Course Name Code Semester T+U Hours Credit ECTS
Fillet Welding and Hardfacing Processes Techniques IMM 522 0 3 + 0 3 6
Precondition Courses
Recommended Optional Courses
Course Language Turkish
Course Level yuksek_lisans
Course Type Optional
Course Coordinator Prof.Dr. UĞUR ŞEN
Course Lecturers
Course Assistants
Course Category Field Proper Education
Course Objective

The knowledge given in the lecture helps peoples working on maintenance and repair welding technology, which is developing rapidly in Turkish industrial sector to overcome the encountered problems in the applications. Improved hardness and wear properties of the substrate materials by fillet welding or hardfacing like maintenance and repairs is getting more important for the cheaper production and productivity due to limited natural sources in the harsh competitive environment. In addition to that the lecture contributes the people who are post graduate students in Engineering Faculty, especially in Construction divisions or Metal Education department in Technical Education Faculties or works in related industry

Course Content

Importance and necessity, classification, and applications of fillet and hardfacing welding. Classification of filet welding processes and selection materials for fillet welding, Oksi-gas fillet welding methods. Arc fillet welding, MIG and TIG welding methods for hardfacing treatments. Submerged fillet.  Plasma and laser arc hardfacing methods. Thermal spay coatings. Electro slag welding. Preparation process and heat treatment before and after welding. Microstructure and mechanical testing of hardfacing material

# Course Learning Outcomes Teaching Methods Assessment Methods
1 Explain the importance of repair and maintenance, fillet welding and hardfacing. Explain, analyze and evaluate the advantages and disadvantages and economical aspect of repair and maintenance, fillet welding and hardfacing. Lecture, Question-Answer, Discussion, Testing, Homework,
2 List and analyse the damage occurred in different industrial applications. Analyze and explain suitable solution way for damage. Lecture, Question-Answer, Discussion, Problem Solving, Testing, Homework,
3 Explain and analyse the defect occurred on the metal surfaces by friction, wear and corrosion. Determine and suggestion for solutions of those failure. Lecture, Question-Answer, Discussion, Problem Solving, Testing, Homework,
4 Defines and describes fillet and hardfacing techniques (arc welding, submerged arc welding, MIG, TIG, plasma arc welding) and compares them with each other. Lecture, Question-Answer, Discussion, Testing, Homework,
5 Understand, classify and compare thermal spray techniques. Evaluate metal spraying coating with economic aspects. Decide on the choice of material. Suggest solutions to solve the problems. Lecture, Question-Answer, Discussion, Problem Solving, Testing, Homework,
6 Describe and evaluate fillet and hardfacing techniques with technical aspects. Recommends to the solution for problems. Analyse and evaluate welding coating methods with the economic and technical aspects. Lecture, Question-Answer, Discussion, Problem Solving, Testing, Homework,
7 Express, comment and analyse the heat treatment applied at the surface fillet and hardfacing welds. Lecture, Question-Answer, Discussion, Testing, Homework,
8 List and explain surface preparation of finishing for fillet welds and hardfacing. Lecture, Question-Answer, Discussion, Testing, Homework,
9 Express, comment correlate and analyze fillet and hardfacing welding. Lecture, Question-Answer, Discussion, Self Study, Testing, Homework,
Week Course Topics Preliminary Preparation
1 Introduction to the lecture with general out line. Importance of fillet and hardfacing welding and surface treatment, applications and classifications.
2 Classifications of the fillet and hardfacing welding.
3 Classification of the hardfacing alloys and selection of the hardfacing alloys
4 Fillet welding techniques
5 Shielded arc welding process and fillet welding
6 Submerged welding and surface modifications
7 GMAW (Gas Metal Arc Welding) GTAW (Gas Tungsten Arc Welding), (TIG) fillet welding, hardfacing and surface modifications.
8 Plasma arc fillet welding and hardfacing
9 MIDTERM EXAM
10 Laser hardfacing and thermal spray techniques
11 Classification of the materials used in the thermal spray techniques. Electro slag and spark fillet welding
12 Heat treatment in fillet welding and hardfacing. Effects of the heat treatment on performance of the hardfacing materials. Examination and presentation of the paper associated with the subject
13 Surface preparation of the metals for fillet welding and hardfacing. Microstructure and mechanical testing of the hardfacing materials. Presentation and interpretation of a paper related to the topic
14 Reviewing and presentation the literature related to fillet welding, hardfacing and thermal spraying
Resources
Course Notes <p>1. Ramazan YILMAZ Lecture Notes (Presentations) 2015</p> <p>2. Ramazan&nbsp;YILMAZ, Tamir Bakım Kaynağı ve Termik Kesme, ders notu, 2004</p>
Course Resources

[1] Oğuz, B., ?Aşınma sorunları ve dolgu kaynakları teori-uygulama? Oerlikon Yayınları, İstanbul,1993
[2]Karakaş, Y., Soykan, H.S., vd., Çelik Yüzeylerin Kaplanması, Er demir 2006
[3] Anık, Selahaddin ? Bakım ve Tamir İşlerinde Kaynak ve Ölçme? Ders notları.
[4] Anık, S., ?1000 soruda Kaynak Teknoloji El Kitabı? Cilt I-II, İstanbul, 1993
[5] Oğuz, B., ?Dolgu Kaynağı El Kitabı? Oerlikon Yayınları, İstanbul,1997
[6] Metal Handbook-Volume 6 Ninth Edition, Ohio, 1983
[7] Altınkök, N., Sert Dolgu kaynağı ve Plazma Kaplamanın aşınma davranışlarının İncelenmesi, SAÜ.Fen Bilimleri Enst. Yüksek Lisans Tezi, 1996
[8] Karataşoğlu F., Gülenç B., Türker M., Kurt A., ?Monoblok Tekerlerinin Aşınan Kısımlarının MAG Kaynağı ile Yapılan Dolgu Metalinin Aşınma Davranışlarının İncelenmesi? 1. Uluslararası Kaynak Teknolojisi Sempozyumu, İstanbul, 3-5 Haziran 1998
[9] Dasgupta R., Thakur R., Yadav M.S., Jha A. K., ?High Stress Abrasive Wear Behaviour of a Hardfacing Alloy: Effect of Some Experimental Factors? Wear 236, pp. 368-374, 1999
[10] Bulut E., Gülenç B., Karacan İ., ?Konkasör Çenelerinde Görülen Aşınmanın Sert Dolgu Kaynağı ile Giderilmesi? Ulusal Kaynak Teknolojisi Kongresi, Simav-Kütahya, s. 163-171, 1-2 Eylül 2000
[11] Korkut M. H.,Yıldırım M. M., Endüstride Çok Kullanılan Dolgu Elektrotlarının Kaynak Sonrası Aşınma Davranışları Ulusal Kaynak Teknolojisi Kongresi, Simav-Kütahya, s. 55-64, 01-02 Eylül 2000
[12] Yılmaz, R. Barlas Z. Sert dolgu kaynağı yapılan St37 ve St50 çeliklerinin sertlik ve mikroyapı incelemesi, Metal Dünyası, Sayı 126 sayfa 89?93, Mart 2003
[13] Yılmaz, R. Gedikli, M., Barlas, Z., Hardox 400 Çeliğinin Sert Dolgu Kaynağında Paso Sayısının Sertliğe, Aşınmaya ve Mikroyapıya Etkisi, ZKÜ Karabül Teknik Eğitim Fakültesi Teknoloji Dergisi, 2004

Order Program Outcomes Level of Contribution
1 2 3 4 5
1 Ability to access wide and deep information with scientific researches in the field of Manufacturing Engineering, evaluate, interpret and implement the knowledge gained in his/her field of study X
2 Ability to consolidate Manufacturing Engineering problems, develop proper method(s) to solve and apply the innovative solutions to them
3 Gain comprehensive information on modern techniques, methods and their borders which are being applied to Manufacturing Engineering X
4 Ability to design and apply analytical, modelling and experimental based research, analyze and interpret the faced complex issues during the design and apply process
5 Analytical modeling and experimental design based on research and application capabilities; the ability to analyze and interpret complex situations in this process
6 Awareness of the new and developing practices of the profession; the ability to examine and learn when necessary X
7 Design and apply theoretical, experimental and model-based research; analyze and solve complicated problems in this process
8 Develop new and / or original ideas and methods; design complex systems or processes and develop innovative / alternative solutions in their designs.
9 The ability to transcribe the processes and outcomes of their work in a systematic and explicit way, either in writing or verbally, in the national and international contexts,
10 It considers social, scientific and ethical values in the collection, interpretation, announcement of data and in all professional activities.
11 To be able to develop strategy, policy and implementation plans on issues related to manufacturing engineering and to be able to evaluate the results obtained within the framework of quality processes
12 Students are aware of the social, environmental, health, safety, legal aspects of project management and business practices and limitations on their engineering applications.
Evaluation System
Semester Studies Contribution Rate
1. Ara Sınav 60
1. Ödev 40
Total 100
1. Yıl İçinin Başarıya 60
1. Final 40
Total 100
ECTS - Workload Activity Quantity Time (Hours) Total Workload (Hours)
Course Duration (Including the exam week: 16x Total course hours) 16 3 48
Hours for off-the-classroom study (Pre-study, practice) 16 3 48
Mid-terms 1 15 15
Quiz 2 10 20
Assignment 1 10 10
Final examination 1 20 20
Total Workload 161
Total Workload / 25 (Hours) 6.44
dersAKTSKredisi 6