerged plane surface, force on a vertical submerged plane surface.

Buoyancy and floatation; Archimedes principle, stability of immersed and floating bodies, meta centric hight.

III Kinematics of fluids; classification of fluid flow,acceleration, flow rate and continuity equation, differential equation of continuity.

IV Fluid dynamics; Euler’s equation for frictionless fluid, dynamic equation with friction, energy equation, Bernoulli’s equation, application to siphon,venturi, orifice.

Dimensional Analysis and Dynamic Similarity, dimensionless groups, mechanically similar flows, Reynold’s number, Froude number, surface tension, other numbers. Viscosity; definition, units of dynamic viscosity, kinematic viscosity.

V Flow of incompressible fluids in Pipes; laminar and turbulent flow, critical Reynold’s number, energy relations for pipe flow, friction losses in circular pipes, Hagen-Poiseuille law for laminar flow in circular pipes, velocity distribution in circular pipes.

VI Boundary Layer Flow; boundary layer, separation, transition between laminar and turbulent flow, momentum study of boundary layer, logarithmic and universal velocity distributions.

VII Fluid Measurement; Pitot tube, venturi meter, , orifice meterweirs, notches.Meters for measuring mass rate of flow.

Recommended Books :

•  Introduction to Fluid Mechanics and Fluid Machines, S.K. Som and G. Biswas Tata Mcgraw Hill.

•  Fluid Mechanics, A. K. Jain.

   

AME – 14 Heat Transfer

I Conduction : Derivation of transient heat conduction equation in 3 – D Cartesian coordinates.

II Steady state conduction (without heat generation) through a single and composite wall. Steady radial heat flow through hollow cylinder, critical thickness of insulation. Cooling by fins.

III Unsteady heat flow in a semi – infinite solid, long cylinder and sphere. Dimensionless numbers, Heisler charts.

IV Convection :

Bief review of hydrodynamic equations of boundary layer theory, analysis of thermal boundary layer by control volume, laminar heat transfer over flat plate. Fully developed heat transfer through smooth pipes. The cases of constant heat flux and constant wall temperature boundary conditions.

Overall heat transfer coefficient; dimensional analysis and dimensionless numbers.

Natural convection.

V Heat exchangers, parallel flow and counter flow heat exchangers, log mean temperature difference, NTV method.

VI Radiation :

Theory of thermal radiation; electromagnetic spectrum, Planck’s law, Wien’s displacement law, Stefan Boltzman equation, black and gray bodies, Kirchoff’s law. Heat exchange between black and gray surface

Recommended Books :

•  Heat and Mass Transfer by Nag P.K., Tata McGraw Hill & Co. Second Edition, 2007.

•  Fundamentals of Heat and Mass Transfer by Kothandaraman C.P., New Age Intl.(P) Ltd., Third Edition, 2006.

•  Fundamentals of Engineering Heat and Mass Transfer, Revised 2 nd Ed., R.C. Sachdeva, New Age International Publishers.

AME – 15 Welding & Allied Processes – I

Historical evolution of welding ; classification of welding processes; flame, arc,resistance, solid state etc., oxy-gas and related welding processes; characteristics of flames produced by different fuel gases, combustion chemistry of Acetylene, flame types and their applications, methods of safe handling and working, hazards and their prevention.

Electrical power in welding ; direct current & polarity, alternating current. Magnetism in welding; use of capacitor & condenser, welding transformers, rectifying brdige; half wave and full wave rectification; uses of transistor, thyristor and inductors. Hazards associated with welding power sources.

Welding Arc and the types, structure, mechanism, stability and characteristics. Temperature distribution across the Arc. Mechanism of Arc Blow, its effects and remedies; Types of Metal Transfer – short circuit transfer, types of globular transfer. Forces affecting types of Metal Transfer.

Power sources for arc welding ; static and dynamic characteristics, flat and drooping characteristics, arc stability, open circuit voltage, short circuit current, duty cycle; inverters; sine wave and square wave A.C., and D.C. power sources. Pulse welding; arc striking methods.

Principles of gas shielded arc welding; physical phenomena, operating principles of TIG, MIG/MAG and flux cored processes, inert and active gases and their effects on arc characteristics, filler materials.

TIG welding ; arc ignition methods, choice of type of current, polarity, shielding gas and electrodes type according to application, joint preparation, equipment and accessories.

MIG / MAG and flux cored Arc welding processes; equipment and accessories, metal transfer modes – dip, globular, spray, pulsed and rotating; consumables, shielding gases and filler materials. Joint preparation.

MMA; equipment and power source characteristics; Covered electrodes; types and functions of coating, slag – metal and gas metal reactions influence of coating on weld metal transfer, handling and storage, joint design.

Recommended Book :

•  Welding Engineering and Technology – R.S. Parmar, M/s. Khanna Publishers, 2-B Nath Market, Nai Sarak, Delhi – 110 006.

•  A Textbook of Welding Technology – O. P. Khanna.

•  Welding Handbook, American Welding Society, Section-II : Gas Arc and Resistance.

•  The Science and Practice of Welding, Vol-1 : Welding Science and Technology.

•  The Science and Practice of Welding, Vol-2 : The Practice of Welding : A.C. Davies, Cambridge University Press (Website : www.cambridge.org).

•  Messler R.W., Principles of Welding, John Wiley & Sons, 1999.

•  Welding Technology for Engineers, Eds. Baldev Raj, V. Shankar, A.K. Bhaduri, Narosa Publishing House, Third Reprint – 2009.

AME – 16 Welding Metallurgy I

Structure and properties of pure metals; crystal lattice structure types and imperfections; micro and macro structure; solid state transformation, elastic / plastic deformation, recrystallisation , cold and hot deformation, work hardening and strain ageing.

Review of Steel Making Processes; deoxidation , dephosphorisation, desulphurization and other special treatments. Defects in steels.

Classification and grouping of steel.

Principles of alloying, strengthening mechanisms – cold working, solid solution, precipitation hardening, solid state transformation; intermetallic compounds; ageing; types of phase diagrams – non, fully and partly soluble components; Principles of construction of phase diagrams and their use; the Fe – C equilibrium diagram; effects of alloying elements on the diagram, closed gamma loop, broadened gamma area; segregation and coring ; relationship between microstructure and mechanical properties. Phase transformation in steel; pearlitic, Bainitic, martensitic reaction and related properties; hardenability. Heat treatment of steels; austenitising annealing, normalizing, spheroidising, stress relieving; T-T-T and C-C-T diagrams ;isothermal, continuous cooling diagrams for welding, relationship of microstructure and hardness, microstructure and toughness.

Effects of alloying additions in steel – Ni,Cr, Mn, Si, Mo, V. High strength low alloy structural steels. Micro – alloyed HSLA steels; fine grained steels.

Structure of welds; thermal field, peak temperature, cooling rate and thermal cycle, solidification of weld pool, fusion line, HAZ, single and multipass welding. Carbon equivalent. Preheat and interpass temperature. Weldability; definition. Relation between %C and hardness and carbon equivalent and hardenability.

Recommended Text Books :

•  Welding Handbook, American Welding Society, Part-I : Fundamentals of Welding.

•  Metallurgy of Welding – J.L. Lancaster, Woodhead Publishing Ltd., (Website : www.woodheadpublishing.com ).

•  Metals and their Weldability, Welding Handbook, Part-4, American Welding Society.

•  Kou S. Welding Metallurgy, Second Ed., John Wiky & Sons Inc., 2003.

•  A Textbook of Welding Metallurgy, O.P. Khanna, Dhanpat Rai & Sons.

•  John C. Leopold and Damian Kotecki, “Welding Metallurgy and Weldability of Stainless Steels, Asian Ed. By permission of John Wiley & Sons Ltd., New Delhi.

 

Part – C

 

AME – 17 Engineering Economics :

I Consumer behaviour and demand: Concept and definition of demand; types of demand; demand schedule, demand curve and demand function; Laws of demand, elasticity of demand – price elasticity, income elasticity, cross elasticity; demand forecasting, methods of demand forecasting.

II Microeconomics :

Consumer behaviour, production, cross curves, types of industry and profit maximization.

III Macroeconomics :

Macroeconomics data, measuring National income, simple income determination, Government policy, major macro-economics problems.

IV Production functions: product function, period in production; total, average and marginal product, types of production function; laws of increasing, constant and diminishing returns, economies of scale.

VI Cost analysis: opportunity cost, past and future cost, avoidable and unavoidable cost, replacement cost, historical cost, incremental and sunk cost, controllable cost, production and short run cost, relationship between various costs.

VII Break even analysis: limitations, formulae for break even analysis.

VIII Markets: classification on the basis of competition, perfect competition, monopoly, bilateral monopoly, forms of price discrimination, imperfect competition, monopolistic

competition, oligopoly, duopoly; determination of equilibrium price, price control, price support and minimum price fixation, pricing strategy.

IX Sources of finance: financial accounts and management of finance; cost of capital, working capital management, capital market and money market.

Recommended Text Book;

•  Managerial Economics and Financial Analysis, Siddiqui S. A., and Siddiqui A.S., 2005, New Age International (P) Ltd.

•  Engineering Economics , S. K. Poddar.

AME – 18 COMPUTATIONAL METHODS AND COMPUTER PROGRAMMING

Number Systems : Positional and non-positional number systems; binary, octal, hexadecimal number systems and their interconversion. Representation of real, negative real, fined and floating point numbers; binary coded decimal and extended binary coded decimal interchange, ASCII notation.

Binary Arithmetic : Binary addition and subtraction, multiplication, division and their simple examples; Logic gates : AND, OR, NAND, NOR gates.

Elements of Computer Organisation :

CPU, Memory, I /O devices and peripherals and their role in the context of problem solving.

Languages : Assembly Language, high level language, Compiler and assembler, operating systems like DOS, WINDOWS, UNIX.

Programming in C :

The C character set, identifiers and Keywords, data types, variable names,declaration and statements.

Arithmetic, relational and logical operators, increment and decrement operators, assignment operators and expressions, bitwise operators, precedence and order of evaluation. Input and output. Conditionals and branching. Iteration, functions, and recursion. One dimensional array, pointers, multi dimensional arrays.

Structures, Unions and files.

Writing simple C programs to solve problems.

Recommended Text Books :

•  Programming in C, Balaguruswamy.

•  The C Programming Language, Kernighan B.W., and Ritchie D.M.

 

AME – 19 Testing and Quality Assurance .

  I Mechanical Testing ; hardness testing; static tension testing; stress strain curve, proportionality limit, proof stress, yield point phenomena; ductility and toughness; bend / rebend test, torsion test.

Impact toughness; Charpy test, impact toughness at low temperatures, ductile to brittle transition temperature.

II Cyclic stress; fatigue testing, S – N curves, endurance limit, fatigue fracture.

III Creep testing; stress rupture. stress corrosion testing. Proof testing

IV Weld Defects : Classification, origin and identification.

V Non destructive Testing and Inspection; Leak Testing, Liquid Penetrant inspection, magnetic particle inspection, eddy current inspection; Radiographic inspection; X-ray and gamma ray, Ultrasonic inspection, acoustic emission inspection.

Radiographic inspection of pipes and tubes; use of image quality indicators.

VI Concept of quality assurance and quality control; continuous improvement, quality manual, writing quality control procedures, and quality plans for welded fabrication.

VII Introduction to Statistical Quality Control; process control and process improvement, Shewart control charts; construction and interpretation of X bar and R charts; P – chart,C-chart.

VIII Acceptance Sampling; Single, double and sequential sampling plans; O – C curves. Producer’s risk and consumer’s risk.

Recommended Books :

•  Mix P.E. (2005), “Introduction to Non Destructive Testing”, John Wiley & Sons, – New Jersey.

•  Raj Baldev, Jaya Kumar T. and Tavasimuthu M. (1997).” Practical Non Destructive – Testing”, Narosa Publishing House, New Delhi.

•  Halmshaw. R (1996), “Introduction to Non Destructive Testing of Weld Joints,” – Woodhead Publishing Ltd., Cambridge.

•  Metals Handbook, Vol-17, “Non Destructive Evaluation and Quality Control”, – ASM International, 1989.

AME – 20 Welding Metallurgy – II

Alloy systems ;of industrial importance and their properties; structural and high strength steels, Cr-Mo steels, stainless steels and their classification, heat resisting steels and alloys, cryogenic steels.

Cast irons ; microstructure and properties; titanium and its alloys;Al,Mg and their alloys, hard facing alloys; copper base and nickel base alloys.

Absorption of gases; in weld; O 2 , H 2, and N 2 and their effects on weld properties. Gas-metal and slag metal reactions in relation to welding; effect of electrode coating, effect of shielding gases and gas mixtures.

Cracking in welds ; cold cracking; effect of hydrogen and its control, cold cracking susceptibility. Hot cracking; solidification cracking, liquation cracking. Control of hot cracking. Reheat cracking; mechanism in weld metal and HAZ, cracking during heat treatment and multi-pass welding, control of reheat cracking. Lamellar tearing; mechanism, control by material control and joint configuration.

Residual Stress ; definition, effects on the welded fabrication; measurement and control of residual stress.

Distortion in welding ; transverse, longitudinal and angular. Factors responsible for distortion. Distortion control.

Corrosion : Electrode potential, electro-chemical series, redox potential, uniform corrosion, galvanic corrosion, stress corrosion, hydrogen embriltlement, polarization and passivity, microbiological corrosion, inhibition, anodic protection, cathodic protection; types of corrosion, inter crystalline, trans crystalline, knife line attack, pitting, crevice corrosion, protective coatings, oxidation mechanisms.

Weldability ; testing methods; weldability of different engineering alloys; C-Mn steels, stainless steels, creep resistant steels, cast irons, Ni based, Cu based and Al based alloys.

Joining dissimilar metals ; use of Schaeffler / De Long diagram, formation of intermetallic compound, carbon migration.

Protective layers and cladding ; processes for cladding , joining clad steels; corrosion resistance and wear resistance layers, surface coated and galvanized steels.

Recommended Text Books

•  Metallurgy of Welding, J. F. Lancaster, Woodhead Publishing Ltd. (Website : www.woodheadpublishing.com ).

•  Metals and their Weldability, Welding Handbook, Part-4,American Welding Society.

•  Kou. S. Welding Metallurgy, Second Ed., John Wilby & Sons Inc., 2003.

•  A Text book of Welding Metallurgy, O.P. Khanna, Dhanpat Rai 7 Sons.

•  John C. Leopold and Damian Kotecki, “Welding Metallurgy and Weldability of Stainless Steels, Asian Ed. By permission of John Wiley & Sons Ltd., New Delhi.

AME – 21 WELDING APPLICATIONS

I Application of Welding in : tubular joints; T,Y, X and K joints. Stress concentration factor, concept of hot spot stress. Pipes ; welding processes for pipe joining. Pressure vessels ; classification, typical shell to shell and plate connections, head and closure design. Pressure vessel cladding. Pressure piping ; materials and welding processes.

II Welding Costs ; Analysis, Deposition Rate, Cost of Labour, Consumables, equipment and Energy; Welder’s duty cycle, calculation of welding costs, return on investment.

III Welding Repair Procedure specification, Welding Repair plan, Welding Repair Procedure qualification. Welder and Welding operator qualification to be applied to Repair Welds.NDT of Weld Repair.

IV Fitness for Purpose ; Effect of Imperfection size, morphology and location on structural integrity. Typical Methods of conducting engineering critical assessment of a welded structure.

V Health, Safety and Environment Risk Assessment; hazards of electric power, problems with shielding gases, Radiation and radiation hazards to human body, eye protection, Welding fume emission, exposure, ventilation and fume extraction, Noise and ear protection, Health and Safety aspects of testing and inspection.

Recommended Text Books :

•  Welding Technology and Design, Revised 2 nd Ed., V.M. Radhakrishnan; New Age International Publishers. (Website : www.newagepublishers.com ).

AME – 22 Welding and Allied Processes – II

Submerged Arc Welding; process principles, arc striking methods, selection of current, polarity and consumables according to application, fluxes in SAW; types – agglomerated, sintered, neutral and active fluxes, basic fluxes; joint design, single and multi wire techniques, slag – metal and gas – metal reactions.

Resistance welding; overview of spot, projection, butt, seam and flash;equipment and accessories, temperature distribution, control of welding parameters, current, pressure, time, pulse etc., typical joint preparation.

High Energy Beam Welding Processes; Laser, Electron Beam and Plasma; principles of each process; application areas of each process, equipment and accessories of each process, joint preparation, comparison between the high energy processes, hazards and safety associated with each process.

Other welding Processes – brief introduction and the field of application of electro – slag, friction, friction stir, magnetic pulse, ultrasonic, explosive, diffusion, alumino – thermic, high frequency, stud and cold pressure welding processes.

Cutting and other edge preparation processes; mechanical cutting, oxygen cutting and oxy – fuel gas cutting, principles of arc cutting processes – arc air, carbon and metal arc, oxy – arc cutting processes. Plasma cutting and gouging, laser cutting, electron beam drilling, arc and flame gouging, water jet cutting.

Surfacing and spraying; cladding techniques, spraying with powder, flame spraying, arc spraying, plasma spraying. Spraying materials, cold and fusion techniques.

Mechanised processes and robotics; differences between mechanization, automation and robotisation , sensors, narrow gap welding – SAW, MIG / MAG, TIG, orbital welding -MIG / MAG, TIG.

Brazing and Soldering ; bonding mechanisms, surface tension, wetting and capillary, survey of brazing and soldering techniques, consumables and fluxes for brazing and soldering, braze welding; soldering techniques – dip, vapour phase.

. Recommended Text Books

•  Welding Engineering and Technology-R.S. Parmar, M/s. Khanna Publishers, 2B Nath Market, Nai Sarak, Delhi-10006.

•  A Textbook of welding Technology-O.P. Khanna.

•  Welding Handbook, American Welding Society, Section-II : Gas, Arc and Resistance.

•  The Science and Pratice of Welding, Vol-1 : Welding Science and Technology.

•  The Science andPpractice of Welding, Vol-2 : The Practice of Welding : A.C. Davies, Cambridge University Press (Website : www.cambridge.org ).

•  Messler R.W., Principles of Welding, John Wiley & Sons, 1999.

•  Welding Technology for Engineers, Eds. Baldev Raj, V. Shankar,A.K. Bhaduri, Narora Publishing House, 3 rd Reprint,2009

AME – 23 Design for Welding and Weld Procedure

  Types of welded joints ; Butt Joint, Lap Joint, T-Joint, Cruciform Joint, Corner Joint and Edge Joint. Fillet and groove welds. Complete and Partial Joint penetration.

Grove Welds: Classification and types of grove welds, single and double fillet welds, combined partial joint penetration grove and fillet welds, size of fillet and grove welds.

Weld symbols ; standard system of representation of welded joints, brazed and soldered joints.

Design of Welded Joints : Joint design based on stresses in the structure; Joint design for structural elements such as bars, beams, plates, slabs, columns, trusses, plate girders, cylindrical shells and pressure vessels and pipe lines. Design for flanged connections.

Structural hollow sections and branch connections : Welding joint design to control distortion and shrinkage, residual stresses and cracking.

Welding Procedure : Welding Procedure Specification, Welding Procedure Qualification, Welding Procedure Qualification Record. Welding procedures for manual, semi – automatic welding by MMAW, TIG, MIG and Saw processes for materials such as carbon steel, cast iron, low alloys steels, stainless steels and Al alloys. Procedure for pre-heating and post weld heat treatment of weldments.

Introduction to ASME Section IX ; welder qualification, welding operator qualification; standard qualification tests, destructive and non-destructive. Certification of welders and welding operators.

Repair welding ; problems of repair and maintenance welding, welding repair procedure specification, welding repair procedure qualification. NDT of weld repair, welder qualification to be applied to repair welds.

Fitness for purpose ; principles, effect of imperfection size, morphology and position on structural integrity. Typical methods of conducting an engineering critical assessment of a welded structure.

Recommended Text Books

•  Welding Technology and Design – V. M. Radhakrishnan, Revised Second Ed., New Age International Publishers.

•  A Guide to Designing Welds – J.G. Hicks, Woodhead Publising Ltd., (Website : www.woodheadpublishing.com )

 

AME – 24 ADVANCED WELDING TECHNOLOGY

I Surfacing and Spraying :

  Common surfacing techniques and their principles,equipment, common problems; flame spraying with powder, flame spraying with wire, arc spraying with powder, arc spraying with wire, plasma spraying with powder. Surface preparation of the base material, spraying materials, structure of sprayed layer, substrate structure, cold and fusion techniques.

Cladding and protective layers; processes for cladding, joining of clad steels, welding procedure, Welding of linings, joint design.corrosion resistant and wear reristant layers. Coatings ; surface coated steels, galvanised steels, painting, problems of joining coated steels.

II Advanced Welding Processes ; plasma, electron beam, laser, electro-slag, friction, friction stir, magnetic pulse, ultrasonic, explosive, diffusion,stud and cold pressure welding processes; principles, equipment and accessories, wire and shielding media,application areas and quality standards.

III Advances in welding consumables and techniques in welding low weldable metals and high alloyed weld metals – titanium, magnesium, tantalum, zirconium, inconel, Cr-Ni-Mn steels, maraging steels; suitable welding processes and filler materials.

IV Joining Dissimilar Materials ; choice of processes, effect of dilution, consumables, welding problems such as formation of intermetallic compounds, carbon migration, disbonding etc., examples viz high alloyed steel with m.s., stainless steel with m.s., Ni alloys with m.s., stainless steel and copper alloys, steel and Al alloys, copper and Al alloys, Ni and Cu.

V Welding of Polymers ; hot plate, butt fusion, hot gas welding, extrusion welding, induction welding, resistance welding, implant welding, high frequency, friction, electro – fusion, ultrasonic and vibration welding, adhesive bonding.

VI Joining processes for Ceramics and Composites :

VII Computer applications in welding technology; CAD, N. C. Machines, Robotics.

Recommended Text Books

Welding Engineering and Technology-R.S. Parmar, M/s.Khanna Publishers, 2B Nath

•  Market, Nai Sarak, Delhi-10006.

•  A Textbook of Welding Technology – O. P. Khanna.

•  Welding Handbook, American Welding Society, Section-II : Gas, Arc Resistance.

•  The Science and Practice of Welding, Vol-1: Welding Science and Technology.

•  The Science and practice of Welding, Vol-2: The Practice of Welding : A.C. Davies, Cambridge University Press(Website :www.cambridge.org ).

•  Messler R.W., Principles of Welding, John Wiley & Sons, 1999.

•  Welding Technology for Engineers, Eds. Baldev Raj,V.ShankarA.K. Bhaduri, Narora Publishing House, 3 rd Reprint, 2009.

 

B) New Course Curriculum and syllabi

 

Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations

 

 

(Effective from June 2020, Modified in September 2022)

 

Introduction

 

Welding Engineering and Technology is the backbone of varied industries such as construction, fabrication, ship building, power generation, pressure vessels, underwater piping, desalination plants, automobile, etc. Only few institutions are offering undergraduate and post graduate courses in Welding Engineering and Technology. The professionals working in industries, having a diploma or degree in traditional engineering branches have few avenues for improving their knowledge and expertise in the area of welding and joining to keep pace with the continued developments taking place.

 

Keeping the above points in view, a scheme of Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations was prepared by The Indian Institute of Welding, and Enrollment to the first batch of candidates for the Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations was started in 1988.

 

Subsequently, The Indian Institute of Welding has forwarded a scheme of Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations to the Ministry of Human Resource and Development (MHRD) in 1996 seeking its recognition. This case was referred to the AICTE by the MHRD, and based on the comments from the experts of the AICTE, New Delhi in 1997, some revisions in the Curriculum and Syllabus were incorporated and the matter was reconsidered by the AICTE on September 27 2000 and the MHRD accorded recognition to AM-IIW Examinations, and a Gazette Notification was made to this effect on November 18 2000. The Gazette Notification states:

 

“On the recommendations of the High Level Committee for Educational Qualifications, the Government of India have decided that Associate

 

1     Effective from June 2020, modified in September 2022

 

Membership Examination of the Indian Institute of Welding Calcutta is to be treated as a recognized qualification for the purpose of employment under the Central Government to the posts and service for which Bachelor‟s degree in Engineering in the appropriate field is a prescribed qualification.”

 

However, in December 06 2012, MHRD decided that

 

“(ii) All those students who are enrolled with the institutions with permanent recognition upto 31.05.2013 would be eligible for consideration in accordance with MHRD office memorandum/ order in force pertaining to their course for equivalence in Central Government jobs. However, these concerned orders will cease to have effect from 01.06.2013 onwards.

 

• After 31.05.2013, based on the review by the regulator i.e. AICTE, a decision on continuation of the certification of equivalence of degree/ diploma shall be taken by statutory regulator.”

 

The Indian Institute of Welding has presented the detail of Associate Membership of The Indian Institute of Welding (AM-IIW) Examination before the committee constituted by the AICTE to review Professional Bodies/ Institutions in the field of Technical Education on July 04 2017 at the AICTE Head Quarters, New Delhi as invited by the AICTE. The final recommendation from the AICTE is awaited.

 

Meanwhile, The Indian Institute of Welding has decided to reframe course and curriculum of the Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations of its own, and from June 2020 onwards, new enrollment of candidates to this AM-IIW Examination would commence. The candidates who have passed, or would pass, the AM-IIW Examination, will be awarded as a „National Welding Engineer‟.

 

 

 

 

 

 

 

 

 

 

 

2     Effective from June 2020, modified in September 2022

 

AM-IIW Examination System

 

AM-IIW Examination system is an educational programme and certification examination in the field of Welding Engineering. The course curriculum, syllabi and the examination have been so designed that a candidate passing out these examinations may be considered to have enough knowledge in the field of welding and joining. The Indian Institute of Welding, under its consideration, is holding this qualifying professional examination having the same standard as that of a Bachelor degree in Engineering offered by a recognised Indian or foreign University.

 

The Institute conducts AM-IIW examination all over India based on its own course designed to meet industry need. Examination is conducted twice a year, i.e. in Summer and Winter.

 

AM-IIW has been recognized by the International Institute of Welding (HQ at Paris, France/ Jenoa, Italy) as the entry qualification for the International Diploma like International Welding Technologist (IWT), or International Welding Engineer (IWE), etc. after fulfilling some eligibility criterion, attending a course and passing an examination conducted by IIW-India ANB under the authority of International Institute of Welding with guidelines from ‘International Authorisation Board‟ (IAB).

 

Engineering Diploma students in a 3-year course will be allowed to register for AM-IIW Examinations in the final year, and 4-year engineering degree students studying in the 3rd and 4th year are eligible to register. Registration will be valid for six years.

 

A Bachelor of Engineering candidate is exempted from appearing in examinations of some papers that one has passed during their regular course. Any candidate may also seek exemption from appearing in a paper if one passes a similar paper through Massive Online Open Courses (MOOCs) such as NPTEL, etc. The decision on exemption will be taken based on one individual’s claim for exemption with relevant documents related to the detailed course content and that a candidate has passed the paper successfully.

 

 

 

3     Effective from June 2020, modified in September 2022

 

If a candidate passes 75% of all theory papers, that is, 9 out of 12 theory papers, he/ she can undertake Practical (AME-301) and Project (AME-302) papers. For Practical, one has to select the laboratory conducting institute among four such institutes (one each in East, West, North and South of India).

 

After one passes all non-exempted papers and completing an approved Project work on a welding related case study/ problem and Viva Voce as per IIW-India rule, one becomes eligible to become The Associate Member of The Indian Institute of Welding. He will also be awarded a „National Welding Engineer‟.

 

This modified syllabus and rules that are having some minor modifications over the revised syllabus made in June 2020, will be effective from Winter Session of AM-IIW Examination 2022-23.

 

——————————————- xxx ——————————————-

 

4     Effective from June 2020, modified in September 2022

 

Associate Membership of The Indian Institute of Welding (AM-IIW) Examinations

 

 

(Effective from June 2020, Modified in September 2022)

 

Curriculum Structure of AM-IIW Examination System

 

 

 

 

	Part-A			Part-B			Part-C
1.	Material Science			7. Testing & Quality			13. Practical
	(AME-101)			Assurance(AME-201)			(AME-301)
2.	Strength of Materials		8. Welding Metallurgy of				14. Project
	(AME-102)		Non Ferrous Alloys,				(AME-302)
			Dissimilar Welding and
			Cladding (AME-202)
3.	Production			9. Welding and Allied			15. Comprehensive
Engineering (AME-103)				Processes-II			Viva Voce
				(AME-203)			(AME-303)
4.	Welding & Allied			10. Weldment Design,
Processes-I (AME-104)				Welding Procedure and
				Its Applications (AME-
			204)
5.	Welding Metallurgy of			11. Occupational
Ferrous Materials (AME-				Health, Safety and
105)				Environmental Issues in
				Welding and Related
				Areas(AME-205)
6.	Economics of Welding			12. Advanced Welding
and Fabrication				Technology(AME-206)
(AME-106)

 

 

 

 

 

5     Effective from June 2020, modified in September 2022

 

Part – A

 

AME-101 : Materials Science

 

 

Atomic Structure and Types of Bonding between Atoms : Bohr‟s atomic model– electronic configuration of atoms, periodic classification of elements. Binding energy; ionic bonds, covalent bonds, material properties having these bonds. Electronegativity. Metallic bond– materials properties having this bond. Intermolecular forces.

 

Concepts of Crystal Geometry : Space lattice– cubic (simple cubic, BCC and FCC), tetragonal, orthorhombic, rhombohedral, hexagonal, monoclinic and triclinic. Unit cell parameters to specify each crystal system. Crystal directions and planes, Miller indices.

 

Bonding and Defectsin Solids : Crystal symmetry and structure. Crystalline imperfections. Point imperfections and line imperfections or dislocations, edge and screw dislocations, slip planes. Surface imperfections. Polymorphism in metal and ceramics; Amorphous materials– glass and polymer.

 

Alloys : Phase rule, thermodynamic principles of mixing, binary phase diagrams of important alloy systems, solidification, lever rule, solid solutions and governing rules, isomorphous system, eutectic, peritectic, eutectoid and peritectoid reactions. Intermetallic compounds, sigma & other phases.

 

Mechanical Deformation of Materials : Elastic and Anelastic deformation; plastic deformation, stress-strain curve, slip and twin, dislocation theory, critical resolved sheer stress, strengthening mechanisms, precipitation hardening, deformation in polycrystalline material, slip systems. Bauschinger‟s effect and elastic after effect. Work hardening; recovery, recrystallisation and grain growth, preferred orientation.

 

Fracture in Metals and Alloys : Ductile and brittle fracture, impact test, Griffith‟s theory, fracture toughness, ductile-brittle transition, fatigue, creep. Mechanical testing of metals.

 

Ceramic Materials : Structure in silica and silicates, Polymorphism, fracture in glass, electrical properties of ceramic phases, refractoriness, Engineering ceramics, Functional ceramics.

 

Polymers : Classification; degree of polymerization. Formability; addition polymerization, copolymerization, condensation polymerization. Molecular structure; linear, branched, cross linked polymers. Thermoplastic and thermosetting polymers. Structure-property correlation, crystallinity, mechanical properties, applications.

 

Composites : General characteristics, dispersion/ particulate strengthened composites, rule of mixture, fibre reinforced composites, laminated composites- fabrication techniques.

 

 

 

 

6     Effective from June 2020, modified in September 2022

 

Recommended Text Books and References

 

• Material Science and Metallurgy for Engineers, V.D. Kodgire and S.V. Kodgire, Everest Publishing House, Pune (2003).

 

• Material Science and Engineering, 7^thEdition, W.D. Callister Jr., John Willey & Sons (2006).
• Material Science and Engineering– A First Course, V. Raghavan, 4^thEdition, Prentice Hall of India, New Delhi (2004).
• Material Science, S.L. Kakani and A. Kakani, 1^stEdition, New Age International.
• Principles of Engineering Metallurgy, L. Krishna Reddy, New Age International,(1996).

 

7     Effective from June 2020, modified in September 2022

 

AME–102 : Strength of Materials

 

 

Simple Stress and Strain : Stress – strain Diagram for ductile, brittle and plastic materials, concept of true modulus of elasticity, yield stress ultimate stress, working stress, proof stress, and engineering stress, factor of safety, stress concentration, simple problems of thermal stresses and statically indeterminate problems.

 

Elastic Constants : Poisson‟s ratio; bulk modulus; relation between bulk modulus and Young‟s modulus ; modulus of rigidity and shear modulus, relation between modulus of rigidity and Young‟s modulus.

 

Plane Stress and Strain : Basic concepts; principal and principal strains; Mohr‟s circle of stresses. Stress tensors, von Mises stress, Equivalent stress and equivalent strain, von Mises and Tresca criteria.

 

Bending of Beams : Types of beams, supports and loads; concentrated load, uniformly distributed load, gradually varying load; bending moment and shear force diagrams.

 

Stresses in Beams : Theory of simple bending; neutral axis, moment of resistance, section modulus flexural equations. Bending stress distribution in beams.

 

Shear stress distribution in beams of rectangular, solid circular, and I– section beams.

 

Deflection of Beams : Differential equation of the Elastic Curve; relation between deflection, shape, shear force and bending moment; simple problems of deflection of beams.

 

Buckling of Columns : Euler‟s theory ; critical loads; short and long columns.

 

Torsion of Circular Shafts : Torsional stress and strain, polar moment of inertia, power transmitted by a shaft. Shear stress distribution across solid and hollow shafts.

 

Thin Cylinder under Internal Pressure : Circumferential and longitudinal stress; change in volume due to internal pressure; simple problems.

 

Recommended Text Books and References

 

• Elements of Strength of Materials, 5^th Edition, S. Timoshenko and D.H. Young, Affiliated EWP (1968).

 

• Strength of Materials, S.S. Rattan, McGraw-Hill Publication (2008).
• Strength of Materials, G.H. Ryder, Macmillan (1969).
• Strength of Materials, B.S. Basavarajaiah and P. Mahadevappa, Taylor & Francis (2010).

 

• Mechanics of Materials, E.P. Popov, Prentice Hall (1952).

 

 

 

 

 

 

 

8     Effective from June 2020, modified in September 2022

 

AME–103 : Production Engineering

 

 

Metal Casting : Types of patterns and core boxes; metal flow in a mould; gating and risering; casting processes; green and dry sand, other sand casting processes, metal mould casting processes, precision casting processes. Melting furnaces; casting defects, inspection and rectification. Solidification of metals and alloys, cast structure.

 

Metal Forming : Principles of metal forming, Cold and hot working processes; principles of processing maps, dynamic recrystallization, various metal forming processes; Rolling, forging, extrusion, punching, blanking, coining, drawing, bending, production of pipes, tubes, plates etc. machine and drop forging, dies for drop forging, forging hammers and presses, rolling mills, extrusion press, etc., formability testing.

 

Machining and Machine Tools : Definition of Machining and Machine Tools. Elements of Mechanics of metal cutting, types of chips, cutting tools, tool geometry in ASA, ORS and NRS systems, shear angle and shear strain, tool materials and their properties, forces on cutting tool, Merchant‟s circle diagram, tool failure, tool life, cutting fluid, speed, feed and depth of cut, power requirements. Various machining operations, turning, milling, shaping, planing, drilling, thread cutting, gear cutting, grinding, superfinishing. Machine tools used for these operations, motions needed for machining on respective machine tools and their structures.

 

Elementary Ideas on Fabrication Processes : Brief introduction to welding, brazing, soldering, and other semi-permanent/ temporary joining processes used for fabrication, fitment of components, assembly sequence, shell forming, heat treatment.

 

Surface Modification Technology : Case hardening by flame, case carburizing, nitriding, carbunitriding; Coating- PVD and CVD techniques; Cladding; thermal spraying.

 

Metrology : Limit, fit and tolerance, Tolerancing Grade as per IS standard, Use of comparators, Measurement of flatness and surface finish, Use of gauges- GO and NOT GO gauges, thickness gauge, thread pitch gauge, radius gauge.

 

Production Planning and Control :Process and Production Planning and control; Production planning, Gantt chart, inventory control, inventory policies, EOQ; Method and work study; Time study, systems of rating, time standard.

 

 

Recommended Text Books and References

 

• Production Technology, Vol. I and Vol. II, R.K. Jain, Khanna Publication (2001).
• A Text Book of Production Engineering, P.C. Pandey, C.K. Singh and Balbir Singh, Standard Publishers Distributors (1972).

 

• Production Technology Manufacturing Processes, Vol. I and Vol. II, O.P. Khanna and G.K. Lal, Dhanpat Rai Publications, New Delhi.

 

• Materials and Manufacturing Processes, E.P. Degarmo, J.T. Black and R.A. Kohser, Pearson.

 

9     Effective from June 2020, modified in September 2022

 

AME–104 : Welding & Allied Processes – I

 

 

Introduction : Historical evolution of welding ; classification of welding processes; flame, arc, resistance, solid state, etc., oxy-gas and related welding processes; characteristics of flames produced by different fuel gases, combustion chemistry of Acetylene, flame types and their applications, methods of safe handling and working, hazards and their prevention.

 

Electrical Power in Welding : Direct current & polarity, alternating current. Magnetism in welding; use of capacitor & condenser, welding transformers, rectifying bridge; half wave and full wave rectification; uses of transistor, rectifiers, thyristor, microprocessors and inductors, welding generators, invertors. Hazards associated with welding power sources.

 

Welding Arc : Physics of arc, Ionization of gases, Open Circuit Voltage, Arc stabilitiy, AC and DC Arc: types, structure, mechanism, stability and characteristics. Temperature distribution across the Arc. Mechanism of Arc Blow, its effects and remedies; Types of Metal Transfer – short circuit transfer, types of globular transfer; Forces affecting types of Metal Transfer.

 

Power Sources for Arc Welding : Static and dynamic characteristics, flat and drooping characteristics, short circuit current, duty cycle; sine wave and square wave A.C., and D.C. power sources. Introduction to waveform controllable rectifier-inverter power sources, microprocessor control, Pulse welding; Arc striking methods, Classification of power sources based on insulation, environmental protection (water ingress).

 

MMAW : Equipment and power source characteristics; Covered electrodes; types and functions of coating, slag metal and gas metal reactions influence of coating on weld metal transfer, handling and storage, joint design, advantages and disadvantages of MMAW.

 

TIG Welding : Physical phenomena, operating principles of TIG, TIG welding; arc ignition methods, choice of type of current, polarity, shielding gas and electrodes type according to application, joint preparation, equipment and accessories, Autogenous welding, variants of TIG welding, orbital welding, tube to tube sheet welding, internal bore welding, pulsed TIG welding, AC and DC TIG welding.

 

MIG/MAG (GMAW) and Flux Cored Arc Welding : MIG/MAG (GMAW) and Flux Cored Arc Welding Processes, inert and active gases and their effects on arc characteristics, filler materials. Metal transfer modes – dip, globular, spray, pulsed and rotating; consumables, welding equipment, Voltage and current characteristics. Effect of shielding gas on metal transfer, pulsed and synergic MIG welding, MIG welding equipment, flux cored and metal cored arc welding, consumables for MIG welding, joint preparation.

 

 

 

10  Effective from June 2020, modified in September 2022

 

Submerged Arc Welding : Principles, arc striking methods, selection of current, polarity and consumables according to application, fluxes in SAW; types– agglomerated, sintered, neutral and active fluxes, basic fluxes; joint design, single and multi wire techniques, slag–metal and gas–metal reactions.

 

Cutting and Other Edge Preparation Processes : Mechanical cutting, oxygen cutting and oxy–fuel gas cutting, principles of arc cutting processes– arc air, carbon and metal arc, oxy–arc cutting processes. Plasma cutting and gouging, laser cutting, electron beam drilling, arc and flame gouging, water jet cutting.

 

Recommended Text Books and References

 

• Welding Engineering and Technology, R.S. Parmar, Khanna Publishers, New Delhi.

 

• A Textbook of Welding Technology, O.P. Khanna, Dhanpat Rai Publication, New Delhi (1980).

 

• Welding Handbook, American Welding Society, Section-II : Gas Arc and Resistance.

 

• The Science and Practice of Welding, Vol-1 : Welding Science and Technology, Cambridge University Press.

 

• The Science and Practice of Welding, Vol-2 : The Practice of Welding : A.C. Davies, Cambridge University Press.

 

• Principles of Welding, Messler R.W., John Wiley & Sons (1999).
• Welding Technology for Engineers, 3^rd Reprint, Eds. Baldev Raj, V. Shankar, A.K. Bhaduri, Narosa Publishing House, New Delhi (2009).

 

 

11  Effective from June 2020, modified in September 2022

 

AME–105 : Welding Metallurgy of Ferrous Materials

 

 

Physical Metallurgy of Steels : An introduction to iron and steel making, ingot metallurgy and continuous casting, solid state transformations in iron and steel, Fe-C diagram. Time temperature transformation (TTT) diagram, pearlite, bainite and martensite phases and their influence on properties of steel, annealing, normalizing, quenching and tempering. Effect of alloying elements in steels on Fe-C diagram and TTT diagram, Continuous cooling transformation (CCT) diagram, hardenability of steels.

 

Physical Metallurgy of Fusion Zone and Heat Affected Zone : Weld thermal cycle, slag-metal and gas-metal interaction in the fusion zone, Solidification of the weld fusion zone, segregation, constitutional supercooling, microstructural evolution in the fusion zone of steel weld metal during cooling, Weld metal microstructure for good strength and toughness, Definition of Heat Affected Zone and different parts of the Heat Affected Zone, Effect of heat input and thermal diffusivity on the size and shape of fusion zone and HAZ, Solid state transformations in the HAZ, Effect of multi-pass welding in fusion zone and HAZ microstructure, Concept of carbon equivalent for steel welds, Generation of residual stresses in the welds, Stress relieving and post weld heat treatment of the steel welds.

 

Weldability of Steels : Cracking in welds: Hydrogen Assisted Cracking, hot cracking reheat cracking and lamellar tearing. Concept and definition of weldability, weldability of steels, , Concept of carbon equivalent, low hydrogen consumables and cooling time t8/5. Preheating and post heating and their predication for safe welding…

 

Different Steels and Their Weldability : C-Mn steels, Effect of alloying elements on weldability of steels, Steels for high strength applications, low temperature applications, high temperature applications, HSLA steels, High strength steels, Maraging steels, armour steels. Reheat Cracking in alloyed steels, Welding consumables for different steels.

 

Stainless Steels : Different type of stainless steels; hot cracking in austenitic stainless steels and role of delta ferrite, Schaeffler, WRC 92 diagram, Sensitization, intergranular corrosion and stress corrosion cracking, Stabilized and low carbon austenitic stainless steels, Duplex Stainless steels, pitting corrosion, Concept of PREN, welding consumables for different stainless steels.

 

Welding of Cast Iron : Different forms of cast iron, selection of consumables for welding cast iron, procedures for removal of defects in case of repair welding, control of heat input, preheating and post heating during welding of cast iron.

 

Recommended Text Books and References

 

• Welding Handbook, American Welding Society, Part-I: Fundamentals of Welding.
• Metallurgy of Welding, J.L. Lancaster, Woodhead Publishing Ltd.
• Metals and Their Weldability, Welding Handbook, Part-IV, American Welding Society.
• Welding Metallurgy, 2^nd Edition, S. Kou, John Wiley & Sons(2003).

 

12  Effective from June 2020, modified in September 2022

 

• A Textbook of Welding Metallurgy, O.P. Khanna, Dhanpat Rai & Sons (1980).

 

• Welding Metallurgy and Weldability of Stainless Steels, Asian Edition, J.C. Leopold and D. Kotecki, John Wiley & Sons Ltd., New Delhi.

 

13  Effective from June 2020, modified in September 2022

 

AME–106 : Economics of Welding and Fabrication

 

 

Consumer Behaviour and Demand : Concept and definition of demand; types of demand; demand schedule, demand curve and demand function; Laws of demand, elasticity of demand– price elasticity, income elasticity, cross elasticity; demand forecasting for welded or fabricated products, methods of demand forecasting.

 

Microeconomics : Consumer behaviour, production, cross curves, types of industry and profit maximization.

 

Macroeconomics : Macroeconomics data, measuring National income, simple income determination, Government policy, major macro-economics problems.

 

Estimation of Welding and Fabrication Cost : Estimation of costs for preparation of jobs for welding, cutting, machining, edge preparation etc, estimation of amount of welding consumable to be used. Cost of estimation for inspection and testing of the welds, Cost of qualification of welders, consumables and procedures. Total estimation of fabrication cost. Requirements for setting up welding and fabrication shops.

 

Production Functions : Product function, period in production; total, average and marginal product, types of production function; laws of increasing, constant and diminishing returns, economies of scale.

 

Cost Analysis : Opportunity cost, past and future cost, avoidable and unavoidable cost, replacement cost, historical cost, incremental and sunk cost, controllable cost, production and short run cost, relationship between various costs.

 

Break Even Analysis : Limitations, formulae for break even analysis.

 

Market : Classification on the basis of competition, perfect competition, monopoly, bilateral monopoly, forms of price discrimination, imperfect competition, monopolistic competition, oligopoly, duopoly; determination of equilibrium price, price control, price support and minimum price fixation, pricing strategy.

 

Sources of Finance : Financial accounts and management of finance; cost of capital, working capital management, capital market and money market.

 

 

Recommended Text Books and References

 

• Managerial Economics and Financial Analysis, S.A. Siddiqui and A.S. Siddiqui, New Age International (2005).

 

• Engineering Economics, S.K. Poddar, The Association of Engineers, India Publication, Kolkata.

 

 

 

 

 

 

 

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Part – B

 

 

AME–201 : Testing, Inspection and Quality Assurance

 

 

Mechanical Properties : Tensile properties of weld joints, Hardness of weld metal, HAZ and hardness profile across the welds, Vickers, Brinell, Rockwell Hardness testing, Microhardness testing, Tensile testing of all weld metal and transverse weld joint, preparation of weld joint specimens for tension testing, Preparation of specimens for impact testing of weld metal and HAZ, Impact testing at sub zero temperatures, Estimation of Ductile Brittle transition temperatures.

 

Tests under Cyclic Stress : Principles of Fatigue damage, Testing for Low cycle and high cycle fatigue, S–N curves, endurance limit, fatigue fracture.

 

Other Destructive Tests : Principles of creep, standard creep curve, Creep Test, Stress rupture tests, Stress corrosion testing, Hydro static testing and pneumatic testing of components Proof testing.

 

Weld Defects : Classification, origin and identification. Type of cracking welds (Cold cracking, Hot cracking, Reheat Cracking, Lamellar tearing), Assessment of susceptibility to cracking from chemical composition and welding parameters, Estimation of preheat and post heat condition to prevent HAC, Assessment of hot cracking susceptibility using Schaeffler diagram.

 

Weldability Tests : Self restraint and external restraint tests, Weldability tests to assess different forms of cracking, Assessment of cracking susceptibility from the test results.

 

Non destructive Testing and Inspection : Surface inspection, Visual Inspection, Leak Testing, Liquid Penetrant inspection, magnetic particle inspection, eddy current inspection;

 

Volumetric Inspection : Radiographic inspection; X-ray and gamma ray, Radiographic inspection of pipes and tubes; use of image quality indicators, principles of digital and microsfocal radiography, X-ray generators and gamma sources for radiographic inspection, Ultrasonic inspection, pulse echo mode, Effect of frequency angle of ultrasonic wave propagation on inspection, A-Scan, B-Scan and C-Scan modes, Reference defects for calibration of the signals, acoustic emission inspection;

 

Field Techniques to identify base metal and weld metal: positive material identification (PMI) principle through X-ray fluorescence (XRF), optical emission spectrometry (OES).

 

Concept of Quality Assurance and Quality Control : Inspection, quality control quality assurance and total quality management, roles and responsibilities Continuous improvement, quality manual, Introduction to ISO standards and ASME pressure vessel and piping code.

 

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Quality Assurance in Welding: Welder qualification, consumable qualification and Procedure qualification, Essential, non-essential and supplementary essential variables, Grouping of base metals and filler wires for the purpose of weld qualification as per ISO specification and ASME pressure vessel and piping code. Preparation of Procedure Qualification Report writing, quality control procedures, and quality plans for welded fabrication.

 

Introduction to Statistical Quality Control : Process control and process improvement, Shewart control charts; construction and interpretation of X bar and R charts; P–chart, C-chart.

 

Acceptance Sampling : Single, double and sequential sampling plans; O–C curves.

 

Producer‟s risk and consumer‟s risk.

 

 

Recommended Text Books and References

 

• Introduction to Non Destructive Testing, P.E. Mix, John Wiley & Sons, New Jersey (2005).

 

• Practical Non Destructive Testing, Baldev Raj, T. Jaya Kumar and M. Tavasimuthu, Narosa Publishing House, New Delhi (1997).

 

• Introduction to Non Destructive Testing of Weld Joints, R. Halmshaw, Woodhead Publishing Ltd., Cambridge (1996).

 

• Metals Handbook, Vol.17, Non Destructive Evaluation and Quality Control, ASM International (1989).
• Fundamentals of Quality Control and Improvement, 3rd Edition, A. Mitra, John Wiley.

 

• Statistical Quality Control: A Modern Introduction, 6th Edition, D.C. Montgomery, Wiley India.

 

• Total Quality Management, 3rd Edition, P.M. Charantimath, Pearson India.

 

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AME–202 : Welding Metallurgy of Non Ferrous Alloys, Dissimilar Welding and Cladding

 

 

Introduction to Aluminium and Magnesium Alloys and Their Welding : Introduction to physical metallurgy of Al alloys, principles of precipitation hardening, heat treatable and non-heat treatable alloys, Choice of welding processes for welding of Al alloys, Cracking in Al alloys, selection of welding consumables for Al alloys, post weld heat treatment to Al alloys, Friction stir welding of Al alloys. An introduction to welding of Mg and Mg alloys.

 

Welding of Nickel, Copper and Titanium Base Alloys : Solid solution strengthened and precipitation hardened Ni base alloys, Susceptibility of the alloys to hot cracking and reheat cracking, Microstructural changes during ageing on these alloys. Welding of Cu and Cu alloys. Welding of Ti and its alloys, effect of oxygen contamination on properties of these alloys, welding processes for welding of Ti alloys, Heat treatable and non-heat treatable Ti alloys.

 

Dissimilar Welding : Welding of steels to stainless steels, Shaffler, Delong and WRC 92 diagrams for selection of welding consumables, Buttering during dissimilar welding,

 

Welding of stainless steels to Ni base alloys, selection of welding consumables.

 

Welding of Al/Al alloys and Ti/Ti alloys to steel: Difficulty in fusion welding, non fusion techniques, friction welding, explosive welding etc.

 

Surfacing and Hardfacing : Purpose of surfacing, welding processes employed for surfacing, Dilution during surfacing, Alloys used for surfacing, consumables available for surfacing, Welding of plates with surfacing.

 

Hardfacing : Purpose of hardfacing, alloys and consumables available for hardfacing, Controlling dilution and cracking during hardfacing, stress relieving heat treatment after hardfacing, concept of wear plate, the prefabricated plates for wear resistance application

 

Repair Welding : Difference between welding defects detected during fabrication and the defects formed in service, Problems of repair and maintenance welding, welding repair procedures to avoid post weld heat treatment, welding repair procedure qualification. Use of austenitic stainless steel and Ni base alloy consumable for repair of defects formed during service, NDT of weld repair, welder qualification to be applied to repair welds.

 

 

Recommended Text Books and References

 

• Metallurgy of Welding, J.F. Lancaster, Woodhead Publishing Ltd.
• Metals and Their Weldability, Welding Handbook, Part-IV, American Welding Society.

 

• Welding Metallurgy, 2^nd Edition, S. Kou, John Wiley & Sons (2003).

 

17  Effective from June 2020, modified in September 2022

 

• A Text book of Welding Metallurgy, O.P. Khanna, Dhanpat Rai & Sons, New Delhi (1980).

 

• Welding Metallurgy and Weldability of Stainless Steels, Asian Edition, J.C. Leopold and D. Kotecki, John Wiley & Sons, New Delhi.

 

18  Effective from June 2020, modified in September 2022

 

AME–203 : Welding and Allied Processes – II

 

 

Resistance Welding : Principles of resistance welding process, the concept of weld lobe, pressure resistance, spot resistance and flash resistance welding, Overview of spot, projection, butt, seam welding; equipment and accessories, temperature distribution, control of welding parameters, current, pressure, time, pulse etc., typical joint preparation. Evaluation of quality of the resistance welds.

 

High Energy Beam Welding Processes :Concept of key hole welding, Principles Laser beam welding, Type of lasers used for welding and cutting, Pulsed laser welding, Advantages of laser beam welding, Estimation of laser power, pulsed lasers for welding, Laser welding in conductive and key hole modes, Laser surfacing.

 

Electron Beam welding, details of the equipment, requirement of vacuum, relationship between beam energy, material and thickness that can be joined; Preparation of jobs for laser and electron beam welding.

 

Plasma Welding; A variant to TIG process, Key hole plasma welding, microplasma welding and Plasma transferred Arc surfacing, Gases for plasma welding,

 

A comparison of advantages, limitations and application of these processes,

 

Other fusion Welding Processes: Electroslag Welding, Electrogas welding, Thermit welding, principles and Applications

 

Solid State Welding Processes : Friction welding, principles, equipments, , testing, Applications for dissimilar metal welding, friction stir welding, principles, equipment, advantages of continuous welding without fusion, importance of tool material and design, properties of the weld joints, applications for dissimilar joining, microstrurcture of the stirred zone, deformed zone and heat affected zone, applications and limitations magnetic pulse welding, ultrasonic welding, explosive welding, diffusion bonding , , high frequency, stud and cold pressure welding processes.

 

Thermal Spraying : Spraying with powder, flame spraying, arc spraying, plasma spraying. Spraying materials, cold and fusion techniques.

 

Joining of Polymers, ceramics and composites: Joining of polymers: Hot plate welding, hot gas welding, extrusion welding, induction welding, resistance welding, implant welding, high frequency welding, friction welding, electro–fusion, ultrasonic and vibration welding, adhesive bonding.

 

Joining of Ceramics and composites: Brazing of ceramics, Transient liquid phase bonding, Adhesive bonding, Plasma Spark Sintering.

 

Brazing and Soldering : Bonding mechanisms, surface tension, wetting and capillary, survey of brazing and soldering techniques, consumables and fluxes for brazing and soldering, braze welding; soldering techniques– dip, vapour phase. brazing alloys for different applications and temperatures, product forms of brazing alloys, vacuum

 

 

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brazing, Active brazing alloys to join metals to ceramics, different soldering alloys, lead free soldering alloys, Evaluation of the joint integrity.

 

 

Recommended Text Books and References

 

• Welding Engineering and Technology, R.S. Parmar, Khanna Publishers, New Delhi.

 

• A Textbook of welding Technology, O.P. Khanna, Dhanpat Rai & Sons, New Delhi (1980).

 

• Welding Handbook, American Welding Society, Section-II: Gas, Arc and Resistance.

 

• The Science and Practice of Welding, Vol.1: Welding Science and Technology, Cambridge University Press.

 

• The Science and Practice of Welding, Vol.2: The Practice of Welding: A.C. Davies, Cambridge University Press.

 

• Principles of Welding, R.W. Messler, John Wiley & Sons (1999).
• Welding Technology for Engineers, 3^rd Reprint, Baldev Raj, V. Shankar and A.K. Bhaduri, Narora Publishing House, New Delhi (2009).

 

 

20  Effective from June 2020, modified in September 2022

 

AME–204 : Weldment Design, Welding Procedure and Its Applications

 

 

Applications of Welding : Tubular joints; T,Y, X and K joints. Stress concentration factor, concept of hot spot stress. Pipes; welding processes for pipe joining. Pressure vessels; classification, typical shell to shell and plate connections, head and closure design. Pressure vessel cladding. Pressure piping; materials and welding processes.

 

Types of Welded Joints : Butt Joint, Lap Joint, T-Joint, Cruciform Joint, Corner Joint and Edge Joint. Fillet and groove welds. Complete and Partial Joint penetration.

 

Grove Welds: Classification and types of grove welds, single and double fillet welds, combined partial joint penetration grove and fillet welds, size of fillet and grove welds.

 

Weld Symbols : Standard system of representation of welded joints, brazed and soldered joints.

 

Design of Welded Joints : Joint design based on stresses in the structure; Joint design for structural elements such as bars, beams, plates, slabs, columns, trusses, plate girders, cylindrical shells and pressure vessels and pipe lines. Design for flanged connections.

 

Structural Hollow Sections and Branch Connections : Welding joint design to control distortion and shrinkage, residual stresses and cracking.

 

Residual Stress : Definition, Evolution of residual stresses during welding. Role of phase transformation and physical properties of base metals. effects on the welded fabrication; measurement and control of residual stress. Methods to bring down the residual stresses.

 

Distortion in Welding : Transverse, longitudinal and angular. Factors responsible for distortion. Distortion control in the design, fabrication and post fabrication stages

 

Fracture of Weldment : Fracture behaviour of weld metal and heat affected zone.

 

Fitness for Purpose : Principles of fracture toughness, effect of imperfection size, morphology and position on structural integrity, concept of leak before break Typical methods of conducting an engineering critical assessment of a welded structure.

 

 

Recommended Text Books and References

 

• Welding Technology and Design, V.M. Radhakrishnan, 2^nd Edition, New Age International.

 

• A Guide to Designing Welds, J.G. Hicks, Woodhead Publising Ltd.

 

 

 

 

 

 

 

 

21  Effective from June 2020, modified in September 2022

 

AME–205 : Occupational Health, Safety and Environmental Issues in Welding and Related Areas

 

 

Introduction : Occupational Health and Safety Risks at Work– Basics Principles.

 

Risks in Welding and Their Control : Occupational Health and Safety Risks in various types of welding and control measures, Health hazards of Welding Fumes (Combination of metals and gases) and factors affecting welding fumes. Typical particulate matter in welding fumes, Effect of flux coating on welding fumes, Carcinogenic p articulate matter in welding fumes (hexavalent Cr and Mn particulate matter), Electrical Safety in Welding. Environmental Hazards of Welding activities and Mitigation strategies. Welding helmets, shade levels for glasses used for different welding processes, requirement for design of welding booth, use of curtains to shield ultraviolet radiation.

 

Safety and Health Hazards of Welding in Confined Spaces : Fire and Explosion, Oxygen Deficiency while carrying out TIG welding or MIG welding in confined spaces, Exposure to Toxic Substances.

 

Safety in Areas Related to Welding : Safety in Surface Preparation Activities and Material Handling. Safety in Quality related Processes such NDT, usage of aerosol-based and radioactive materials.

 

Selection and Usage of Personal Protective Equipment : Specification, method of usage, limitations, up keep, etc. Hygiene, Health Monitoring and Training. Fire prevention and fighting. First-Aid and Emergency response.

 

Applicable Standards & Legislations Related to Occupational Health& Safety.

 

 

Recommended Text Books and References

 

1. Welding Health & Safety: A Field Guide for OSHE Professionals, M.K. Harris, AIHA Press Publication, USA (2002).

 

2. Health and Safety in Welding and Allied Processes, J. Blunt and N.C. Balchin, Elsevier Publication (2002).

 

3. Welding, D. Geary and R. Miller, 2^nd Edition, McGraw Hill (2011).
4. Welding and Metal Fabrication, L. Jeffus, Cengage Publication (2006).

 

5. How to Weld, T. Bridigum, Motorbooks Publication (2008).
6. Welding Principles and Application, L. Jeffus, Cengage Publication (1984).
7. Safety for Welders, L. Jeffus, Cengage Publication (1980).

 

8. Welding Essentials, Question and Answers, W. Galvery and F. Marlow, Industrial Press (2001).

 

9. Welding Processes Handbook, 2^nd Edition, K. Weman, Woodhead Publishing (2003).
10. Hazardous Substances in Welding and Allied Processes (IIW Collection), V.E.S. Ciobanu, L. Costa and W. Zschiesche, Springer Publication (2020).

 

11. Factories Act and BOCW Act-Relevant Sections.

 

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AME–206 : Advanced Welding Technology

 

 

 

Advanced GTAW processes: Manual TIG welding with automatic wire feeder, Fully automated Narrow Gap hot wire TIG welding, A-TIG welding, Orbital TIG welding, Tube to Tube sheet welding, Internal bore welding K-TIG Welding, Square Wave A/C GTA welding for Al welding, interpulse GTA welding.

 

Advanced MIG welding processes: Pulsed MIG welding, synergic pulse MIG welding, Twin arc Tandem MIG, MIG welding variants with controlled heat input and reduced spatter: CMT (cold metal transfer)-MIG, Surface Tension Transfer MIG and Regulated Metal Transfer MIG.

 

Advanced Submerged Arc Welding: Narrow Gap Submerged Arc Welding, Tandem Twin wired Submerged Arc Welding, Strip cladding using submerged arc welding, Submerged arc welding with multiple power source and multiple wire feeders, Single wire SAW with auxiliary wire (hot or cold) wire feeding.

 

Laser Hybrid TIG Welding and Laser Hybrid MIG welding. Ultrasonic welding, Magnetic pulse welding, Magnetically Impelled Arc Butt (MIAB) welding.

 

Digital Power Sources for Arc welding : Power sources with automatic data acquisition systems, provision for online modification of the welding parameters, Power sources which continuous acquisition and storage of the welding data, Power sources with Ethernet connection for data transmission and cloud storage.

 

Welding Automation : System Automation and Robotic Automation, Instrumentation and control systems for system automation in welding power source, integrated controls systems, for arc start, wire feed, torch or job movement, gas flow, Arc Gap Controls, Seam tracking etc. Devices and sensors for welding automation.

 

Robotic welding, principles of robotic engineering, sensors, actuators, programming, software, Five axis and six axes controls, interfacing robot with power sources, safely locks, Interfacing engineering drawing with robotic welding.

 

Additive Manufacturing Using Welding : Concept of additivie manufacturing, system requirements, Wire Arc Additive manufacturing and Laser based powder added additive manufacturing, Welding processes that can be used for additive manufacturing, Difference in the microstructure and properties of products produced by AM with those produced by conventional routes., Defects in products formed by additive manufacturing, Applications of additive manufacturing

 

Note : Students are expected to learn the concept and applications along with advantages and limitations of these advanced processes, and they may recommend a particular process to suit an application.

 

Recommended Text Books and References

 

• Welding Engineering and Technology, R.S. Parmar, Khanna Publishers, New Delhi.

 

23  Effective from June 2020, modified in September 2022

 

• A Textbook of Welding Technology, O.P. Khanna, Dhanpat Rai & Sons, New Delhi (1980).

 

• Welding Handbook, American Welding Society, Section-II: Gas, Arc, Resistance.

 

• The Science and Practice of Welding, Vol.1: Welding Science and Technology, Cambridge University Press.

 

• The Science and practice of Welding, Vol.2: The Practice of Welding: A.C. Davies, Cambridge University Press.

 

• Principles of Welding, R.W. Messler, John Wiley & Sons (1999).

 

• Additive Manufacturing: Principles, Technologies and Applications, C.P. Paul and A.N. Jinoop, McGraw Hill, 2021.

 

• Advances in Welding Technologies for Process Development Edited By Jaykumar Vora, Vishvesh J. Badheka, 2020, CRC Press.

 

• Advanced Welding  Processes  Technologies  and  Process  Control,  John  Norrish,

 

• Website of Miller, https://www.millerwelds.com/

 

• Website of TWI, https://www.twi-global.com/search

 

24  Effective from June 2020, modified in September 2022

 

Part – C

 

 

AME–301 : Practical

 

 

Ten Practicals from the list of practical experiments/ practices covering different welding processes, testing (destructive and NDT) techniques, edge preparation, surfacing techniques, etc. would have to be undertaken at are commended organization.

 

 

Group A (Any Two)

 

 

1. Tension and Compression Test in a Universal Testing Machine

 

2. Bend-Rebend Test in a Universal Testing Machine

 

3. Shear Test in a Universal Testing Machine

 

 

Group B (Any Five)

 

 

4. Practice module on SMAW for bead on plate welding and butt joining

 

5. Practice module on GMAW for bead on plate welding and butt joining

 

6. Practice module on GTAW for bead on plate welding and butt joining

 

7. Practice module on Resistance welding and observation of weld bead cut section to observe nugget diameter under different welding conditions

 

8. Practice module on gas welding and cutting

 

9. Practice module on gas brazing

 

10. Investigation on the effect of varying welding conditions on weld bead geometry in arc welding

 

11. Investigation on the effect of varying welding conditions on weld bead geometry in a welding process other than arc welding

 

 

Group C (Compulsory)

 

 

12. Hardness Test of two different materials in Brinell/Vickers Hardness Tester and Rockwell Hardness Testing Machine and Impact Test

 

 

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13. NDT on welded samples in terms of DP test/ magnaflux test and study of radiography films and ultrasonic test results to find out flaws present in a weld

 

 

Group D (Any One)

 

 

14. Preparation of edge by machining/ grinding and welding using multi-passes

 

15. Metallographic sample preparation to observe bead profile, microstructure of weld metal, HAZ and base metal and to measure width of HAZand observation of microhardness or Rockwell hardness in C scale across the weldment

 

26  Effective from June 2020, modified in September 2022

 

AME–302 : Project

 

 

A Project may be carried out on fabrication/ experimental investigation/ testing/ quality control or assurance related to welding and joining. A candidate will do the project individually under the guidance of a teacher/ an experienced engineer. The candidate needs to prepare a comprehensive project report after completing the work to the satisfaction of the supervisor and it should contain the following:

 

1. A Title page describing the title of the project, Detail of the candidate, Name, Designation and Affiliation of the Supervisor(s) and at the bottom of the page, AM-IIW Examination, The Indian Institute of Welding and its full address.

 

1. Certificate page by the Supervisor(s)

 

• Acknowledgement by the candidate

1. Abstract (It should summarize the work done)

 

1. Contents

 

1. Chapter I: Introduction (It should briefly introduce the topic, importance of the area of work done and the Objective of taking the project)

 

• Chapter II: Literature Review (It should give an overview of the works done in the chosen area of work and the present status of known methods/ technology followed by Gap in Literature and aim of the Work to do.)

 

• Chapter III: Materials and Methods (It should contain the detail of the work done mentioning detail of Equipment/ Methodology used, experiment/ test done, etc.)

 

1. Results and Discussion
2. Conclusion

 

1. References (It should list reference literatures, such as published Research article in a Journal/ Conference article/ Book/ Handbook/ Internet Source, etc. in the following format:

 

• Khanna P and Maheshwari S (2020); Development of a mathematical model for predicting angular distortion in butt welded stainless steel 409M plates in GMAW process, Indian Welding Journal, 53(1), pp.57-66.

 

• Badheka VJ and Albert SK (2009); Improving the weld penetration by application of oxide coating in GTAW of P91 steel, Proceedings of the National Welding Seminar, Kolkata, India, p.18.

 

• Lippold J, DuPont JC, DuPont JN, Kiser SD (2009); Welding Metallurgy and

 

Weldability of Nickel Base Alloys, John Wiley and Sons, Inc., New Jersey.

 

[4]https://www.nickelinstitute.org/~/Media/Files/TechnicalLiterature/Copper_Nic

kel Alloys Properties andApplications_12007_.pdf

 

 

The project report is to be submitted to the Controller of Examinations, AM-IIW Examinations, The Indian Institute of Welding for its examination. If the project report is found by the examiner not up to the standard, the same would have to be resubmitted after incorporation of necessary corrections as suggested by the examiner.

 

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AME–303 : Comprehensive Viva Voce

 

 

The Comprehensive Viva-Voce will be conducted by a Committee consisting of few experts to assess the understanding of the candidate on welding and allied areas with regard to the papers he/ she passed in AM-IIW Examinations including Practical and Project.

 

 

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