Aluminum Hull Repair Course
This course teaches you to diagnose and repair boats with aluminum hulls: identifying marine alloys, preparing joints and MIG and TIG welding techniques. You will also learn to prevent and treat galvanic corrosion and to protect the hull with suitable paint systems.
Prior knowledge check
These are the skills this program gives you. Tick the ones you already master and we will tell you which part of the syllabus is for you.
You are starting from scratch in this subject. The program is designed precisely for that.
What is the Aluminum Hull Repair Course?
This short course teaches you to diagnose and repair boats with aluminum hulls: identifying marine alloys, preparing joints and MIG and TIG welding techniques. You will recognize 5083, 5086 and 6082 alloys, remove oxide and bevel joints correctly, weld with pulsed MIG and AC TIG, control corrosion with anodes and galvanic isolation, and protect the hull with primers and copper-free antifouling.
What sets this course apart: marine metallurgy, with 5000 and 6000 series alloys; applied welding, covering parameters, defects and quality control; corrosion, whether galvanic, pitting or caused by stray currents; reference standards, with ISO 12215 and ISO 9606-2 studied as course content; and a practical case in which you repair a damaged area of the hull.
Program highlights
- Marine metallurgy: 5000 and 6000 series alloys and their tempers.
- Applied welding: parameters, defects and quality control.
- Corrosion: galvanic, pitting and stray current corrosion.
- Reference standards: ISO 12215 and ISO 9606-2 studied as course content.
- Diagnosis: ultrasonic thickness gauging and dye penetrant testing.
- Practical case: repairing an impact-damaged area of a hull.
Syllabus of the Aluminum Hull Repair Course
5 modules. Select a module to see its content.
Marine aluminum and hull construction
- 1.1. Marine alloys: 5083 and 5086 for plate, 6061 and 6082 for extrusions, and H111 and T6 tempers
- 1.2. Properties compared with steel: density, elastic modulus, thermal conductivity and fatigue
- 1.3. Hull types: RIBs with aluminum hulls, workboats, catamarans and sailing yachts
- 1.4. Structure: frames, longitudinals, bulkheads and scantlings according to ISO 12215
- 1.5. Loss of strength in the heat-affected zone and how to take it into account in repairs
Diagnosing hull damage
- 2.1. Types of damage: impact dents, fatigue cracks, cracked welds and perforations
- 2.2. Ultrasonic thickness measurement and mapping of areas with material loss
- 2.3. Dye penetrant testing to locate cracks in weld beads and joints
- 2.4. Assessing deformation with straightedges, templates and comparison with lines plans
- 2.5. Damage report: extent, probable cause and proposed repair by zones
Welding and forming aluminum
- 3.1. Preparation: removing the oxide layer with a dedicated stainless brush and degreasing with acetone
- 3.2. Pulsed MIG welding: ER5183 or ER5356 wire, argon or argon-helium gas, push-pull feed
- 3.3. AC TIG welding: wave balance, filler rods and applications
- 3.4. Welding defects: porosity, lack of fusion and hot cracking; causes and prevention
- 3.5. Cutting, bending and forming plate, renewing panels and controlling distortion
Corrosion and hull protection
- 4.1. Galvanic corrosion: the galvanic series in seawater and critical couples with stainless steel, bronze and copper
- 4.2. Stray currents and pontoon earthing: galvanic isolators and transformers
- 4.3. Aluminum or zinc anodes: surface calculation, location and checking with a reference electrode
- 4.4. Insulating stainless fittings with gaskets, bushes and non-conductive sealants
- 4.5. Paint systems: epoxy primer, anti-corrosion barrier and antifouling free of copper oxide
Practical case: repairing a damaged area
- 5.1. Inspecting a hull with an impact at the bow, measuring thickness and diagnosing cracks
- 5.2. Repair plan: cutting out the damaged area, internal reinforcement and welding sequence
- 5.3. Preparing the new 5083 plate, fitting, tack welding and pulsed MIG welding
- 5.4. Inspecting weld beads with dye penetrant and watertightness testing of the repaired area
- 5.5. Anti-corrosion treatment, painting, fitting anodes and a technical report on the repair
Duration and format of the Aluminum Hull Repair Course
It is 300 hours. Tell us how many you can study each week and we will tell you when you will really finish.
This is the pace at which most students finish. It fits well with the installment plan.
Academic leadership and faculty
The Navalis teaching team: working professionals who teach and supervise the programs.
Dr. Marina AlcoverAcademic Director and Head of Quality Assurance
Eng. Diego CifuentesSenior Lecturer in Naval Welding and Non-Destructive Testing; Head of QA/QC for Welded Joints
Capt. Javier Abaroa (MCA)Senior Lecturer in Ship Handling, Electronic Navigation (ECDIS/Radar/ARPA) and GMDSS; STCW Compliance and Bridge Resource Management Coordinator
Dr. Pau FerrerSenior Lecturer in Naval Architecture and Simulation; Director of the Hydrodynamics and CFD Laboratory
Dr. Nuria LlobregatSenior Lecturer in Marine Meteorology, SAR and Operational Safety; Navigation Risk Management Coordinator
Eng. Javier BañulsSenior Lecturer in Electrical Engineering, Automation and ETO Engineering; Electronic Integration and Engine Alarms Coordinator
Eng. Sofía MarquinaSenior Lecturer in Materials, Composites and Corrosion Protection; Coordinator of the Advanced Paints and Coatings Line
Eng. Tomás RieraSenior Lecturer in Propulsion, Alternative Energy and Hybrid Systems; Energy Performance and Vibration CoordinatorObjectives of the Aluminum Hull Repair Course
Career opportunities after the Aluminum Hull Repair Course
Questions about the Aluminum Hull Repair Course
Basic welding knowledge is recommended. The course focuses on what is specific to aluminum: preparation, parameters, filler materials and typical defects.
No. Welder qualification under ISO 9606-2 is obtained by passing a test before an authorized examining body. The course studies the standard as a reference and prepares you technically for the process, as a complement to any qualifications you already hold.
Copper is far more noble than aluminum and causes severe galvanic corrosion of the hull. That is why antifoulings without copper oxide are used, such as those based on copper thiocyanate or without metallic biocides.
Yes. They are a common repair case and are included as a hull type in module 1, together with workboats, catamarans and sailing yachts.
The heat of welding softens the alloy in the heat-affected zone. Module 1 explains this effect and how repairs are designed to compensate for it.
The course is taught online and comprises 300 hours of study across 5 modules of about 60 hours each and ends with an applied practical case.
More programs in Shipyard and finishes
Admission process
No waiting for a call back. If your documents are in order, you can enroll in the same session.
- Profile: aimed at welders and metal fabricators who want to specialize in the marine sector, boatyard technicians and maintenance staff for workboats and leisure craft.
- Language: sufficient command of English to follow the classes and the technical documentation.
- Technical resources: a computer with a stable internet connection, an up-to-date browser and a camera for live sessions and project presentations.
- Admission: enrollment is open all year round; online application, review of your profile and a short interview with the academic team.
- 01ApplicationYour details, background and documents.
- 02Instant reviewWe check that everything is complete and in order.
- 03EnrollmentChoose full payment or instalments and reserve your place.
Admission is provisional until the committee validates the documents provided. If you do not meet the requirements, the full amount is refunded.
Ask us before you enroll
Leave your details and admissions will write to you to answer any questions. If you are already sure, you can apply and pay in the same session.