The Ohio State University
Welding Engineering Program

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WE601 Welding Applications

Well, you have made it through most of the introductory courses in welding engineering!  You have studied about a lot of different welding processes, you have designed some structures, and you have selected materials for making those structures.  But what happens when things go wrong?  Can you do a failure analysis on broken parts to determine what went wrong and recommend how to fix it or keep it from failing again?  That is what we are going to do in this welding applications class.  But first we need to talk about a couple of more welding processes which have not yet been emphasized much.  These processes are solid state bonding and resistance welding.  Once that is done, you will be placed in a group to start your own “welding engineering consulting company”.  Your company will be given some failures and you must help us fix the problems.  Good Luck!



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Course Objective

This course is designed for 3rd year welding engineering students who have had previous courses in welding processes, physics of welding, chemistry of welding, electronics of welding, engineering design and engineering materials.  WE601 is designed to begin the process of tying all these concepts into an engineering package.


Learning Outcomes

  • Understand the relationship between atomic bonding mechanisms and cold welding

  • Understand the importance of surface barriers to the production of good cold and resistance welds

  • Be able to recommend surface cleaning techniques to improve bonding processes.

  • Be familiar with a variety of cold bonding techniques and the parameters required to obtain acceptable welds.

  • Understand the relationship between material properties and cold bonding processes for sound weld production

  • Understand the factors effecting heat generation in resistance  welding

  • Understand heat balance problems and solutions in resistance

  • Be aware of various forms of resistance welding processes

  • Understand the welding power supply control mechanisms in resistance welding

  • Have an introductory understanding of resistance welding monitoring and feedback control.

  • Understand techniques used for failure analysis and proposing of corrective actions

  • Understand the relationship between materials process and design in welded structural failures

  • Experience team work in the process of examining failures.

  • Be able to report the results of failure analysis and make corrective recommendations.



  • Solid State Welding

  • Atomic Bonding / Free Energy

  • Surfaces - Barriers to Bonding

  • Surface Cleaning

  • Cold Welding  - Roll Bonding

  • Friction Welding

  • Ultrasonic Welding

  • Diffusion Welding

  • Hot Isostatic Pressure Welding

  • Explosion Welding

  • Resistance Welding

  • Heat Generation

  • Welding Applications

  • Power Supply Control

  • Application Class Case Studies (selected from)

    • Structural Steel Fabrication, Transportation Equipment, Pressure Vessel, Shipbuilding, Offshore Equipment, Aerospace, Mechanical Equipment, Refinery and Piping Equipment





Learning Resources


  • Course Notes - Resistance & Welding Applications


  • Welding Handbook, Vol.1, Welding Technology, American Welding Society, 1987

  • The Procedure Handbook, Lincoln Arc Welding Foundation


Schedule Information

SP Qtr. 3 classes/week

Course Lectures


Atomic Bombing free energy

Surfaces barriors and cleaning
Cold Welding
Friction Welding
Ultrasonic Welding
Diffusion Welding
Spot Welding
Other Processes
Power Supply Control
Heat Balance


Instructor Info

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David W. Dickinson


Phone: (614) 292-0801

Link to Bio-Sketch

Teaching and Research Interests:

Resistance Welding, Welding Metallurgy, Welding Project Management, Welding Production, Sensing and Control of Welding Processes, Welding Fume and Noise Studies, Educational Technology Development, Continuous Quality in Manufacturing and Educational Environments


Rensselaer Polytechnic Institute Troy, New York

B.S. Materials Engineering, 1967

Ph.D. Materials Engineering, 1972

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Last edit: 03/10/2003

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