Welding Process, Inspection and Metallurgy: 5-Day Advanced Professional Training Course

Course Overview

This comprehensive 5-day advanced welding course integrates welding process engineering, metallurgical principles, and weld inspection methodologies designed for professionals across Saudi Arabia (KSA), Oman, UAE, Qatar, Kuwait, Bahrain, and African industrial markets. This program delivers critical expertise in welding metallurgy, non-destructive testing (NDT), quality assurance, and failure analysis essential for oil and gas, petrochemical, power generation, construction, and manufacturing sectors throughout the GCC region and Africa.

Target Audience

• Welding inspectors and quality control engineers in KSA and GCC industries

• Metallurgical technicians working in Oman manufacturing and African mining sectors

• Welding engineers designing procedures for Saudi Aramco and ADNOC projects

• NDT technicians requiring advanced inspection certification across Middle East

• Maintenance supervisors overseeing critical infrastructure in GCC countries

• Project managers responsible for fabrication quality in African construction

Day 1: Welding Metallurgy Fundamentals and Material Science

Morning Session: Material Science for Welding Applications

• Atomic structure and bonding mechanisms in metallic materials

• Crystal structures: BCC, FCC, HCP and their impact on weldability

• Phase diagrams interpretation: Iron-Carbon equilibrium diagram analysis

• Microstructural components: ferrite, austenite, pearlite, martensite, bainite

• Heat treatment fundamentals: annealing, normalizing, quenching, tempering

• Mechanical properties: tensile strength, hardness, toughness, ductility testing

• Material specifications common in GCC projects: ASTM, ASME, API standards

Afternoon Session: Weldability and Heat-Affected Zone (HAZ)

• Weldability assessment criteria for carbon steels, alloy steels, stainless steels

• Heat-affected zone (HAZ) characteristics and microstructural transformations

• Welding thermal cycles and cooling rate calculations

• Grain growth mechanisms and coarsening effects on mechanical properties

• Preheating and post-weld heat treatment (PWHT) requirements

• Carbon equivalent formulas (CE, Pcm) for crack susceptibility prediction

• Hydrogen-induced cracking prevention in high-strength steel applications

• Material selection for Saudi petrochemical plants and African pipeline projects

Learning Outcomes: Deep understanding of metallurgical principles governing weld joint performance in critical GCC infrastructure and African industrial applications.

Day 2: Advanced Welding Processes and Process Variables

Morning Session: Arc Welding Process Metallurgy

• Submerged Arc Welding (SAW): high-deposition applications in pressure vessel fabrication

• Shielded Metal Arc Welding (SMAW) metallurgy: electrode coating effects

• Gas Metal Arc Welding (GMAW): metal transfer modes and microstructure control

• Gas Tungsten Arc Welding (GTAW): precision welding for aerospace and nuclear applications

• Flux-Cored Arc Welding (FCAW): slag-metal reactions and alloy transfer

• Welding consumable selection per AWS A5 specifications and Saudi Aramco requirements

• Shielding gas metallurgy: oxidation prevention, nitrogen pickup, porosity control

Afternoon Session: Specialized Welding Processes

• Resistance Welding (RSW): automotive and manufacturing applications across GCC

• Friction Stir Welding (FSW): solid-state joining for aluminum in African industries

• Laser Beam Welding (LBW): high-precision applications in Oman manufacturing

• Electron Beam Welding (EBW): vacuum welding for critical aerospace components

• Plasma Arc Welding (PAW): keyhole and melt-in modes for specialized applications

• Welding process selection matrices for different materials and service conditions

• Economic analysis of welding process selection for African infrastructure projects

• Process parameters optimization: current, voltage, travel speed, heat input control

Learning Outcomes: Comprehensive knowledge of welding process metallurgy and optimal process selection for diverse GCC and African industrial requirements.

Day 3: Welding Defects, Discontinuities and Failure Analysis

Morning Session: Weld Discontinuities Classification

• Planar vs volumetric defects: criticality assessment for structural integrity

• Porosity types: gas porosity, wormholes, cluster porosity, root causes

• Incomplete fusion and penetration: joint design and procedure issues

• Cracks classification: hot cracks (solidification, liquation) vs cold cracks (hydrogen)

• Lamellar tearing in thick plate T-joints for offshore structures

• Undercut, overlap, and slag inclusions: formation mechanisms and prevention

• Spatter and arc strike damage: acceptance criteria per ASME Section VIII

• Reheat cracking in Cr-Mo steels used in GCC power generation plants

Afternoon Session: Metallurgical Failure Analysis

• Fracture mechanics fundamentals: brittle vs ductile failure modes

• Stress corrosion cracking (SCC) in Arabian Gulf marine environments

• Fatigue failure analysis: cyclic loading in offshore platforms and African bridges

• Corrosion mechanisms: uniform, pitting, crevice, galvanic corrosion in welds

• High-temperature failures: creep, oxidation in refinery equipment

• Case studies: weld failures in Saudi industrial facilities and African mining operations

• Root cause analysis methodology and corrective action implementation

• Metallographic examination techniques: specimen preparation, etching, microscopy

Learning Outcomes: Expert-level defect recognition and failure analysis capabilities essential for quality assurance in high-stakes GCC and African projects.

Day 4: Non-Destructive Testing and Weld Inspection Methods

Morning Session: Visual and Surface Inspection Techniques

• Visual weld inspection (VT): systematic examination per AWS D1.1 and ASME B31.3

• Inspection tools: weld gauges, fillet gauges, Hi-Lo gauges, magnifiers

• Surface preparation and cleanliness requirements before inspection

• Liquid Penetrant Testing (PT/DPT): fluorescent and visible dye methods

• Magnetic Particle Testing (MT): wet fluorescent and dry powder techniques

• Surface crack detection in carbon steel structures across KSA construction sites

• Acceptance standards: workmanship vs fitness-for-service criteria

• Documentation requirements for Saudi Aramco contractor approval

Afternoon Session: Volumetric Inspection Methods

• Radiographic Testing (RT): X-ray and gamma-ray imaging principles

• Film interpretation: porosity, cracks, lack of fusion identification on radiographs

• Ultrasonic Testing (UT): pulse-echo technique, A-scan interpretation

• Phased Array Ultrasonic Testing (PAUT): advanced inspection for pipeline girth welds

• Time-of-Flight Diffraction (TOFD): accurate crack depth sizing

• Eddy Current Testing (ECT): heat exchanger tube inspection applications

• Inspection frequency and sampling plans per API 570 and API 510

• Digital radiography and computed tomography in modern GCC facilities

Learning Outcomes: Comprehensive NDT knowledge enabling certification pathways (ASNT Level II/III, PCN) for high-demand inspection careers in Middle East and Africa.

Day 5: Welding Codes, Standards and Quality Management

Morning Session: International Welding Standards

• ASME Boiler and Pressure Vessel Code (BPVC): Section II (Materials), VIII (Pressure Vessels), IX (Qualifications)

• AWS Structural Welding Codes: D1.1 (Steel), D1.2 (Aluminum), D1.6 (Stainless)

• API Standards: API 1104 (pipelines), API 653 (storage tanks), API 510 (pressure vessels)

• ISO 3834: Quality requirements for fusion welding of metallic materials

• EN Standards: European compliance for GCC export-oriented manufacturers

• Saudi Aramco Engineering Standards (SAES): mandatory requirements for KSA projects

• ADNOC specifications: welding requirements for UAE oil and gas sector

• African standards harmonization: ARSO guidelines for regional projects

Afternoon Session: Quality Management and Welding Coordination

• Welding Procedure Specification (WPS) development and qualification

• Procedure Qualification Record (PQR): essential and supplementary variables

• Welder Performance Qualification (WPQ): testing and recertification requirements

• Welding Procedure Data Sheet (WPDS) for production control

• International Welding Engineer (IWE) and International Welding Inspector (IWI) certifications

• Quality control plans for African infrastructure megaprojects

• Traceability systems: material certificates, welding consumables, welder identification

• Pre-qualification programs for Saudi contractor approval

• Practical workshop: WPS writing exercise for pressure piping application

• Final examination and course certification

Learning Outcomes: Mastery of codes, standards, and quality systems required for compliance in GCC regulatory environments and international African projects.

Course Benefits for GCC and African Professionals

✓ Industry-recognized certification aligned with Saudi Aramco, ADNOC, SABIC requirements
✓ Advanced metallurgical knowledge for materials used in Middle East extreme environments
✓ NDT competency preparation for ASNT, PCN, CSWIP certification exams
✓ Practical failure analysis skills reducing downtime in African mining and GCC petrochemical operations
✓ Career advancement to welding engineer, QC manager, inspection supervisor roles
✓ Bilingual technical training (English/Arabic) for regional accessibility

Investment in Professional Excellence

This advanced welding course addresses the critical skills gap in quality assurance and engineering positions across Saudi Arabia’s Vision 2030 industrial diversification, Oman’s manufacturing expansion, UAE’s aerospace sector, and African infrastructure renaissance. Certified professionals command premium salaries (SAR 8,000-20,000 monthly in KSA) and enjoy exceptional career mobility across oil and gas, power generation, shipbuilding, and construction sectors throughout the Middle East and Africa.

Register now to elevate your expertise and secure leadership positions in the GCC’s booming industrial economy and Africa’s emerging markets!

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