Welding engineering topic directory
Dedicated guides cover welding processes, materials and metallurgy, design, standards, quality, inspection and manufacturing practice. Every guide links to its corresponding interactive training module.
Open interactive portalWelding processes and equipment
Introduction to welding processesWelding processes — professional selection and industrialisationISO 4063 processesISO 4063 — welding, brazing, soldering and cutting processesElectrical engineering for weldingA welding power source is not a ‘box of amps’. It is a fast control system that regulates an unstable plasma load.Welding arcThe arc is not merely a ‘spark’. It is a controlled plasma energy converter.Welding power sourcesWelding power sources — static and dynamic characteristicsShielding gasesColour identification of industrial-gas cylindersWelding positionsWelding positions according to EN ISO 6947:2011Welding consumablesWelding processes and equipmentGas weldingOxy-fuel gas weldingTIG/WIGTIG/GTAW — complete moduleMIG/MAGMIG/MAG — complete moduleTubular cored wires / FCAWFCAW is not merely ‘MAG with a different wire’. A tubular cored wire is a small metallurgical reactor in the arc.MMAMMA/SMAW — manual metal arc welding with a covered electrodeSAWSAW — submerged-arc weldingResistance weldingFundamental principlePlasma / laser / electron beamThree highly concentrated energy sources — three different equipment systems, sources and emission modes.Other processesOther welding processesCutting, gouging and surfacingCutting is not merely material separation. It is the first thermal operation applied to the future welded joint.Hardfacing and wear mechanismsOverlay welding is surface engineering, not merely ‘adding material by welding’.Mechanisation and roboticsRedesigned trainer: translations and rotations are separated by coordinate frame.Brazing and solderingBrazing and soldering — soft, hard and high-temperature joiningJoining of plasticsPlastics are not joined like metals: polymer softening, chain diffusion and controlled cooling determine the result.Ceramics and compositesFor ceramics and composites, the main question is not “which process can weld this?”, but how to transfer the load without destroying the material.Preheat, interpass and postheatingEngineering design of preheat, interpass temperature and postheating, including physical principles, equipment, risks and WPS/WPQR links.Measurement of welding parameters and arc energyMeasurement of voltage, current, travel speed, power and arc energy with correct sampling, synchronisation and metrological traceability.Measurement of shielding and backing gasesFlow, pressure, leakage, residual oxygen, dew point and atmosphere exchange for weld-pool shielding and root purging.
Materials and welding metallurgy
Crystal latticesCrystal lattices, slip systems and atomic defectsFe–Fe₃CInteractive metastable Fe–Fe₃C diagramIRA / ARA / CCTIRA diagramMicrostructuresPhases and microstructures of steels, weld metal and cast ironsHAZ / TOOHAZ microstructure simulatorCEV / CET / PCMCEV / CET / PCM calculatorHydrogen-assisted crackingHydrogen-assisted cracking—risk calculatorHot cracking / FNFerrite number / hot-cracking trainerHeat treatmentHeat treatment of steelsStructural steelsReal steels—CCT/TTT teaching moduleSpecial steels—overviewSpecial steels — standards and technology overviewCreep-resistant and heat-resistant steelsHeat-resistant and creep-resistant steelsMaterial creepMaterial creep — long-term time-dependent deformationCryogenic steelsCryogenic steels and welded jointsStainless steelsSchaeffler / DeLong / WRC-1992—stainless steelsElement affinityElement affinity — interactive periodic tableCast ironsCast irons — metallurgy, welding and repairAluminiumAluminium and its alloys — welding without shortcutsCopper, nickel and titaniumCopper, nickel and titanium — special non-ferrous materialsDissimilar-material jointsDissimilar-material joints — dilution, interfaces and lifeCorrosionCorrosion — forms and damage mechanismsProtective coatingsProtective layers and surface treatments
Design and structural engineering
Fundamentals of elasticity and strength of materialsFundamentals of elasticity and strength for welded structuresHooke’s lawHooke’s law — interactive engineering diagramTypes of welded jointsTypes of welded joints and their structural functionJoint preparation—ISO 9692Joint preparation according to EN ISO 9692ISO 13920 tolerancesWeldment tolerances according to EN ISO 13920:2023Weld calculationsWeld calculation trainerStatically loaded welds1. Weld design modelFatigue of welded jointsFatigue-loaded weldsFracture mechanicsFracture mechanics of welded structuresStresses and stress concentrationsStresses and stress concentration in welded jointsDesign of welded details1. Five layers of a sound welded detailPressure vessels / piping / bridges / cranesApplications of welded structuresAluminium structuresWelded aluminium structuresISO 2553 welding symbolsISO 2553 — weld symbols on technical drawings
Fabrication, quality, inspection and safety
ISO 3834EN ISO 3834 — quality requirements for fusion welding of metallic materialsISO 14731 welding coordinationISO 14731 – welding coordinationWPS / pWPS / WPQR / ISO 15614Interactive WPS and working-WPQR generator with heat-input calculation, examinations, live preview and PDF output.ISO 9606 / ISO 14732ISO 9606 — welder qualificationInspection and test planITP – Inspection and Test PlanMaterial traceabilityMaterial, weld and process traceabilityWeld imperfectionsAn imperfection is not automatically an unacceptable defectISO 5817 / ISO 10042ISO 5817 — imperfection acceptance trainerMechanical and destructive testingMechanical testsNDT inspectionNDT of welds — non-destructive testing and examinationISO 9712NDT personnel to EN ISO 9712Distortion and residual stressesWelding always creates a temperature gradient. The question is whether the manufacturer controls it.Fixtures, positioners and clampingWelding fixtures and positionersWeld repairsWeld and nonconformity repairsOccupational health and safetyWelding safety — hazards and standards frameworkWelding economicsWelding economics — weld cost and calculatorStandards—overviewWelding standards—IWE mapEN 1090 EXCEN 1090 — EXC trainerTemperature measurement and control in weldingContact probes, thermocouples, Pt100 sensors, pyrometers and thermal cameras, including emissivity, uncertainty, attachment and recording.PWHT and local heat treatmentDesign, execution and documentation of the post-weld heat-treatment cycle, including zones, thermocouples, insulation and metallurgical risks.Hydrogen control of welding consumablesStorage, drying, holding, issue, exposure and traceability of electrodes, cored wires, solid wires and fluxes.