New Course, ABE 501

ABE 591 K Spring 2003

Engineering Faculty Document No. 32-02

 

January 9, 2003

 

 

TO: Engineering Faculty

 

FROM: The Faculty of the School of Agricultural and Biological Engineering

 

RE: New Dual-Level Course, ABE 501

 

The faculty of the Department of Agricultural and Biological Engineering has approved the following new course. This action is now submitted to the Engineering Faculty with a recommendation for approval.

 

ABE 501 Welding Engineering

 

Sem. 2, Class 3, cr. 3 (Offered in alternating years)

 

Prerequisite: ABE 450

 

Design of weldments and modeling of heat transfer and residual stresses of the welding processes. Finite element theory of non-linear properties for the many processes including laser, submerged arc, manual, Gas Tungsten Arc Welding (GTAW), plasma, electron beam. Metallurgy topics will include continuous cooling transformation curves in optimizing engineered joint strength including cutting and welding.

 

Reason:

 

This class has been offered three times as an ABE 591 with good enrollment of 6 in 2001, 13 in 2002, and 10 in 2003. This course is organized to provide engineers with welding background for small production volumes. The need was expressed by Midwest industries who hire our students. Background in heat transfer, cooling, metallurgy and the processes for various productivity rates will be covered. Simulation of distortion and cracking are the major areas where engineering knowledge is needed to assure faster production process start-up-times.

 

 

 

 

_________________________________________________

Vincent F. Bralts

Head, Department of Agricultural and Biological Engineering

 


ABE 501 Welding Engineering Sem. 2., Class 3. cr. 3, Prerequisite: ABE 450 (Offered in alternating years)

 

Design of weldments and modeling heat transfer and residual stresses of the welding processes. Finite element theory of non-linear properties for the many processes including laser, submerged arc, manual, Gas Tungsten Arc Welding (GTAW), plasma, electron beam. Metallurgy topics will include continuous cooling transformation curves in optimizing engineered joint strength including cutting and welding.

 

ABE 501

Welding Engineering

 

 

Instructor: Professor Gary W. Krutz, Ph.D., P.E.

 

Text: Welding Metallurgy (Carbon & Alloy Steels), Vol. 1 Fundamentals

By G. E. Linnert, AWS Publisher, 1994

 

Reference: Machine Design by G.W. Krutz, 1999

 

Prerequisite: ABE 450 or equivalent

 

Lecture: Tuesday 9:30 - 10:20 ABE

Wednesday 1:30 - 3:20 ABE

 

HWK due the following class meeting

 

Jan

14

Chapter 2 - Krutz

 

 

15

Chapter 6.2 pgs. 179-197 – Krutz

Hwk 6.6, 6.7, 6.8, 6.9, 6.11

 

21

Videos 1, 2 and 3

 

 

22

Chapter 5 – Linnert

Demo – Scott Brand manual weld

 

 

28

Chapter 6 – Linnert pgs. 441-477

Hwk #1

 

29

Videos 4, 5 and 6

 

Feb

4

TIG welding – Linnert pgs. 478-501

Hwk #2

 

5

Demo – Scott – TIG welding

 

 

11

Submerged arcs (UCS), pgs. 501-547

Hwk #3

 

12

Practice weldings & test weld

 

 

18

Electron Beam, etc., pgs. 548-593

 

 

19

Hardness test in MET

Hwk #4

 

25

Friction Welding, ultrasonic welding, etc.,

pgs., 594-620

 

 

26

Soldering, brazing

Hwk (Krutz) 6.12

Mar

4

Exam #1

 

 

5

Gas Cutting, pgs., 621-651

 

 

11

Field trip – Plasma Cutting & TIG ( 2PM)

HWK #5

 

12

Projects start

 

 

22

Cat Simulation – Harlow

 

 

23

Projects (continued)

 

 

29

Thermo Changes, pgs., 653-707

 

 

30

PC – meet with Prof. Krutz weekly (i.e., tours)

 

Apr

1

FEA – nonlinear K & C and C

Hwk#6

 

2

Project Draft Due – 10 minute presentations

 

 

8

FEA – heat of transformation & fusion

Hwk #7

 

9

Chapter 8 – Plastic Welding in lab

Hwk #8

 

15

FEA – gauss flux – time dependant

 

 

16

Chapter 9 (to pg. 855) – CCT curves

Hwk # 9

 

22

Residual stresses – handouts

 

 

23

Toughness in welds, pgs., 856-891

Hwk #10

 

29

Robot welding (tolerance stackup)

 

 

30

Project Due – Review for final

 

 

 

Purdue Student Honesty Policy in effect.

 

Class Goals:

 

1.                   Become proficient in designing a welded joint.

 

2.                   Capable of specifying welding process for manufacturability.

 

 

3.                   Complete a welding engineering design project (15 page report). Practical

hands-on-experience.

 

4.                   Understanding FEA (thermo and elastic-plastic) non-linear affects caused by

Welding (i.e., commercial CAT program)

 

5.                   Becomes knowledgeable of the 20 plus welding, cutting, and brazing processes.

 

6.                   Evaluate weld quality – understand certification process.

 

 

Justification: Many joining processes use automatic welding in automotive construction and component manufacturing. The demand for background in welding engineering has been expressed by mid-west industry.