Fundamentals of thermo-mechanical & fatigue analysis of welded structure

By Prof. Pankaj Biswas | IIT Guwahati

Learners enrolled: 126 | Exam registration: 1

ABOUT THE COURSE:

In manufacturing industry over 30% production costs is spent on welding. Knowledge of welding technology, welding deigns, thermos-mechanical and fatigue analyses of welded structures are highly essential in most of the manufacturingindustries. In this present course the primary focus is on basic fundamental of thermos-mechanical and fatigue analysis of welded structure and its importance in industries. This course will also cover different types of thermo-mechanical and fatigue life predictionrelated problem. This course will also include the basics of fusion welding metallurgy. Further this course will also highlight the fundamental of different types of numerical methods used in welding analysis, basics of FE transient elastoplastic thermos-mechanical analysis and detail steps involved in finite element (FE) simulation of weld induced thermal history, residual stresses and distortion using commercially available FE software package ANSYS.

INTENDED AUDIENCE: Students/ Researchers/ technical persons form industry

PREREQUISITES: BE/B-Tech in Mechanical/Production/ Manufacturing sciences/Power plant engineering/ naval architecture/ ocean engineering.

INDUSTRY SUPPORT:Any type of manufacturing industry i.e. automobile,shipbuilding, aeronautical, railway industries etc.

Summary

Course Status :	Upcoming
Course Type :	Elective
Language for course content :	English
Duration :	12 weeks
Category :	Mechanical Engineering Manufacturing Processes and Technology
Credit Points :	3
Level :	Undergraduate/Postgraduate
Start Date :	20 Jan 2025
End Date :	11 Apr 2025
Enrollment Ends :	27 Jan 2025
Exam Registration Ends :	14 Feb 2025
Exam Date :	03 May 2025 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Analysis of heat flow in welding: Basics of 3D transientheat transfer analysis, Heat flow in fusion welding, Heat transfer analysis of solid state welding, Effect of operating parameters, Different heat source models for fusion welding, Calculation of peak temperature, and Cooling rate of welds.

Week 2: Effect of welding thermal history on welded structure:Effect of welding thermal history and other operating variables on residual stresses and distortions, Thermal effects of welding on parent metal and its mechanical properties, Calculation of welding shrinkage, Heat treatment of welded structure, weldability of structural steels, Thermo-mechanical and overstressing techniques, Hydrogen embrittlement, Hot and cold cracking.

Week 3: Basics of welding design: Principle of sound welding design, Joint design, Allowable Strength of welds, Engineering design versus Welding design, Fundamental of fracture mechanics for welding, Theories of failures.

Week 4: Design of welded joint for torsional moment and fluctuating loading: Analysis of welded joint subjected to torsional moment, Analysis of welded joint subjected to combined stresses and fluctuating loading, Examples on combined loading.

Week 5: The methods of structural fatigue: Fatigue-Analysis Methods, Fatigue Design Methods, Fatigue-life Estimation Methods, Fatigue and creep properties of welded joints, Methods for improving the fatigue strength.

Week 6: The methods of structural fatigue: Fatigue-Analysis Methods, Fatigue Design Methods, Fatigue-life Estimation Methods, Fatigue and creep properties of welded joints, Methods for improving the fatigue strength.

Week 7: Design & analysis for fatigue loading: Basics of fatigue analysis, mechanism of fatigue fracture, design of welde joints for fatigue loading, infinite and finite life fatigue problems, Rain flow counting method, Examples of Rain flow counting.

Week 8: Design & analysis for fatigue loading: Cumulative fatigue life, Miner’s rule for Cumulative fatigue life, Examples of Miner’s rule, Modified Goodman’s diagram and Problems on Modified Goodman’s diagram.

Week 9: Design & analysis for fatigue loading: different methods for evaluation of fatigue life of homogeneous welds, crack propagation approach using linear elastic fracture mechanics, Concept of Paris law, Examples of fatigue analysis by Paris law.

Week 10: Design & analysis for fatigue loading: Global and local fatigue analysis for welded fatigue analysis i.e. nominal stress method, hot spot stress method, effective notch stress method, Problems on above methods.

Week 11: Finite Element (FE) fundamentals required in welding analysis: Concept of different types of numerical methods used in welding analysis, Governing equations and its FE derivation, Basics of FE transient elastoplastic thermos-mechanical analysis.

Week 12: Welding Simulation using FE Software ANSYS: FE transient thermal analysis of weld induced thermal history, residual stresses and distortion, basics of fatigue life prediction by FE simulation.

Books and references

1. Fuchs H. O. and Stephen R I.,“Metal Fatigue in Engineering”, John Wiley. 2000

2. Gray T. G. F. and Spence J., “Rational Welding Design”, Butterworths. 1992 .

3. O. Grong, Metallurgical Modelling of Welding, 2nd Ed. IOM publication, 1997.

4. V. M. Radhakrishnan, Welding Technology and Design, New age. 2002.

5. Dr. O. P. Khanna, Welding Technology, Reprint: 2002.

6. L-E Lindgren, Computational Welding Mechanics, Woodhead Publishing Limited,2007.

Instructor bio

Prof. Pankaj Biswas

IIT Guwahati

Prof. Pankaj Biswas working as a Professor in the Dept. of Mechanical Engineering, IIT Guwahati. I am working in the area of welding technology, 3-D printing and forming by line heating for the past 17 years. My areas of research are on computational weld mechanics, similar and dissimilar friction stir welding, friction stir welding of steel, hybrid welding technology, Finite Element analysis of weld induced distortion and residual stresses, Analysis of large welding structure, forming by line heating and modeling of welding processes using soft computing techniques. I guided 02 PDF, 10 PhD scholars in the area of welding and forming. Currently I am guiding 02 NPDF and 10 PhD students in the welding, 3-D printing and line heating areas. I already published about 104 journal articles, 95 conference proceedings, 28 book chapters and 06 patents. I worked in ten sponsored / consultancy projects. Currently, I am working in another eight sponsored / consultancy projects. I got IEI Young Engineers Award 2013- 2014’ in Mechanical Engineering discipline.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.

The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).

Date and Time of Exams: May 3, 2025 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.

Registration url: Announcements will be made when the registration form is open for registrations.

The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.

Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

Please note that assignments encompass all types (including quizzes, programming tasks, and essay submissions) available in the specific week.

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Guwahati .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team