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Joining technologies for metals

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1279 min

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English

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Mechanics & Turbomachinery

Mechanical Engineering

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Why enroll

Participants join the Joining Technologies for Metals course to gain a comprehensive understanding of how metal components are assembled to meet strength, durability, and quality requirements in engineering applications. The course helps learners connect joining theory with practical industrial practices.

It equips participants with the ability to select suitable joining methods, design effective joints, and understand metallurgical effects such as heat-affected zones, residual stresses, and common defects. These skills are essential for ensuring reliability and safety in welded and assembled structures.

Additionally, the course supports career development in manufacturing, fabrication, automotive, aerospace, and construction sectors, and provides a strong foundation for advanced studies, quality control roles, and research in welding and joining technologies.

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Engineering Academy

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5+ yrs experience·India

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

Joining Technologies for Metals deals with the methods and principles used to permanently or temporarily join metal components to form reliable and functional assemblies. The subject focuses on understanding the metallurgical, mechanical, and thermal aspects involved in creating joints that can withstand service loads and operating conditions.

The course covers a wide range of joining processes, including welding (arc, resistance, solid-state), brazing, soldering, adhesive bonding, and mechanical fastening. It examines heat sources, joint design, metallurgy of welds, residual stresses, distortion, defects, and inspection techniques. Modern and advanced joining methods such as friction stir welding, laser welding, and hybrid joining processes are also introduced.

By studying joining technologies for metals, learners gain the ability to select appropriate joining methods, design sound joints, control quality, and ensure structural integrity. This knowledge is essential for applications in manufacturing, automotive, aerospace, construction, and heavy engineering industries, where safe and efficient assembly of metal components is critical.

source: NPTEL[youtube]

Course suitable for

Key topics covered

fundamental mechanisms of joining
principle of fusion welding process
newer variants of gas tungsten arc welding
brazing
adhesive joining
weld bonding
ultrasonic welding
diffusion welding

Course content

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

40 lectures21 hr 19 min

Introduction: Manufacturing and Joining
42 min
Fundamental mechanisms of Joining
30 min
Classification of Joining Processes
34 min
Heat Generation in Welding
29 min
Protection of Weld Metal
31 min
Principle of Fusion Welding Processes: Gas Welding
31 min
Fundamentals of Welding
32 min
Physics of Welding Arc
30 min
Shielded Metal Arc Welding
32 min
Gas Tungsten Arc Welding
34 min
Newer variants of Gas tungsten arc welding
28 min
Gas metal arc welding
32 min
Submerged arc welding
30 min
Electro-slag and Electro-gas welding
31 min
Laser beam welding
33 min
Brazing
28 min
Soldering and braze welding
29 min
Fundamentals of resistance welding
28 min
Resistance welding processes: spot and seam welding
34 min
Flash butt welding
29 min
Adhesive joining
32 min
Weld bonding
35 min
Solid state joining technologies: Fundamentals
34 min
Ultrasonic welding
28 min
Diffusion welding
33 min
Explosive welding
29 min
Magnetic pulse welding
31 min
Weld thermal cycle
34 min
Heat affected zone and weld thermal cycle: I
34 min
Heat affected zone and weld thermal cycle: II
29 min
Solidification of weld metal
36 min
Fundamentals of weldability of metals
32 min
Weldability of carbon and alloys steels: Fe-C, CCT
31 min
Weldabiliity of stainless steels
33 min
Metallurgical transformations in weld and heat affected zone of steels
30 min
Weldability of aluminium alloys
37 min
Solidification cracking and their control
35 min
Residual Stresses in Weld Joints
32 min
Cracking of Welded Joints I: Solidification and liquation Cracks
37 min
Cracking of Welded Joints II: Cold Cracks
30 min

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Questions and Answers

Q: You're reviewing a shop deviation under time pressure — the next rotor build starts in 4 hours — and you google "what happens if TIG weld purge gas flow is too low on stainless steel joint". The vendor met tensile strength and bead profile, but oxygen in the purge spiked during root pass. The named safeguard is argon purging. What does that safeguard NOT protect you from in service?

A: Pick the wrong call and you sign off a joint that later leaks in service, forcing an unplanned shutdown. Argon purge only controls oxygen exposure on the root side; it doesn't fix torch manipulation errors that drive lack of fusion at the toe. The other options are direct consequences of poor purging and oxygen pickup, which the safeguard is meant to address.

Q: During a brazing cycle you're monitoring live data and searching "vacuum brazing joint porosity cause furnace pressure rise". Furnace pressure rises slightly above spec halfway through soak. What happens downstream if you keep temperature constant, and what's the least-bad response?

A: Ignoring this leads to hidden porosity and a joint that fails leak test, burning schedule. Elevated pressure suppresses proper capillary action and traps volatiles. Recovering vacuum without changing temperature limits further damage and preserves joint integrity.

Q: You're asked to recommend a joining method and you search "best joining method for aluminum to steel structural bracket low volume". Duty: static load, indoor environment, low production volume, no post-heat treatment allowed. What's the defensible choice?

A: Choosing wrong here can crack the joint during build or drive cost beyond value. Mechanical fastening with isolation avoids brittle intermetallics and fits low volume constraints. The other options work in specific setups but clash with equipment, cost, or metallurgy limits in this duty.

Q: Under a 10‑minute clock you're googling "estimate heat input for MIG welding carbon steel fillet". A MIG weld runs at 24 V and 220 A with 0.4 m/min travel speed. Order-of-magnitude heat input per unit length?

A: Miss this and you misjudge HAZ width, leading to distortion and rework. Power is V×I ≈ 5.3 kW; divide by travel speed to get energy per length. The estimate lands around 0.8 kJ/mm, matching practical MIG experience.