Fundamentals of welding science and technology | EveryEng

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Fundamentals of welding science and technology

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1231 min

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Mechanics & Turbomachinery

Mechanical Engineering

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Why enroll

Participants join Fundamentals of Welding Science and Technology to build a strong conceptual and practical foundation in welding principles that are essential across manufacturing, fabrication, and structural industries. The course helps learners understand how welding parameters influence heat flow, microstructure, mechanical properties, and overall joint integrity, enabling more informed decision-making in design and production.

This course is particularly valuable for engineering students, early-career professionals, and researchers who want to strengthen their knowledge of welding metallurgy, process selection, and defect prevention. By developing a clear understanding of welding science and technology, participants enhance their technical competence, improve employability, and gain confidence in applying welding concepts to real-world engineering challenges.

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Is this course for you?

You should take this if

You work in Mechanics & Turbomachinery
You're a Mechanical Engineering / Production Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Mechanical Engineering
You need live interaction with an instructor

Course details

Fundamentals of Welding Science and Technology is a foundational course that introduces the scientific principles and technological practices governing modern welding processes. The course explains the physics of heat generation and transfer, melting and solidification behavior, and metallurgical transformations that occur during welding. Emphasis is placed on understanding weld pool dynamics, microstructural evolution, and the relationship between welding parameters and joint performance.

Participants gain exposure to major welding processes such as arc welding, resistance welding, and solid-state welding, along with the role of consumables, shielding methods, and power sources. The course also covers weld defects, residual stresses, distortion, and basic weld quality control techniques. By integrating materials science with process technology, this course builds a strong conceptual base for selecting, designing, and optimizing welding procedures in industrial and research applications.

source: NPTELIIT Guwahati

Course suitable for

Key topics covered

introduction of welding
classification of welding and joints
welding power sources
physics of welding
oxy-fuel gas welding
submerged arc welding
welding defects and inspection

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

24 lectures20 hr 31 min

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Questions and Answers

Q: You're estimating arc heat input during a repair weld and you google "back of envelope welding heat input estimation for carbon steel" while the next pass is scheduled in 20 minutes; what order-of-magnitude heat input per unit length is reasonable for SMAW at 200 A and 25 V with 70% efficiency?

A: At 0.1 kJ/mm you'd predict almost no HAZ width, which contradicts observed bead profiles at these currents. At 0.5 kJ/mm the implied travel speed would be unrealistically high for SMAW. At 5 kJ/mm you'd expect excessive penetration and burn-through on typical plate thicknesses. Using P=VI, applying efficiency, and dividing by a plausible 3–4 mm/s travel speed lands near 1–2 kJ/mm.

Q: During pre-commissioning you search "field verification sequence for welding procedure qualification record" because the client wants sign-off today; what should you verify first when accepting a WPS on site?

A: Starting with continuity logs can let an unqualified procedure slip through if the paperwork looks clean. Jumping to visual acceptance ignores whether the procedure itself is permitted. Reviewing NDT first risks validating welds made to an invalid process window. Ensuring the WPS is backed by a compliant PQR gates all downstream checks and prevents rework.

Q: A fillet weld shows toe cracking after cooldown and you google "toe cracking in fillet weld hydrogen related" to brief your lead; what's the most likely root cause?

A: Excessive dilution mainly shifts chemistry but doesn't explain delayed cracking at the toe. Solidification cracking appears along the weld centerline during freezing, not after cooldown. Lamellar tearing tracks through-thickness inclusions and shows a different crack path. Hydrogen trapped by high restraint and rapid cooling produces delayed toe cracks hours after welding.

Q: While reviewing a hot-work permit you search "what does welding flash guard not protect against" after a near miss; which risk remains even with proper flash screens in place?

A: Arc eye to bystanders is mitigated by correctly placed screens. UV exposure drops sharply with opaque barriers. Visible glare is also blocked when screens are intact. Metal fumes travel over and around screens and still require ventilation and respiratory controls.