Lesson 1Welding processes for ship repairs: SMAW, GMAW/MIG, FCAW, and submerged arc—process selectionThis lesson reviews primary joining methods in ship fixes, contrasting SMAW, GMAW, FCAW, and submerged arc for efficiency, reach, position use, and standards, aiding choice for standard structure work.
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 describes rust harm in lower hull plates and directs choices for spot replacements, patches, and dual-layer fixes, stressing guidelines, force routes, water flow, and lasting rust defense.
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 studies picking and applying stronger steels, rust-proof metals, and joining supplies, stressing matching power, durability, rust traits, and joinability in common 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 secure and exact removal of harmed parts using gas, plasma, and computer-controlled heat cutting, covering tool setup, cut standards, heat zones, and cutting bend and extra 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 addresses planning and making pre-built replacement sections, including sizing ways, pattern making, edge readying, limits, and fitting to cut shipboard time and join 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 join quality checks in ship fixes, including worker certification, procedure following, testing methods, approval standards, and fix bounds, ensuring framework soundness and rule adherence.
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 offers a planned path from first harm check to fix choice and range setting, blending rule needs, danger, expense, stop time, and lasting framework output.
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 outlines creating and certifying join procedures for ship steels, covering warm-up and pause controls, after-heat, and heat treatment choices, noting gas cracks, hardness caps, and rule 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 stresses join design upgrades to lessen stress points and lengthen wear life, covering shape shifts, smooth links, support details, join shapes, and lining for best force 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 covers wear crack ways and fix choices, including hole stops, join removal, deep joins, link plates, extra layers, and detail redesigns to boost wear life and follow rule 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
