Lesson 1Welding processes for ship repairs: SMAW, GMAW/MIG, FCAW, and submerged arc—process selectionLooks back at main joining ways used in ship fixes, comparing stick, gas wire, flux wire, and sand join for work speed, get-in, place ability, and quality, guiding choice for usual structure fixes.
Stick setup and yard usesGas wire and MIG types in fixesFlux wire no-gas and gas typesSand join for panel new onesChoice decision factorsBend control and heat putLesson 2Corrosion repair for bottom shell plating: local renewals, patch plating, and double-skin/trim patch solutionsExplains rust damage ways in bottom skin plates and guides choice of local new, patches, and double-skin fixes, with focus on rules, load ways, water out, and long rust protection.
Rust types in bottom skin areasRules for local plate newDesign of insert and patch platesDouble-skin and edge patch ideasSize checks and rule okayPaint, blocks, and seal partsLesson 3Use of advanced materials and consumables: higher-strength steels, corrosion-resistant alloys, and consumable selectionLooks at choice and use of stronger steels, rust-stop alloys, and join supplies, focusing on matching strength, bend, rust way, and join-ability in usual ship fix cases.
Types of stronger ship steelsRust-stop alloys in fixesMatching and over suppliesHydrogen-stop supply typesStore and handle of sticksDifferent metal join plansLesson 4Cutting and removal: oxy-fuel, plasma, and CNC/high-precision thermal cuttingExplains safe and true removal of damaged parts using gas fire, plasma, and machine heat cut, dealing with tool setup, cut good, heat zones, and less bend and re-do.
Choice of cut way by jobGas fire cut setup and safeHand and machine plasma cutMachine and guide cutControl of heat zone and edge goodBend control in removalLesson 5Prefabrication and modular panel replacement: templates, edge preparation and tolerancesCovers planning and making block new panels, including measure ways, template make, edge ready, allowed space, and line up to less on-ship fit time and join bend.
Damage check and panel mapTemplate ways and computer scanShop make and fit checksEdge ready and base gapsSize allowed and smoothLift, handle, and placeLesson 6Weld quality control: welders qualification, NDT acceptance criteria, and repair limitsCovers join quality watch in ship fix, including joiner okay, join plan follow, test ways, okay rules, and fix limits, making sure structure strong and rules match.
Joiner okay and keepLook check and join measuresSound and x-ray testMagnet particle and color dyeOkay rules and problem limitsFix join and recheck stepsLesson 7Damage assessment to repair decision framework and scope definitionGives a planned frame from first damage check to fix choice and job size, mixing rule needs, risk, cost, stop time, and long structure work.
First check and data getUse of test and thick measuresLeft strength and bend checksTemp vs long fixesFix size and job pack defineWork with rule and ownerLesson 8Welding procedure specifications (WPS), preheat/postheat, PWHT considerations for common ship steelsDescribes making and okay of join plans for ship steels, including warm before and between, after heat, and heat treat after, with care to hydrogen break, hard limits, and rule papers.
Key join plan changes and rangesWarm before and between temp controlAfter heat for hydrogen moveHeat treat after need, ways, and limitsHard and small structure controlJoin plan okay and papersLesson 9Joint design improvements to reduce stress concentrations and extend fatigue lifeFocuses on join design better to less stress build and make tiredness life longer, covering shape changes, soft turns, back parts, join shapes, and line up to best load move.
Check of old join partsNotch effects and stress upSmooth turns and slopesBack bars and start tabsBest join shapes and endsLine up and fit allowedLesson 10Fatigue crack repair strategies: stop-holes, full-penetration welds, splice plates, doublers and redesign of detailsDetails tiredness crack ways and fix choices, including stop holes, join remove, full join, splice plates, add plates, and redesign parts to better tiredness life and match rule guide.
Find tiredness weak partsCrack measure and watch waysStop holes and crack stop drillFull join fix stepsUse of splice plates and addsPart redesign to less hot spots
