Lesson 1Welding processes for ship repairs: SMAW, GMAW/MIG, FCAW, and submerged arc—process selectionThis lesson reviews key welding methods for ship fixes, comparing SMAW, GMAW, FCAW, and SAW for speed, access, positions, and quality, and helps pick the best for common structure repairs.
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 in bottom plating and guides choices for local fixes, patches, and double-skin options, stressing class rules, load flow, drainage, and lasting rust protection.
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 checks picking and using stronger steels, rust-proof alloys, and welding fillers, matching strength, toughness, rust resistance, and weld ease for ship repair jobs.
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, precise removal of damaged parts using oxy-fuel, plasma, and CNC cutting, covering setup, cut quality, heat effects, and reducing bends 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 panels, using measurements, templates, edge prep, tolerances, and fit to cut shipboard 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 checks in ship repair, including welder tests, procedure rules, NDT methods, pass limits, and fix caps to ensure strong builds and rule compliance.
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 clear path from damage checks to repair plans and scope, mixing class needs, risks, costs, downtime, and long-term strength.
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 testing WPS for ship steels, covering preheat, postheat, and heat treatment choices, watching for cracks, hardness, 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 better joint designs to cut stress points and boost fatigue life, using shape changes, smooth joins, backs, weld shapes, and alignment for good load sharing.
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 fatigue crack causes and fixes like stop-holes, weld removal, full welds, splice plates, doublers, and redesigns to lengthen life and meet 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
