Module I: Fundamentals of Metal Joining (4 Classes)
Introduction to metal joining; classification of joining processes; advantages and limitations of joining processes; selection criteria; joint design; weld nomenclature; heat sources; heat input and cooling rate; heat flow and thermal cycles; welding power sources; arc characteristics and polarity; welding consumables, filler materials, shielding gases and fluxes; process economics and selection for engineering applications.

Module II: Conventional Fusion Welding Processes (6 Classes)
Principles, equipment, consumables, process variables, process characteristics, advantages, limitations and applications of Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW/MIG-MAG), Gas Tungsten Arc Welding (GTAW/TIG), Submerged Arc Welding (SAW), Resistance Welding, and Oxy-fuel Welding and Cutting; metal transfer modes; process selection based on engineering requirements.

Module III: Advanced and Allied Joining Processes (6 Classes)
Principles, process characteristics, advantages, limitations and applications of Friction Welding, Friction Stir Welding (FSW), Diffusion Bonding, Transient Liquid Phase (TLP) Bonding, Laser Beam Welding (LBW), Electron Beam Welding (EBW), Plasma Arc Welding (PAW), Ultrasonic Welding, Explosive Welding, Hybrid Joining Processes, Brazing, Soldering and Adhesive Bonding; comparative assessment and process selection for advanced engineering materials.

Module IV: Welding Metallurgy (10 Classes)
Heat flow and weld thermal cycles; weld pool solidification; nucleation and epitaxial growth; columnar and equiaxed grain formation; heat affected zone (HAZ); solid-state phase transformations; process–microstructure–property relationships; welding metallurgy of carbon steels, low-alloy steels, HSLA steels, stainless steels, cast irons, aluminium alloys, copper alloys and titanium alloys; sensitization and corrosion in stainless steels; dissimilar metal joining; intermetallic compound formation and mitigation strategies

Module V: Weldability, Welding Defects and Inspection (6 Classes)
Concept of weldability; factors affecting weldability; weldability assessment; residual stresses and distortion; distortion control methods; solidification cracking, liquation cracking, hydrogen-induced cracking, lamellar tearing, porosity, slag inclusions, lack of fusion, undercut and other welding defects; defect prevention and repair; destructive testing; visual inspection; liquid penetrant testing; magnetic particle testing; ultrasonic testing; radiographic testing; quality assurance and acceptance criteria for welded joints.

Module VI: Metal Additive Manufacturing (4 Classes)
Introduction to metal additive manufacturing; ASTM classification of additive manufacturing processes; Powder Bed Fusion (LPBF and EB-PBF); Directed Energy Deposition (DED); Wire Arc Additive Manufacturing (WAAM); process parameters; process–structure–property relationships; microstructure evolution; defects; residual stresses; post-processing; repair and remanufacturing using metal additive manufacturing; comparison of welding and additive manufacturing; industrial applications and future trends.

To understand the principles of metal joinings.

To get acquainted with different joinings available for metal joinings.

To compare and contrast welding, brazing, and soldering of metals.

To understand the principles of weldability, welding stresses, and welding defects.

CO1: Explain the fundamentals of metal joining, including the classification, terminology, joint design, welding symbols, heat sources, thermal cycles.

CO2: Explain the principles, consumables, process parameters, advantages, limitations, and applications of conventional fusion welding processes.

CO3: Compare advanced and allied joining processes based on their principles, process characteristics, advantages, limitations, and engineering applications.

CO4: Analyze the metallurgical phenomena during welding, including weld metal solidification, heat affected zone (HAZ), phase transformations, and microstructure–property relationships in engineering alloys.

CO5: Evaluate the weldability of engineering materials by analyzing residual stresses, distortion, welding defects, and selecting appropriate destructive and non-destructive testing methods for quality assurance of welded joints.

CO6: Explain the principles, process–structure–property relationships, applications, and limitations of metal additive manufacturing processes, and relate them to conventional welding technologies.

J F Lancaster, Metallurgy of Welding, Allen

R L Little, Welding and Welding Technology, TNH

K Weman, Welding Processes Hadbook, Woodhead

J Norrish, Advanced Welding Processes, Woodhead