Lesson 1Welding processes for ship repairs: SMAW, GMAW/MIG, FCAW, and submerged arc—process selectionThis lesson reviews key welding methods in ship fixes, comparing SMAW, GMAW, FCAW, and SAW for output, reach, position skills, and quality, guiding choices for common structure fixes.
SMAW setup and shipyard applicationsGMAW and MIG variants in repairsFCAW self-shielded and gas-shieldedSubmerged arc for panel renewalsProcess selection decision factorsDistortion and heat input controlLesson 2Corrosion repair for bottom shell plating: local renewals, patch plating, and double-skin/trim patch solutionsThis lesson explains rust damage ways in bottom shell plates and guides picking local renewals, patches, and double-skin fixes, stressing class rules, load routes, water flow, and lasting rust shields.
Corrosion types in bottom shell regionsCriteria for local plate renewalsDesign of insert and patch platesDouble-skin and trim patch conceptsScantling checks and class approvalCoating, anodes, and sealing detailsLesson 3Use of advanced materials and consumables: higher-strength steels, corrosion-resistant alloys, and consumable selectionThis lesson looks at choosing and using stronger steels, rust-proof metals, and welding supplies, focusing on matching power, toughness, rust habits, and joinability in usual ship fix cases.
Grades of higher-strength ship steelsCorrosion-resistant alloys in repairsMatching and overmatching consumablesHydrogen-controlled consumable typesStorage and handling of electrodesDissimilar metal joint strategiesLesson 4Cutting and removal: oxy-fuel, plasma, and CNC/high-precision thermal cuttingThis lesson explains safe and exact removal of damaged parts using oxy-fuel, plasma, and CNC heat cutting, covering tool setup, cut standards, heat zones, and cutting bend and redo work.
Selection of cutting process by taskOxy-fuel cutting setup and safetyManual and mechanized plasma cuttingCNC and template-guided cuttingControl of HAZ and edge qualityDistortion control during removalLesson 5Prefabrication and modular panel replacement: templates, edge preparation and tolerancesThis lesson covers planning and making modular replacement panels, including measure ways, template making, edge readying, allowances, and lining up to cut shipboard fit time and welding bends.
Damage survey and panel mappingTemplate methods and digital scanningShop fabrication and fit-up checksEdge preparation and root gapsDimensional tolerances and fairnessLifting, handling, and positioningLesson 6Weld quality control: welders qualification, NDT acceptance criteria, and repair limitsThis lesson covers weld quality checks in ship fixes, including welder training, procedure rules, NDT ways, approval standards, and fix limits, ensuring structure soundness and rule following.
Welder qualification and continuityVisual inspection and weld gaugesUltrasonic and radiographic testingMagnetic particle and dye penetrantAcceptance criteria and defect limitsRepair welding and reinspection stepsLesson 7Damage assessment to repair decision framework and scope definitionThis lesson gives a planned frame from first damage check to fix choice and scope setting, mixing class needs, risks, costs, stop times, and long-term structure work.
Initial inspection and data collectionUse of NDT and thickness measurementsResidual strength and buckling checksTemporary versus permanent repairsRepair scope and work package definitionCoordination with class and ownerLesson 8Welding procedure specifications (WPS), preheat/postheat, PWHT considerations for common ship steelsThis lesson describes making and checking WPS for ship steels, including pre-heat and pass control, post-heat, and heat treatment choices, noting hydrogen breaks, hardness limits, and class papers.
Essential WPS variables and rangesPreheat and interpass temperature controlPostheat for hydrogen diffusionPWHT need, methods, and limitsHardness and microstructure controlWPS qualification and recordsLesson 9Joint design improvements to reduce stress concentrations and extend fatigue lifeThis lesson focuses on joint design upgrades to cut stress spots and lengthen tiredness life, covering shape changes, soft links, back details, weld shapes, and lining for best load pass.
Assessment of existing joint detailsNotch effects and stress raisersSmooth transitions and tapersBacking bars and run-on tabsOptimized weld profiles and toesAlignment and fit-up tolerancesLesson 10Fatigue crack repair strategies: stop-holes, full-penetration welds, splice plates, doublers and redesign of detailsThis lesson details tiredness crack ways and fix choices, including stop-holes, weld removal, full joins, splice plates, doublers, and detail redesigns to better tiredness life and follow class advice.
Identification of fatigue-prone detailsCrack sizing and monitoring methodsStop-holes and crack arrest drillingFull-penetration weld repair stepsUse of splice plates and doublersDetail redesign to reduce hotspots
