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  #
(1) Importance of Welding Technology
(2) Global Welding Technology Till To-date
(3) Welding Technology & Challenges in Malaysia
a) Ways forward with welding Technology & NDE in Malaysia

b) What Welding Codes to follow in Malaysia?

c) Certification of Qualified Welders & Welding Inspectors

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    (

The a

 brought advances in 

, in
which blacksmiths pounded & heated metal repeatedly
until bonding occurred.
Globally & generally, development of welding technology
and welding processes in general is very slow.

`

`
 caused a major surge in the use of welding
processes; with the various military powers attempting to
determine which of the several new welding processes
would be best.
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Cont¶d Advancement of Welding Technology

To cope with the industrial demands, welding can be done in many

different environments, including 
, 

 
and in 

 .

Regardless of locations, however, welding remains dangerous, and

precautions must be taken to avoid 
, 
 , 

,
   
, and over-exposure to 
  .



 and 
 were among the first processes to
develop late in the century (20th Century), and
  

followed soon after.
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Cont¶d Advancement of Welding Technology

Welding was gradually transformed during the 1ðth century

a) In 1m00, 


  discovered the 


.

b) In the late 1m00s, a Russian,        invented
 



 ± this continues the advancement in arc welding.
c) In 1m3], 


  discovered , but its use was not
practical in welding until about 1ð00, when a suitable  

was developed.

d) Followed by an American, !
!  , with 

 

,
which used a carbon electrode, gained popularity.
10
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Cont¶d Advancement of Welding Technology

e) In 1mð3, R


 was invented and, the first patents
went to  R
  who produced further advances over the
next 1± years.
f) Around that time another process, 
, became well
established. At first, oxyfuel welding was one of the more popular
welding methods due to its portability and relatively low cost.

g) Around 1ð00,   



released a  

 


in Britain, which gave a more stable arc.

h) In 1ð1ð, !     invented 

  

 for welding,
but did not become popular for another decade.
11
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Cont¶d Advancement of Welding Technology

 
  became a subject receiving much attention,

to protect welds from the effects of oxygen and nitrogen in
the atmosphere. 
  and 
 were the primary
problems, and the solutions that developed included the use
of
 , and  
as welding atmospheres.

During the 1ð20s, major advances were made in welding

technology, including the introduction of 
 

, in which electrode wire was fed continuously.

12
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Cont¶d Advancement of Welding Technology

During the `

`
 , further advances allowed for the welding of
reactive metals like 
 
and
 
. This in conjunction
with developments in 
 
, 
  

, and
 led to a major expansion of 
 .

As the 20th century progressed, it was largely replaced with arc

welding, as
  
 (known as ) for the electrode that
stabilize the arc and shield the base material from impurities
continued to be developed.

Many different 
 
 can be used for welding, including a
 
, an 

, a  
, an 

, 
 , and

 
.
13
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)* 
 


+(


+(
 # a detailed, precise, explicit presentation of a plan
or proposal
# a set of rules of procedures and standards of materials
designed to secure uniformity and to protect the public
interest.
+

# something that is established by authority, custom or
general consent as a model or example to be followed.
)# an accepted procedure, custom or habit having the force
of a regulation.
Organizations that write codes( AWS, AISC, ASME, API, SAE
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Cont¶d Advancement of Welding Processes

During 20th century, many new welding methods were invented.

(a) In 1ð30, the release of 

, which soon became
popular in shipbuilding and construction.
(b) 




 (SAW) was invented the same year
(i.e. 1ð30) and continues to be popular today.

(c)  


 (GTAW), after decades of
development, was finally perfected in 1ð'1

(d)  
 

 (GMAW) followed in 1ð'm, allowing
for fast welding of  



 but requiring
expensive shielding gases. 1]
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Cont¶d Advancement of Welding Processes

(e)  


 

 (SMAW) was developed during
the 1ð±0s, using a flux coated consumable electrode, and it
quickly became the most popular metal arc welding process.
(f) In 1ð±V, the 



 (FCAW) process debuted,
in which the self-shielded wire electrode could be used with
automatic equipment, resulting in greatly increased welding
speeds.
(g) In the same year,  


 (PAW) was invented.

(h) 
 
 (ESW) was introduced in 1ð±m, and it
was followed by its cousin, 
 
 (EGW) in
1ð]1. 1V
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Cont¶d Advancement of Welding Processes

From ]0s onwards, several modern welding techniques were developed.

(1) Manual methods ± Shielded Metal Arc Welding (SMAW), now one of
the most popular welding methods until today.

(2) Semi-automatic and automatic processes

± Gas Metal Arc Welding (GMAW)
± Submerged Arc Welding (SAW)
± Gas Tungsten Arc Welding (GTAW)
± Flux-Cored Arc Welding (FCAW)
± Plasma Arc Welding (PAW)
± Electroslag Welding (ESW)
1m
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Cont¶d Advancement of Welding Processes

Developments continued with the invention of Laser Beam Welding
(LBW) and Electron Beam Welding (EBW) in the latter half of the
century.
± Both have proved to be especially useful in high-speed, automated
welding
± Both of these processes continue to be quite expensive due the high cost
of the necessary equipment, and this has limited their applications

Today, the science continues to advance.

Robot welding (vs. Automatic and/or Mechanised Welding) is becoming
more commonplace in industrial settings, and researchers continue to
develop new welding methods and gain greater understanding of weld
quality and properties.
1ð
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| 




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..Cont¶d Challenges in Welding Technology in 21st Century in Malaysia

a) During V0s & m0s, mainly manual welding processes being used
b) During ð0s, mechanized and automatic welding processes begin
to take their roles for onshore fabrication
c) Until late ð0s and towards 21st Century, Oil & Gas Industries
embark to venture into deepwater projects ± automatic welding
for on-site fabrication and AUT for fast and accurate weld
quality check gain their importance
± Difficult to employ long-term qualified welders
± Consistency in reproducing high quality welds
± Short/tight schedule granted for fabrication work
± High oil prices encouraging more field development 21
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‡ .
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..Cont¶d Challenges in Welding Technology in 21st Century in Malaysia


 
     
  



    





0 ,
1!
 


  ± Manipulated by hand


  
0  ± Wire Feed is Mechanized
  
0  ± All main operations are Mechanized,
except Handling of Work Pieces
!
  ± All Operations are Mechanized
)%  ± Using a Manipulator to programme to different welding
directions and fabrication geometries.
23
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Cont¶d Challenges in Welding Technology in 21st Century in Malaysia

 
 



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Cont¶d Challenges in Welding Technology in 21st Century in Malaysia

. &
,'

 2.3
+
 # VTI, DPI, MPI, EMI
+%

 # gradually taken over by UT; and AUT also
replacing conventional RT

(' 

 # e.g. valves, nozzles; Computed
Radiography (CR)

!
/

  *
2!/3
Promising !/( ToFD + Focused Pulse Echo (PE) ± good for
ECA application (can lead to a substantial reduction in repair rate compared with
radiography, ~ <1% is achievable)
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.&&!/ *

.
The field of Non-Destructive Testing (NDT) in weld testing and
inspection is advancing rapidly through the innovations of
Automated Ultrasonic Testing (AUT) technology.
AUT technology has replaced radiographic inspection techniques as
the NDT industry standard system for the testing and inspection of
pipeline welding.
± AUT examination for girth welds of new construction onshore,
cross-country and offshore pipelines.
± AUT in terms of its design, efficiency and high level of
detection and accuracy.
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!,


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( #
23 +
 # The radiation hazard is eliminated.
23  ,  
# Processing chemicals and waste are eliminated
243 ! 

 # The management of safety systems, licensing and other
paperwork is reduced.
253 6

# The movement of radioactive isotopes especially by air has
become increasingly difficult. No consumables such as film or chemicals are
required. Handling of records is easier, and longer archival lives are
achieved.
273 | 
(*( # All AUT equipment is external, thus no crawlers
or stop trolleys are required.
283 # The cycle time is less than that required for radiography.
293  
# AUT allows defect height to be sized, whereas radiography
presents a two-dimensional image. AUT is a more reliable method for
detection of planar defects.
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(a) Non-Focused Pulse Echo( no good for ECA application
(b) ToFD + Focused Pulse Echo (PE)
(c) Phased Array( multiple wave forms from one transducer ('m
elements), main factor affecting is (
.
23 


 !/#
‡ Pipe surface condition
‡ Wall thickness variation
‡ Difficult to inspect for bevel joint( avoid Vo ± 2Vo;
i.e. <±o is the best angle
‡ Changes of materials through a weldment and by the large
grains (e.g. CRA). 2m
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111
- Welding procedure qualification test (WPQT)
- Welding Procedure Specification (WPS)
- Welding Procedure Qualification Record (WPQR/WPAR)
- Welder Qualification Test (WQT)

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Cont¶d Challenges in Welding Technology in 21st Century in Malaysia


 <

:


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1 ;(


‡ Welders¶ Qualification ± basically remain following the
conventional approach
‡ Need to be trained and know to handle welding equipment

‡ Extra training and knowledge to master computerised systems

‡ Tracking welders¶ qualification and validity

‡ r

, iMOS initiated by AWF supported by 13 Asian
countries; China, India, Indonesia, Iran, Japan, Korea, Malaysia,
Mongolia, Myanmar, Philippines, Singapore, Thailand, Vietnam,.
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Requires skilled labour to make good welds

Melting of flux coating forms gas and slag to protect the weld pool from oxidation
Limited productivity - frequent need to replace electrode
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Continuous welding wire on spool

Requires skilled labour
Welding sets are precision equipment 3V
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The iron pillar at Delhi has attracted
the attention of archaeologists and
corrosion technologists as it has
withstood corrosion for the last 1]00
years.

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