- •Затверджено Методичною радою нтуу “кпі”
- •Module 1 text a
- •1. Learn the following words and word combinations:
- •9. Put the questions to the underlined words.
- •10. Communicative situations:
- •11. Summarize and retell the text. Text b welding: introduction
- •1. Learn the new words and word combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Are the following statements about the text true or false? Why?
- •5. Complete the following sentences:
- •6. Find in the text the English equivalents of the following word combinations.
- •7. Chose the correct definition to the word:
- •8. Fill in the gaps with proper prepositions.
- •9. Put the questions to the underline words or word combinations.
- •10. Communicative situations:
- •11. Make up a summary of the text and use it to retell the text. Text c bending, projection, shearing, staking
- •Exercises
- •1. Learn the following words and word combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Translate from Ukrainian into English.
- •5. Combine the following words to get proper terms:
- •6. Make the nouns from the verbs:
- •7. Put the verbs in brackets in the correct form.
- •8. Fill in the gaps with the proper prepositions.
- •9. Complete the following sentences:
- •Self-assessment module 1
- •4. Give the English equivalents of the words:
- •6. Choose the topic and prepare your mini-presentation:
- •Module 2 text a systems of automatic control of arc welding
- •Exercises
- •1. Learn the following words and word-combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Are the following statements about the text true or false? Why?
- •5. Complete the following sentences choosing the right word in brackets.
- •6. Put the following words in the correct order.
- •7. Put questions to the following answers:
- •8. Find the English equivalents of the following words:
- •9. Find in the text the sentences with Passive Voice.
- •10. Retell the text. Text b electro-slag welding
- •Exercises
- •1. Learn the new words and word combinations:
- •Text c ultrasonic welding
- •Exercises
- •6. Put all possible questions to the following sentences:
- •Self-assessment module 2
- •2.Give the Ukrainian equivalents of the following words and word-combinations:
- •3. Are the following statements true or false?
- •4. Give the definitions to the following words:
- •5. Make up your own sentences using the following words and word combinations:
- •6. Choose the topic and prepare your mini-presentation:
- •Module 3 text a friction stir welding (fsw) of aluminium alloys
- •Exercises
- •1. Learn new words and word combinations:
- •10. Complete the questions on the text.
- •11. Communicative situations:
- •12. Retell the text. Text b plasma
- •Exercises
- •5. Continue the following sentences:
- •6. Fill in the gaps using the following words and word-combinations:
- •7. Find in the text the sentences with Passive Voice.
- •8. Make 10 questions to the text.
- •9. Choose the correct verb form in the following sentences:
- •10. Retell the text. Text c laser welding
- •Exercises
- •1. Learn the following words and word combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Decide, whether the statements below are true or false. Why?
- •5. Put all possible questions to the sentences.
- •6. Choose the correct definition to the word:
- •7. Fill in the gaps with a proper article.
- •Self-assessment module 3
- •2. Make the verbs from the nouns:
- •3. Give the definitions to the following words:
- •4. Are the following statements true or false?
- •5. Give the Ukrainian equivalents of the words:
- •6. Choose the topic and prepare your mini-presentation:
- •Module 4 text a some aspects of corrosion of high-alloy steel
- •Exercises
- •1. Learn the following words and word-combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Are the following statements about the text true of false? Why?
- •5. Fill in the gaps using the following words and word-combinations:
- •6. Put all possible questions to the following sentences:
- •7. Complete the following sentences from the text:
- •8. Put the following verbs in the correct form.
- •9. Find in the text the sentences with the modal verbs. Explain them.
- •10. Put ten questions to the text.
- •11. Retell the text. Text b electric welding of soft tissues in surgery
- •Exercises
- •1. Learn the following words and word combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Combine the following words to receive proper terms:
- •5. Insert the following preposition (in-5,with-2, on-1, by-2, of-4, for-2).
- •6. Give three forms of comparison of the following adjectives:
- •7. Translate from Ukrainian into English.
- •8. Put the verbs in brackets in a proper form.
- •9. Complete the questions on the text.
- •10. Communicative situations:
- •11. Retell the text. Text c thermit welding
- •Exercises
- •1. Learn the following words and word-combinations:
- •2. Read and translate the text.
- •3. Answer the following questions:
- •4. Are the following statements about the text true or false? Why?
- •5. Fill in the gaps using the following words and word-combinations:
- •6. Translate into Ukrainian paying attention to the Participles.
- •Self-assessment module 4
- •2. Give the English equivalents of the following words and word-combinations:
- •3. Are the following statements true or false?
- •4. Read the text. Comment on the advantages and disadvantages of the floating welded mega-structures.
- •5. Choose the topic and prepare your mini-presentation:
- •Appendix
- •2. English proverbs and sayings.
- •Content
2.Give the Ukrainian equivalents of the following words and word-combinations:
Disturbance, weld width, magnetic stirring, groove, blast furnace jacket, source of heat, leap, welding gap, billet, ingot, mould, new in essence, cross-section, plate, bond-zone, sheet separation, feasible, current conductive slag.
3. Are the following statements true or false?
The systems for automatic control can be divided into ten groups.
These systems are rather expensive.
The electric arc process of consumable electrode melting has successfully been used in welding practice for about 100 years.
Electro-slag welding is a very efficient, single pass process carried out in the vertical or near vertical position and used for joining steel plates or sections in thickness of 25 mm and above.
Ultrasonic welding is totally like the fusion welding.
The controls for ultrasonic welding are complex.
The controls for ultrasonic welding are complex.
4. Give the definitions to the following words:
Torch, alloy, appliance, helmet, casting, beam, welder, pipe, jet, heater.
5. Make up your own sentences using the following words and word combinations:
Electrode, influence, source, wire, rate, self-regulation, eliminate, process, consumable, solid, liquid, conductive, substrate layer, diffusion.
6. Choose the topic and prepare your mini-presentation:
“The advantages of the systems of automatic control in welding.”
“The principal risks of ESW.”
“The equipment for ultrasonic welding.”
Module 3 text a friction stir welding (fsw) of aluminium alloys
Nowadays, aluminium alloys are used in many applications in which the combination of high strength and low weight is attractive. Shipbuilding is one area in which the low weight can be of significant value. In fact, the first aluminium boat was built in 1891 and the first welded aluminium ship in 1953.
The two most frequently used aluminium alloys for shipbuilding are AA 5083 for plates and AA 6082 for extrusions. The main alloying element in the 5000 series is magnesium. Magnesium content of around 5% provides good strength and high corrosion resistance in seawater. The 6000 series is mainly alloyed with magnesium and silicon, which results in a hardenable alloy. It is also of interest in many other applications, such as the topside structures of offshore platforms, railway wagons and in the brewing industry.
Mig(metal inert gas) welding is a flexible and productive method and is therefore widely used for welding aluminium alloys in shipbuilding. However, two disadvantages with MIG welding are the deformation of the base material and a decrease in the strength of the heat affected zone. Other fusion welding techniques such as TIG (tungsten inert gas) and plasma welding are also widely used. However these methods have the same weakness as MIG welding. An alternative to other fusion welding methods is recently introduced Friction Stir Welding technique.
The components that are going to be joined are placed on a backing plate and clamped using a powerful fixture. A rotating tool consisting of a specially profiled pin with a shoulder, is forced down into the material until the shoulder meets the surface of the material. The material is thereby frictionally heated to temperatures at which it is easily plasticised. As the tool is moved forward material is forced to flow.
The technique was developed at the beginning of the 1990s and processing technologies has been further developed. The first installation has been used successfully for more than one year for joining long plates and panels, up to 6 m by 16 m. Friction stir welds were produced in AA 5083 and AA 6082 aluminium using different combinations of plate thickness and welding speed.
There is no question that the usage of aluminium is increasing within the welding fabrication industry. Manufacturers often adopt this material either through the innovation, or as a result of pressure applied by their users. The unique characteristics of aluminium – light weight, excellent corrosion resistance, high strength, high toughness, extreme temperature capability, versatility of recycling capabilities – make it one of the current favoured choices of material for many engineers and designers for a variety of welding fabrication applications. Because of the increased use of aluminium as a manufacturing material, the conversion from steel to aluminium within the welding fabrication industry is becoming increasingly common. The successful conversion from steel to aluminium welding is largely dependent on an understanding of the fundamental differences between these two materials. The most common problems encountered when changing to aluminium welding are feedability, porosity, cracking and filler alloy selection.
Most unprotected aluminium base alloy or filler alloy combinations are quite satisfactory for general exposure to the atmosphere. In cases in which a dissimilar aluminium alloy combination of base and filler is used, and electrolyte is present, it is possible to set up a galvanic action between the dissimilar compositions. Corrosion resistance can be a complex subject when it comes to service in specialized highly- corrosive environments and may necessitate consultation with engineers.
Although the practical application of the FSW technique has been successful, there is still a lack of design data and understanding of the failure mechanisms. Much of the micro structural knowledge of friction stir welds is at embryonic stage.