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Modular Learning Systems (Modules)
Modules can be purchased online at or by calling 1.800.844.6790

Module 1 - Welding Health & Safety 
Protect yourself and your company with this module designed to work in conjunction with your local code. Learn a general awareness of health and safety aspects related to welding and similar processes. Items specific to hazards, noise, safety practices for welding and cutting, WHMIS, electrical shocks, protective clothing and devices, fume generation and ventilation, and welding and cutting in confined spaces are covered.

Module 2 - Engineering Drawings, Basic Joints & Preparation for Welding
This module provides an overview of material preparation for welding and how this is detailed on engineering drawings and blue prints. The reader will have an understanding of the basic joints and weld types used for welded connections. The remainder of the module focuses on the terminology for welding, cutting and preparation of joints and describes the various methods used by fabricators and manufacturers.

Module 3 - Symbols for Welding
This module is designed to be used by all levels within a fabricating environment to understand the basic language of welding and fabricating. The user will have the understanding and knowledge to create and interpret welding symbols for fillet welds, groove welds, plug and slot welds as well as spot, seam and stud welds. The symbols for brazing and nondestructive examination symbols are reviewed also.

Module 4 - Welding Processes and Equipment
After reviewing the content the user will have a firm understanding of the five main welding processes, the equipment and how operating variable effect their operation. In addition several other processes such as plasma arc, laser and electron beam welding are reviewed to give the reader a broad understanding of welding and joining technology available for all types of fabricators and manufacturers.

Module 5 - Power Sources for Arc Welding
This module provides a detailed description of how the modern welding machine operates and how from its operation you can maximize its effectiveness on the shop floor. The module covers basic electrical principles, characteristics of the welding arc, equipment design, control systems, arc starting systems, pulse controls, and how to select the correct power source for your application.

Module 6 - Electrodes and Consumables
This module will acquaint the reader with the major types of electrodes and consumables available for use, and describe their major characteristics. The modules details the major North American Standards - CSA and AWS used to classify consumables and describes the functions of alloying elements, flux compositions and the requirements of the specific classification standards.

Module 7 - Welding Distortion and Residual Stress
This module focuses on how welding causes distortion and residual stress in fabricated assemblies. The causes of distortion are reviewed and the reader gains a better understanding of how welded assemblies react during the fabricating process. Preventative and corrective actions for controlling distortion and residual stresses in welded assemblies are also reviewed showing the various jigs, fixtures and methods for control during welding.

Module 8 - Basic Steel Metallurgy and Material Specification
This module will give a foundation for understanding the effects of welding on metals and the various metallurgical phenomena that occur in the welds. The topics covered include how steels are made, the microstructures that make up steels, how heating and cooling effect the properties of steel and how steels are classified. This is the foundation of other metallurgical principles needed to understand how steels react to welding.

Module 9 - Introduction to Welding Metallurgy
This module expands on metallurgical concepts, and focuses on the development of sound welding procedures to provide adequate metallurgical properties to the welded assemblies. Heat flow , crack formation, metallurgical transformations associated with welding and the effects of Hydrogen on the weld are discussed to provide the user with sound metallurgical principles to create effective welding procedures.

Module 10 - Weld Faults and Causes
This module will assist individuals in identifying typical weld defects and explain their causes and the corrective action to resolve defective welds. The module breaks down the defects into their major types - Dimensional, Structural Discontinuities and Defective properties. Each section provides descriptive and pictorial descriptions of the defects their causes and what can be done to correct them.

Module 11 - Basic Inspection Technology
This module provides the reader with a general overview of weld inspection techniques. A general description of visual inspection, radiography, magnetic particle (MPI), ultrasonic(UT), liquid penetrants (LPI) and acoustic emission are reviewed. After completing this module users will have be in a position to understand the basics of the inspection methods and interpret the information provided by an Inspector on a weld inspection report.

Module 12 - Mechanical Testing of Welds
The reader will review and understand the basic principles of destructive testing of welds. This module reviews the methods of testing and the information obtained from Tension Testing, Guided Bend Tests, Nick-Break Testing, Hardness Testing Toughness Testing including Charpy Impact Tests, and Drop Weight Tests. After this review the reader will have a working understanding of the principles of mechanical testing used to evaluate weld quality.

Module 13 - Codes and Standards
Standards play a key role in the performance and output of today’s fabricators. Most welding personnel, supervisors, engineers and inspectors are in daily contact with references to wide variety of codes and standards, and a clear understanding of their purpose, origin and use is essential. This module has been developed to provide overviews and a general understanding of many of the welding related standards that welding professionals encounter on a daily basis.

Module 14 - Basic Concepts of Quality
Quality forms the basis of any successful operation or product. From the earliest of time quality has played a major role in the development of technology and society. This module provides the user with an overview of the ISO 9000 Standard and provides specific examples of how this would relate to welding operations. The module looks at quality control versus quality assurance, prevention of mistakes and the steps necessary to achieve registration.

Module 15 - Functions of the Inspector
The functions and responsibilities of an Inspector can be wide ranging. The Inspector can be employed on a full time basis or as a third party role. This module defines the roles of an Inspector and reviews the key responsibilities such as verifying operations, checking qualifications of individuals and the use of approved procedures. The module provides a road map to the inspector of the basic tasks.

Module 16 - Techniques of Visual Inspection
This module reviews the wide range of techniques in the inspection of welds, and welded products traditionally used for “visual” inspection. The reader will be introduced to the equipment used, sources of measurement errors, control and verification distortion, weld dimension verification and recognition of weld faults such as undercut, cracks and their acceptance criteria.

Module 17 - Surface Inspection
Surface inspection methods are not complex, but a firm understanding of their application and types of defects that they can detect are key to the successful inspection of a weld. After reviewing this module the reader will have a sound understanding of the principles of Liquid Penetrans (LPI), Magnetic Particle (MPI), and other methods such as Eddy Current and Leak Testing used to inspect welds.

Module 18 - Radiographic Inspection
This module is designed to provide a more detailed review of the radiographic inspection process. Many welding professionals will be introduced to this inspection method during their careers and this module will give the user a firm understanding of how it is applied, what defects can be detected and what techniques can be employed for various applications. In addition the basic safety practices are also reviewed.

Module 19 - Ultrasonic Inspection
This module is designed to provide a more detailed review of the ultrasonic inspection process. Many welding professionals will be introduced to this inspection during their careers and this module will give the user a firm understanding of how it is applied, what defects can be detected and what techniques can be employed for various applications. The reader will also be introduced to critical parameters for successful application.

Module 20 - Structure and Properties of Metals
This module is not specific to any one metal but covers metals in general, emphasizing the relation between the metal’s fundamental properties and its welding behaviour. The structure of metals and how these effect the way metal reacts to welding are discussed. Alloying of metals and how information can be extracted from Phase Diagrams is also reviewed.

Module 21 - Welding Metallurgy of Steels
This module expands on some of the basic principles discussed in Modules 8, 9, and 20 to provide the user with information to make welding decisions that will influence the final weld properties. The effects of carbon, thickness and work hardening, grain size of steels are reviewed as well as the Heat Affected Zone (HAZ) properties produced from welding. The effects of stress relieving and heat treatment of welded components are also reviewed.

Module 22 - Welding Metallurgy of Stainless Steels
Most stainless steels are readily welded, but only if the correct consumable and procedure are used. The special properties of stainless steel allow it to be used in a wide variety of aggressive environments. The incorrect welding of this material can lead to rapid corrosion and potentially early failure. This module will provide the user with the information necessary to make sound welding decisions relating to stainless steel fabrication.

Module 23 - Welding Metallurgy of Non-Ferrous Metals and Cast Iron
Non-ferrous metals play an important role in modern engineering applications. Although not welded in the same quantities as steel the understanding of their welding behaviour is essential for their effective implementation. This module will provide the user the major problems associated with welding these materials and the key elements of a welding procedure for successfully joining non-ferrous and cast irons.

Module 24 - Aluminum Welding, Materials and Metal Preparation
This module provides an overview of the common processes used in the fabrication of Aluminum Components. The module provides a general description of common aluminum alloys and then reviews the methods required to effectively prepare and pre-assembly aluminum assemblies for welding. The module also reviews the importance of maintaining the preparation equipment used exclusively for aluminum fabrication.

Module 25 - Aluminum Welding, Welding with Inert Gas Shielded Processes
This module provides the reader with a review of the GTAW and GMAW processes used to fabricate aluminum components. Operating difficulties and successful techniques for welding aluminum are detailed in the module and provide a sound foundation for these welding applications.

Module 26 - Aluminum Welding, Plasma Cutting, Brazing and Other Joining Processes
This module focuses on alternate processes for preparing and welding aluminum. The reader will review the principles of each process and see how it is applied specifically to aluminum fabrication techniques.

Module 27 - Aluminum Welding, Supervision, Safety and Quality Control
This module address the unique requirements for a successful aluminum welding operation. It looks at the role of the welding supervisor, and welding engineer in an aluminum fabrication environment and the unique requirements to maintain the welding operations.

Module 28 - Aluminum Welding, Corrosion and Strength of Aluminum (Terms and Symbols)
This module address the unique properties of aluminum and how fabrication techniques can affect the final strength and corrosion properties of the fabricated assemblies. The reader will be introduced to specific techniques and methods to ensure a sound aluminum structure is produced.

Module 29 - Aluminum Welding, Design of Welded Joints
This module reviews the basic design concepts used when fabricating aluminum components. Joint design and weld profiles are reviewed in relation to the final weld properties and strength required. Basic design equations and graphical information are provided to assist the designer of welded aluminum connections.

Module 30 - General Design Considerations for Welding
Welding as a means of joining metals has opened new horizons for the application of steels The intent of this module is to provide the reader with the elements necessary to make sound and economic welding design decisions and identify the key engineering factors. The module will also provide general guidance relating to design requirements from a variety of North American Standards and Codes.

Module 31 - Flexible Connections
The objective of this module is to cover the area of flexible connections, identify their behaviour, discuss briefly the design assumptions for each specific type and provide detailed observations and practical guidelines relating to the economy of fabrication and welding. The reader will also be provided with references from a number of North American design standards used to fabricate these connections.

Module 33 - Welded Trusswork
The emphasis of this module is on the developing a sound understanding of the structural requirements of truss joints in order to achieve sound and efficient welding design. The module reviews light and heavy truss sections, open-web steel joists and hollow structural sections. Basic formulae and methods used to calculate size and lengths of welds are also presented for a variety of truss joints.

Module 34 - Miscellaneous Structural Welding Design
This module provides the user with a variety of details relating to structural welding design not covered in Modules 30 - 33. The module addresses such items as Stud girders, Beam with Web Openings, Open Web Expanded Beams, Continuous Beams, Column Splices and Column Base design. Contained within the module are a number of completed examples which guide the designer in calculating weld requirements.

Module 35 - Fracture - Fundamentals
Pictures of dramatic brittle fractures (ships cracked in two or pressure vessels blown apart) are well known to most engineers. This module reviews both ductile and brittle fracture, transition behaviour, micro-mechanisms, fractures in welded structures and basic fracture mechanics. Basic calculations relating to fracture mechanics are also presented in the module for use in predicting brittle fracture events.

Module 36 - Fracture - Applications
This module adds to the information presented in Module 35.The reader will review such things as the major toughness tests used to evaluate base materials and welded connections, and review how post-weld heat treatment can effect fracture characteristics of a welded structure. The reader will also develop a fracture control plan for welded structures and learn how to perform simple defect evaluations using fracture mechanics.

Module 37 - Fatigue - Fundamentals
Although seldom occurring with a catastrophic consequences, fatigue failures result in costly repairs and loss of production. Minimizing the risk of fatigue failure involves conscious decisions during design, fabrication, and inspection stages. The module will also look at how welding affects fatigue behaviour, Miner’s Rule and how crack growth laws can be applied to determine fatigue life in a welded structures

Module 38 - Fatigue - Applications
The biggest challenge to the engineer designing to prevent fatigue failure is to recognize the likely fatigue behaviour of the various structural details they may wish to use. The module provides the user with an understanding of fatigue design curves, stress range categories, effects of secondary stresses and provides the understanding necessary to perform simple fatigue analysis of structures.

Module 39 - Weld Mechanics
The non-uniform heating associated with welding produces two side effects - residual stresses and distortion. This module provides an explanation of the origins of residual stresses and the common stress patterns in common welded components. The module also provides guidance on estimating distortion from welding and the effective implementation of flame heating procedures used to correct distortion.


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