•Equipment Gets the Most out of Pulsed Welding

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July 2008 WELDING JOURNAL • VOLUME 87 NUMBER 7 JULY 2008

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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING SELECT ARC:FP_TEMP 6/5/08 9:49 AM Page C2

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CONTENTS July 2008 • Volume 87 • Number 7 AWS Web site www.aws.org Departments Features 30 Press Time News ...... 4 30 Packaging for Productivity Editorial ...... 6 There are many ways to increase productivity, but sometimes packaging is one area that is overlooked International Update ...... 8 I. Mitchell News of the Industry ...... 12 32 Save Time and Money with Resistance Welding Letters to the Editor ...... 18 Simulation Software Stainless Q&A ...... 20 Simulation of welding conditions, materials, and joint design can lead to great cost savings at production time New Products ...... 24 K. R. Chan Conferences ...... 52 38 Improved Pulsed Gas Metal Arc Welding Nets Coming Events...... 54 Higher Productivity Get the most out of your welding operation with new and Welding Workbook ...... 58 improved equipment Society News ...... 59 C. Roehl and K. Stanzel Tech Topics ...... 64 42 Welding Weaves Live Entertainment Magic Interpretations D14.3; B2.2 ..64 Welding “behind the scenes” helps make extravaganzas 32 big time hits Guide to AWS Services...... 86 K. Campbell New Literature...... 90 Personnel ...... 92 Welding Research Supplement Classifieds ...... 94 Advertiser Index...... 98 167-s Liquation of Mg Alloys in Friction Stir Spot Welding The properties and characteristics of magnesium alloys joined with solid-state welding were investigated Y. K. Yang et al. 178-s Experimental and Numerical Analysis of the Friction Welding Process for the 4340 Steel and Mild Steel Combinations A model was developed to predict stress, strain, and geometry of welds S. A. A. Akbari Mousavi and A. Rahbar Kelishami 38 187-s A Friction-Based Finite Element Analysis of Ultrasonic Consolidation Distributions of temperature and plastic deformation from Welding Journal (ISSN 0043-2296) is published friction stress were studied monthly by the American Welding Society for C. Zhang and L. Li $120.00 per year in the United States and posses- sions, $160 per year in foreign countries: $7.50 per single issue for domestic AWS members and $10.00 per single issue for nonmembers and $14.00 single issue for international. American Welding Society is located at 550 NW LeJeune Rd., 42 Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2

Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or re- sale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

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PRESS TIME NEWS

Airgas to Provide Jobs, Welder Training to War Veterans Publisher Andrew Cullison Editorial Airgas, Inc., Radnor, Pa., has set a goal to hire 100 veterans who have served in Iraq Editorial Director Andrew Cullison and Afghanistan over the next 12 months. The company will also offer its Welding 101 Editor Mary Ruth Johnsen course to any veteran interested in exploring a welding career. Associate Editor Howard M. Woodward Additionally, the company has pledged $300,000 to Operation Homefront, a charity Associate Editor Kristin Campbell that supports America’s soldiers by providing emergency assistance and moral support Peer Review Coordinator Erin Adams to the families troops leave behind when they are deployed and to wounded service members when they return home. The donation will be paid in increments of $100,000 Publisher Emeritus Jeff Weber per year over the next three years, with 70% going toward Operation Homefront’s projects to assist wounded soldiers. Graphics and Production Production Manager Zaida Chavez USEC Awards $92 Million Contract to Teledyne Brown Senior Production Coordinator Brenda Flores Advertising USEC Inc., Bethesda, Md., awarded a $92 million contract to Teledyne Brown Engi- National Sales Director Rob Saltzstein neering Inc., Huntsville, Ala., to manufacture 540 gas centrifuge service modules for its Advertising Sales Representative Lea Garrigan Badwy American Centrifuge uranium-enrichment program. Advertising Production Manager Frank Wilson Critical to the operation of the centrifuge machines, service modules are welded, steel frame structures with pipe headers and valves, control and instrument cabling, ven- Subscriptions tilation ductwork, and electrical distribution cables. [email protected] Teledyne Brown recently opened a new manufacturing facility in Huntsville to handle this contract. It expects to add nearly 200 jobs at the facility, which is being expanded American Welding Society from 130,000 to 206,000 sq ft needed for production operations. 550 NW LeJeune Rd., Miami, FL 33126 (305) 443-9353 or (800) 443-9353 North American Robot Orders Decline 17% in First Quarter Publications, Expositions, Marketing Committee North American robotics companies reported new orders sold to North American D. L. Doench, Chair manufacturers fell 17% in the first quarter of 2008 from the same quarter in 2007, but Hobart Brothers Co. revenue rose 5%. Additionally, orders to nonautomotive companies surged, an encour- T. A. Barry, Vice Chair aging sign for future robotics growth, according to the Robotic Industries Association Miller Electric Mfg. Co. (RIA), Ann Arbor, Mich. J. D. Weber, Secretary A total of 3828 robots valued at $288.1 million were sold in the opening quarter by American Welding Society North American-based robotics companies, according to new figures released by RIA. R. L. Arn, WELDtech International When sales to companies outside North America are included, the totals are 4281 S. Bartholomew, ESAB Welding & Cutting Prod. robots valued at $311.3 million, a decline of 15% in units and a gain of 6% in revenue. J. Deckrow, Hypertherm J. Dillhoff, OKI Bering Also, orders to automotive manufacturers and their suppliers fell 34% in units. J. R. Franklin, Sellstrom Mfg. Co. “Welding and coating/dispensing orders showed big declines because these are heav- J. Horvath, Thermadyne Industries ily tied to automotive. Assembly and material-handling applications showed gains be- D. Levin, Airgas cause many of these applications are also extensively used in nonautomotive industries,” J. Mueller, Thermadyne Industries said Jeffrey A. Burnstein, executive vice president of RIA. R. G. Pali, J. P. Nissen Co. J. F. Saenger Jr., Consultant Plastic Welding Certification Facility Offers Courses S. Smith, Weld-Aid Products D. Wilson, Wilson Industries A new plastic welding training center offers plastic fabricator education, hands-on J. C. Bruskotter, Ex Off., Bruskotter Consulting Services H. Castner, Ex Off., Edison Welding Institute training, and certification in plastic welding and portable extrusion welding in accor- L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems dance with The Welding Institute (TWI) specification, thanks to STAR Process Heat G. E. Lawson, Ex Off., ESAB Welding & Cutting Prod. Systems LLC and RRE Inc. — The Plastic Welding School. The two organizations E. C. Lipphardt, Ex Off., Consultant recognized the need to offer a formal training program and facility on how to weld plas- S. Liu, Ex Off., Colorado School of Mines tics. The program is based on European CEN (Committee for Standardization) and C. Martin, Ex Off., Phoenix International DVS (German Welding Society) plastic welding standards. E. Norman, Ex Off., Southwest Area Career Center The training facility for RRE Inc. — The Plastic Welding School is located at STAR R. W. Shook, Ex Off., American Welding Society Process Heat Systems LLC in Farmingdale, N.J. The class schedule is the third week of each month. Standard courses offered are as follows: ATC61 — 3 Day Extrusion Weld- ing; ATC62 — 2 Day Gas Appreciation; ATC66 — 5 Day Hot Gas Welding; and ATC68 Copyright © 2008 by American Welding Society in both printed and elec- — 3 Day Plastic Welders Certification. tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not in- R.B.A. Doubles Manufacturing Space tended for use without independent, substantiating investigation on the part of potential users. Broadwind Energy, Inc., Naperville, Ill., recently announced its heavy steel fabrication company, R.B.A. Inc., Manitowoc, Wis., a provider of subcontract machining, fabrication, refurbishing, welding, and assembly, has acquired a second facility. Located in Clintonville, Wis., it comprises approximately 60,000 sq ft. The company has begun hir-

ing employees and expects to add approximately 40 people. MEMBER 4 JULY 2008 weld mold:FP_TEMP 6/4/08 12:47 PM Page 5

For Info go to www.aws.org/ad-index Editorial for July 2008:Layout 1 6/6/08 4:43 PM Page 6

EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding Officers The Many Rewards of President Gene E. Lawson Volunteerism ESAB Welding & Cutting Products Vice President Victor Y. Matthews After many years of working for my livelihood, it dawned on me that besides being an The Lincoln Electric Co. employee of a company, I was actually a volunteer. After all, no one made me choose the Vice President John C. Bruskotter company I worked for. I made the choice based on the work available, reputation of the Bruskotter Consulting Services, LLC company, salary, and workmates. I could leave employment at any time. What made me remain with the business? Was it the pay, the challenge of the work, working with others Vice President John L. Mendoza to reach a common goal? The reality was I remained an employee for all of those rea- CPS Energy sons and others. When I came to grips with my volunteerism, my work actually seemed more pleasant. Treasurer Earl C. Lipphardt The thought that I could make an employment change if necessary was like a breath of Consultant fresh air. My attitude was changed forever. I’ve belonged to several associations in my life, becoming a member for the usual rea- Executive Director Ray W. Shook sons: boss asked me to, friend belonged, hoped to parlay my involvement into something American Welding Society for the better. I became a member of the American Welding Society in the same man- ner. As a manager I asked a coworker and friend — the fabrication supervisor at our Directors company — to visit a welding school and give his take on its teaching methods and whether it was a place from which we could obtain welders. The owner of the school was B. P. Albrecht (At Large), Miller Electric Mfg. Co. on the local Section executive committee and invited my colleague to attend a Section O. Al-Erhayem (At Large), JOM meeting. The invitation was passed on to me, and together we attended. The rest is his- A. J. Badeaux Sr. (Dist. 3), Charles Cty. Career & Tech. Center tory. In 1993, I became a member of the AWS voluntarily as did the fabrication supervi- J. R. Bray (Dist. 18), Affiliated Machinery, Inc. sor. Our reason was that we could associate with people with a goal common to ours. Welding and fabrication was my career choice, and with the American Welding Society H. R. Castner (At Large), Edison Welding Institute I was able to associate with like-minded people — and we were all volunteers. Of course, N. A. Chapman (Dist. 6), Entergy Nuclear Northeast at that time, little did I realize that this involvement would grow, but I found I was able J. D. Compton (Dist. 21), College of the Canyons to juggle the duties of the Section with my regular employment responsibilities. Over time, my responsibilities to the Section grew as well. G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services What keeps me volunteering and what maintains my interest is the work I do and the D. A. Flood (Dist. 22), Tri Tool, Inc. enthusiasm I feel from my family, each of the AWS staff members, and my fellow Board M. V. Harris (Dist. 15), Valley National Gases and Section members and their families. We are all united in supporting the welding R. A. Harris (Dist. 10), Consultant community. Look at the makeup of the AWS Section leadership and national Board of Directors. All facets of the welding industry are present — from representatives of weld- D. C. Howard (Dist. 7), Concurrent Technologies Corp. ing equipment manufacturers to educators to end users — and from such a variety of J. Jones (Dist. 17), Thermadyne locations. Each of these people has his or her own reasons for volunteering. W. A. Komlos (Dist. 20), ArcTech LLC I ask you to seek out others whom you feel could benefit from becoming a volunteer. D. J. Kotecki (Past President), The Lincoln Electric Co. An associate, supervisor, mentor, relative, friend may enjoy the challenges we volunteers face. Although juggling daily life and employment with planning a Section meeting, bal- D. Landon (Dist. 16), Vermeer Mfg. Co. ancing the Section checkbook, arranging a plant tour, or other tasks seems like a lot of R. C. Lanier (Dist. 4), Pitt C.C. work, the time required is often not as much as it would at first seem. I’ve learned dur- J. Livesay (Dist. 8), Tennessee Technology Center ing my time as a volunteer that we have plenty of time to do the things we want to do. D. L. McQuaid (At Large), DL McQuaid & Associates My local Section is blessed with several businesses that volunteer to support a monthly meeting. Equipment vendors, technical colleges, end users, and inspection companies S. Mattson (Dist. 5), Mattson Repair Service volunteer on an annual basis. Their efforts are so greatly appreciated. The cost of the S. P. Moran (Dist. 12), Miller Electric Mfg. Co. food and beverages is paid by a businesses; members and guests attend at no cost. The R. L. Norris (Dist. 1), Merriam Graves Corp. cost to the business varies, but it can be up to several hundred dollars plus the effort of locating a guest speaker. What better way to showcase your business? This is a great way T. C. Parker (Dist. 14), Miller Electric Mfg. Co. to volunteer if you feel that your time is restricted. We’ve found through this arrange- W. R. Polanin (Dist. 13), Illinois Central College ment that Section member attendance has increased W. A. Rice (At Large), OKI Bering, Inc. as has the involvement of many students. A scholar- N. S. Shannon (Dist. 19), Carlson Testing of Portland ship is actually awarded to the student who attends the most Section meetings — another way in which volun- E. Siradakis (Dist. 11), Airgas Great Lakes teerism has its rewards. K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv. I thank the friend who offered me a chance to join G. D. Uttrachi (Past President), WA Technology, LLC the AWS as a volunteer. He remains a member, D. R. Wilson (At Large), Wilson Industries became a CWI, and is very active as a Section officer. Do the same for a person in your life: Offer him or her an opportunity to volunteer and support our industry.

John C. Bruskotter AWS vice president

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Your single source for industrial Welding Automation. In a world where productivity is key to global competition, more fabricators are turning to automation solutions from ESAB. From a single tractor component or mechanized gantry to a complete turn-key production system, ESAB offers a wide range of automation solutions to meet every need. When ESAB builds the entire system, we can integrate the welding process, arc path and material handling systems to ensure project success. And, of course, we supply the technical support and training you need to keep your system running efficiently. Whatever your automation need, ESAB is the company to trust for superior solutions. For Info go to www.aws.org/ad-index

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INTERNATIONAL UPDATE

Lloyd’s to Fund Chair in Materials Table 1 — Sales and Forecasts of Various Types of Welding Equipment Fabrication and Engineering and Consumables through 2013 (in $millions)

The Lloyd’s™ Register Educational Trust recently funded a Type of Equipment 2006 2007 2008 2013 CAGR% new chair in Materials Engineering and Fabrication at The Open 2008–2013 University, a distance learning institution headquartered in Mil- Welding equipment and 9842 10,219 10,677 13,615 5.0 ton Keynes, UK. The award is for $1.18 million spread over five consumables years. It will support research investigating the structural integrity Welding gases 1911 1968 2017 2618 5.4 of welded joints, as well as for developing improved methods for Safety and protective 367 383 406 487 3.7 residual stress analysis. equipment “We are delighted that Lloyd’s Register Educational Trust has Welding robots and 86 96 108 148 6.5 selected us for this major award,” said Dr. Michael Fitzpatrick, accessories who leads the structural integrity research activity at The Open Total 12,206 12,666 13,208 16,868 5.0 University. “It will allow us to boost our work in structural integrity assessment of welded joints, which is already recognized increase to $16.8 billion by 2013, a compound annual growth rate as world-leading.” (CAGR) of 5%, according to a report from BCC Research Michael Franklin, director of the trust, said, “A large part of (www.bccresearch.com). the Educational Trust’s work is to support fundamental engineer- The market is divided into applications of welding equipment ing research to address problems and challenges and to find so- and consumables, welding gases, safety and protective equip- lutions that will be for the public benefit. In the last few years, ment, and welding robots and accessories (Table 1). Of these, we have committed around ($19.6 million) to support research welding equipment and consumables has the largest share of the programs at a number of universities around the world. The award market. Worth an estimated $10.7 billion by the end of the year, to The Open University brings them into this unique and impor- this segment should reach $13.6 billion in 2013. This segment is tant group.” steadily growing since consumables are not only required for new The award will complement a broader collaboration on engi- equipment but also for all existing equipment. neering teaching and research between the university and TWI The safety and protective equipment segment is also growing aimed at addressing skills shortages in the engineering workforce. steading as safety regulations are enforced globally. Laser Mechanisms Relocates Its More industries are automating and robotic welding is becoming a standard feature of such automation. The market for European Office welding robots is growing at a higher rate than any other market for industrial robots. Expected to be worth $108 million this year, Laser Mechanisms, Inc., Farmington Hills, Mich., recently this segment should reach $148 million by the end of the study moved its Laser Mech Europe sales offices from Destelbergen period, for a CAGR of 6.5%. to Mariakerke, Belgium. The 2500-sq-ft facility houses sales of- For more information on the report titled Welding Equip- fices, showroom, training room, meeting room, and an expanded ment and Supplies: The Global Market (AVM040B), contact warehouse. BCC Research, 40 Washington St., Suite 110, Wellesley, Mass.; “This relocation allows us to more effectively service our ex- (866) 285-7215, or [email protected]. panding European customer base with state-of-the-art beam- delivery components and laser system solutions,” said Arvi Ra- Loyalist College to Begin Welding Program maswami, managing director, Laser Mech Europe. Laser Mechanisms designs and manufactures laser beam de- The School of Skills Training at Loyalist College, Belleville, livery components and articulated arm systems for high-power Ont., Canada, will offer a one-year certificate program in weld- CO2, YAG, and fiber lasers for numerous industrial applications. ing techniques beginning in September. The program was devel- For more information, visit www.lasermech.com. oped in resonse to industry’s need for welding professionals. Students will receive extensive welding theory and hands-on ex- Linde Sells Its Colombian Subsidiary to perience in the college’s welding shop. There will be a strong em- Chilean Firm phasis on safety, and students will learn to create and interpret blueprints as well as develop their skills in math and computer applica- The Linde Group recently sold its Colombian subsidiary, Cryo- tions. The program will also introduce students to robotic welding gas S.A., to Indura S.A., the Chilean industrial gases and weld- and practical experience using the college’s full-size robots. ing company. The divestiture was an antitrust condition imposed “The truly exciting part of this new program is the career op- by the Colombian regulatory authorities arising from the 2006 portunities that students can anticipate following graduation,” acquisition of The BOC Group plc by Linde. said Tom Malloy, dean of skills training, access and continuing Cryogas S.A. employs approximately 400 people and achieved education. “Some may choose to work as welder fabricators, sales of about $76 million in the 2007 fiscal year. welder fitters, production welders, or millwright welders, while others will become structural plate fitters or welding inspectors. Global Market for Welding Equipment and The program is also suited to individuals who are already working within the industrial and agricultural sectors. Welding adds Supplies Worth $16.9 Billion by 2013 another dimension to the skills they are able to bring to the work- place as employees or within their own businesses. Industry has The global market for welding equipment and supplies will told us they need welders. Our goal is to prepare our graduates be worth $13.2 billion by the end of this year and is expected to to fill this void.”◆

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WeldingWelding in in Aircraft and AerospaceAerospace Conference Conference

The aircraft and aerospace industry is making great strides in cost reduction. One aspect of this is utilizing composites in place of aluminum. Another innovation is to build critical parts from the ground up, rather than ordering expensive forgings and castings that have to be machined down to size. Welding is in the very thick of it on both fronts. Improved processes are being developed to weld carbon fiber composite structures. In the world of “born to shape parts,” innovative welding processes like electron beam, laser, and others are getting the job done efficiently and economically. September 16-17, 2008 Wichita, Kansas

At this AWS conference in Wichita, emphasis will be given to friction stir welding, fiber laser welding, and the gas-shielded welding processes. The role of titanium is growing, and the emergence of a number of new aluminum-lithium alloys poses new welding challenges. Ultrasonic welding, a front-runner for the welding of thermoplastic composites, will be on the agenda, as well. Plans for vehicles to carry humans to the moon by 2010 (and later, to Mars) will also be discussed.

Titanium Friction Stir Welding Advanced Manufacturing and Developments in Usage of and Laser Welding Repair of Nickel and Titanium Fiber Lasers for Aerospace Development for Commercial Alloys Welding Applications Aircraft Nick Kapustka, Applications Engineer, Eric Stiles, Applications Manager, IPG Daniel G. Sanders, Senior Technical Arc Welding, Lasers & Automation, Midwest Operations, IPG Photonics, Fellow, Director of M&P Science, Edison Welding Institute, Columbus, OH Wixom, MI Materials & Process Technology, The Boeing Co., Seattle, WA Development of Third Laser Weldbonding of Thin Generation of Aluminum Aluminum Structures Potential Uses for Fiber Lasers Lithium Alloys George Ritter, Technology Leader, in Aerospace Applications Michael Niedzinski, Director of Plastics and Adhesives, Edison Welding Paul Denney, Laser Researcher, Technology and Standardization USA, Institute, Columbus, OH Connecticut Center for Advanced Alcan Aerospace, Chicago, IL Technology, Inc., East Hartford, CT Metal Part Fabrication and Returning to the Moon: Component Repair with Laser Friction Stir Weld Assembly of Welding and Fabrication of the Engineered Net Shaping the Eclipse 500 Very Light Jet Ares I Upper Stage Hardware at Rich Plourde, Director, Aerospace and Brent Christner, Manager, Materials and Marshall Space Flight Center Defense Business Development, Process Engineering, Eclipse Aviation, Jeff Ding, Aerospace Welding Engineer, Optomec, Inc., Albuquerque, NM Albuquerque, NM NASA Marshall Space Flight Center, Huntsville, AL Eddy Current Array and Electron Beam System Ultrasonic Phased-Array Technology for Welding and Path Independence of Friction Technologies as Reliable Tools Additive Manufacturing Stir Welding for Inspection of Friction Stir Robert C. Salo, Sales Manager, Western Dr. Dwight Burford, Senior Research Welds Region, Sciaky, Inc., Chicago, IL Scientist, Director, Advanced Joining & Michael Turner, Advanced Technical Processing, National Institute for Sales, Olympus NDT, Kansas City, MO; High Powered Ultrasonics and Aviation Research, Wichita State and Andre Lamarre, Business Thermal Stir Welding University, Wichita, KS Development Director, Aerospace and Jeff Ding, Aerospace Welding Engineer, Defense, Olympus NDT, Quebec City, NASA Marshall Space Flight Center, Aerospace Gas Tungsten Canada Huntsville, AL Welding Wyatt Swaim, Chief Executive Officer, WJS Consulting Inc., Geuda Springs, KS

AWS Welding in Aircraft and Aerospace Conference Broadview Hotel • Wichita, Kansas September 16-17, 2008

To register or to receive a descriptive brochure, ® call (800) 443-9353 ext. 455, (outside North America, call 305-443-9353), or visit Founded in 1919 to advance the science, technology and application of welding and allied processes including www.aws.org/conferences joining, brazing, soldering, cutting and thermal spraying. NI July 2008:Layout 1 6/6/08 2:57 PM Page 12

NEWS OF THE INDUSTRY

Koike Aronson/Ransome Celebrates 90th Anniversary and Plant Expansion

Koike Aronson/Ransome, Inc., Arcade, N.Y., a designer and manufacturer of welding positioners and thermal cutting products, as well as portable and gas apparatus equipment, recently held an open house on May 16. About 90 attendees showed up. “I want to thank everybody for coming to help us celebrate not only Koike’s 90th year in business, but the completion of our latest expansion,” said company President and CEO Jerry Leary. He also expressed gratitude to the company’s 172 employees. After detailing Koike’s history, Leary talked about its challenging times. “From 1985 to 2003, the company did very poorly,” he said. It had an oner- ous debt along with a deficit, and just 73 employees. “We were literally out of business,” Leary said, but after Labor Day 2003, “some of the things we had put in place started to kick in, and the rest is history.” Since this point, revenues have tripled, and debts and deficits have been eliminated. The Arcade location grew through many factors. First, management was reorganized at the end of 2002. It purchased Ransome Manufactur- ing the previous year. Another transformation was how the company sold products; it changed to independent manufacturing representatives in Canada, the United States, and South America. The following also helped: Customer service got restructured; two nonperforming offices were closed; factory efficiencies were improved, leading to good lead and delivery times; distribution policies were restructured; reor- ganization took place from a traditional format to three business units for cutting machines, positioners, and portable gas appara- tuses; a management by objective and incen- tive system was implemented; new products were added; the portable and gas apparatus sales/inventory moved to Houston, Tex.; and Shown at the Koike open house are a customer visit program started. (from left, front row) Rachael Recent successes have occurred as well. In Becht, HR and safety manager, and 2006, Wyoming County, N.Y., honored Koike Angela Wiseman, administrative as the Manufacturer of the Year. In 2007, it assistant; (from left, back row) Jerry received ISO 9001 certification; the first Leary, president and CEO, and Paul 11,000-sq-ft expansion finished; and the King, plant manager. Worldwide Koike Group Presidents Meeting took place for the first time in Arcade. This year, the company has been certified by the state of New York as an Empire Zone, quali- fying it for state tax credits in exchange for $11 million in investments at the Arcade location; and moving in the second expansion of 20,000 sq ft started in May. Koike’s weld shop primarily Koike Sanso Kogyo Co., Ltd., in Japan, is uses the gas metal arc and its parent company. Other operations exist in flux cored arc welding the Netherlands (Koike Europe B.V.), China processes. Its entire product (Koike Engineering Tangshan Co., Ltd.), and line is welded here — posi- South Korea (Koike Korea Engineering Co., tioners, cutting machines, Ltd.). and any assemblies. Eighteen New goals have been set. “In the next 14 welders, two cutters, and one to 18 months, we’re planning a new addition, metal finisher work in this and that will create more jobs here,” Leary area. said. The company is creating a line of down- draft and cutting tables in 2008, too. Koike’s demonstration room, completed last November, New York State Senator Dale Volker offered his congratulations. “This provides visitors the ability to try various machines and turnaround is unbelievable. It shows you what American and Japanese decide what works for them. Four to five customers are ingenuity can do, and how you can take a business that had major prob- brought here a week. lems and through great management and through intelligence, turn it around,” Volker said. “This is an enormous worldwide operation out of Arcade, N.Y., that’s making Arcade a name throughout the world.” He added, “It’s companies like this that give you great heart.” Additionally, the day included guided plant tours of the machine, electric, and weld shops; shipping department; and demonstration room. All of the fabrication, welding, and cutting are done in-house. Building of the company’s third 6-kW laser to be made in the United States will take place at this facility. The event ended with a barbecue lunch. — KRISTIN CAMPBELL, associate editor

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Welder Training Begins at Iron Workers Center in Utah

The first welding classes at Iron Workers Local 27 Training Facility, West Valley City, Utah, took place April 26. This event represented a goal for Michael L. McDonald, the Local 27 business manager, who wanted this section to have a place of its own. It is hoped American Welding Society accreditation for the Iron Workers National Certification Program will be achieved soon. “We are proud of our new facility and are excited about our ability to continually improve the quality of the training received by our journeymen and apprentices,” said Bob North, president, Iron Workers Local 27/director of apprenticeship and training. “We are now in a position to reach our ultimate goal of providing, to our signatory employers, the best trained workforce in our five state jurisdiction.”

A student practices shielded metal arc welding at the new Iron Work- ers Local 27 Training Facility. This photo also shows the booth setup complete with an exhaust hood above the welding fixture.

Instructor Todd Anderson (left) is shown teaching Maria Sandness, one of two females currently in the program. For info go to www.aws.org/ad-index

WELDING JOURNAL 13 NI July 2008:Layout 1 6/6/08 2:58 PM Page 14

Director of Apprenticeship and Training Bob North (left) is shown with instructor Brett Windley.

The 7500-sq-ft building houses 23 welding booths and three class- rooms. Training is provided in shielded metal arc, gas tungsten arc, flux cored arc, and gas metal arc welding. Neal Borchert and Jim Truett from Miller Electric Mfg. Co., along with Mike Weaver of Airgas, helped with pricing various types of equipment. Four instructors, three of whom are Certified Welding Inspec- tors, teach three hours on Monday and Wednesday evenings, and six hours on Saturday. Students range from apprentices just starting or having some welding experience to journeymen wanting

For info go to www.aws.org/ad-index

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to learn or brush up on their techniques; they are all either members of Local 27 or travelers from other local trade organizations. After apprentices finish four years of training, they become journeymen and can make a good living. In addition, a structure is set up to learn steel erection techniques; a concrete form teaches working on a rebar wall; an ornamental mock-up provides learning on window wall and cur- tain wall systems; and a preengineered metal building mock-up will be purchased in the near future. For more information, visit the Iron Workers Web site at www.ironworkers.org or go to www.ironworkers27.com. College of New Caledonia Receives Nearly $1 Million for New Trades Equipment

The British Columbia Ministry of Advanced Education has approved targeted funding for the College of New Caledonia (CNC) in the amount of $905,375 to purchase new equipment for three existing trades programs. Among the recipients is the welding program with welding machines, feeders, welding tent, forklift, and ironworker cutting devices. “The new funding will allow our students to learn on the most up-to-date, technologically advanced equipment. It’s essential to allow the college to continue to meet community needs for trades workers throughout the region,” said Lynn Jacques, CNC’s VP Academic. Senator Barack Obama Visits CMW

CMW Inc., a manufacturer of highly engineered metal alloys and composites used in a broad array of industrial applications,

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For info go to www.aws.org/ad-index WELDING JOURNAL 15 NI July 2008:Layout 1 6/6/08 3:06 PM Page 16

cific concern over one of the major challenges CMW and similar employers face regarding workforce development and hiring qualified people. Obama called CMW “a model of the kind of company that we should be seeing all across America where management and labor are working together for decent wages and decent benefits.” Approved Electroslag Welding in Florida Speeds Splicing of Bridge Girder Flanges

Florida Structural Steel (FSS), Tampa, Fla., sees economic advantages in splicing bridge girder flanges with the new narrow- gap electroslag welding (NG-ESW) technique. According to Dale Ison, manufacturing manager, it cuts welding time for butt-splices of top and bottom flanges by about two-thirds. The Federal Highway Administration (FHWA) approved the use of NG-ESW in March 2000, rescinding a moratorium imposed in 1977. The technique applies to bridge steel members that are in tension, reversal, or compression, but not fracture- CMW recently hosted Illinois Senator Barack Obama at its Indi- critical steel members or those in geographic Zone 3. Only Texas ana facility. Pictured (from left) are Jennifer Sniderman, Obama, and Florida have allowed this welding technique for splicing of and Mark Gramelspacher. main members in their bridges. “Florida Department of Transportation (FDOT) wrote it into enjoyed a recent visit to its Indianapolis, Ind., facility from U.S. their new specifications for Section 460, Structural Steel and Mis- Senator and presidential hopeful Barack Obama. Obama toured cellaneous Metals,” said Ison. “Florida Structural Steel is work- the company’s operations with Mark Gramelspacher, president ing on ten girder bridges for the Courtney Campbell Causeway of CMW. Also, he met many employees, listened and responded interchange, in the vicinity of Tampa International Airport. This to questions about American manufacturing and his proposed project falls under the 460 specifications, so FSS applied to FDOT policies, and then conducted a nationally televised town hall for, and received, permission to use NG-ESW to butt-splice girder meeting with approximately 200 people from the Indianapolis flanges. This interchange project involves ten girder bridges and community. about 1400 flange butt splices. Gramelspacher kicked off this meeting with general comments “Unfortunately,” said Ison, “we did not qualify for NG-ESW about the family-owned business. Additionally, he expressed spe- in time to use it on all ten girder bridges in the project. FSS will

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Workers’ Compensation, division of Safety and Hygiene. • Airgas, Inc., Radnor, Pa., has acquired A&N Plant, a Euro- pean-based supplier of new and reconditioned rotating, positioning, and welding equipment. • CFD-online, an online center for Computational Fluid Dynam- ics, has set up a forum for users of Flomerics EFD suite of simulation software at www.cfd-online.com/Forum/efd.cgi. • Coghlin Companies Inc. completed acquiring the assets of KEF, Inc. (doing business as Stonebridge), a Worcester, Mass.-based precision machining and certified welding company. • The GBC Materials business of Morgan Advanced Ceramics is offering online ordering capabilities at www.gbcmaterials.com/ acatalog/ for its VX Super Refractory Crucibles. • GEA PHE Systems, a international supplier of plate heat ex- changers (PHE), has acquired the assets of Canadian PHE This Florida Structural Steel operator adjusts a flange butt joint specialist ViEX, based in Newmarket near Toronto. welding jig for Arcmatic electroslag equipment. The narrow-gap • Aerojet, Sacramento, Calif., has earned The Boeing Co.’s Sup- electroslag welding technique cuts flange butt joint weld time. plier of the Year award. It has been the sole supplier to Boe- ing for the F-22 Raptor welded titanium forward booms. • Manoir Industries SA, Paris, has acquired Hi-Tech Fabrication probably use it on six bridges, portions of which have already Ltd., Burton on Trent, Staffordshire, UK, a provider of welded been erected.” Ison also noted the electroslag equipment came assemblies in heat- and corrosion-resistant steels and alloys. from Arcmatic Corp., Vallejo, Calif. • This year marks the 50th anniversary of Guild International, All the electroslag bridge welds made by FSS undergo 100% Bedford, Ohio. The company is a world-wide supplier of coil ultrasonic and X-ray inspection, as required by the code. “KTA- end joining equipment for the steel processing, tube produc- Tator, Inc., Pittsburgh, Pa., is witnessing the inspections for us,” ing, and stamping industries. he noted. • Presented by the Laser Institute of America, Orlando, Fla., the 3rd Pacific International Conference on Applications of Lasers Industry Notes and Optics was held in April in Beijing, China. Also, this conference hosted the first International Enterprise Summit. • Stillwater Technologies, Inc., Troy, Ohio, a contract tooling • Jackson Products, Inc., St. Louis, Mo., has entered into an and machining company and manufacturer of resistance weld- agreement to acquire a 70% stake in Changzhou Shine Sci- ing consumables and accessories, held an open house on May ence & Technology Co., Ltd., of the People’s Republic of China, 17 to celebrate its 50th anniversary. The event was followed a manufacturer of welding safety products. by a picnic lunch. • Memphis-based gas and welding distributor nexAir has • Del Moerke Jr. and son Steven Moerke have purchased D/F launched its new Web site, www.nexair.com, offering a Mate- Machine Specialties, Inc., North Mankato, Minn., from the rial Safety Data Sheets library and industry news updates. other Moerke family members. For 40 years, the company’s • Actuant Corp. has completed the purchase of Superior Plant welding products have been used on automatic and robotic gas Services LLC in a deal worth $57 million. The acquired com- metal arc and gas tungsten arc welding systems. pany will be managed in part with Hydratight, Red Wing, Minn., • Honeywell, Morris Township, N.J., has acquired Norcross Safety one of the businesses comprising Actuant’s Industrial Segment. Products LLC, Oak Brook, Ill., a manufacturer of personal • Rankin™ Industries, Ranch Cucamonga, Calif., has been reg- protective equipment, for approximately $1.2 billion. istered by Intertek Testing Services as conforming to the re- • Pennington Allen Capital Partners LLC, Tulsa, Okla., has com- quirements of ISO 9001:2000. The certification is applicable pleted its investment in Mathey Investments, Inc., a developer to its management systems for the design and manufacture of and manufacturer of pipe cutting and beveling machines, weld- buildup and hardfacing welding products. ing electrodes, and flux ovens. • Valley National Gases, LLC, has acquired the gas and welding • Lincoln Electric Holdings, Inc., Cleveland, Ohio, has acquired business of N. H. Bragg & Sons. Also, the company is moving Electro-Arco, S.A., a privately held manufacturer of welding its corporate headquarters to Independence, Ohio. consumables based near Lisbon, Portugal. • The American Iron and Steel Institute is rolling out the Bar • At the annual Excellence in Industrial Technologies Awards Steel Fatigue blog, www.autosteel.org/barfatigueblog, an online Banquet and Networking Sessions in San Antonio, Tex., Frost tool for automotive engineers. & Sullivan honored various companies including ABB Low • Orbitiform Group, Jackson, Mich., recently announced Tool Voltage Drives, Bohler Welding Group USA, Inc., ESAB Weld- & Assembly Systems, Inc., has joined the company as sales rep- ing & Cutting Products, and Kobelco Welding of America, Inc. resentatives for Ontario. • ITT Corp. has completed the acquisition of Kaliburn Inc., Charleston, S.C., a designer and manufacturer of plasma arc cutting equipment and consumables, through its wholly owned Do You Have Some News to Tell Us? subsidiary Cleveland Motion Controls, Inc., Cleveland, Ohio. • At the 2008 International Glove Association (IGA) annual If you have a news item that might interest the readers of meeting in March, the IGA reviewed its 2003–2007 U.S. hand the Welding Journal, send it to the following address: protection market demand study. Industrial glove demand had a 6.5% compound annual growth rate over the study period. Welding Journal Dept. • Clearview Capital, LLC, Old Greenwich, Conn., has completed Attn: Kristin Campbell 550 NW LeJeune Rd. acquiring Mayo Welding Services, Inc., Berthoud, Colo., as an Miami, FL 33126. add-on transaction to Hettinger Welding, LLC. • AK Steel’s Zanesville (Ohio) Works has been honored with Items can also be sent via FAX to (305) 443-7404 or by two awards for its safety performance by the Ohio Bureau of e-mail to [email protected].

WELDING JOURNAL 17 Letters to the Editor July 2008:Layout 1 6/6/08 1:07 PM Page 18

LETTERS TO THE EDITOR

Electron Diffusion Inquiry Dale Flood cathode zone is a model that aims at ex- Gets Resolved AWS District 22 Director plaining the transition from the solid cath- Project Manager, R&D for ode to the plasma arc column. Model cal- TRI TOOL INC. culations show that the back diffusion elec- A reader questions a statement in the arti- El Dorado Hills, Calif. trons represent less than 1% of the total cur- cle ‘Electrode Life: A Measure of System rent (emitted electrons, ions, and back dif- Performance in Plasma Cutting’ published fusion electrons). in the April 2008 Welding Journal pp. The explanation of the electron back dif- 30–32. The authors’ response follows. fusion is tied to the microscopic description Nakhleh Hussary and Thierry Renault, of the fluid (kinetic theory). In this case, the Thermal Dynamics My question originates from the first fluid in front of the electrode is made of elec- paragraph on page 31 with the sentence trons, atoms, molecules, ions, photons; each stating, “Some electrons in the ionization possessing a velocity vector. Due to the large layer with sufficient energy to overcome number of particles involved (for example, the electric field of the space charge layer the number density of air at atmospheric Dear Readers: will diffuse back to the surface of the pressure is 1025/m–3), it is impossible to cathode.” track them all. Therefore, one uses statisti- The Welding Journal encourages The electron is negatively charged, the cal distributions to describe the number of an exchange of ideas through space charge layer is a “cloud” of nega- particles with a given velocity vector. Thus, letters to the editor. Please send tively charged electrons, and the cathode statistically, there will always be a certain your letters to the Welding Jour- is negatively charged so the polarity of the number of particles moving toward the nal Dept., 550 NW LeJeune Rd., space charge layer and the cathode would cathode. Some will have high enough speeds Miami, FL 33126. You can also repel the electron. to overcome the repelling force of the elec- reach us by FAX at (305) 443-7404 Why would an electron diffuse back tric field (an analogy can be made with a through the space charge layer to the cath- rocket escaping the earth’s gravity). Please or by sending an e-mail to Kristin ode? It seems that it should be repelled. note that this description of the near Campbell at [email protected].

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For Info go to www.aws.org/ad-index StainlessQ+A July:Layout 1 6/6/08 3:20 PM Page 20

STAINLESS Q&A BY DAMIAN J. KOTECKI

Q: We are trying to fabricate a number of matching covered electrodes. This costs a trodes is expensive. What can we do to 3 AL6XN vessels ( ⁄8-in. wall thickness) lot of time and money. The covered elec- make successful submerged arc root 1 using ⁄16-in. Alloy 625 filler metal by sub- trode repairs never crack. Then we can passes? merged arc welding. This is the recom- successfully finish the joint with sub- mended filler metal, but we are fairly merged arc. The welders suggest that we A: AL6XN is a trade name for the super- often getting centerline cracks in the root use covered electrodes for the root pass to austenitic stainless steel whose composi- pass. When that happens, we have to begin with, then finish with submerged tion is given by UNS Number N08367. gouge out the cracks and repair with arc. An entire root pass with covered elec- Alloy 625 is a common name given to the

Table 1 — Composition Ranges for AL6XN and Alloys 625 and 22 Filler Metals

Alloy % C % Mn % P % S % Si % Cr % Ni % Mo % N % Cu % Nb % W % Fe AL6XN 0.030 2.00 0.040 0.030 1.00 20.0 to 23.5 to 6.0 to 0.18 to 0.75 Rem. N08367 max max max max max 22.0 25.5 7.0 0.25 max — —

Alloy 625 0.10 0.50 0.02 0.015 0.50 20.0 to 58.0 8.0 to 0.50 3.15 to 5.0 ERNiCrMo-3 max max max max max 23.0 min 10.0 — max 4.15 — max (Ni 6625)

Alloy 22 0.015 0.50 0.02 0.010 0.08 20.0 to 12.5 to 0.50 2.5 to 2.0 to ERNiCrMo-10 max max max max max 22.5 Rem. 14.5 — max — 3.5 6.0 (Ni 6022)

Alloy 276 0.02 1.0 0.04 0.03 0.08 14.5 to 15.0 to 0.50 3.0 to 4.0 to ERNiCrMo-4 max max max max max 16.5 Rem. 17.0 — max — 4.5 7.0 (Ni 6276)

20 JULY 2008 StainlessQ+A July:Layout 1 6/6/08 3:20 PM Page 21

filler metal classified in AWS A5.14 as duces a convex bead shape that some find ilar to those of Alloy 22. Your choice be- ERNiCrMo-3 or in ISO 18274 as Ni 6625. objectionable. Welding with longer elec- tween these two filler metals, should you The composition ranges for the base metal trode extension can reduce dilution, but it decide to follow the Nb-free approach, (from ASTM A240) and filler metal are tends to have problems with consistent can be based on cost and availability.◆ given in Table 1. Note that, even though bead placement (wire wander). Reducing iron is the most prevalent element (about welding current (by reducing wire feed 48% Fe vs. about 25% Ni) in N08367, the speed) can also reduce dilution, but that DAMIAN J. KOTECKI is president, UNS number system assigns a nickel- reduces productivity as well. Damian Kotecki Welding Consultants, Inc. based alloy designation (“N” prefix) to the Perhaps a better solution is to change He is a past president of the American alloy. Most of the world (including ASTM filler metals to one that meets the over- Welding Society, a past vice president of the A240) considers N08367 to be a stainless matching molybdenum requirement but International Institute of Welding, and a steel. Also included in Table 1 is the com- contains no niobium. The most common member of the AWS A5D Subcommittee position range for the filler metal com- choice in this regard is Alloy 22, AWS on Stainless Steel Filler Metals, and the monly known as Alloy 22, AWS A5.14 A5.14 Class ERNiCrMo-10 or ISO 18274 AWS D1K Subcommittee on Stainless Class ERNiCrMo-10 or ISO 18274 Class Class Ni 6022. This filler metal, whose Steel Structural Welding. He is a member Ni 6022, and the composition range for the composition range is included in Table 1, and past chair of the Welding Research filler metal commonly known as Alloy 276, is niobium-free. Therefore, it tolerates a Council Subcommittee on Welding Stain- AWS A5.14 Class ERNiCrMo-4 or ISO wide range of dilution possibilities in SAW less Steels and Nickel-Base Alloys. Send Class Ni 6276, for reasons that will become with minimal risk of solidification crack- your questions to Dr. Kotecki at clear later. Your selection of ERNiCrMo- ing. I assume that you have been using a [email protected], or to 3 filler metal for joining AL6XN follows high-basicity flux for SAW, as these are the Damian Kotecki, c/o Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126. the conventional wisdom with regard to only flux types that work well with ERNi- filler metals for superaustenitic stainless CrMo-3 filler metal. If so, the same flux steels. In order to obtain matching pitting should work well with the ERNiCrMo-10 resistance in the weld metal, it is generally filler metal — in fact, without niobium in Change of Address? necessary to use nickel-based alloy filler the filler metal, you are likely to encounter metal that overmatches the molybdenum better slag removal than you experienced Moving? content of the base metal. ERNiCrMo-3 with the ERNiCrMo-3 filler metal. filler metal is almost certainly the lowest Alloy 276 (AWS A5.14 Class ERNi- Make sure delivery of your Welding cost and most readily available filler metal CrMo-4 or ISO 18274 Class Ni 6276) is Journal is not interrupted. Contact the that meets this requirement. also a possible selection for filler metal. It Membership Department with your The centerline cracks you are observ- too is niobium-free, as can be seen in Table new address information — (800) 443- ing in the root pass are solidification 1. Its welding characteristics are very sim- 9353, ext. 217; [email protected]. cracks. They occur when liquid films per- sist in the weld metal over an extended temperature range while the weld is con- tracting during cooling. I believe the heart of your problem can be summed up in two words — “dilution” and “niobium.” A pretty good rule of thumb in estimating resistance to solidification cracking is that no niobium is good and a lot of niobium is good, but intermediate levels of niobium are dangerous. That is where dilution enters the picture. Welding with covered electrodes is pretty much limited to 30 to 35% dilution under most circum- stances, so that the root pass made with ENiCrMo-3 SMAW electrodes in AL6XN base metal will contain more than 2% Nb, and will be resistant to solidification cracking. However, submerged arc welding often produces 40 to 50% dilution, or even more. Fifty-percent dilution drops the root pass niobium content to about 1.5%, and that is dangerous as regards solidification cracking. This problem is not unique to welding of 6% Mo superaustenitic stainless steels — it is well known also in the welding of 9% Ni steels with ERNiCrMo-3 filler metal for liquid natural gas containment where root pass solidification cracking tends to occur in submerged arc welds. You can take steps in welding the root pass to limit dilution. Welding the root pass with DCEN polarity instead of the more common DCEP polarity is a good way to limit dilution, although it often pro- For info go to www.aws.org/ad-index

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Las Vegas October 6, 2008 at the FABTECH Int’l & AWS Welding Show

This roundup of advancements in the world of cutting will include such processes as oxyfuel cutting, plasma arc cutting, laser cutting, and water jet cutting. A great deal is happening in computerization. Cuts are far more precise, more repeatable, more accurate, and much faster than ever before. Accompanying the improvements in machines and controls are improvements in torches, consumables and cutting heads. A presentation will weigh the relative merits of the many fuel gases that can be put to work on oxyfuel cutting lines. This conference demonstrates that we have entered a new era in thermal cutting. To register or to receive a descriptive brochure, call (800) 443-9353 ext. 455 (outside North America, call 305-443-9353), or visit www.aws.org/conferences Page 22 and 23:FP_TEMP 6/6/08 12:37 PM Page 23

NEW TECHNOLOGIES IN THERMAL CUTTING CONFERENCE Waterjet Systems Can Cut a Wide Variety of Materials Monday, October 6, 2008 • 8:50 AM – 4:05 PM Wiktor Stepien, Vice President-Sales, and Bob Pedrazas, Marketing Las Vegas Convention Center Manager, KMT Waterjet Systems, Baxter Springs, KS Member of AWS, FMA, SME, NAM, or PMA: $345 Waterjet cutting systems are able to cut virtually any material. Nonmembers: $480 Waterjet machining offers many advantages compared to other Registration Code: W81 technologies, including colder cutting, increased precision, and a greater variety of applications. This presentation will be centered on Quality Flame Cutting After 107 Years the use of waterjet cutting applications for flat stock metals (alu- John Dawson, Consultant, ESAB Cutting Systems, Florence, SC minum, stainless steel), ceramics, stone, plastics, and composites A century of advances in flame cutting shows what the past can for the aerospace, automotive, job shops, electronic, stone, glass, teach us about the latest technologies and applications. and metal industries. Video examples will be included within the presentation to demonstrate how waterjet technology can help State-of-the-Art of Mechanized Plasma Cutting Technology, improve the quality, speed and efficiency of these manufactured James Colt, Strategic Accounts Manager, Hypertherm Inc., Hanover, products. NH Mechanized plasma arc cutting has been commercially used since Innovative CNC Control on State-of-the-Art Plasma Shape the early 1960’s for a variety of applications. Plasma has always Cutting Technology had a reputation as the “Productivity Process” due to its ability to Mark Osowski, Product Manager, Burny/AMC Business Unit, ITT cut a wide range of materials and thicknesses at high speeds. Cleveland Motion Controls, Cleveland, OH Advancements in the last ten years have further developed plasma Innovative features developed in Burny CNC controls are tightly into a more refined process that provides dramatically higher cut coupled to Kaliburn plasma systems to create a fully automatic part accuracy, high cutting speeds, full automation shape-cutting motion control process. This talk will detail how capability….all at a lower cost per foot of cut. ITT Cleveland Motion Controls is striving for new technology that takes the waste, both in time and material, out of the How Nesting Solutions Develop a Positive Impact shape-cutting process. Learn how you can save on on Thermal Cutting Processes labor and operating expenses in your plasma appli- Marius Pienaar, Director, SigmaTEK Services, cation. Cincinnati, OH This particular CAD/CAM software is Fuel Gases, Piping, and a Little OSHA designed to achieve the following: inte- John Dawson, President, Thermal gration for scheduling, estimating, Cutting Consulting Inc., Florence, SC engineering and costing; improved The decision as to which fuel gas part quality; improved utilization to use in a specific cutting opera- of materials; and improved cutting tion is not always an easy one. The flow. choice is extensive. It includes acetylene, propane, natural gas, propylene, Introduction to Industrial Lasers MAPP,LPG, etc. However, the appropriate Lou Derango, 2D Product Manager, Mazak choice can be made based on the best per- Optonics Corp., Schaumberg, IL formance/cost ratio. In addition, users of fuel An introduction to basic laser workings and consid- gases who have them piped into their plants are fac- erations with follow-up in a few typical metal applica- ing problems with certain OSHA regulations. This situations. This presentation is meant to be a primer for those tion will be explained. interested in pursuing laser technologies. The follow-up of the presentation will include a few samples of laser processing The Use of CAD/CAM Software to Program Robots to Cut quality with question and answer period. Structural Steel and Pipe Chris Anderson, Technology Leader-Welding, Motoman, W. Computerized Pipe and Tube Cutting Carrollton, OH Jim Blackburn, General Manager, Vernon Tool Co., a Business of Typically, robots are programmed manually with teach pendants Lincoln Electric Co., Oceanside, CA creating point to point programs. Offline programming is done in a Using a Powerpoint presentation, the speaker will briefly discuss similar fashion, but in a virtual environment. Cutting machines use current pipe cutting methods with attendant efficiencies. Specific CAD/CAM software to generate shapes and often automate pro- industries dictate different machine configurations, computer con- gramming tasks such as nesting multiple shapes in an optimized trols, and cutting methods. Recommendations for designing an effi- pattern on a sheet. Utilizing a conversion routine, these shape- pat- cient “burn rack” will be disclosed. terns can be converted to robot programs without the use of tradi- The speaker will also address improvements in mechanized cut- tional programming methods. This allows paths from CAD software ting machines, material handling alternatives and CAD-CAM data such as AutoCad to be converted into cut paths. Cut paths can also flow from popular isometric and structural modeling software. be created from G-code generated out of CAM software. Robotics Machine operations and features are a guide to effective, efficient brings the advantage of 6 degrees of freedom for positioning so shop production and labor saving opportunities. Thirty-five years of beveling and contours can be cut on 3D parts such as structural management provide historical perspective of machine evolution; shapes and pipe. from simple gear-driven machines to 6-axis CAD-CAM driven work cells. ®

Founded in 1919 to advance the science, technology and application of welding and allied joining and cutting processes, including brazing, soldering and thermal spraying. NP July 2008:Layout 1 6/6/08 3:31 PM Page 24

NEW PRODUCTS

welding filter series V, X, and XX have Ultrasonic Spot Welding Machines normal, large, and extra-large viewing Accommodate Large Metal Parts areas, respectively. 3M Welding The company’s C-frame www.speedglas.com metal spot welding machines (888) 364-3577 are now available for applications outside the auto industry. Inverter Power Source The initial development of these machines was part of an Suited for AC/DC Advanced Technology Program Submerged Arc Welding sponsored by Ford Motor Co. and partly funded by a grant from the National Institute of Standards and Technology. In developing the ultrasonic metal welding machines, the company has created units that permit more travel between the tip and anvil and have a deeper throat. WeldMaster™ C-Frame I contains one ultrasonic head and an opposing anvil. Weld- Master™ C-Frame II features two ultrasonic heads; one powers the welding tip, while the other powers the anvil. Ultra- sonic vibration is introduced from both sides of the weldment. This reduces the weld energy and weld time required in making a weld. Also, it reduces the tendency toward tip stick- ing of aluminum parts as well as deformation of the part welded. Each of the spot The Power Wave® AC/DC 1000 in- welding machines is supplied with the company’s microprocessor-controlled 2500-W verter power source is designed as part of power supply. The units can be bench mounted or adapted for robot operation. a modular welding system for single or multiple arc applications targeted at sub- Sonobond Ultrasonics merged arc users who want to increase www.sonobondultrasonics.com productivity and have greater production (800) 323-1269 flexibility. The machine is rated at 1000 A for AC or DC. Each welding arc may be driven by a single machine or a number of Welding Helmet Offers machines in parallel. It produces a variable AC output as well as straight DC pos- Many Adjustments For a itive or negative output. The product also Better Fit uses the company’s Nextweld® Waveform Control Technology®. The AC waveform The 3M™ Speedglas™ 9100 welding can be set to any frequency between 0 and helmet and autodarkening filter series re- 200 Hz. Plus, parameters can be con- places the Speedglas 9000 series. The hel- trolled and regulated automatically so met’s pivot point is located just above the synergic adjustments can be made by the welder’s ears. The cradle design of the machine while welding. head suspension, combined with the head- The Lincoln Electric Co. band’s self-adjusting boogie/twin pads, www.lincolnelectric.com more closely profiles the true shape of the (216) 481-8100 user’s head. The helmet also has a smoother up-and-down pivot action that Low-Hydrogen Covered gently locks in the up position. In addi- Electrode Minimizes tion, the head suspension system provides several adjustment combinations — back- settings are as follows: Shade 5 (for gas Cracking and Spatter and-forth, higher-and-lower, and tilt — welding/cutting), Shade 8 (for micro- so welders can fit the helmet to their per- plasma and low-amp GTAW), and Shades For general purpose, low-hydrogen sonal preferences. The seven dark shade 9–13 for most arc welding processes. The welding applications, the Hobart® 418

24 JULY 2008 NP July 2008:Layout 1 6/6/08 3:31 PM Page 25

Capacitive Discharge Welding Machine Features Improved Productivity

(AWS E7018-1 H4R) is a covered electrode with features that will help improve weld quality and productivity. It provides easy. It also features built-in pressure good arc starts and restarts, produces a plots and statistics, data storage, compen- virtually spatter-free arc, and creates a flat sation and calibration, and a pop up soft weld bead profile with a fine rippled fin- keyboard to facilitate program editing. ished appearance. The product has an easily removable slag as well. The electrode Uson L.P. provides good penetration and a weld www.Uson.com pool that washes into the sidewalls with (281) 671-2000 The 1000Ws Advanced Dual Pulse no undercutting. In low-temperature ap- welding machine provides improved pro- plications, it provides high-impact prop- Stainless Steel Flux Cored ductivity and weld consistency. The unit erties at temperatures as low as –50°F. The Wire Offers Higher includes a user interface incorporating a product is offered in 10- and 50-lb her- Deposition Rates 6.5-in. high-resolution color display. It metically sealed cans and 5- and 10-lb also comes in 100Ws and 300Ws versions. P-Paks (plastic resealable containers). The peak current for pulse 1 and 2 can be monitored, and limits set for each with the Hobart Brothers Co. option of second pulse inhibit. An ups- www.hobartbrothers.com lope function can be programmed on the (800) 424-1543 pulse to gradually increase the weld en- Leak and Flow Tester ergy to alleviate weld splash. The pro- grammable polarity function makes it pos- Provides Gas Control sible to individually select the polarity of Valve Inspection pulse 1 and 2, or have alternating polarity for successive welds. What’s more, the four pulse durations are spread more The Qualitek mR, a single-channel The Stoody® 300 series flux cored wire tester designed for high-volume industrial evenly to offer an increased range of weld- offers high-quality weld deposit, an envi- able materials and parts. leak and flow testing applications, com- ronmentally friendly wire basket, and bines advances in multi-range (mR) test- good feedability to reduce downtime. The Miyachi Unitek Corp. ing technology. It inspects gas control random wound wire provides a higher www.muc.miyachi.com valves, plastic reservoirs, packaging, and deposition rate. The product is stocked in (626) 303-5676 other applications. Two transducer inputs sizes 308L, 309L, and 316L; and in allow the tester to accept pressure decay, both flat/horizontal and all-position GTA Torch Packages differential pressure, mass flow, and load welding grades. cell transducers. A touch-screen color Come in Six Choices graphics display and PC-style menus, in Stoody® Co. Six torch packages include all of the combination with a rotary scroll and click www.stoody.com components necessary for GTAW. Four navigation device, make setup and testing (636) 728-3000

For info go to www.aws.org/ad-index WELDING JOURNAL 25 NP July 2008:Layout 1 6/6/08 3:32 PM Page 26

available with WTP17R, WTP17VR, GMAW Machine Offers WTP26R, or WTP26VR air-cooled GTA Simple Setup torches with rubber cables. The torch packages each contain a 25-ft power cable and cable cover (water-cooled packages), a power cable adapter, and a 15-ft ground cable. Also provided are gas hoses and water hoses (as required), a Smith Equip- ment flow meter regulator, and a welding accessory kit featuring additional nozzles, collets, collet bodies, back cap, and tung- torch packages are for air-cooled applica- sten in every torch package. tions ranging from 150 to 200 A, and two Weldcraft water-cooled torch packages include ei- www.weldcraft.com ther a 250- or a 350-A torch. They are (800) 752-7620

The Millermatic® 180 with Auto-Set™ runs off 230 V, giving the user the capa- 5 bility to weld from 24 gauge up to ⁄16-in. mild steel in a single pass. Auto-Set is designed to work on mild steel using C25 gas (75% argon, 25% CO2). Just select the wire diameter (0.023 or 0.030 in.); set the machine to the material thickness being welded (the company provides a free material thickness gauge to check it with); and start welding. The machine is automatically set to the proper voltage and wire feed speed for the job. An accessory is Miller’s Spoolmate™ 100 Series spool gun. Hooked up to this machine, the series can weld from 18 gauge through ¼-in. aluminum.

Miller Electric Mfg. Co. www.MillerWelds.com (920) 734-9821 Preengineered Welding Cell Offers Flexibility

The PA-55 preengineered Perform-Arc welding cell can accept a payload of up to 250 lb per side and welds typical part sizes that include 12 × 53, 18 × 45, and 24 × 30 in. A platen design provides repeatable fixture locating when multiple fixtures are to be exchanged on the same work cell. It For info go to www.aws.org/ad-index

26 JULY 2008 NP July 2008:Layout 1 6/6/08 3:32 PM Page 27

comes standard with a Panasonic 6-axis robot, an inverter welding machine with artificially intelligent waveform control, and a torch. Full system controls, diagnos- tics, and programming capabilities are managed by the color teach pendant, running Windows CE to flatten the learning curve.

Panasonic Factory Solutions Co. of America www.panasonicfa.com (847) 495-6100 tary inputs, half cycle, and repeat and non- repeat. In addition, the accessory kit in- Weld Control Components cludes precautionary labeling, fuses, and Available for Resistance hardware to mount the components. Welding ENTRON Controls, LLC. [email protected] (864) 416-0190 a higher vapor pressure than MAPP, re- The EN50 basic weld timer is a com- sulting in better performance in colder pact unit that when combined with its temperatures. components, provides a basic control for Manual Torch Fuel resistance welding. The components con- Replaces Discontinued Gas TurboTorch sist of a EN50 timer, SCR firing board, www.turbotorch.com 300-A air-cooled or 1200-A water-cooled The company offers MAP//PRO™ gas (636) 728-3000 SCR contactors, power supplies, and an as a new fuel for the manual cutting in- accessory kit. This timer offers basic con- dustry. The introduction comes after the Welding Ventilation trol and programming features with four announcement that the sole North Amer- Hoods Require No inputs and four outputs, squeeze delay, ican manufacturer of MAPP® gas will no pulsation, upslope, two weld intervals for longer produce this gas as it is closing its Compressed Air preheat/postheat, counter with optional Canadian operations. MAP//PRO, pro- lock-out for electrode maintenance, two- duced by Worthington Cylinders, has a The RHV welding hood is a packaged stage foot switch, interlock output, retrac- higher flame temperature and better com- welding smoke and fume hood for indus- tion option with maintained or momen- bustion intensity than propane. It also has trial air filtration. The units can be con-

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

WELDING JOURNAL 27 NP July 2008:Layout 1 6/6/08 3:33 PM Page 28

figured to cover areas from 4 × 4 to 16 × 16 ft and larger if needed. A three-stage filter system includes the baffle filter, 4- in. pleated filter (Merv 7), and the 95% multipocket main bag filter (Merv 14). The system further incorporates a low static pressure motor blower package, requires no compressed air, and no handling of dust from trays or drums. The filters can be adjusted to include a final HEPA filter for stainless steel or other applications requiring high-efficiency filters.

Industrial Maid LLC www.industrial-maid.com (877) 624-3247 For info go to www.aws.org/ad-index Downtime Eliminated with Reversible Ratchet Headband

The patented SWINGSTRAP™ SUPEREIGHT® cap by Fibre-Metal is a choice when mounting face or welding protection onto a hard hat. To use, simply swing the product forward to wear rear facing and back again for the forward peak position. It eliminates downtime from removing, reversing, and then rein- stalling the whole suspension.

North Safety Products www.northsafety.com (888) 422-3798

For info go to www.aws.org/ad-index — continued on page 93 28 JULY 2008 3M:FP_TEMP 6/5/08 9:47 AM Page 53

For Info go to www.aws.org/ad-index Mitchell Feature July 2008:Layout 1 6/5/08 11:23 AM Page 30

Packaging for Productivity

While packaging may be an easily overlooked area of the welding operation, it can positively contribute to a company’s overall efficiency

BY IVAN MITCHELL

Yet choosing and using the right size, style, and weight of filler metal packaging, along with implementing good storage practices, can contribute meaningfully to a company’s overall efficiency — Fig. 1. First, the proper filler metal packaging can reduce downtime for changeover — all time spent moving a package off the line, retrieving another, and readying it for welding takes away from production. The right package can also help ensure that labor is allocated for value-added activities, or those activities that contribute to the overall throughput. Proper storage of packaging further supports good welding wire performance, which in turn can minimize timely and costly rework that takes away from production. Here are a few packaging factors that in conjunction with the right equipment, appropriate welding wire, and good lean manufacturing and fabricating practices can aid in improving a company’s overall productivity. Remember, the impact filler metal packaging has on productivity may not be immediate, but it can make a difference over the course of time. Less Changeover and Waste = More Arc-On Time

Most types of filler metals — for the sake of this discussion, welding wires (solid, flux cored, and metal cored) — are available in Fig. 1 — Filler metals come in a variety of sizes, styles, and weights; choosing the right pack- a variety of styles and weights. Most range aging can reduce downtime for changeover. from as small as 15-lb spools to as large as 60-lb coils and 900- or 1000-lb drums. The first consideration when choosing hen a company improves its pro- help improve productivity, as well they the right packaging is whether the weld- ductivity, it automatically im- should be. The right power source for the ing operation is inside or outside. For out- Wpacts its bottom line — posi- application can make a measurable dif- side construction, shipbuilding, or general tively. In recent years, the emergence of ference in the speed and quality of weld- field welding applications, portability is lean manufacturing trends and improved ing. So too can the right filler metal — a key in maintaining good productivity; welding processes have supported that metal cored wire process, for example, dragging a large filler metal package goal across many industries. Faster, more certainly completes the job faster than a around is simply not feasible. It takes too efficient workflow simply creates greater shielded metal arc electrode. much time and labor. Instead, a 15-lb throughput. But what about the right filler metal spool would be appropriate. Not surprisingly, when a company (specifically, welding wire) packaging? In a one to two person (indoor) shop looks at its overall welding process, power This too is an important but frequently where the weekly volume of welding wire sources are often the top consideration to overlooked aspect of the welding process. usage falls into the 150- to 200-lb range,

IVAN MITCHELL is application engineering specialist, Hobart Brothers, Troy, Ohio, www.hobartbrothers.com.

30 JULY 2008 Mitchell Feature July 2008:Layout 1 6/5/08 11:24 AM Page 31

33-lb spools can help minimize changeover (as compared to a 15-lb spool, Table 1 — Package Change Cost Analyzer for example) and would be appropriate to the volume of products welded. Con- Estimated Annual Usage (lb) 1,000,000 versely, a 15-person shop that currently Current 900-lb Drum uses 33-lb spools would in all likelihood Package Weight 400 900 Minutes to Change 30 30 use these spools in one day. Moving to 60- Labor Cost $20 $20 lb coils here could minimize the Overhead Cost $30 $30 changeover to once every two days and Cost per Change $25 $25 allow for more arc-on time. Number of Changes per Month 208.3 92.6 These situations are relatively straight- Number of Changes per Year 2500 1111.1 forward: Use a smaller package for Cost of Changes per Month $5208.33 $2314.81 smaller volume production and increase Cost of Changes per Year $62,500 $27,777.78 incrementally according to the number of Monthly Cost Savings of 900-lb Drum $2893.52 welding operators to minimize downtime Yearly Cost Savings of 900-lb Drum $34,722.22 for changeover and aid in greater productivity. However, when a welding operation has more welding operators or an auto- fiber parts into the appropriate waste con- Companies should work with a filler mated system and greater throughput is tainers, and it also lowers the cost of that metal manufacturer or welding distributor desired, choosing the right packaging be- waste disposal. Not to mention, recycla- to assure timely delivery of welding wire to comes a little more complicated. Fortu- ble drums are safer; they reduce the risk a designated location. There should always nately, the option to minimize downtime of injuries caused by cutting away the be enough packages of filler metal in stor- and costs, and improve productivity by metal chimes. age to prevent a production stoppage. Also, going to a larger package usually becomes Steel reels that are often used to hold companies should rotate stock to ensure more practical. solid wires can also be scrapped for recy- that no packaging sits in storage for an ex- For instance, a company that employs cling, again minimizing labor for waste tended period of time; those filler metals robotics or hard fixture automation in its disposal that could instead be used in the delivered first should be used first to gain facility would obviously require a greater weld cell. the best welding performance. volume of welding wire in a larger pack- Upon arrival, the filler metal package age to meet its production goals than a 15- Stay Close, should be placed in an area that is easily man shop. How large is the question. Follow the Rules accessible when changeover is necessary. In many cases, 400- or 600-lb drums Excessive downtime can occur if a weld- work well in high-volume, automated ing operator has to go a far distance to ac- welding operations. Consider a company Where and how a company places its quire another package and that again takes that uses a million pounds of welding wire filler metal package, while it is in use or valuable time away from the weld cell. per year paid out in 400-lb drums. It in storage, can also contribute to the over- Likewise, proper storage of filler metal would require approximately 208 changes all efficiency and productivity of its weld- packages helps ensure top performance per month, or 2496 changes in a year. At ing operation. from the filler metal and can help compa- an average of 30 minutes per changeover, The package, whether a spool, reel, or nies avoid unnecessary rework — welding that company could spend about 104 drum, needs to easily fit into the allotted operators can contribute to a product’s hours of its labor per month changing out footprint in a weld cell lest extra time be throughput rather than spend time repair- the drums. Here, moving to a larger ca- spent trying to maneuver it into the area. ing mistakes. As a rule, until the package pacity drum might make sense; instead of Ideally, it should take up as little space as is opened it should be stored in a dry, well- using those 104 hours for changeover, a possible. In high-volume production fa- ventilated place to protect against mois- larger drum could allow a portion of that cilities, placing two drums on a mezzanine, ture, the number-one culprit of welding time to be used toward meeting greater for example, may be the most appropri- wire damage. Additional storage informa- production goals (Table 1). ate place and the easiest to aid in good tion recommended by the filler metal Here’s how: A 900-lb drum takes the work flow, another factor that contributes manufacturer should always be followed. same 30 minutes to change over, but re- to improved productivity. When one drum quires only 93 changes per month (1116 is empty, the spare one can be engaged per year), for a total monthly changeover and the next spare can be added during a Make an Assessment labor time of 46.5 hours. Subtracted from nonproduction time. the previous 104 hours of changeover per The filler metal package should also Packaging may be an easily overlooked 400-lb drum, that adds up to a savings of be in a place where it is not in the way of area of the welding operation, but it can 57.5 hours per month of labor, or approx- moving equipment, such as forklifts, that positively contribute to a company’s over- imately 690 hours saved per year. These can damage it. Damaged packages can all efficiency. Companies that experience hours can then be reallocated to addi- cause unnecessary downtime for change- excessive downtime for package tional welding and/or other parts of the out, and this damage can also void the war- changeover, have high waste disposal costs welding process (cleaning, fixturing, etc.) ranties provided by filler metal manufac- or increased labor for package disposal, or that instead assist in productivity in- turers. Not only does a company run the those that simply are looking to increase creases. risk of downtime and increased labor for throughput and their bottom line may want Finally, the right weight package can replacing the package, but it could also to look at their current packaging. Filler also minimize labor spent taking care of incur additional cost for new wires. metal manufacturers or a trusted welding waste — labor that can again be spent else- Drums, spools, and reels should not be distributor can provide audits to help com- where to contribute to the company’s pro- double-stacked for the same reason. panies determine which is the best option ductivity. Some filler metal drums are now Stacking can damage the wire, and it can — in addition to the right equipment and 100% recyclable, which minimizes addi- also be dangerous to welding operators welding wire — to help improve workflow tional downtime for separating metal and should the reel or drum fall. and increase productivity.◆

WELDING JOURNAL 31 Chan 7 08:Layout 1 6/5/08 3:37 PM Page 32

Save Time and Money with Resistance Welding Simulation Software

Software takes into account various strengths and limitations of welding processes and materials to predict optimum welding conditions and joint design

BY KEVIN R. CHAN

ignificant time and money can be saved with the use of software that simulates the process of resistance Solidified S Nugget welding. This article provides specific ex- Work Sheets Molten amples of how this has been done with the Nugget finite element modeling software called Sorpas®. This software has been used to assist in the design of resistance welding parts and joints. It determines welding pa- Electrodes rameters, how the welding parameters can be optimized for various conditions in production, and forecasts the microstructure of the parts after welding. This software is currently in use by Fig. 1 — The basics of the resistance welding process. major automotive and manufacturing companies such as GM, Ford, Honda, Volkswagen, Chrysler, Mercedes Benz, Resistance Welding tribution; 3) the metallurgical model, with Volvo, Peugeot, Citroën, Bosch, Siemens, its temperature-dependent properties and and ARO. These and other companies Resistance welding is an inexpensive phase transformation characteristics; and use the software to reduce time and process that requires no shielding gases 4) the mechanical model with its defor- money in resistance welding, from the de- or filler metals to create a metallurgical mation, stress and strain distribution in sign stage to production floor. fusion bond. An electric current is passed the contact areas, electrodes, and geome- through the metals to be welded after a tries of the workpieces (Ref. 1). Each cal- Market Challenges force is applied, and their innate resist- culation or iteration involves the use of ance to the current generates sufficient all four models as shown in Fig. 2. Clearly, there is an imperative to re- heat to create the weldment. This is shown The operator enters into the computer duce costs and the “time to market” in an in four basic steps in Fig. 1. the geometry of the parts, identity of the age of increasing globalization and com- materials to be welded, the interface con- petition. At the same time, many new ditions, and the electrodes employed. In steels that are both stronger and lighter How Simulation Works another window, the user enters the weld- are increasingly being employed to raise ing parameters to be used, such as force, fuel economy and to provide greater crash The software uses the power of mod- time, and current. The user can also ask protection. These driving forces for ern microprocessors to fully articulate all the computer to generate the required change and improvement bring problems the variables in resistance welding. It does welding parameters, and automatically or of increased design and welding complex- this by considering and calculating all the manually alter the extent of accuracy ity when these steels are used. variables through four separate yet fully sought and the overall simulation con- coupled models: 1) the electrical model, trols. When instructed, the computer gen- with its current/voltage distribution and erates welding parameters, welding lobes, KEVIN R. CHAN is with Huys Welding heat generation; 2) the thermal model, and optimizations, based upon the in- Strategies, Weston, Ont., Canada. with its heat transfer and temperature dis- structions it has received. All input vari-

32 JULY 2008 Chan 7 08:Layout 1 6/5/08 3:38 PM Page 33

ables are kept in common welding param- the welding parameters for long-term eters and terminology. In Fig. 3, an exam- performance and quality. ple of one of the printouts available, which provides a summary of the simulation, is Simulating Projection shown. Other reports include real-time animations of the simulated weld, show- Welding at Volkswagen ing such data as deformation and heat and strain distributions. Volkswagen’s patents governing Resist- ance Welding with Additional Elements was Design Stage achieved with the software (Ref. 2). These patents can cover welds in dissimilar met- In the design phase, the characteristics als where additional material is inserted and limitations of various joining at the faying surfaces. processes and materials are weighed and The software was able to reduce the selections made. Engineers consider the testing of their hypotheses by simulating Fig. 2 — The coupling of numerical parts, their design, and how they might fit projection welding that acts in a similar models. together. Today, especially in the automo- fashion to their “additional elements.” tive sector, with our future oil supplies un- Volkswagen believed it would be very time (Fig. 5), it can be seen how one company certain, more and more attention is being consuming and expensive to consider the has used different designs of insulation applied to thinner and stronger alloys to influences of heat, force, and current on (blue) in the part (on the left) to gener- take a larger role in manufacturing. Gen- the myriad different materials considered ate different weld characteristics after erally, all of this analysis has to be done for this process (Ref. 3). The software was simulation (on the right). Modeling and more quickly than in the past. able to significantly reduce and focus the simulation of the differing part configu- Detailed below are examples of how testing window. Volkswagen’s drawings rations were able to show the differences Volkswagen, a manufacturer of micro (Fig. 4) illustrate how modeling and sim- in how the heat was generated in the parts welded parts, and Honda saved time and ulation of projection welding helped and, subsequently, how the weld initiated money at the design stage by using this achieve production welding parameters and grew. Therefore, the engineer could simulation software. They used it to visu- for its innovative process. choose which design looks the most prom- alize the inner workings of the welding Other companies have used the soft- ising and pursue it with additional testing. process, thereby reducing testing and ware to help design the actual part used The simulations can greatly decrease the costs, while at the same time optimizing in production (Ref. 4). In the drawings time to market, while at the same time cre-

Fig. 3 — Report summarizing test results.

WELDING JOURNAL 33 Chan 7 08:Layout 1 6/5/08 3:38 PM Page 34

ating a paper trail where choices made are appropriately documented, with their accompanying result noted. Reducing Test Requirements at Honda

Honda used the software to reduce the number of tests needed to find an inexpensive way to join the hem of an exterior car door and its inner panel without marking the outer surface. The software was used to aid in the optimization of welding parameters and projection design for an indirect hem projection weld (Ref. 5). Fig. 4 — Illustrations of Volkswagen’s patents for Resistance Welding with Additional In this case, physically prototyping the Elements. many different configurations and testing the actual parts was not economically sound. Without simulation, the choices available for welding parameters of a hem projection indirect weld are daunting and perhaps unmanageable with the newer coated steel alloys. However, the software was able to reconfigure the electrodes and tools to accommodate any resistance heating process. Figures 6 and 7 show Honda’s design. The software accurately estimated the effect of different welding parameters and projection nipple heights that would produce an indent-free outer surface. This was possible by running a series of simulations with certain variables altered. Anticipating New Materials

The performance characteristics of some new TRIP and DP steels alter when they are welded. When these new complex phase steels are made, their strength and character arise from the unique mi- Fig. 5 — Example of using different insulation designs (left) to generate different welding crostructure resulting from controlled characteristics. cooling and heating. The fusion nugget and heat-affected zone present a temper-

Fig. 6 — Geometric mesh generated by the software for Fig. 7 — A finished simulation illustrating a specific combination of welding pa- finite element modeling. rameters and projection designs.

34 JULY 2008 Chan 7 08:Layout 1 6/5/08 3:38 PM Page 35

Fig. 8 — A metallographic photograph and a simulation showing Fig. 9 — Graphs indicating time and temperature during the weld- peak temperatures in different regions of the weld and HAZ. ing of specific sites, or nodes, of the weldment (see Fig. 8).

ature range from melting to slight warming around the weld area. This temperature history destroys the carefully created microstructure that gave rise to the steel’s character in the first place and can also lead to other problems such as hardening and cracking. The cooling rate of an advanced steel is often critical to its performance and microstructure. Another issue may be that there is a DP steel welded to a high-strength low-alloy (HSLA) steel, creating a weldment with an unknown mixture of two alloys in the weld. Thus the cooling rate of a weld in an advanced high-strength steel may adversely affect the performance of that steel in a crash. With these types of issues in mind, the University of Waterloo is working with Sorpas® to predict the microstructure, and hence the performance, of a weld in simulation (Ref. 6). Figure 8 is an amalgamation of a metallographic photograph of a weld performed in the university on the left which has then been compared to the earlier simulation on the right to confirm its reliability. Dotted lines indicate the overall accuracy of the simulation. Certain nodal points in the simulation are indicated on Fig. 10 — A published constant cooling diagram indicating the peak temperatures from the drawing, and the simulation indicates Figs. 8 and 9. their peak temperature (far right). These peak temperatures are then generated as graphs (Fig. 9), which indicate the design and prototyping stages of new cooling rate based upon increments in the coarse zone of the HAZ, the fusion products and new materials. The great- weld time of a second weld pulse. Thus it zone, and the intercritical HAZ. Then est use, however, has proved to be in the becomes easy to adjust and document they are referenced to published constant day-to-day use of the software as an aid changes and improvements in a produc- cooling diagrams (CCT), a copy of one to increasing stable and consistent pro- tion setting (Ref. 7). which is reproduced in Fig. 10. Colored duction and the optimization of welding The production environment is prima- dots on the CCT in Fig. 10 tie into the col- parameters. rily concerned with optimizing welding pa- ors on Figs. 8 and 9, indicating the vari- As an example, take the parts in Figs. rameters and to maximize and stabilize ous regions of the weld, based upon peak 8–10. Let us suppose that we want to production. Optimization is an ongoing temperature. It is noteworthy that the sim- change the peak temperature of the weld- process, as parts will have variances in ulated peak temperatures of the weld tie ment and thus control its cooling rate. their fit and setup, and the materials them- into the CCT diagram and the metallo- The software can predict changes in the selves will vary both in their surface prepa- graphic photographic record of the weld. resultant microstructure with changes in ration, cleanliness, and appearance as well the length of heat or numbers of pulsed as in the materials from which they are Production Stage heat inputs. Figure 11 shows results from made (Ref. 8). Therefore, it is every engi- simulation for the temperature history in neer’s desire that he or she can find the Described above is how this software the coarse-grained HAZ and the result- best spot in the weldability lobe to gain can help reduce time and money spent in ant changes to peak temperature and that overall consistency.

WELDING JOURNAL 35 Chan 7 08:Layout 1 6/5/08 3:39 PM Page 36

trode melting, red shows expulsion at the interface between sheets, green for welds, and gray for no welds — Fig. 12. The generation of these weldability lobes was then used as an initial guide to set individual welding machines. It was found that the simulations were, on average, 90% accurate. The company also adopted titanium-carbide metal matrix composite coated electrodes, which were found to have a wider welding lobe than uncoated Class 2 electrodes. The company believes that it has saved $100,000 with the simulation software. The savings came from the following: 1) reduced costs with fewer tests, 2) reduced scrap and wasted time, 3) reduced costs for production maintenance problems, 4) reduced time to respond to OEM Fig. 11 — Variations in the length of a postweld tempering pulse of a weld are graphed for requirements, peak temperature and cooling rate. 5) reduced time for production running, settings determination, and optimization, 6) improved weld quality and production stability, and 7) fewer problems and misunderstand- ings and more accurate and documented procedures. Conclusions

This simulation software for resistance welding, in the hands of a qualified engineer, can significantly reduce the time and expenses of developing new designs and materials, establish better process parameter settings, and improve troubleshooting and weld quality.◆

References

1. Zhang, W. 2004. Design and implementation of software for resistance welding process simulations, SAE. 2. Patent number DE 102 51 414 A1; published 05.19.2004. 3. Simulation of innovative resistance welding processes. 2002. Volkswagen AG, K-EFWW, 17.10. 4. Huys technical bulletin #14 and simulation of resistance projection and spot welding. 2006. SWANTEC Software and Engineering Fig. 12 — Weldability lobe diagram. ApS. 5. Edwards, P., and Chan, K. 2006. Lowering costs by simulating design of complex welds, SMWC. Automotive Parts Supplier lems of poor quality welds, inspection, and 6. Khan, I., et al. 2006. Predicting mi- Optimizes Welding Variables repair (Ref. 9). crostructure using Sorpas cooling rates, Uni- The software has a function to auto- versity of Waterloo. matically generate weld current optimiza- 7. Khan, I., Kuntz, M., and Zhou, N. 2006. As an example, a North American Tier tions based upon a requested size of weld Monitoring the effect of pulsing using Sorpas, 1 automotive supplier that is currently nugget. Complete weldability lobes are University of Waterloo. welding a new line with DP600 steel found calculated in accordance with ISO 8. Zhang, W. 2006. New developments and that its initial welding lobes were very nar- 14327:2004. The weldability lobe gener- challenges in simulation and optimization of resistance welding. Proceedings of the 4th Inter- row and that the welding heat was too ated by the software has solid colors indi- national Seminar on Advances in Resistance high, which caused not only shorter elec- cating risk of expulsion while also indicat- Welding. trode life but also transformer duty cycle ing the nugget size. It also indicates nugget 9. Scotchmer, N. 2005. Widening the weld- issues. In addition, the company had lim- width at the convergence of the weld time ing lobe in the RSW process of advanced high ited time and resources to deal with prob- and weld current. Purple indicates elec- strength steels, BAM.

36 JULY 2008 thermadyne:FP_TEMP 6/6/08 2:55 PM Page 37

For Info go to www.aws.org/ad-index Roehl and Stanzel Feature July 2008:Layout 1 6/5/08 3:44 PM Page 38

Improved Pulsed Gas Metal Arc Welding Nets Higher Productivity

With olderolder GMAW-PGMAW-P machinesmachines fine-tuning thethe arc was complicated, related Scott Exner, manufacturing engineer,engineer, OEM Fabricators,Fabricators, Woodville, Wis. WithWith today’s machines,machines, the company’scompany’s welders onlyonly adjustadjust wirewire feedfeed speed.speed.

f all the recent advances in weld- bead appearance. It really shines on thin for most companies, with solutions avail- ing technology, some of the most materials, aluminum, and highly alloyed able from out-of-the-box, all-in-one ma- Oexciting and beneficial are in the metals where precise heat control pre- chines for small fabricating shops to multi- area of pulsed gas metal arc welding vents melt-through or metal dilution. In GMA process systems with programs op- (GMAW-P). In GMAW-P, as the name many cases, it can replace gas tungsten arc timized for mass production or more spe- implies, the welding current transitions or welding (GTAW) yet provide a similar ap- cialized applications, such as pipe fabri- “pulses” between a high peak current, pearance, while providing the faster travel cation and power plant construction. where metal transfer occurs, to a low back- speeds and decreased training time asso- Additionally, the complex interface of ground current, which maintains the arc ciated with gas metal arc welding yesterday has been replaced by much sim- but allows the pool to cool — Fig. 1. This (GMAW). pler interfaces. Today’s welding operator creates a welding capability with increased Unfortunately, many of those who only needs to know a wire type, size, gas, deposition rates and decreased spatter. tried GMAW-P in the 1990s dismissed the and preferred arc setting, and then adjust Good applications for GMAW-P in- process as too complex — and it was — wire feed speed to weld different thick- clude those prone to such problems as in- often requiring a welding engineer to nesses. This synergic or “one-knob” con- complete fusion, warpage, melt-through, make it work. That has changed. trol, along with the ability to maintain arc spatter, lack of pool control, and poor GMAW-P has now become accessible length regardless of electrode extension,

CHRIS ROEHL and KEN STANZEL are with Miller Electric Mfg. Co. (www.millerwelds.com), Appleton, Wis.

38 JULY 2008 Roehl and Stanzel Feature July 2008:Layout 1 6/5/08 3:44 PM Page 39

Today’s pulsed welding technology enables welders to easily create weld beads of just the right size to eliminate excess heat input, overwelding, and postweld grinding

BY CHRIS ROEHL AND KEN STANZEL

has made it much easier to train new than in other modes. It is also prone to welders and for those new welders to producing spatter. One of its advantages achieve quality results quicker. For many is that, because it produces a smaller, employers facing the welder shortage, this cooler weld pool that solidifies quickly, it capability alone is sufficient to turn to can weld in all positions. GMAW-P. In spray transfer mode, the wire does This, however, is only one of the ben- not short against the base metal. Instead, efits of current GMAW-P technology. with higher heat input, the arc sprays a Others include the following: stream of molten metal across the arc, • Decreased waste and rework. Be- achieving higher deposition rates, but also cause GMAW-P allows precise control of producing a larger weld pool that limits its the heat put into a weld, it eliminates ex- use to horizontal and flat position weld- cess heat that can lead to melt-through or ing. With its higher heat, it is prone to melt- 1 warping on thin materials, especially alu- through on materials thinner than ⁄8 in. minum, and provides better control for In pulsed spray transfer, commonly less-than-optimal fitup — Fig. 2. called GMAW-P, the current switches be- • Eliminate spatter and associated tween a high peak current and a low back- costs. Today’s systems monitor arc condi- Fig. 1 — The components of a GMAW-P ground current. At the current’s peak, a tions thousands of times per second and waveform. droplet is pinched off the wire and sprayed can detect and clear a short before it be- toward the weldment. The current then comes a problem or causes spatter — Fig. drops to a background level. During this 3. This eliminates the need to apply and ter likely to be encountered. This elimi- period the pool is allowed to freeze remove antispatter material. Parts can nates operator guesswork and helps less slightly, providing the out-of position ca- often go to painting without the need for skilled welders become productive pabilities. Yet the process maintains many postweld grinding. quicker. benefits of spray transfer, such as good fu- • Allow out-of-position welding. Un- • Larger wires — less cost. GMAW-P sion, high deposition rates, and/or fast like spray transfer, which requires weld- can also allow the operator to use larger- travel speeds. ing in the flat or horizontal positions, diameter wires. Larger-diameter wires are GMAW-P allows the pool to freeze usually less expensive per pound than First and Second slightly between current peaks. This thinner wires. In the case of aluminum, Generation GMAW-P means it can be used in out-of-position larger wire is easier to feed and less prone welding and eliminates the need to repo- to birdnesting. sition weldments, as one would with spray • Decreased training time. Today’s In general, there are several parame- transfer. GMAW-P technology enables new oper- ters considered when an engineer creates • More productive aluminum welding. ators to start making production-quality a pulsed waveform, as listed below. While it used to require a skilled GTA welds in less time, and it gives experienced 1. Peak current (heat). Increasing peak welder to achieve a good bead appearance operators even more control over bead current increases melt-off rate and arc on aluminum, GMAW-P rivals gas tung- appearance. It allows operators to hold a length, and slightly increases average am- 3 1 sten arc welding in appearance and can short ( ⁄8- to ⁄2-in.) electrode extension for perage and heat input. replace that process in many applications, better control over the weld pool. Further, 2. Background current (arc stability). increasing travel speeds by 30% and re- it automatically compensates for contact Increasing background current increases ducing heat by 50% — Fig. 4. Addition- tip-to-work-distance variations, maintain- arc length, average amperage, heat input, ally, becoming proficient in GMAW-P re- ing a constant electrode extension to en- penetration, and pool fluidity. quires less training than with GTAW. sure a consistent weld. 3. Pulse frequency. Increasing the Compared to short-circuit gas metal arc pulses per second increases arc length, av- welding, GMAW-P ensures good fusion. Origins of GMAW-P erage amperage, and heat input. • Maintain base metal chemistry. 4. Pulse width. Increasing pulse width Many applications, such as cladding with Pulsed gas metal arc welding was de- increases arc length, heat input, and pen- Inconel®, require precise control over the veloped as an alternative to short circuit etration and cone width. heat in order to maintain the chemistry and spray transfer modes in the shipbuild- 5. Pulse rise and falloff time. Adjust- and properties of the alloy — Fig. 5. The ing industry. ing these can affect the sound and feel of precision of GMAW-P provides this level In short circuit transfer, the welding the arc. Some of today’s high-end of control. Systems optimized for these wire shorts against the base metal many machines tailor these values for specific applications, both in manufacturing and times each second to deposit metal into applications. construction, will contain programs for the weld pool. Wire feed speeds, deposi- These parameters will vary according each alloy, shielding gas, and wire diame- tion rates, and voltages are typically lower to wire size and alloy, metal thickness, po-

WELDING JOURNAL 39 Roehl and Stanzel Feature July 2008:Layout 1 6/5/08 3:45 PM Page 40

Fig. 2 — With GMAW-P, operators at Metal Shark Aluminum Boats, Jeanerette, La., can make long welds without having ribs in place because the welding process does not cause any heat-related distortion.

sition of weldment, type of gas, desired was fortunate, the programs worked as in- bead profile, and operator preference. tended; however, field conditions often In the preinverter days, however, when didn’t match the lab conditions and could GMAW-P was introduced, very few of necessitate altering the programs. This these parameters could be adjusted. Op- could mean having a welding engineer or Fig. 3 — By switching to a GMAW-P system erators were limited to setting the fre- the manufacturer reprogram each of the for its mild steel, welded barbells, Iron Grip quency to 60, 120, and, in some cases, 180 teach points. Or it could mean flying in a Barbell Co., Santa Ana, Calif., was able to Hz (multiples of input frequency) and welding engineer to change the programs eliminate the need to apply antispatter, peak amperage. on site. while increasing productivity by 16%. The introduction of inverters gave In addition, response times were much much more control over the pulse param- slower than with today’s technology. Over- eters. An inverter takes input power, fil- shoots and undershoots, which refer to GMAW-P offers. ters it, and creates an output that is inde- the control circuit’s going beyond the tar- For example, one popular all-in-one pendent of input. They are lighter than geted peak or background current, were GMA/GMAW-P machine contains pulse conventional power sources, and some difficult to control and could lead to arc programs for mild steel, stainless steel, continue to provide a stable output re- outages. If a short circuit did occur, it 4000 and 5000 series aluminum, and metal gardless of wide fluctuations in input could take several cycles to clear it. The cored wire in various wire sizes and gas power. responsiveness of the technology has been combinations. The user only has to dial in Unfortunately, the ability to set all of likened to driving a car and trying to ad- the wire size, type and gas, and adjust wire the pulse parameters added a layer of just your direction by looking in the feed speed based on material thickness. complexity to the equipment that usually rearview mirror and only opening your An arc control switch allows the user to required a welding engineer to operate. eyes once every minute. set arc preferences, such as length and There were no formulas. Typically, a weld- Unfortunately, this generation of width. ing engineer would set up the equipment GMAW-P machines turned off many com- More advanced equipment contains in a lab and develop programs, each based panies to the possibilities GMAW-P more programs and is optimized for use on material, gas, and wire diameter. At 15 offered. in high-volume manufacturing, pipe fab- “teach points” in the wire feed speed spec- rication, shipbuilding, power plants, and trum, the engineer would adjust pulse pa- Taking Today’s Pulse other applications where special alloys are rameters for optimal results. These results used. It does this without sacrificing ease were then stored. If the operator chose a With current technology, response of operation. For instance, a welder who wire feed speed between the teach points times have vastly improved to thousands wants to lay down Inconel® cladding can (based on material thickness), the inverter of times per second, and the programs are simply turn to that program, set the de- would interpolate the nearest teach points more robust. Although top-line machines sired arc length and wire feed speed, and to arrive at the parameters. give the option to easily write one’s own start welding. This was a laborious process, and most programs, today’s user is freed from set- Today’s technology offers adaptive manufacturers developed a library of ting pulse parameters and is able to take GMAW-P, which will maintain arc length common welding programs. If the user immediate advantage of the benefits even if the electrode extension changes.

40 JULY 2008 Roehl and Stanzel Feature July 2008:Layout 1 6/5/08 3:45 PM Page 41

Constant Voltage (CV) craters or for providing better arc starts are easily built in. On some of today’s top- While some GMAW-P machines adapt line models, a series of programs can be to changes in arc length by varying the chosen ahead of time to be available at pulse parameters, the technology found the click of the gun’s trigger (or instruc- in today’s top-line machines also changes tion from the robot controller), allowing how they regulate voltage and current in an easy switch between preferred settings the peak and background phases to opti- for various weld configurations. mize travel speed and pool control on dif- Another feature found in some top ferent materials. The regulation of volt- models is the ability to switch between var- age in both the peak and background ious GMA processes on the fly. Software- Fig. 4 — Pulsed GMAW (top) improves phases of the pulse cycle is ideal for in- driven GMAW-P programs allow the user bead appearance and pool control so much creasing travel speed. While the need for to use one wire and one gas for several that pulsed GMAW can substitute for AC speed is universal, materials such as alu- processes and eliminate the need and time GTAW (bottom) in many applications. minum and stainless steel require a softer to switch between machines for multipass Switching processes often increases travel arc to remain stable. The softening is welding procedures. speeds by 30% or more. added with a slope or curve to the fall edge of the pulse transition. Take Your Pulse Again These systems may be optimized for specific uses, such as fixed automation, If your view of GMAW-P was shaped flexible automation, and semiautomatic by experiences with the earlier technol- and pipe fabrication, as well as specialized ogy, it’s time to take another look. You no programs for aluminum and stainless longer have to be a welding engineer to welding and high-speed, out-of-position take advantage of the benefits GMAW-P welding ideal for automated systems. New has to offer. It’s not a cure all. Conven- programs can easily be developed and tional gas metal arc welding will always shared, across the plant or across the have a place. But for those who can take country, and uploaded with a standard advantage of GMAW-P, from small fabri- Personal Data Assistant (PDA). cation shops to large manufacturers, dou- Because of the sophisticated software ble-digit productivity increases are the in today’s units, programs for controlling norm and not the exception.◆

Fig. 5 — Welders become productive more quickly with the newer pulsed equipment because setup is quicker, less complicated, and requires less training, noted Brad Hooper, supervisor, Northeast Regional Maintenance, Covanta Energy.

As an example, when welding into a corner, adaptive GMAW-P machines will sense the voltage change and immediately increase or decrease power to maintain the arc length. This gives the user the ability to hold a shorter arc length for more control without fear of shorting the wire. This benefits both the novice welder who may vary electrode extension and the experienced welder who wants more pool control. For info go to www.aws.org/ad-index

WELDING JOURNAL 41 Campbell Circus Article July 2008:Layout 1 6/5/08 3:22 PM Page 42

WeldingWelding WeavesWeaves LiveLive EntertainmentEntertainment MagicMagic

“Over The Top” cast members from the current Ringling Bros. and Barnum & Bailey® Circus, now in its 138th edition, pose for a group shot.

s a child, you may have dreamed Circus, Disney on IceSM, and Disney Live! small task, this type of work goes on at the about running away to join the cir- We have 18 shows traveling worldwide.” site year after year. cus, but have you ever wondered The buildings at Feld’s Florida location AA Operating a Production what makes the circus run? house different departments that contain The Greatest Show On Earth® is made everything from materials and machines for possible thanks in part to the dedicated fabricating scenery to warehousing for the When a show is to be built, the company industry professionals at Feld Entertain- colorful costumes worn by human and ani- hires a director along with a creative team ment, Inc.’s, operational office in Pal- mal performers. Also included are areas to encompassing choreography, music, scenic, metto, Fla. Approximately 200 employees support a transportation department, pur- costume, lighting, and video, who work to- work at the facility; of those, about 15–20 chasing, IT, portable ice floor operations, gether on the vision of what the show be- do some welding. The company’s corpo- lighting, sound, safety, scenic shop, cos- comes. The venues Feld presents its nu- rate offices are in Vienna, Va. tume, and rail car operations. merous shows in are basically used as a “We are the world’s largest producer “Our job is to build the shows and to shell. The company supplies everything of live family entertainment,” said Scott support those on the road,” Dickerson needed to put on a show, such as sets, Dickerson, vice president, Florida opera- said. And while making ornate sets for portable ice floors, lighting, and sound. tions and show support. “This includes shows or revamping the rail cars the cir- Sometimes items are built to fit a particu- Ringling Bros. and Barnum & Bailey® cus entertainers travel and live in is no lar venue depending on size limitations.

KRISTIN CAMPBELL ([email protected]) is associate editor of the Welding Journal.

42 JULY 2008 Campbell Circus Article July 2008:Layout 1 6/5/08 3:22 PM Page 43

Take a behind-the-scenes look at where Feld Entertainment builds nearly everything needed to produce circus, ice skating, and stage shows

BY KRISTIN CAMPBELL

The Fine Points of Fabrication Assembling Handy Objects

Sam Morton, show equipment manu- With new projects to handle practically facturing manager, manages the fabrica- each week, welder Terrance Evans finds tion shop responsible for building items his work exciting. “I just love creating that attach to the trusses, packaging, crat- stuff,” Evans said. One of his past cre- ing, as well as performance, backstage, ations, was ring curves for the circus using and all support equipment. steel tubing and GMAW. “When you build equipment people Recently, he was building wardrobe have to hang on and their lives depend on racks on which to hang costumes — Fig. it that’s unique,” Morton said. 1. “It’s like a portable closet,” Evans said. Gas metal arc welding (GMAW) is the Made with carbon steel tubes, each 6-ft- standard process used at the facility. Gas tall rack will have two legs with a round tungsten arc welding (GTAW) is per- bar across the top for the hangers, braces formed on aluminum. on its bottom to provide support, and A breakdown of the metals used in this wheels for mobility. A lot of preparation shop is 80% steel, 19% aluminum, and 1% was required for Evans to fabricate the stainless. Animal enclosures, feeding trays pieces and weld them together. After- like those to hold meat for the tigers, and ward, they will be painted, get loaded on items that cannot have any rust are made a truck, and shipped out. with stainless steel. Not that long ago another welder, Dan Oxyacetylene and plasma cutting are Robinson, was in the process of putting also utilized. “If we are cutting plate steel, together the bases for sets of crates — Fig. we use plasma. That’s mostly new fabri- 2. Made from mild steel, T-bar specifically, cation. We use the (acetylene) torch for these will contain curtains around 30 ft existing stuff,” Morton explained. The tall and 60–70 ft wide. “It’s a box on thicknesses range from 16 gauge to 1 in. wheels,” Robinson said. They will have In addition, the circus travels with a plywood sides and lids; holes were also maintenance shop. Shows are equipped punched in the metal to hold the plywood. with GMA/flux cored arc machines capa- For these, Robinson did cutting, fitting, ble of welding steel or aluminum. “That and used GMAW. way someone who is on tour can do minor “You never know what you are going repairs,” Morton said. to see coming in the door every day,” Robinson said. He has even made trapeze platforms and enclosures for animal acts. Making Items Transportable

Just like sets, wardrobe racks, and crates need to be easily moved around, the same is true for other pieces. Even the circus equipment will eventually end up on a truck, so everything built has to break down for fitting either into a shipping container, which still ends up on a truck, or into a semi. Crates are built to fit side by side for fitting in a truck or a container for shipping. The semi tractor-trailer beds are 53 ft long. “We can’t take it down to the last nut and bolt, but it needs to fit in a truck,” Dickerson said. “We want it strong, but Fig. 1 — Terrance Evans (left) is hard at not too heavy, so we can break it down.” work welding wardrobe racks to hold cos- Therefore, a fine balance is required tumes. On the right are some of these items to build articles durable enough to last waiting to be assembled. and be safe, while being able to be taken

WELDING JOURNAL 43 Campbell Circus Article July 2008:Layout 1 6/9/08 1:44 PM Page 44

ager, also works in the scenic shop. “We get to play with all kinds of shapes and materials. We’re actively doing something new all the time,” Freddes said. Figuring out how the components will work is challenging, Freddes added; building them normally takes three months or so. Full production takes more than a year of thought. When looking for fabricators, skill levels are tested, and on-the-job training takes place. Many new people learn GTAW here. “When hiring a new employee, most have an architectural/welding background,” Papineau said. Extra teaching Fig. 2 — Welder Dan Robinson is pictured occurs as well at in-house sessions each along with one of the large crates being made to year. “We really like to cross train as much serve as a holding area for curtains. “Every day as possible,” he added. is different,” he said about his job. Creating Stunning Scenery

Projects range from simple to elabo- Scene Shop Aspects rate. “When we start working on a show, we start with the framework,” Papineau Rick Papineau is director of the Ha- said — Figs. 3, 4. “So the shop will be filled genbeck Wallace scenic shop. Named for with welding at the beginning, later paint- an old circus, this area covers 35,000 sq ft ing may fill the shop. Everyone here is ba- and employs 20 full-time staff; temporary sically an artist.” Free-form work occurs workers are hired as necessary. Ten or here, too, and one bending machine was eleven employees here can weld. even built in-house. apart for shipping. After all, a show may “We don’t get technical drawings — “Almost all the underframing is made last five or six years. “We have one show the designers just give us drawings of what of aluminum. A variety of materials is used that’s been on the road since 1995,” Dick- they want it to look like when it’s done,” for the rest. If it’s a structural element, we erson said. “We have made creative Papineau said. This provides flexibility in use steel,” Papineau explained. Primarily changes to the show; however, the infra- how a task is accomplished. GTAW is used on aluminum, although structure remains essentially the same.” Matt Freddes, studio production man- tacking may take place using GMAW.

Fig. 3 — Before and after shots showing the fabrication of a dragon float for “Circus of Dreams,” the 136th edition of Ringling Bros. and Barnum & Bailey® Circus, as well as the completed project in expanded form.

44 JULY 2008 Campbell Circus Article July 2008:Layout 1 6/5/08 3:29 PM Page 45

Fig. 4 — A whale’s beginnings for the “Finding Nemo” show starting with a metal frame (top), and then finished with exterior paint (right).

Fig. 5 — This staircase model has an all-aluminum frame. It shines twinkly LED lights, can be controlled to rotate, and emits fog.

In particular, due to its light weight, stand on are periodically inspected be- grapp added. This reinforced area is to 6061 aluminum is used for frames. “We cause of the stress the animals’ weight puts keep the handler from being crushed by also use it because we have to avoid rust. on them. the elephants, especially in the case of a With the ice shows, everything’s wet in a rail accident. However, some animals couple of hours,” Freddes said. Town without a Zip Code travel on transport vehicles. Other cast Various materials are used over the members travel in their own RVs because frames with any combination of the fol- To get from city to city, most of the cir- some acts own the animals and prefer to lowing: wood; rubber-coated foam; fiber- cus performers, along with the animals, live where their animals are. glass; Lexan, styrene, and vacuum-formed travel by railroad. In fact, the Ringling The Gold Unit travels entirely by truck. plastics; assorted cloths (muslin, spandex, Bros. and Barnum & Bailey® circus trains This strictly overland division goes to etc.); screen mesh; plate aluminum; car- are the largest privately owned trains in smaller cities than the other units. bon fiber; and vinyl sheet goods. America. Consisting of the Red and Blue Earlier this year, a round staircase sec- Units, these trains bring the show to many Rebuilding Rail Cars tion of scenery was built in the shop for a regions of the United States. new Disney show — Fig. 5. It contains an “The trains are about 63 cars long and The company’s rail car department re- all-aluminum frame, and the unit breaks include flat cars and coaches. One train furbishes the rail cars that make up the into ten pieces. “We use a lot of pins be- currently has 62 cars and the other 65,” circus trains. Workers need 9000 hours to cause bolts can get lost. We make it as easy said Roy Fullgrapp, vice president of com- completely recycle one train car. Work on the show’s crew as possible,” Freddes bined operations. All year, they stay on starts in January, and the cars are deliv- said. “We rarely build a square box in generator power. ered in November or December. this shop.” On every trip, planned water stops for Usually four cars per year are reno- Additionally, the scenic sections are all the animals are scheduled as well. “We vated, and this is a combination of cars not critical assemblies, so there is no for- build a room in the elephant cars with housing performers and animals. “The mal inspection, but the tubs the elephants video monitors for the handler,” Full- train grew by a car this year. We sent four

WELDING JOURNAL 45 Campbell Circus Article July 2008:Layout 1 6/5/08 3:30 PM Page 46

Fig. 6 — Views of a rail car’s exterior and interior while being made to serve as living accommodations. The hallway will be down one side. People live in them for two years at a time.

to them, but only three came back,” Dick- Amtrak standards.” erson said. These are remodeled to spe- Inspection takes place cial specifications depending on who is as well. “We check the going to live there. structure for cracks with George Barnhart, manager of exterior dye penetrant,” Fullgrapp rail car production, mentioned 24 people said. Dye penetrant testing work on the trains overall; the different is done on some other trades include seven in welding/ components, too; this kind fabricating. of testing is done in-house. The circus is phasing out its remaining Besides those being steel cars and replacing them with alu- refurbished, the company minum or stainless steel. Shielded metal keeps additional rail cars arc welding, GMAW, and GTAW are used on its lot. “We’re storing on the rail cars along with plasma arc cut- the extras for when we get ting and carbon arc gouging. The tanks the time to redo them and are all GTA welded. The cars exteriors are as backups,” Fullgrapp sandblasted prior to painting. explained. “Steel cars Shown is a rail car in the beginning we’re scrapping out. Alu- stages of gutting and stripping — Fig. 6. minum and stainless steel This will be a standard car with eight liv- cars we’ll refurbish.” The ing quarters. Each living unit includes life expectancy of a circus space for a small refrigerator, stove top, car is 20 years. TV, sinks, and a bedroom area. Cabinets “We build all of the ac- are outsourced. “It’s much like building a cessories that go under- house,” Fullgrapp said. Framing, electri- neath,” Barnhart said, cal, safety equipment, and plumbing work such as water tanks and will also take place. New holes are cut for donnikers (septic or black windows whenever needed. It might be for water tanks). Fig. 7 — Giant tarps provide shade from the sun, allowing a couple and child though other layouts “If we do a repair on workers to stay cooler while performing tasks on rail cars. are for individuals. “We make it as homey the truck portion of the as we can,” Barnhart said. car (the undercarriage Old rail cars are bought from Amtrak part), we send it to Geor- salvage and refurbished as opposed to gia for heat treatment,” Fullgrapp added. important role in making sure these shows buying new ones. “A brand-new car is During the summer, these rail cars are become a reality for people to enjoy. And about $7 million, and there’s a four-year covered with large tarps to provide a bet- to think, this side is only one part of a waiting list,” Fullgrapp said. Another rea- ter environment for workers; after all, it whole arena that includes numerous fac- son for using old cars is that newer ones gets quite warm in Florida — Fig. 7. “It tors like the performers (clowns, acrobats, have a lower profile (meaning they are not also helps keep the grey paint from blow- daredevils, dancers, ice skaters, actors) as as high as the older ones used), because ing around the yard and to allow the paint well as animals (tigers, elephants, horses) most new cars are built for commuter to dry if it rains,” Fullgrapp said. playing their roles. trains rather than cross-country use. So the next time you take a child to see “When we rebuild them now, every- Springing Ahead one of these productions, you’ll know thing is 100% flame retardant,” Fullgrapp some of what it takes to make the circus said. “We also recertify them so they meet Staff members at Feld’s facility play an run.◆

46 JULY 2008 Page 47:FP_TEMP 6/6/08 1:04 PM Page 47

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College Southern Hills Career Center Allentown, Pennsylvania (334) 493-3573 McDonough, Georgia Shreveport, Louisiana Springfield, Missouri Georgetown, Ohio (610) 820-9551 (770) 914-3516 (318) 676-7811 (417) 447-8108 (937) 378-6131 Southern Union State College South Carolina Opelika, Alabama Idaho Maine Nebraska Vantage Vocational School Florence Darlington Tech College (334) 745-6437 Idaho Natl. Lab Welder Test Facility Northern Penobscot Tech. Central Comm. College Van Wert, Ohio Florence, South Carolina Idaho Falls, Idaho Lincoln, Maine Grand Island, Nebraska (800) 686-3944 (843) 661-8171 Wesco Gas & Welding Supply, Inc. 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Worth College Aberdeen, Maryland Latrobe, Pennsylvania Bates Technical College Groosmont Union High School Fort Wayne, Indiana (410) 575-7295 New York (724) 539-9788 Tacoma, Washington El Cajon, California (260) 480-2081 Lucius Pitkin Co. (253) 596-1700 (619) 590-3965 Massachusetts New York, New York Greater Altoona Career & Tech. Ctr. Ivy Tech. College of Indiana Plumbers Local-12 (212) 233-2737 Altoona, Pennsylvania West Virginia Southern California Edison Power Evansville, Indiana Boston, Massachusetts (814) 946-8450 Mercer County Tech Education Ctr. Westminster, California (812) 426- 2865 (617) 288-6200 Niagara Career & Techical Center Princeton, West Virginia (714) 895-0655 Sanborn, New York Greater Johnstown Career & Tech. Ctr. (304) 425-9551 Ivy Tech. Community College Triangle Engineering, Inc. (800) 836-7510 ext. 4535 Johnstown, Pennsylvania Florida Indianapolis, Indiana West Hanover, Massachusetts (814) 269-1490 Ext. 153 Wyoming International Welding Services (317) 921-4783 (781) 878-1500 Niagara Metallurgical Inc Eastern Wyoming College Miami, Forida Buffalo, New York Indiana County Tech Center Torrington, Wyoming (305) 597-5959 Ivy Tech. Community College Michigan (716) 894-1904 Indiana, Pennsylvania (800) 658-3195 South Bend, Indiana Huron Tech. Training Center (724) 349-6700 N.D.T. and Inspections, Inc. (574) 289-7001 New Boston, Michigan Welder Training & Testing Services Hollywood, Florida (800) 322-0946 Buffalo, New York Lehigh Career & Tech Institute (954) 450-8536 Kansas (716) 831-1404 Schnecksville, Pennsylvania KAW Area Tech. School National Testing & Research Lab (610) 799-1348 Pinellas Tech Education Ctr. Topeka, Kansas Detroit, Michigan North Carolina Clearwater, Florida (785) 273-7140 (313) 834-7500 Central Piedmont Comm. College NDT Nondestructive Testing GRP (727) 538-7167 Charlotte, North Carolina Aliquippa, Pennsylvania Tindle Construction Washtenaw Comm. College (704) 330-4428 (724) 378-3900 Neodesha, Kansas Ann Arbor, Michigan (620) 325-3299 (734) 973-3452 Are you a training institution or inspection service? Certifying welders can be a great business opportunity! The demand for AWS Certified Welders is increasing dramatically, leading to revenue growth for schools, testing labs, and inspection companies that have gained recognition by AWS as Accredited Testing Facilities. To become an ATF, you must meet the criteria in AWS QC4 and B5.4 standards, submit a suitable quality manual, undergo an AWS audit, and have an AWS Certified Welding Inspector on staff to test and qualify welders. AWS will publicize your firm on its website and in the Welding Journal, and will provide an AWS Accredited Test Facility plaque. Application information is available at www.aws.org/certification/ATF To explore this rewarding opportunity, call (800) 443-9353, ext. 448 or 211, or email [email protected]

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AWSAWS Conference Conference on on FrictionFriction Stir Stir Welding Welding

Las Vegas October 8, 2008 at the FABTECH Int’l & AWS Welding Show

If you and your company are just starting out with friction stir welding (FSW), or if you are interested in learning more about FSW, this is the conference for you. This conference will not be a gathering of academics talking about theory. The aim of this conference is to provide those interested in considering use of FSW with pertinent information on the process so they can evaluate its feasibility for their applications.

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FRICTION STIR WELDING CONFERENCE features and advanced control algorithms. In this Wednesday, October 8, 2008 • 8:30 AM – 2:30 PM presentation, the requirements of the FSW process and the Las Vegas Convention Center implications on the equipment selection will be discussed. Member of AWS, FMA, SME, NAM, or PMA: $345 The basics of force control and position control modes are Nonmembers: $480 presented and the advantages of each control mode will be Registration Code: W83 discussed. Commercially available machine configurations from several manufacturers will be presented. These Friction Stir Welding History and Licensing include simple two-axis seam welders through multi-axis Ian Smith, TWI Ltd. complex contouring machines with advanced pin-control This presentation will contain a brief review of the history features. of the early development of FSW and its rapid takeup by industry. It will also discuss the approach TWI uses for the Eddy Current Array and Ultrasonic Phased-Array control and exploitation of the intellectual property. Finally, Technologies for FSW Inspection it will briefly review the very large number of patents filed Michael Moles, Olympus NDT by FSW users. Ultrasonic phased-array technology has demonstrated over the years its capabilities to reliably inspect aluminum Friction Stir Welding Tool Designs friction stir welds, as many aerospace manufacturers have Iain Smith, TWI Ltd. used it during their manufacturing process. Recent This presentation will describe the evolution of FSW tool developments in eddy current array technology added new designs from the simple forms used to establish the perspectives to the FSW evaluation. It is now possible to process through to the most popular types used today, and characterize the tool penetration and minimize the some indications of the future challenges for tools. presence of an oxide layer, so-called kissing bond.

Friction Stir Welding and Processing Cost/Benefit Analysis for Friction Stir Welding Murray Mahoney, Consultant Jeff DeFalco, ESAB General discussion of FSW including metal flow and defect A cost/benefit comparison is made between conventional avoidance, temperature gradient issues, lap vs. butt joints, fusion-type welding processes to FSW by evaluating their some tool material and tool design considerations, current relative production output, production costs, and weldability applications, FSW limitations, benefits such as properties, attributes in various heavy industry applications. Applications and the solid state benefits of welding unweldable alloys will include joining both low and high melting point alloys and zero emissions, all as they apply to Al, Cu, and Fe while assigning numbers to each evaluation. based alloys. A description of friction stir processing and its benefits will be included. Robotic Friction Stir Welding, Friction Stir Processing and Supporting Operations Advances in Friction Stir Welding Tool Technology John Hinrichs & Christopher Smith, Friction Stir Link Scott Packer, Advanced Metal Products FSW and FSP are relatively new processes. Principles of Limitations of FSW have included the feasibility of joining the friction stir welding process and FSW and FSP with high melting-temperature materials such as steels, robots will be discussed. Several FSW robotic applications stainless steels, and nickel-base alloys. Tool materials able and an FSP robotic application will be discussed. In to withstand the high temperatures along with adequate addition, robotics used to support manufacturing of FSW wear resistance during the joining process are required. products will be described. Generally, there have been two distinct material systems used, including polycrystalline cubic boron nitride (PCBN) Friction Stir Welding Standards and Specifications and tungsten based materials such as tungsten rhenium Used in Today’s U.S. Manufacturing and Fabrication alloys. This presentation will cover the development of R. Jeffrey Ding, NASA Marshall Space Flight Center PCBN materials for FSW, and the development of Discussions will include the AWS FSW Specification for composite tungsten rhenium alloys with PCBN and Aerospace Applications. The presentation will also cover diamond reinforcement. standards used in private industry.

Friction Stir Welding Machines and Configurations Q&A / Panel Discussion Tim Haynie, Transformation Technologies, Inc. Friction stir welding is performed on a variety of equipment To register or to receive a descriptive brochure, call types ranging from simple milling machine to highly (800) 443-9353 ext. 455 (outside North America, call sophisticated purpose-built FSW systems with specialized 305-443-9353), or visit www.aws.org/conferences Page 50:FP_TEMP 6/6/08 1:37 PM Page 50

CALL FOR PAPERS

Abstract Deadline: July 15, 2008 Manuscripts Due: October 15, 2008

The American Welding Society® and ASM International® are again organizing the world-recognized International Brazing & Soldering Conference (IBSC). This four-day event will begin with Short Courses offered on Sunday, followed by a three-day Technical Program Monday-Wednesday. IBSC brings together scientists, engineers and technical personnel from around the globe involved in the research, development, and application of brazing and soldering. Parallel sessions allow us to present the latest advances in these joining technologies and will be organized to permit interaction between the two disciplines.

IBSC 2009 Program Organizers invite to submit your work for consideration of inclusion in the technical program. They are accepting 150-200-word abstracts describing original, previously unpublished work. The work may pertain to current research, actual or potential applications, or new developments. Whereas commercialism must be avoided to maintain the high level of technical quality and integrity of the IBSC conferences, the new brazing applications and case histories are most welcome.

The technical program will include a special day session focused on practical and innovative applications of brazing and soldering. The Tabletop Exhibit will provide a forum for commercial presentations and demonstrations of state-of-the-art brazing and soldering materials, processes and equipment. Check our website for details. The Poster Session will allow yet another opportunity to present the interesting developments in brazing and soldering technologies.

A Conference Proceedings containing only full manuscripts of the accepted research papers will be published to capture these high-quality technical presentations for later reference. Presentations focused on practical applications of brazing and soldering will also be included in the conference proceedings.

Below are some of the topical areas covered at IBSC Aircraft and Aerospace Furnace / Vacuum Brazing Power and Electrical Equipment Automotive and Transportation Joint Design and Reliability Sensors / Micro-Electronics Brazing and Soldering Standards Lead Free Solders Solder Joining Methods Ceramic / Glass to Metal Joining Light Metals Special / Advanced Brazing Processes Chemical and Petroleum Production Materials and Process Design / Control Structural Solder Applications Composite Materials Medical/Dental Test Methods and Evaluation Electronic Packaging / Sensors Mining & Heavy Equipment Thermal Management Filler Metal Properties Modeling and Process Control Vacuum Brazing Fluxes and Atmospheres Consumer Products Gasses and Plumbing Fixture Design and use Factory Automation LEAN Brazing Processes Musical Instruments Job-Shop & Process Customization Low Volume Critical Components

To submit your work for consideration, visit our website at www.aws.org/education/ibsc and follow the instructions at “CLICK HERE TO SUBMIT YOUR ABSTRACT”. All abstracts submissions must be completed by close-of-business on Tuesday, July 15, 2008. Before submitting your abstract, we ask that you carefully consider your ability to present your work at the conference. Speakers are required to pay a (reduced) conference registration fee, and are totally responsible for their travel, housing and any related expenses. This premiere event is truly one that anyone involved in the brazing and soldering community should plan to attend.

Mark your calendar now, and if you are interested in presenting your work at the conference, submit your abstract no later than July 15, 2008.

Page 51:FP_TEMP 6/6/08 12:47 PM Page 51 AWS Conference on Welding Education Las Vegas October 6, 2008 at the FABTECH Int’l & AWS Welding Show

This conference has been developed specifically for welding/materials joining educators. The conference presentations will focus on those topics that directly affect educators, the futures of their respective programs, and their students.

Monday, October 6, 2008 • 8:50 AM – 4:15 PM Conference fee: $149 Registration Code: W80

To register or to receive a descriptive brochure, call (800) 443-9353 ext. 455 (outside North America, call 305- 443-9353), or visit www.aws.org/conferences

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CONFERENCES

Welding in Aircraft & Aerospace Conference aluminum-lithium alloys pose challenges to welding technologies. Ultrasonic welding, a front-runner for the welding of ther- Wichita, Kansas moplastic composites, will also be on the agenda. Sept. 16, 17 The vehicles planned to carry man to the moon by 2010 and later even to Mars — part of the Orion project — will also be discussed. Innovations in the aircraft and aerospace industries will take center stage at this conference. These industries are taking giant Welding of Engineering Plastics and steps in cost reduction. One is the use of composites in place of aluminum in aircraft and space vehicles. Another is to find ways Composites Conference to build critical parts from the ground up, rather than ordering Orlando, Florida expensive forgings and castings that have to be machined down November 11, 12 to size, at great expense. Welding is in the very thick of it on both fronts. Improved Welding has found a new home in the fabrication of engineer- processes are being developed to weld many of the carbon coming plastics. The welding of engineering plastics is already a way of posite structures. In the world of “born to shape parts,” such life in the automotive industry, and this technology is spilling over processes as electron beam and laser beam welding are being into many areas, including equipment used in medicine. Engineer- called on to get the jobs done quickly, efficiently, and at reason- ing plastics, as opposed to commodity plastics, include such ther- able cost. Emphasis will be given to friction stir welding, fiber moplastic grades as nylon, polycarbonates, polypropylene, ABS, laser welding, and the gas-shielded welding processes. The role PVC, acetals, acrylics, vinyls, and others. The established welding of titanium is growing, while the emergence of a number of new processes for plastics include ultrasonic welding, hot plate welding, vibration welding, spin welding, and hot gas welding. Laser weld- Here’s What’s Happening at the Show ing is also starting to attract considerable attention. Among the speakers at the Orlando conference will be ex- The following conferences will be held during the FABTECH perts from several of the plastics-producing companies and engi- International & AWS Welding show on the dates listed. For more neers who are knowledgeable about the processes used to weld information, contact American Welding Society (800/305) these materials. 443-9353, ext. 455, or visit www.aws.org/conferences.

◆ New Technologies in Thermal Cutting, Oct. 6 For more information, please contact the AWS Conferences and ◆ New Nondestructive Testing Technologies, Oct. 7 Seminars Business Unit at (800) 443-9353, ext. 455. You can also visit ◆ Friction Stir Welding, Oct. 8 the Conference Department at www.aws.org/conferences for upcoming conferences and registration information.

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COMPARE NETWORK PREVIEW ENHANCE thousands of pieces with thousands of more than 500 of your professional of equipment and industry peers to find the newest products development through numerous services solutions to your and technologies from hundreds of educational under one roof business challenges leading suppliers programs and events

October 6-8, 2008 COSPONSORED BY Las Vegas Convention Center Las Vegas, Nevada USA

www.aws.org/show INDUSTRY PARTNER CE JULY:Layout 1 6/6/08 2:25 PM Page 54

COMING EVENTS NOTE: A DIAMOND (♦) DENOTES AN AWS-SPONSORED EVENT.

SAIL 2008, 2nd Int’l Forum on Shipyard Applications for Indus- Canadian Manufacturing Week — Metal Finishing Expo. Sept. trial Lasers. Aug. 18, 19, Williamsburg Hospitality House, 23–25. Int’l Centre, Toronto, Canada. Contact Society of Mfg. Williamsburg, Va. Visit www.arl.psu.edu/sail2008.html. Engineers, (313) 425-3187, www.sme.canada.ca/cmw.

SES 2008 Annual Conf. — The World of Standards — Is It Re- Guangzhou Int’l Trade Fair for Moldmaking and Tooling, De- ally a Zoo Out There? Aug. 18, 19, Marriott San Diego Mission sign, and Application Development. Sept. 24–26, Guangzhou Valley, San Diego, Calif. Contact H. Glenn Ziegenfuss, Int’l Convention & Exhibition Center, Guangzhou, China. Visit [email protected]; or visit www.ses-standards.org. www.asiamold-china.com.

Coatings for Africa 2008. Aug. 19–21, Champagne Sports Re- ♦FABTECH International & AWS Welding Show. Oct. 6–8, Las sort, Central Drakensberg, Kwazulu-Natal, South Africa. E-mail Vegas Convention Center, Las Vegas, Nev. This show is the largest [email protected]; visit www.coatingsforafrica.org.za. event in North America dedicated to showcasing the full spectrum of metal forming, fabricating, tube and pipe, welding equipment, 2nd Int’l Orthotropic Bridge Conf. Aug. 25–29, Sacramento, and technology. Contact American Welding Society, (800/305) Calif. Sponsored by the American Society of Civil Engineers. 443-9353, ext. 455; www.aws.org. Visit www.orthotropic-bridge.org; call (916) 961-2723. ♦New Technologies in Thermal Cutting. Oct. 6, Las Vegas Con- ♦Welding in Aircraft and Aerospace Conf. Sept. 16, 17, The vention Center, Las Vegas, Nev. In conjunction with the Broadview, Wichita, Kan. Contact American Welding Society FABTECH International & AWS Welding Show. Contact Amer- (800/305) 443-9353, ext. 455; visit www.aws.org/conferences. ican Welding Society, (800/305) 443-9353, ext. 455; www.aws.org.

Friction Stir Technologies and Applications for Defense Appli- ♦New Nondestructive Testing Technologies Conf. Oct. 7, Las cations Workshop. Sept. 17, 18. Living/Learning Center, Univer- Vegas Convention Center, Las Vegas, Nev. In conjunction with sity of Pittsburgh at Johnstown, Pa. Organized jointly by Navy the FABTECH International & AWS Welding Show. Contact Metalworking Center and Navy Joining Center. Visit American Welding Society, (800/305) 443-9353, ext. 455; www.nmc.ctc.com/index.cfm?fuseaction=eventinfo&eventid=50. www.aws.org.

Let Phoenix protect your profi ts, one electrode at a time.

-Safety yellow color -Durable steel construction -Calibrated thermostatic control -Spring latch insulated lid with lanyard -Low wattage wire-wrap heating element -Clamp for removable and stationary cord -Optional calibrated digital thermometer -One year product warranty -Union made in the U.S.A.

Phoenix DryRod®II. Don’t settle for anything less. 414.973.3400 www.dryrod.com For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

54 JULY 2008 CE JULY:Layout 1 6/6/08 2:25 PM Page 55

♦Friction Stir Welding Conf. Oct. 8, Las Vegas Convention Cen- Courses. An AWS Accredited Testing Facility. Courses held year- ter, Las Vegas, Nev. In conjunction with the FABTECH Interna- round in Allentown, Pa., and at customers’ facilities. Contact: tional & AWS Welding Show. Contact American Welding Society, Welder Training & Testing Institute, (800) 223-9884, (800/305) 443-9353, ext. 455; www.aws.org. [email protected]; visit www.wtti.edu.

ISR ’08, 39th Int’l Symposium on Robotics. Oct. 15–17, COEX CWI Preparation. Courses on ultrasonic, eddy current, radiogra- Convention Center, Seoul, Korea. Visit www.isr08.org. phy, dye penetrant, magnetic particle, and visual at Levels 1–3. Meet SNT-TC-1A and NAS-410 requirements. Contact T.E.S.T. 2nd Int’l Railroad Symposium and Trade Exposition. Oct. 15–17, NDT, Inc., (714) 255-1500, www.testndt.com. Haydarpasa Train Station, Istanbul, Turkey. Visit www.irsturkey.org. CWI Preparatory and Visual Weld Inspection Courses. Classes presented in Pascagoula, Miss., Houston, Tex., and Houma and ICALEO® 2008, 27th Int’l Congress on Applications of Lasers & Sulphur, La. Contact: Real Educational Services, Inc., (800) 489- Electro-Optics. Oct. 20–23. Pechanga Resort & Casino, Temec- 2890, [email protected]. ula, Calif. Contact Laser Institute of America, (800) 345-2737, (407) 380-1553, www.icaleo.org. Environmental Online Webinars. Free, online, real-time seminars conducted by industry experts. For topics and schedule, visit ♦Welding of Engineering Plastics and Composites Conf. Nov. 11, www.augustmack.com/Web%20Seminars.htm. 12. Contact American Welding Society, (800/305) 443-9353, ext. 455; www.aws.org/conferences. EPRI NDE Training Seminars. EPRI offers NDE technical skills training in visual examination, ultrasonic examination, ASME 8th Int’l Symposium of the Japan Welding Society. Nov. 16–18, Section XI, and UT operator training. Contact Sherryl Stogner, Kyoto, Japan. Visit www.nta-aps.jp/8WS/. (704) 547-6174; [email protected].

PACE 2009, The Power of Paint & Coatings. Feb. 15–18, 2009, Essentials of Safety Seminars. Two- and four-day courses are New Orleans Convention Center, New Orleans, La. Visit held at numerous locations nationwide to address federal and www.pace2009.com. California OSHA safety regulations. Contact American Safety Training, Inc., (800) 896-8867, www.trainosha.com. ♦IBSC, 4th Int’l Brazing and Soldering Conf. April 26–29, 2009, TBA. Contact American Welding Society, (800/305) 443-9353, Fabricators and Manufacturers Assn. and Tube and Pipe Assn. ext. 455; visit www.aws.org. Courses. Call (815) 399-8775; visit www.fmametalfab.org.

JOM-15, 15th Int’l Conf. on the Joining of Materials, and 6th Int’l Conf. on Education in Welding. May 3–6, 2009, Helsinør, Den- mark. Contact JOM Institute, [email protected].

Educational Opportunities

Advanced Concepts in Laser Safety. Aug. 11–13, Orlando, Fla. Contact Laser Institute of America, www.laserinstitute.org, (800) 345-3737.

AWS Certified Welding Supervisor Examination (CWS 550), Preparation Course. A week-long course beginning Aug. 25, Nov. 17. Contact Hobart Institute of Welding Technology, www.welding.org, (800) 332-9448, (937) 332-5000.

Automotive Body in White Training for Skilled Trades and Engineers. Orion, Mich. A 5-day course covers operations, troubleshooting, error recovery programs, and safety procedures for automotive lines and integrated cells. Contact Applied Mfg. Technologies, (248) 409-2000, www.appliedmfg.com.

Basic Plate and Sheet Metal Welding. Cleveland, Ohio. A six- week course beginning Aug. 4, Sept. 15, Oct. 27. Contact The Lincoln Electric Co., (216) 486-1751, www.lincolnelectric.com/ knowledge/training/weldschool/courses.asp.

Boiler and Pressure Vessel Inspectors Training Courses and Seminars. Columbus, Ohio. Call (614) 888-8320; visit www.nationalboard.org.

CWI/CWE Course and Exam. Troy, Ohio. This is a ten-day program. Contact Hobart Institute of Welding Technology, (800) 332-9448, www.welding.org/technical/schedule2008.html.

CWI/CWE Prep Course and Exam and NDT Inspector Training For info go to www.aws.org/ad-index

WELDING JOURNAL 55 CE JULY:Layout 1 6/6/08 2:26 PM Page 56

Firefighter Hazard Awareness Online Course. A self-paced, ten- Pipeline Rehabilitation and Repair. July 22, 23, Houston, Tex. module certificate course taught online by fire service profes- Visit www.ttoolboxes.com/training_support/PDF/PPRT_TR_07e.pdf. sionals. Fee is $195. Contact Industrial Scientific Corp., (800) 338-3287; www.indsci.com/serv_train_ffha_online.asp. Pipe Welding. Cleveland, Ohio. A three-week course beginning Aug. 4, Sept. 15, Oct. 27. Contact The Lincoln Electric Co., 1 Fundamentals of Brazing Seminars. A 2 ⁄2-day course beginning www.lincolnelectric.com/knowledge/training/weldschool/courses. Sept. 9, Toronto, Ont., Canada; Oct. 21, Milwaukee, Wis. Topics asp, (216) 486-1751. include technology overview, fundamental steps of brazing, braze design, filler metals, heating methods, and problem solving. Call Plastics Welding School. A two-day, hands-on course for certifi- (414) 769-6000, ext. 505; visit www.lucasmilhaupt.com. cation to European DVS-approved plastics welding standards for hot gas and extrusion techniques. Contact Malcom Hot Air Gas Detection Made Easy Courses. Online and classroom cours- Systems, www.plasticweldingtools.com. es for managing a gas monitoring program from gas detection to confined-space safety. Contact Industrial Scientific Corp., (800) Shielded Metal Arc Welding of 2-in. Pipe in the 6G Position — 338-3287; www.indsci.com/ serv_train.asp. Uphill. Troy, Ohio. Contact Hobart Institute of Welding Tech- nology, (800) 332-9448, www.welding.org. Hellier NDT Courses. Contact Hellier, 277 W. Main St., Ste. 2, Niantic, CT 06357; (860) 739-8950; FAX (860) 739-6732. Structural Welding: Design and Specification Seminars and AWS D1.1, Structural Welding Code — Steel. Contact Steel Industrial Ventilation Conf. Oct. 13–15, Birmingham, Ala. Both Structures Technology Center, www.steelstructures.com, (248) lectures and hands-on used to present step-by-step training in the 893-0132. design of ventilation systems. Visit www.engineering.arizona.edu/ visitors/epd/conferences.html. Tool and Die Welding Courses. Troy, Ohio. Contact Hobart Institute of Welding Technology, (800) 332-9448, Laser Safety Officer Training Courses. July 14–16, Nashville, www.welding.org. Tenn.; Aug. 11–13, Denver, Colo.; Dec. 8–10, Orlando, Fla. Contact Laser Institute of America, (800) 345-3737, Unitek Miyachi Corp. Training Services. Offers personalized www.laserinstitute.org. training services on resistance and laser beam welding and laser marking. Call (626) 303-5676; visit www.unitekmiyachi.com. Laser Safety Officer with Hazard Analysis Training. Sept. 15–19, San Francisco, Calif.; Nov. 3–7, Boston, Mass. Contact Laser Vibration Institute Courses. Willowbrook, Ill. July 20–Aug. 1, Institute of America, (800) 345-3737, www.laserinstitute.org. Rotor Dynamics and Balancing; July 20–Aug. 1, Introduction to Machinery Vibrations. Visit www.vibinst.org. Laser Safety Online Courses. Courses include Medical Laser Safety Officer, Laser Safety Training for Physicians, Industrial Victor Training Seminars. Programs for gas apparatus and serv- Laser Safety, and Laser Safety in Educational Institutions. ice repair technicians, end users, and sales personnel. Visit Contact Laser Institute of America, (800) 345-3737, www.victorequip.com. www.laserinstitute.org. Welding Courses. A wide range of specialized courses presented Laser Safety Training Courses. Courses based on ANSI Z136.1, throughout the year. Contact The Lincoln Electric Co., Safe Use of Lasers, presented in Orlando, Fla., or at customer’s www.lincolnelectric.com/knowledge/training/weldschool/courses. site. Contact Laser Institute of America, (800) 345-3737, asp, (216) 486-1751. www.laserinstitute.org. Welding Introduction for Robot Operators and Programmers. Machine Safeguarding Seminars. Contact Rockford Systems, This one-week course is presented in Troy, Ohio, or at customers’ Inc., (800) 922-7533, www.rockfordsystems.com. locations. Contact Hobart Institute of Welding Technology, (800) 332-9448, ext. 5603; www.welding.org. Machining and Grinding Courses. Contact TechSolve, www.TechSolve.org. Welding Skills Training Courses. Courses include weldability of ferrous and nonferrous metals, arc welding inspection and quali- Maintenance Welding Course. Cleveland, Ohio. Teaches auto- ty control, preparation for recertification of CWIs, and others. motive repair and construction welding using SMA, GMA, and Contact: Hobart Institute of Welding Technology, (800) 332- GTA welding, and oxyfuel cutting. Aug. 18–22, Oct. 13–17, Nov. 9448, visit www.welding.org. 17–21. Contact Lincoln Electric Co., www.lincolnelectric.com to obtain Bulletin ED.122, or call (216) 383-8325.

Motorsports Welding Schools. Cleveland, Ohio. Basic Materials Courses: July 28–Aug. 1, Sept. 8–12, Sept. 22–26, Oct. 6–10, Nov. 10–14, Dec. 1–5. Advanced Materials Courses: Sept. 15–19, Oct. An Important Event 13–17, Dec. 8–12. Contact Lincoln Electric Co., (216) 481-8100, www.lincolnelectric.com/focus/motorsports/school/school.asp. on Its Way?

NACE Int’l Training and Certification Courses. Contact Send information on upcoming events to the Weld- National Assoc. of Corrosion Engineers, (281) 228-6223, ing Journal Dept., 550 NW LeJeune Rd., Miami, FL www.nace.org. 33126. Items can also be sent via FAX to (305) 443- 7404 or by e-mail to [email protected]. NDE and CWI/CWE Courses and Exams. Allentown, Pa., and at customers’ locations. Contact Welder Training and Testing Institute, (800) 223-9884, www.wtti.edu.

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AWS Certification Schedule Certification Seminars, Code Clinics and Examinations Application deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee.

Certified Welding Inspector (CWI) 9-Year Recertification Seminar for CWI/SCWI

LOCATION SEMINAR DATES EXAM DATE LOCATION SEMINAR DATES EXAM DATE Corpus Christi, TX EXAM ONLY Jul. 19 Orlando, FL Sept. 8-13 NO EXAM Dallas, TX Oct. 20-25 NO EXAM Beaumont, TX Jul. 20-25 Jul. 26 Miami, FL Dec. 1-6 NO EXAM Milwaukee, WI Jul. 20-25 Jul. 26 For current CWIs and SCWIs needing to meet education requirements without taking the exam. If needed, recertification exam can be taken at any site listed Cleveland, OH Jul 27-Aug. 1 Aug. 2 under Certified Welding Inspector. Denver, CO Jul 27-Aug. 1 Aug. 2 Certified Welding Supervisor (CWS) Philadelphia, PA Jul 27-Aug. 1 Aug. 2 LOCATION SEMINAR DATES EXAM DATE Miami, FL Aug. 3-8 Aug. 9 Philadelphia, PA Aug. 18-22 Aug. 23 San Diego, CA Aug. 3-8 Aug. 9 Atlanta, GA Sept. 15-19 Sept. 20 Charlotte, NC Aug. 10-15 Aug. 16 Tulsa, OK Oct. 20-24 Oct. 25 San Antonio, TX Aug. 10-15 Aug. 16 Atlanta, GA Nov. 17-21 Nov. 22 Long Beach, CA Dec. 8-12 Dec. 13 Rochester, NY EXAM ONLY Aug. 16 CWS exams are also given at all CWI exam sites. Bakersfield, CA Aug. 17-22 Aug. 23 Portland, ME Aug. 17-22 Aug. 23 Certified Radiographic Interpreter (CRI) Salt Lake City, UT Aug. 17-22 Aug. 23 LOCATION SEMINAR DATES EXAM DATE St. Louis, MO Aug. 18-22 Aug. 23 Houston, TX Sept. 7-12 Sept. 13 Denver, CO Sept. 15-19 Sept. 20 Pittsburgh, PA Sept. 7-12 Sept. 13 Philadelphia, PA Oct. 20-24 Oct. 25 Seattle, WA Sept. 7-12 Sept. 13 Seattle, WA Nov. 17-21 Nov. 22 Miami, FL EXAM ONLY Sept. 18 Jacksonville, FL Dec. 8-12 Dec. 13 Las Vegas, NV Sept. 14-19 Sept. 20 Radiographic Interpreter certification can be a stand-alone credential or can exempt you from your next 9-Year Recertification. Minneapolis, MN Sept. 14-19 Sept. 20 Certified Welding Educator (CWE) St. Louis, MO Sept. 14-19 Sept. 20 Seminar and exam are given at all sites listed under Certified Corpus Christi, TX EXAM ONLY Sept. 20 Welding Inspector. Seminar attendees will not attend the Anchorage, AK EXAM ONLY Sept. 20 Code Clinic portion of the seminar (usually first two days). Miami, FL Oct. 19-24 Oct. 25 Senior Certified Welding Inspector (SCWI) New Orleans, LA Oct. 19-24 Oct. 25 Exam can be taken at any site listed under Certified Welding Inspector. No preparatory seminar is offered. Tulsa, OK Oct. 19-24 Oct. 25 Long Beach, CA Oct. 26-31 Nov. 1 Code Clinics & Individual Prep Courses The following workshops are offered at all sites where the CWI Newark, NJ Oct. 26-31 Nov. 1 seminar is offered (code books not included with individual prep Portland, OR Oct. 26-31 Nov. 1 courses): Welding Inspection Technology (general knowledge and Cleveland, OH Nov. 2-7 Nov. 8 prep course for CWI Exam-Part A); Visual Inspection Workshop (prep course for CWI Exam-Part B); and D1.1 and API-1104 Atlanta, GA Nov. 16-21 Nov. 22 Code Clinics (prep courses for CWI Exam-Part C). Dallas, TX Nov. 16-21 Nov. 22 On-site Training and Examination Roanoke, VA Nov. 16-21 Nov. 22 On-site training is available for larger groups or for programs Corpus Christi, TX EXAM ONLY Nov. 22 customized to meet specific needs of a company. Call ext. 219 for Sacramento, CA Nov. 30-Dec. 5 Dec. 6 more information. Spokane, WA Nov. 30-Dec. 5 Dec. 6 International CWI Courses and Exams Syracuse, NY Nov. 30-Dec. 5 Dec. 6 AWS training and certification for CWI and other programs are St. Louis, MO EXAM ONLY Dec. 6 offered in many countries. For international certification program schedules and contact information, please visit Miami, FL Dec. 7-12 Dec. 13 http//:www.aws.org/certification/inter_contact.html Reno, NV Dec. 7-12 Dec. 13

For information on any of our seminars and certification programs, visit our website at www.aws.org/certification or contact AWS at (800/305) ® 443-9353, Ext. 273 for Certification and Ext. 455 for Seminars. Please apply early to save Fast Track fees. This schedule is subject to change without notice. Please verify the dates with the Certification Dept. and confirm your course status before making final travel plans.

WELDING WORKBOOK Datasheet 297 Troubleshooting Flux Cored Arc Welding

Several types of discontinuities can result from improper pro- affect the weld appearance, and therefore adversely affect the cedures or practices during flux cored arc welding (FCAW). Al- reputation of FCAW. These problems and discontinuities, along though many of the discontinuities are innocuous, they adversely with their causes and remedies, are shown in the table below.

Problem Possible Cause Corrective Action

Porosity Low gas flow Increase gas flowmeter setting. Clean spatter-clogged nozzle. High gas flow Decrease to eliminate turbulence. Excessive wind drafts Shield weld zone from draft or wind. Contaminated gas Check gas source. Check for leak in hoses and fittings. Contaminated base metal Clean weld joint faces. Contaminated welding wire Remove drawing compound on wire. Clean oil from rollers. Avoid shop dirt. Rebake welding wire. Insufficient flux in core Change electrode. Excessive voltage Reset voltage. Excess electrode stickout Reset stickout and balance current. Insufficient electrode stickout (self-shielded electrodes) Reset stickout and balance current. Excessive travel speed Adjust speed.

Incomplete fusion or penetration Improper manipulation Direct electrode to the joint root. Improper parameters Increase current. Reduce travel speed. Decrease stickout. Reduce wire size. Increase travel speed (self-shielded electrodes). Improper joint design Increase root opening. Reduce root face.

Cracking Excessive joint restraint Reduce restraint. Preheat. Use more ductile weld metal. Improper electrode Check formulation and content of flux. Insufficient deoxidizers or inconsistent flux-fill in core Check formulation and content of flux.

Electrode feeding Excessive contact tip wear Reduce drive roll pressure. Melted or stuck contact tip Reduce voltage. Adjust backburn control. Replace worn liner. Dirty wire conduit in cable Change conduit liner. Clean out with compressed air.

Excerpted from the Welding Handbook, Vol. 2, ninth edition.

58 JULY 2008 Society News JULY:Layout 1 6/6/08 1:48 PM Page 59 SOCIETYSOCIETYNEWSNEWS

BY HOWARD M. WOODWARD AWS Nominates National and District Officers for 2009

Victor Y. Matthews John C. Bruskotter John L. Mendoza William A. Rice Jr. president vice president vice president vice president

he 2006–2007 Nominat- rectors for the three-year term ing Committee has an- Jan. 1, 2009, through Dec. 31, Tnounced its slate of can- 2011. The nominees are didates who will stand for Michael R. Wiswesser, Dis- election to AWS national of- trict 3; Kenneth A. Phy, Dis- fices for the 2009 term, which trict 6; George D. Fairbanks begins January 1, 2009. Jr., District 9; Sean P. Moran, Nominated are the follow- District 12; Mace Harris, Dis- ing candidates: trict 15; John R. Bray, District Victor Y. Matthews,for 18; and Nanette Samanich, president; John C. Bruskot- District 21. ter, John L. Mendoza, and William Rice for vice presi- Nominated for President dents; and Donald B. DeCorte Victor Y. Matthews and Thomas A. Siewert for di- Victor Y. Matthews, an Donald B. DeCorte Thomas A. Siewert rectors-at-large. (Three vice AWS Distinguished Member, presidents and two directors-at- is currently completing his director-at-large director-at-large large are to be elected.) third term as an AWS vice The National Nominating president. A member of the pany’s first-ever welding robot Award in 1995. Committee was chaired by Cleveland Section for 39 for piecework. In 1990, he He is the past president of Past President Damian J. years, he began his career at joined the Service Depart- the Lincoln Electric Em- Kotecki. Serving on the com- The Lincoln Electric Co. in ment with responsibility for ployee’s Association and Sick mittee with Kotecki were B. P. 1963 as a bend brake opera- engine-driven welding ma- Benefit Fund. Matthews also Albrecht, M. J. Lucas, D. J. tor. He attended Lincoln’s chines. In 1992, he was as- is a past chairman of the Landon, J. E. Greer, W. E. welding school and earned all signed responsibility for Cleveland Section. He served Honey, W. A. Komlos, D. J. of the diplomas it had to offer. Cleveland-manufactured con- as national chairman of the Li- Nangle, R. G. Pali, R. L. Nor- He progressed to work in the sumable products worldwide. aison Committee for the 1995 ris, O. P. Reich, E. Siradakis, Electrode Research and De- Currently, he is responsible Welding Show held at the and K. R. Stockton. Gricelda velopment group for 13 years. for consumables, GTA and Cleveland IX-Center. Cur- Manalich served as secretary. Matthews moved to the man- SMA welding machines, rently, he serves on the Silent The Nominating Commit- ufacturing facility as plant plasma arc cutting machines, Auction Committee, Stan- tees for Districts 3, 6, 9, 12, 15, welding engineer where he inverters under 300 A, and is dards Council, Districts Coun- 18, and 21 have selected the worked for 12 years. He auto- liaison to the Italian sub- cil, and the Membership Com- following candidates for elec- mated many workstations and sidiaries. Lincoln recognized mittee. He served eight years tion/reelection as District di- put into production the com- him with its Man of the Year on PEMCO, the Executive

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Committee, the Professional Develop- ment Council, TFPS, and Government Affairs Liaison Committee.

Nominated for Vice President John C. Bruskotter John C. Bruskotter is currently completing his second term as an AWS vice president. He operates Bruskotter Con- sulting Services, working for an independent oil and gas operator. Previously, he worked for several years as a project manager with Dynamic Industries, Inc. From 1986 to 2000, he was employed with Houma Industries, Inc., where his positions included fabrication and quality con- Michael Wiswesser Kenneth A. Phy George D. Fairbanks Jr. trol manager, vice president of operations District 3 director District 6 director District 9 director onshore, offshore fabrication and coatings, and warehousing and maintenance. business marketing from West Virginia University of Wisconsin-Madison. He was Bruskotter joined the AWS New Or- University with postgraduate studies in elected an AWS Fellow in 1994. He has leans Section in 1993, where he served as journalism, publications, psychology, and received the McKay-Helm Award, R. D. its treasurer and vice chair. From 1999 to labor relations. An AWS member for Thomas Jr. International Lecture Award, 2000, he served as both the Section chair- more than 25 years, he has completed nu- R. D. Thomas Memorial Award, Best of man and District 9 deputy director. merous welding-related courses pre- Program Award from The Lincoln Elec- sented by AWS, Hobart Brothers, Union tric Foundation, and the George E. Willis Nominated for Vice President Carbide, Stoody, The Lincoln Electric Award. John L. Mendoza Co., and Thermal Dynamics. John L. Mendoza is currently complet- Nominated for District 3 Director ing his first term as an AWS vice presi- Nominated for Director-at-Large Michael Wiswesser dent. He is a journeyman welder, AWS Donald B. DeCorte Michael Wiswesser has been elected Certified Welding Inspector, and Certi- Donald B. DeCorte is vice president, to his first term as District 3 director. After fied Welding Educator, who has per- sales and marketing, a member of the receiving his bachelor’s degree in business formed power plant maintenance for CPS board of directors, and a co-owner of administration from Kutztown University, Energy, San Antonio, Tex., for 32 years. RoMan Mfg. Inc. in Grand Rapids, Mich., he joined the Welder Training and Test- In 1994, he was promoted to Technical where he has worked for 14 years. A mem- ing Institute (WTTI) in Allentown, Pa., Trainer, responsible for developing train- ber of the AWS Detroit Section since as operations manager. He has directed ing programs and training power plant 1980, he has chaired most committees, the expansion of a number of educational welders. In 1996, he earned his Craft In- served as Section chairman (2003–2004), programs, including welding and nonde- structor certification from the National and has been active nationally and inter- structive testing. He serves as vice presi- Center for Construction Education and nationally on Society business. He served dent on WTTI’s board of directors, and Research and was hired as an adjunct on four Detroit Sheet Metal Welding Con- serves as treasurer on the Pennsylvania welding instructor for Texas A&M Uni- ference committees and chaired the ven- Association of Welding Educators board versity. In 2005, Mendoza was elected to dor display committee. DeCorte has been of directors. the State of Texas Board of Directors for in the welding industry for 29 years, work- the SkillsUSA College/Postsecondary di- ing primarily in the resistance welding Nominated for District 6 Director vision. For the past two years, he has field. He studied marketing, manage- Kenneth A. Phy chaired the Texas SkillsUSA welding comment, and business communications at Kenneth A. Phy has been elected to his petition. He is a 32-year member of the Malcomb College in Warren, Mich., and first term as District 6 director. Phy has International Brotherhood of Electrical Davenport University in Grand Rapids. worked in the nuclear power industry Workers, Local 500, and a past chair of since 1986. Currently, he is senior project the St. Philip’s College welding advisory Nominated for Director-at-Large manager at Entergy Nuclear Operations, committee. He has received the District Thomas A. Siewert Inc., James A. FitzPatrick Nuclear Power Dalton E. Hamilton Memorial CWI of the Thomas A. Siewert is the leader of the Plant in Lycoming, N.Y. Earlier he Year Award. Structural Materials Group at the Na- worked for J. P. Bell & Sons, Rochester, tional Institute of Standards and Technol- N.Y., as a mechanical field engineer, and Nominated for Vice President ogy in Boulder, Colo. During the past 25 as a project piping engineer at Catalytic, William A. Rice Jr. years, his group has worked on projects Inc., in Philadelphia, Pa. He has been an William A. Rice Jr. serves as a part- such as investigations into the failures of AWS Certified Welding Inspector, and time CEO for OKI Bering Supply, and is pipelines and buildings (including the has performed welding engineering and a member of the boards of trustees for sev- World Trade Center towers), as well as inspection work to the ASME Boiler and eral health and financial organizations in weld sensing and consumable issues. Ear- Pressure Vessel Code, Section XI. He West Virginia. Rice worked for Airgas lier, he was manager of R & D at Alloy earned his degree in mechanical engi- from 1993 to 2001, where he served as its Rods in Hanover, Pa. He has been a neering from Spring Garden College in president and COO. From 1971 to 1992, member of AWS since 1969, served as a Philadelphia, Pa. he was president of Virginia Welding Sup- Section chairman, and has participated on ply Co. and president of several other both national and local committees for Nominated for District 9 Director welding-related companies, which he later more than 30 years. Siewert is a frequent George D. Fairbanks Jr. sold to Airgas. He served as chairman of contributor to Welding Journal, where he George D. Fairbanks Jr. has been the state VICA welding contests from serves as a peer reviewer. He received his elected to his first term as District 9 di- 1979 to 1983. Rice earned his degree in PhD in metallurgical engineering from the rector after fulfilling the last two years of

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Sean P. Moran Mace Harris John R. Bray Nanette Samanich District 12 director District 15 director District 18 director District 21 director

John C. Bruskotter’s term. Currently, he gineering. Moran is a Certified Welding in Pearland, Tex., one of the Associated is president of Fairbanks Inspection & Inspector, Certified Welding Educator, Equipment LP companies. An AWS Testing Services. Previously, he was sen- and Certified Welding Supervisor. He is member since 1988, he was elected to the ior welding inspector at Gonzales Indus- vice chairman of the Education Scholar- Houston Section Membership Commit- trial X-Ray. Earlier, Fairbanks worked 16 ship Committee, second vice chairman of tee in 1989, and has since served in most years as a CWI and an API 653 inspector Volume 3 Handbook Committee, and is posts, including Section chairman. in a metallurgical and testing lab. He a member of the Product Development joined the AWS Baton Rouge Section in and D1.1 Committees. 1980, where he has held many offices, in- Nominated for District 21 Director cluding six terms as chairman. He holds Nominated for District 15 Director Nanette Samanich numerous certifications, including Certi- Mace Harris Nanette Samanich has been elected fied Welding Inspector and Certified Mace Harris, an account manager at to her first term as District 21 director. Welding Educator. In 2004, he received Valley National Gases in Richfield, Currently, she is a senior inspector with the National Dalton E. Hamilton CWI of Minn., has been reelected to his second Ninyo & Moore in Las Vegas, Nev. She the Year Award. term as District 15 director. Earlier, he studied welding at the Community Col- worked for Reynolds Welding Supply as lege of Southern Nevada and Hobart In- Nominated for District 12 Director a route salesman, and as a mechanic and stitute of Welding Technology. She is a Sean P. Moran a welder. An AWS member since 1990 Certified Welding Inspector, an ACCP Sean P. Moran has been reelected to with the Northwest Section, he served on Level II visual inspector, and a certified serve a second term as District 12 direc- various Section committees, worked his fireproofing inspector. Samanich has tor. Currently, he is a business develop- way through the chairs, and served as served AWS in the Nevada Section as ment manager at Hobart Brothers Co., chairman 1999–2000. Currently, he is the chairman (2001–2004), and as District 21 an ITW company. He joined the ITW cochair of the scholarship committee, a deputy director from 2000 to 2001, and welding group in 1999 as a welding engi- position he has held for many years. He from 2006 to the present. She has re- neer. He has worked ten years as a weld- also plays a leadership role in the Min- ceived the AWS District Meritorious ing instructor for secondary and postsec- nesota SkillsUSA welding contests. Award, and Section and District CWI of ondary public and private institutions. He the Year Awards. She has been featured has practical background in pipe fabrica- Nominated for District 18 Director in a women in welding article in the tion and equipment manufacturing. He John R. Bray March 2002 Welding Journal and another received his teaching certificate from the John R. Bray, after fulfilling the term in Nevada Women magazine. She is a University of North Texas, welding engi- vacated by John Mendoza, has been member of American Institute of Steel neering degree from The Ohio State Uni- elected to his first term as District 18 di- Construction, International Code versity, and master’s in engineering man- rector. Since 1996, Bray has served as Council, and the National Association agement from Milwaukee School of En- president of Affiliated Machinery, Inc., of Women in Construction.♦

Nominations Sought for National Offices

WS members who wish to nomi- Nominating Committee; or biographical material on each candidate, nate candidates for President, 2. Present their nominations in-person including a written statement by the can- AVice President, Treasurer, and Di- at the open session of the National Nom- didate as to his or her willingness and abil- rector-at-Large on the AWS Board of Di- inating Committee meeting scheduled for ity to serve if nominated and elected, let- rectors for the term starting January 1, 2:00 to 3:00 P.M., Tuesday, October 7, ters of support, plus a 5 × 7-inch head- 2010, may either: 2008, at Las Vegas Convention and Visi- and-shoulders color photograph. 1. Send their nominations electroni- tors Authority, Las Vegas, Nev., during Note: Persons who present their nom- cally by September 2, 2008, to Gricelda the 2008 FABTECH International & inations at the Show must provide 20 Manalich at [email protected], c/o Ger- AWS Welding Show. copies of the biographical materials and ald D. Uttrachi, Chairman, National Nominations must be accompanied by written statement.

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Student Chapter High-Achievers Recognized

On hand for the presentation of the AWS Colorado School of Mines Student Chapter Award Matt Haubert (right) receives the Student (District 20) are (front row, from left) Scott Gordon, Juan Madeni, Grant Hudish, Student Chapter Award from his welding instruc- Chapter Advisor Steven Liu, awardee Erik Soderstrom, and Karem Tello. Back row, from tor and Chapter Advisor Craig Donnell for left, are Christine Hillier and John Nickell. service to his school, community, and employer. Haubert has participated in many school functions and has worked on sev- AWS Staff Members Wear the Leathers eral community service projects. He is presently employed at MTS Burgess, Tem- perance, Mich., where he participates in the School-to-Work option through Whitmer Career and Technology Center, Toledo, Ohio (District 11). An AWS Member for two years, he is an outstanding student who plans to excel in the welding industry.

District 16 Director Awards Announced

District 16 Director David Landon has nominated the following Mem- bers to receive the District Director Award for 2007–2008:

Mike Meyers, Eastern Iowa Section Eric Peterson, Iowa Section Bob Evans, Siouxland Section Shown during a hands-on course presented to train all AWS headquarters staff members on Rick Hanny, Nebraska Section the fine art of welding are (from left) instructor U.S. Army SFC and CWI Mike Murphy; Jairo Greg Reeder, SE Nebraska Section Mayorga (Information Systems); staff engineers Matt Ruben, Annette Alonso, Stephen Bor- Dan Rucker, Mid-Plains Section rero, and Selvis Morales; Yoyi Acosta (technical coordinator); staff engineer Reino Starks; Justin Fort, Kansas City Section. Angela Miller (Webmaster); and Rick Reed (Marketing).

AWS Foundation Kicks Off Its 8th Annual Silent Auction

he AWS Foundation solicits dona- from a variety of companies including To donate a gift card, call Nazdhia tions of national company gift cards Macy’s, Home Depot, Tony Roma’s, Bass Prado-Pulido at (800) 443-9353, ext. 250, Tto auction during its 2008 Silent Pro Shops, JC Penney, Omaha Steaks, etc. or e-mail [email protected]. Special Auction. All funds raised will go toward The cards may be purchased by you and thanks go to the first donors to the 2008 scholarships. The gift cards will be avail- donated, or you may send a check and the Silent Auction: able for bid during the FABTECH Inter- Foundation will purchase gift cards in your national & AWS Welding Show to be held name. With the holidays coming right AWS Rochester Section Oct. 6–8, 2008, at Las Vegas Convention after the Show, we have found that gift Nancy and Barry Carlson Center, Las Vegas, Nev. Solicited are gift cards offer a great way for Show attendees Ray and Sandy Shook cards in denominations of $200 to $250 to do their gift-shopping early. Howard M. Woodward

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Indiana Section’s Mid-West Welding Tournament Marks Its 30th Successful Year

elding students from Indiana, Kentucky, and Illinois com- Wpeted April 8–10 for top honors at the 30th Annual Mid-West Team Weld- ing Tournament hosted by the AWS Indi- ana Section. The 110 students in 22 teams competed for more than $10,000 in tro- phies and prizes. Making it all happen were Gary Tucker, John Myers, Ric Eck- stein, Tony Brosio, Bennie Flynn, Chair Gary Dugger, Dave Jackson, Mike Ander- son, Bob Richwine, Dick Alley, District 14 Director Tully Parker, Dennis Klingman from Lincoln Electric, and Dennis Marks, representing AWS headquarters. Concurrently, a Weld Job Fair, open to the public, offered representatives from 15 companies the opportunity to discuss their job openings and demonstrate their latest welding products. Dave Jack- son cooked the hundreds of hot dogs and burgers served free to the crowd. The tournament, held at New Castle Area Vocational School in New Castle, Ind., concluded with an awards-presentation program and dinner. Dennis Marks, AWS managing director, education services, was the featured speaker. Some of the Indiana Section members who made the 30th Annual Mid-West Team Welding Welding instructor Mike Anderson pre- Tournament a success are (standing, from left) John Myers, Dave Jackson, Vice Chair Tony sented the special awards including the Brosio, Chairman Gary Dugger, and Ric Eckstein; and (front, from left) Secretary Bob Rich- Dan Rayshick Award to Ed Wyatt, Clif- wine, Bennie Flynn, and Gary Tucker. See additional photos on page 78. ford Hunt Awards to Praxair and Bob Richwine, Ivan Simmons Award to Her- student team completed projects using question written exam on welding theory. vey Parker, and the AWS Professionalism shielded metal arc, gas metal arc, gas Already, plans are underway to make and Sportsmanship Award to Phil Bedel. tungsten arc, and flux cored arc welding, the 31st Annual Mid-West Welding Tour- As in the past tournaments, each five- and one team member who took a 300- nament a bigger and better event.♦ Districts Council AWS Attends Japan Welding Show Approves Section Charters

n May 18, 2008, after due consideration, Districts Council Oapproved: The charter of the AWS Chile Inter- national Section. The Council in other actions also: Approved the Student Chapter charter for the AWS Des Moines High School Central Campus Student Chapter, Dis- trict 16 Approved the Student Chapter charter for the Los Angeles Trade- Technical College Student Chapter, District 21, and Jeff Weber (far right), AWS associate executive director, along with a line of dignitaries, pre- Approved the AWS ESPE-Ecuador pares to cut the ribbon in the opening ceremony for the Japan International Welding Show Student Chapter, Quito, Ecuador. 2008. Organized by the Japan Welding Engineering Society and Sanpo Publications, Inc., The Council approved the reinstate- the show attracted 202 exhibitors to five exhibition halls in the Intex Osaka exhibition comment of the Student Chapter charter plex. Weber represented the American Welding Society in the ceremony, as well as in meet- for AWS Texas A&M Student Chapter, ings with the representatives of the show organizers. He, along with Welding Journal Pub- District 18. lisher Andrew Cullison, staffed the AWS exhibition at the show.

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Tech Topics

WS was approved as an accredited cation and abilities in welding industry Interpretations standards-preparing organization work such as development of machine Aby the American National Stan- troubleshooting, processes controls, qual- D14.3/D14.3M:2005, dards Institute (ANSI) in 1979. AWS rules, ity standards, problem solving, etc. Specification for Welding as approved by ANSI, require that all stan- Stakeholders: Manufacturing organi- Earthmoving, Construction, and dards be open to public review for com- zations involved with resistance welding, Agricultural Equipment ment during the approval process. Draft such as automotive, aerospace, resistance copies of AWS national standards may be welding equipment manufacturers, and Code Provision: Subclause 1.1.1 obtained from Rosalinda O’Neill, suppliers to these industries. Revised stan- AWS Log: D14.3-05-I01 (800/305) 443-9353, ext. 451, dard. Call A. Alonso, ext. 299. [email protected]. The review expiration D14.8M:200X (ISO 17844:2004 IDT), Inquiry: Would it be appropriate date is shown. Welding — Comparison of Standardized to use standard AWS D14.3/D14.3M: Methods for the Avoidance of Cold Cracks. 2005 for tower cranes although they This is the U.S. national adoption of ISO are not self-propelled, as they are Standards for Public Review 17844:2004, Welding — Comparison of similar to mobile cranes and drag B5.6:200X, Specification for the Quali- Standardized Methods for the Avoidance of lines? fication of Welding Technicians. New — Cold Cracks. $25. 6/23/08. Stakeholders: Companies seeking Response: Yes. G2.3M/G2.3:200X, Guide for the Join- guidance on the avoidance of cold cracking of Wrought Solid Solution Austenitic ing using the following main input param- Stainless Steels. New — $54.50. 6/30/08. eters: steel composition, welding heat input, joint geometry and material thick- AWS B2.2-91, Standard for ness, weld hydrogen level, and preheat. Brazing Procedure and ISO Standards for Public Review Revised standard. Call M. Rubin, ext. 215. Performance Qualification Copies of the following draft Interna- tional Standards are available for review Code Provision: Section 1.2.2 and comment through your national stan- Standards Approved by ANSI dards body, which in the United States is C3.3:2008, Recommended Practices for Inquiry: NFPA 99, Standard for ANSI, 25 W. 43rd St., 4th Fl., New York, the Design, Manufacture, and Examination Health Care Facilities, refers to ASSE NY 10036; (212) 642-4900. Any comments of Critical Brazed Components. Approved 6010, Medical Gas Systems, Installer, regarding ISO documents should be sent 4/21/08. Inspectors and Verifiers, for the quali- to your national standards body. In the D10.7M/D10.7:2008, Guide for the Gas fication of “installers” of medical gas United States, if you wish to participate in Shielded Arc Welding of Aluminum and piping. The latter requires that in- the development of International Stan- Aluminum Alloy Pipe. Approved 4/21/08. stallers be certified to ASSE 6010 by dards for welding, contact Andrew Davis, a third party. That certification [email protected]; (305) 443-9353, ext. 466. process may include requiring in- Otherwise contact your national standards Technical Committee Meetings stallers to demonstrate brazing pro- body. All AWS technical committee meetings ficiency by taking a brazing qualifi- ISO/DIS 9606-1.2 — Qualification are open to the public. Persons wishing to cation test. May an organization that testing of welders — Fusion welding — attend a meeting should dial (305) 443- is a recognized third-party certifier Part 1: Steels 9353 and the extention of the staff secre- of medical gas installers in accor- ISO/DIS 17672 — Brazing — Filler tary of the committee listed below. dance with NFPA-99 be a “Qualifier” metals July 15, 16, D14I Subcommittee on in accordance with AWS B2.2? Welding Hydraulic Cylinders. Des Moines, Iowa. Call M. Rubin, ext. 215. Response: AWS does not endorse New Standards Projects July 25, Committee on Personnel and or certify an employer, individual, or C1.5:200X, Specification for the Quali- Facilities Qualification. Pittsburgh, Pa. third party as a “qualifier” under the fication of Resistance Welding Technicians. Call J. Gayler, ext. 472. provisions of AWS B2.2. As long as This specification establishes the require- Aug. 13, International Standards Ac- the inquirer complies with the re- ments for qualification of Resistance tivities Committee. Hartford, Conn. Call quirements of the Referencing Doc- Welding Technicians (RWT) employed in A. Davis, ext. 466. uments (such as NFPA-99 and ASSE the welding industry. The minimum expe- Aug. 13, 14, Technical Activities Com- 6010), the inquirer may be considered rience, examination, application, qualifi- mittee. Hartford, Conn. Call J. Gayler, a “qualifier” in accordance with B2.2; cation, and requalification requirements ext. 472. however, it is the responsibility of the and methods are defined herein. This Aug. (TBA), D3 Committee on Weld- inquirer to determine compliance specification offers a method for techni- ing in Marine Construction. Ketchikan, with the referencing documents. cians to establish a record of their qualifi- Alaska. Call B. McGrath, ext. 311.♦

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International Certification Agents Meet in Miami

he International Agency Sympo- France, Malaysia, Chile, and Brunei. AWS agencies with the development of strate- sium was held at AWS headquar- Executive Director Ray Shook opened the gies that improve and promote AWS in- Tters in Miami, Fla., April 28–30 for program with an introduction of Bob terests within the international market. 42 attendees representing welder certifi- Wing of World Engineering Xchange Ltd. Presently, AWS has 16 international cer- cation agencies in India, Dubai, Nigeria, (WEX). In February, WEX was engaged tification agents operating certification Egypt, Russia, Saudi Arabia, Taiwan, as the Society’s agency responsible for au- programs in 20 countries. The symposium China, Korea, Japan, Singapore, Hong diting AWS certification seminars and successfully brought WEX together with Kong, Portugal, Mexico, Spain, Trinidad, exams outside the United States, and as- the international agencies for a unique Brazil, Venezuela, Ecuador, Colombia, sisting AWS’s international certification networking experience.

Nominees Solicited for Prof. Masubuchi Award

November 3 is the deadline for sub- ment of materials joining through re- tions, honors, awards, plus at least three miting nominations for the 2009 Prof. search and development. The award, letters of recommendation from re- Koichi Masubuchi Award. The award is presented during the FABTECH Inter- searchers to Prof. John DuPont, presented each year to one person, 40 national & AWS Welding Show, includes [email protected]. The award is sponsored years old or younger, who has made sig- a $5000 honorarium. Send a résumé list- by the Dept. of Ocean Engineering at nificant contributions to the advance- ing background, experience, publica- Massachusetts Institute of Technology.

Nominees Sought for Robotic Arc Welding Awards

December 31 is the deadline for sub- arc welding, including the introduction of tions, and awards. Send your nomination mitting nominations for the 2009 Robotic new technologies, establishment of the package to Wendy Sue Reeve, 550 NW and Automatic Arc Welding Award. The proper infrastructure (training, service, LeJeune Rd., Miami, FL 33126. Contact award consists of a $1500 honorarium and etc.) to enable success, and any other ac- Reeve at [email protected], or call a plaque. Funded by private contributions, tivity that significantly improved the state (800/305) 443-9353, ext. 293. the award is presented during the of a company and/or industry. The award was established in 2004 by FABTECH International & AWS Weld- The nomination packet should include the AWS D16 Robotic and Automatic Arc ing Show. It recognizes individuals for a summary of the candidate’s accomplish- Welding Committee, with the approval of their achievements in the area of robotic ments, professional experience, publica- the AWS board of directors.

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New AWS Supporters

Supporting Companies Eagle Steel Products, Inc. Membership Counts Arkansas Industrial Fabricators, Inc. 5150 Loop Rd. 1455 Hwy. 270 E. Jeffersonville, IN 47130 Sheridan, AR 72150 Member As of Enviro Noise Control Corp. USA Grades 6/01/08 Centric Alloys Corp. 1635 Foxtrail Dr. 350 S. Main St., Ste. 215A Loveland, CO 80538 Sustaining...... 498 Doylestown, PA 18901 Harden’s Welding Service Supporting...... 317 Dean Steel 13702 Gillman Park Educational...... 456 5366 N. Valley Pike Houston, TX 77073 Affiliate...... 430 Harrisonburg, VA 22802 Military Products Group Welding distributor...... 50 Reynolds Mfg. Co., Inc. 37190 Sugar Ridge Rd. Total corporate members...... 1,751 621 Railroad Ave. North Ridgeville, OH 44039 Individual members...... 48,083 Avonmore, PA 15618 Proventus Structural Services, LLC Student + transitional members...... 5,061 Southern Metal Fabricators, Inc. 1428 Pine Wild Dr. Total members...... 53,144 1215 Frazier Rd. Columbus, OH 43223 Albertville, AR 35950 Ranch Land Service 3135 Arena Rd. Indo Arab Welding Institute Affiliate Companies Colorado Springs, CO 80921 Puthenchantha PO Advanced Maintenance Welding Vallikunmam, Alappuzha District Via Del Palazzo 437 Kerala 690501, India Seravezza, LU 55047, Italy Educational Institutions Barbara Jordan High School for Careers Jacobs Creek Job Corps Aidam Architectural Iron Works 5800 Eastex Freeway USDA Forest Service PO Box 1385 Houston, TX 77026 984 Denton Valley Rd. Corrales, NM 87048 Bristol, TN 37620 Black Hawk College Boise Ironworks 1501 State Hwy. 78 Lubbock ISD 6475 W. Contractors St. Kewanee, IL 61443 Advanced Technology Center Boise, ID 83709 3201 Ave. Q, Lubbock, TX 79411 Centro Tecnico Indura Limitada Custom Design Iron Works, Inc. Camino a Melipilla #7060 MIRDIF Security & Safety Consultants 9182 Kelvin Ave. Casilla 13850 Correo 21 Zabeel St. Karama Chatsworth, CA 91311 Cerrillos, Santiago, R.M. 9201355, Chile Dubai 6067, UAE

Davis Fabricators, Inc. Gulf Technical and Safety Northlands Job Corps Center 15765 W. State Rte. 2 Training Centre LLC 100A MacDonough Dr. Oak Harbor, OH 43449 PO Box 25159, Abu Dhabi, UAE Vergennes, VT 05491

Submit Your ‘Image of Welding’ Nominations Now

uly 31 is the deadline for submitting Section (AWS local Section) priority programs. your nominations for the Image of Large Business (200 or more employees) The winners will be announced at the JWelding Awards. You may submit Small Business (less than 200 employees) Image of Welding Awards Ceremony to your nominations online at http://awssec- Distributor (of welding products) be held during the FABTECH Interna- tion.org/ index.php/forms/iow, or download Educator (welding instructor) tional & AWS Welding Show, Oct. 6–8, the form and mail your nomination. Educational Facility (for welder training) 2008, at the Las Vegas Convention Cen- The Image of Welding Awards are Nominations will be judged by the ter in Las Vegas, Nev. issued in each of seven categories to Welding Equipment Manufacturers How to submit your nominations: recognize individuals and organizations Committee (WEMCO). This commit- You may complete the form online or that have shown exemplary dedication tee is composed of executives of weld- print and mail your nomination to AWS to promoting the image of welding in ing industry suppliers who have a mis- Image of Welding Awards, 550 NW LeJe- their communities. sion to promote the welding equipment une Rd., Miami, FL, 33126. The categories are: market. Enhancing the image of weld- Questions? Call AWS at (800/305) Individual (yourself or other person) ing as a critical industry is among its 443-9353, ext. 416.

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District 1 Director: Russ Norris Phone: (603) 433-0855 CENTRAL MASS.- RHODE ISLAND APRIL 4 Activity: Welding students from Old Colony Regional Vo Tech High School, Rochester, Mass., traveled to Assabet Val- ley Regional Technical High School in Marlborough, Mass., to participate in demonstrations of blacksmithing skills presented by metal fabrication instructors Neil Mansfield, Mark Chludenski, and George Aziz.

MAINE APRIL 19 Activity: The Section hosted exams for 26 Shown are the attendees at the Central Massachusetts/Rhode Island Section’s program. members seeking Certified Welding In- spector 9-year recertifications and ASME endorsements at Holiday Inn — West, in Portland, Maine. A family affair, District 1 Director Russ Norris and his father, Russell, supervised the exams, while Russ’s daughter, Teila Norris, served as the B Test supervisor.

APRIL 22 Activity: The Maine Section members vis- ited New England School of Metal Work- ing in Auburn, Maine. Warren Swan, head welding instructor, guided a tour of its new self-contained traveling welding facility, offering welding equipment demos and hands-on exercises in GTA, FCA, GMA, Neil Mansfield demonstrates his black- and SMA welding. The school uses the fa- smithing skills for Old Colony and Assabet cility for specialized welder training, Teila Norris and Russell Norris, her grand- Vo Tech welding students at the Central welder certifications, and preparing father, proctored the Maine Section’s CWI Massachusetts-Rhode Island Section pro- WPSs. The school is working on becom- exams. gram held in Marlborough, Mass. ing an AWS Accredited Test Facility. District 2 Director: Kenneth R. Stockton Phone: (732) 787-0805 NEW JERSEY APRIL 15 Speaker: William B. Heins, program manager, materials and weld training Affiliation: Northampton C. C. Topic: Welding in the shadow of Bethle- hem Steel Activity: The slate of nominees for incom- Dave Griep (left) is shown with speaker Shown April 22 during the Maine Section ing officers was approved. Awards were William Heins at the April 15 New Jersey tour are instructors Ron Guimond (left) and presented to Vince Murray, Don Smith, Section program. Warren Swan.

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Josh Kryeski (left) receives a scholarship Shown at the New Jersey Section April 15 are (from left) Vince Murray, Don Smith, Jim from Dave Hibshman, Reading Section Dolan, Jeff Wiswesser, and Bob Petrone, awards chairman. treasurer, in April. Dave Griep, Jim Dolan, Bob Wlazlowski, and Jeff Wiswesser. George Sheehan, stu- District 3 dents’ activities chair, reported that he is Director: Alan J. Badeaux Sr. completing preparations for this year’s Phone: (301) 753-1759 SkillsUSA competition. Bob Petrone will proctor this year’s CWI seminar and exam in Newark, N.J., Oct. 26–Nov. 1. READING MARCH 20 Speaker: Bill Cotton, district manager NEW JERSEY- Affiliation: Thermadyne Industries, Inc. PHILADELPHIA Topic: Oxyfuel equipment and safety tips MAY 3 Activity: The Section’s scholarship recip- Activity: The New Jersey Section mem- ient was selected, and final arrangements bers joined with Philadelphia Section were made for the welding contest awards members to host the SkillsUSA compe- banquet. Local welding students at- Jeff Wiswesser (left) receives the speaker of tition at Somerset Vocational High tended the program. the year award from Gus Manz (center) and School in Bridgewater, N.J. Eighteen stu- Steve DePhillipps Jr., New Jersey Section dents competed in the welding competi- APRIL 17 chairman. tion and 12 students participated in the Activity: The Reading Section held its ornamental ironwork contest. The awards-presentation and students’ night awards-presentation ceremony was held program at Berks Career & Technology at the New Jersey Convention Center in Center in Leesport, Pa. Francis Butkus Somerville, N.J. and Secretary Merilyn McLaughlin organized the event. Josh Kryeski received a Section scholarship from Treasurer NEW YORK Dave Hibshman. Joe Young received a APRIL 7 certificate of appreciation for serving as Speaker: Bob Waite, P.E. chairman. The participants in the recent Affiliation: B. Waite Welding Engineer welding contest were recognized, includ- Consultant Co. ing welding instructors Dale Roberts, Topic: Torch safety tips Daniel Millan, Charles Shappell, Sharon Activity: The meeting was held at Buck- Bally, John Boyer, and Brian Yarrison. ley’s Restaurant in Brooklyn, N.Y. The students taking first-place honors in the first, second, and third levels, respectively, are Alex Ferrara, Austin Chavous, A student works to win in the SkillsUSA PHILADELPHIA and Isaiah Roeder. The judges for the competition hosted by the New Jersey and APRIL 28 event included Harvey Glantz, Dennis Philadelphia Sections on May 3. Speakers: Frik Hefer, R&D director; and Hornberger, David Hibshman, Paul Lev- Randy Dry, field service director engood, John Miller, Ben Roseta, and Affiliation: Orgo-Thermit, Inc. David Butkus. The Center’s culinary arts Topic: Explanation of the thermite weld- students prepared and served the dinner. ing process used to join railroad rails Activity: This students’ night program was attended by 22 students, four welding instructors, seven board members, District 4 and District 2 Director Ken Stockton. Director: Roy C. Lanier Following the talks, the group reassem- Phone: (252) 321-4285 bled outside to watch Hefer and Dry demonstrate the joining of two rail sec- NORTHEASTERN Students proudly display their winning entry tions using the thermite process. The pro- CAROLINA in the New Jersey Section SkillsUSA orna- gram was held at Gloucester County In- APRIL 18 mental welding contest. stitute of Technology in Sewell, N.J. Activity: The Section hosted its seventh

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The Philadelphia Section’s students’ night attendees featured thermite experts Frik Hefer (center-left) and Randy Dry (center-right).

Instructor Brandon Hoffner (right) con- New York Section members posed for a group shot during their April meeting. gratulates Chucki Creech on winning first place in the Northeastern Carolina Section welding competition. annual AWS Carolina-Virginia welding competition at Rowan-Cabarrus C. C. (RCCC), in Salisbury, N.C. Eight schools participated in the contest that tested GMA and GTA welding, blueprint reading, plasma arc cutting, and fabrication skills. The project was to assemble and weld a model train engine. The judging was performed by both industrial welding engineers and AWS Certified Weld- ing Inspectors. Local and national companies contributed many fine prizes. Brandon Hoffner, a RCCC welding in- Shown at the Reading Section program are (from left) Vice Chair Ed Yanowski, speaker structor, facilitated the event. The win- Bill Cotton, Chair Joe Young, Andrew Raugh, Peter Shaub, and Treasurer Dave Hibshman. ners were Chucki Creech, Jason Hill, Jesse Ellis, Jared Mangaro, Alec Smith, Leo Melton, Aaron Dunn, and Tony Vance. District 5 Director: Steve Mattson Phone: (904) 260-6040 ATLANTA MARCH 20 Speaker: Carl Matricardi, Section chair Affiliation: WeldingSolutions, Inc., owner Topic: Case study of a billboard collapse Joe Young receives a certificate of appreci- caused by weld failure ation for serving as Reading Section chair- First-place winners in the Reading Section Activity: The Section is working with its man from Secretary Merilyn McLaughlin contest are (from left) Austin Chavous, members driving in from the Macon, Ga., at the April program. Alex Ferrara, and Isaiah Roeder.

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Atlanta Section Chair Carl Matricardi Shown at the Northeastern Carolina Section welding contest are (from left) Jason Hill, (left) is shown with brazing expert Wayne Jesse Ellis, Jared Mangaro, Alec Smith, Leo Melton, Aaron Dunn, and Tony Vance. Engeron during his April 9 seminar.

area to charter a new Section closer to Macon. The meeting was held at Sidney Lee Welding Supply in Hampton, Ga.

APRIL 9 Activity: Wayne Engeron, Engeron Tech- nology Group, presented a seminar on brazing metals and alloys. The program was held at Dekalb Technical College in Clarkston, Ga.

FLORIDA WEST COAST APRIL 19 Activity: The Section hosted its annual Shrimp-a-Roo outing for more than 100 Atlanta Section members are shown at the March 20 program. members and guests at Sons of Italy Lodge in Tampa, Fla. Highlights included a live band, door prizes, and a wide variety of foods. R. C. Urbanski received his AWS Life Membership Certificate Award for 35 years of service to the So- ciety, and Eric K. Bigham received his Silver Membership Certificate Award for 25 years of service. The event organizers included Special Events Chair Eric Bigham and Chairman Al Sedory.

SOUTH CAROLINA Shown at the Florida West Coast Section’s Taking care of business at Florida West APRIL 17 Shrimp-a-Roo event are (from left) Life Coast Section’s Shrimp-a-Roo raffle table Speaker: Bryan Howard, gas specialist Member R. C. Urbanski, Chairman Al Se- are (from left) Treasurer Bill Machnovitz, Affiliation: Praxair dory, and Silver Member Award winner Special Events Chair Eric Bigham, and Topic: Bulk and microbulk gas storage, Eric Bigham. Chair Al Sedory. safety, and economics Activity: The Section held its election of officers for the 2008–2009 term. The meeting was held at Trident Technical College in North Charleston, S.C. Also representing Praxair at the program were David Orr and Richard Temple. District 6 Director: Neal A. Chapman Phone: (315) 349-6960 District 7 Shown at the South Carolina Section program are (from left) speaker Bryan Howard, Chair Director: Don Howard Gale Mole, and Praxair representatives Richard Temple and David Orr. Phone: (814) 269-2895

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Attendees at the Holston Valley students’ night program posed for a group shot.

Columbus Section Chair Kevin Clear (left) presents a speaker gift to Gordon Smith at the Feb. 21 meeting.

The top scorers in the Holston Valley Section’s welding contest are (from left) Adam Vest, Chris Canter, Chad Ramey, and Adam Duncan. COLUMBUS FEBRUARY 21 Speaker: Gordon Smith Affiliation: GE Super Abrasives Topic: Diamonds — Their history, formation, production, and industrial applications Shown at the April 17 Columbus Section Activity: The Section hosted a St. Valen- program are Chair Kevin Clear (left) with tine’s banquet and dance program for speaker Bill Hamilton. members, students, and their guests. The event was held at Arlington Café in Columbus, Ohio.

APRIL 17 Speaker: Bill Hamilton Affiliation: AlcoTec Wire Corp. Columbus Section Chair Kevin Clear (left) Topic: Hot cracking in aluminum welds is shown with speaker Bill Bruce at the May Activity: This Columbus Section program 8 meeting. was held at Arlington Café in Columbus, Ohio. Pinnacle Mfg. Co., LLC, in Boaz, Ala., to study the manufacture of storage con- MAY 8 tainers used in the oil industry. Leading Speaker: Bill Bruce the tour were Controllers Jason Satter- Affiliation: CC Technologies, Inc. field and Joby Satterfield. Topic: Essential elements of an in-service welding program Students studied welding demonstrations Activity: This Columbus Section program HOLSTON VALLEY during the Northeast Tennessee Section’s was held at Arlington Café in Columbus, APRIL 23 program held at Tennessee Technology Ohio. Activity: The Section hosted its fourth Center. annual students’ night program at Ten- nessee Technical Center in Surgoinsville, NORTHEAST TENNESSEE Tenn. Jerry Sullivan, welding instructor, APRIL 15 District 8 organized the event. Highlights included Activity: The Section hosted a students’ Director: Joe Livesay a welding skills contest with 27 students day program at Tennessee Technology Phone: (931) 484-7502 competing in high school and tech school Center in Knoxville, Tenn. About 130 stu- categories, and a barbecue dinner pre- dents participated in the event. Presen- GREATER HUNTSVILLE pared by the Tech Center staff. The top tations were given by Jeff Hankins, Susan MARCH 20 welders were Adam Vest, Chris Canter, Smith, Wayne Summers, Gary Lancaster, Activity: The Section members toured Chad Ramey, and Adam Duncan. Chris Griffey, Chandy Hensley, Derek

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Ballentine, and James Hensley. The organizations represented included Oak Ridge H. S., Miller-Motte T. C., Plumb- ing & Steamfitters Union, Navy Career Center, Sheet Metal Workers Union, Ten- nessee Career Center, and Workforce Connections Youth Programs. The event concluded with a tour of the facility featuring demonstrations in each area, including welding, auto body technology, refrigeration, machine tool, and drafting technologies. Welding instructor Jeff Hankins, Oak Ridge H. S., organized the program.

Roy Scott (center-right), of Northrop Grumman Ship Systems, is shown with the New Or- leans Section door prize winners (from left) Paul Graves, Shane Tate, and Kerry Kaufman. District 9 Director: George D. Fairbanks Phone: (225) 473-6362 MOBILE APRIL 10 Speaker: Bradley Byrne, chancellor Affiliation: Alabama Board of Education Topic: Progress in the two-year system in Alabama Activity: Chairman Randy Henderson presented William Todd Donald the Sec- tion Private Sector Instructor Member- ship Award, Lindsey LeBlanc the Section Membership Award, and James Smith the District Educator Award. The meeting was held at Saucy-Q Bar B Que in Mo- Mobile Section Chair Randy Henderson New Orleans Section speaker Mark Foret bile, Ala. (left) presents a speaker gift to Bradley (right) is shown with Chairman Travis Byrne. Moore. NEW ORLEANS APRIL 22 Speaker: Mark Foret Affiliation: Northrop Grumman Ship Sys- tems, Avondale, La. Topic: New designs in shipbuilding Activity: Following the talk, the 55 attendees took a shop tour and watched a demonstration of the submerged arc welding process. Travis Moore, Section chair, presented a sponsor-appreciation award to Roy Scott, representing Northrop Grumman Ship Systems, donor of the door prizes. The program was held at Industrial Welding Supply in Boom- William Todd Donald (right) accepts the Steve DeHart (left) receives an apprecia- town, La. Private Sector Instructor Membership Sec- tion award from Richard Harris, District tion Award from Mobile Section Chair 10 director, at the NW Pennsylvania Sec- Randy Henderson. tion program. District 10 Director: Richard A. Harris Phone: (440) 338-5921 NW PENNSYLVANIA APRIL 8 Activity: The Section participated in an oxyfuel safety seminar conducted by Paul Shields, district sales manager for The Harris Products Group. The program, held at Tristate Business Institute in Erie, Pa., attracted 101 attendees. District 10 Director Richard Harris presented Steve Paul Shields presented a seminar on oxy- DeHart, a past Section chairman, with an fuel safety for the NW Pennsylvania Sec- Mike Palko chaired the Detroit Section’s appreciation award for his contributions tion members. Sheet Metal Welding Conference XIII. to the Section.

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District 11 Director: Eftihios Siradakis Phone: (989) 894-4101

DETROIT MAY 15 Activity: The Section hosted Sheet Metal Welding Conference XIII at Schoolcraft College. Mike Palko, Ford Motor Co., chaired the event. This biennial event provides welding professionals a unique opportunity to discuss the challenges and advances in the sheet metal welding field. The proceeds benefit the Section’s scholarship fund. Earlier, at the same facility, the Section conducted a high school welding contest at Schoolcraft College. The Section awarded $4500 in scholarship funds to the winners. Taking top honors were David Woller, Neil Marshall, and Demarco Hunt. Shown are the contestants in the Detroit Section’s high school welding contest. The trophy winners are (from left) David Woller, Neil Marshall, and Demarco Hunt. NORTHWEST OHIO APRIL 3 Activity: The Section members attended a motor vehicle materials and processes program held at Owens C.C. in Perrys- burg, Ohio. More than 20 racing and pulling-type vehicles were on display. Karl Hoes, a Lincoln Electric welding school instructor, explained what materials and welding processes were used in each vehicle’s construction. The Univer- sity of Toledo, University of Northwest- ern Ohio at Lima, and Bowling Green State University had vehicles on display. More than 500 people attended the event.

MAY 7 Speaker: Theresa Pollick, public information officer Affiliation: Ohio DOT Topic: Current and future projects for district highways Activity: This was the Northwest Ohio The District 12 conference attendees are (from left) Dan Crifase, Jim Harrison, District 12 Section’s old timers’ and awards banquet Director Sean Moran, Ray Connelly, Jeff Weber, Ken Karwowski, Craig Wentzel, Dave Ram- held at H. J’s Prime Cut in Toledo, Ohio. seur, Chuck Frederick, Nick Freiburg, Jerry Blaski, and Cory Satka. William McCleese was awarded his Sil- ver Membership Certificate for 25 years DISTRICT 12 Conference of service to the Society. MAY 9 Activity: Representatives from each of the District 12 Sections met at Marshall Whitmer Career Erdman & Associates, Inc., in Madison, Tech Center Wis. Participating were District 12 Direc- Student Chapter tor Sean Moran, Dan Crifase, Craig MAY 5 Wentzel, Dave Ramseur, Nick Freiburg, Activity: Matt Haubert was presented the Cory Satka, Jim Harrison, Ray Connelly, AWS Student Chapter Member Award Ken Karwowski, Chuck Frederick, Jerry by Craig Donnell, Chapter advisor. See Blaski, and Jeff Weber, AWS associate photo on page 62. executive director.

LAKESHORE APRIL 10 District 12 Speaker: Duane Miller, manager, engi- Director: Sean P. Moran neering services Duane Miller (right) is shown with James Phone: (920) 954-3828 Affiliation: The Lincoln Electric Co. Hoffman, Lakeshore Section chair.

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Topic: Design and weldability of high- strength steels Activity: The Section presented its Rudy Baumann Ben Mueller Scholarship Awards to Jason Staral, Bradley Bruseth, and Matthew Kent, students at Lakeshore Technical College. The meeting was held at Water’s Edge Restaurant in Two Rivers, Wis.

APRIL 26 Activity: The Lakeshore Section held a sporting clay shoot outing for its last meeting event for the year. The members Shown at the Lakeshore Section program are (from left) Sean Moran, District 12 director; met at Triple J Game Farm and Sport- James Hoffman, Section chairman; scholarship recipients Jason Staral, Bradley Bruseth, ing Clays in Reedsville, Wis., to test their and Matthew Kent; Hildegard Baumann; welding instructor John Schaefer; and Ben Mueller, skills and enjoy dinner. The windy con- retired welding instructor. ditions and cold temperature made the event a challenge for even the best shoot- ers. The door prizes were donated by local welding equipment suppliers.

MADISON-BELOIT MARCH 19 Speaker: Ann Grevenkamp, compliance officer, industrial hygienist Affiliation: OSHA Topic: Update on the OSHA hexavalent chromium guidelines Activity: The program was held at Coli- seum Bar in Madison, Wis. Shown at the Lakeshore Section clay shoot outing are (from left) Secretary Dave Ramseur, Steve Miller, Lee Levenhagen, Milt Kemp, Jim King, Steve Miller Jr., Dan Jochman, Bill APRIL 16 Krcma, Andy Miller, and Jim Becker. Speaker: Sean Moran, District 12 director Affiliation: Miller Electric Mfg. Co., product manager Topic: Benefits of AWS membership Activity: This Madison-Beloit Section program was held at Coliseum Bar in Madison, Wis.

MILWAUKEE APRIL 17 Activity: The Section members toured Super Steel Corp. in Milwaukee, Wis., to study its operations. The company de- Shown at the March 19 Madison-Beloit Section program are (from left) Jeff Alsip, Bill Daw- signs, builds, and delivers passenger and son, Burt Wheeler, Chairman Ben Newcomb, Nicole Karlen, Jim Harrison, Dave Diljak, freight railroad locomotives, agricultural Jim Pfeil, Paul Elmer, David Burrow, speaker Ann Grevenkamp, and Jerry Hemmerling. equipment, and other heavy industrial equipment. Featured is the company’s extensive welder training program detailed by Chris Nielsen, senior welding engineer. Keith S. Trafton, CEO and president, conducted the tour.

MAY 15 Activity: The Milwaukee Section members toured the Trek Bicycle Co. in Wa- terloo, Wis., to study the manufacture of high-end carbon-fiber and aluminum bikes. Karen Gilgenbach, Section vice chair, presented scholarship awards to Terry Herman, Michelle Freeman, Joseph Chaney, Dmitri Sasic, and Bobbi Shown at the April 16 Madison-Beloit Section program are (from left) Bryan Kwapis, Jim Bishofberger. The dinner was held at Pine Pfeil, Jim Harrison, Bill Dawson, Dave Diljak, District 12 Director Sean Moran, and Chair- Knoll Restaurant in Lake Mills, Wis. man Ben Newcomb. Forty-six members and guests attended.

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Racine-Kenosha Section members are shown during their tour of CNH Global.

Logan Wojcik recently joined the Racine- Shown at the Milwaukee Section tour are Chairman Jerry Blaski (center) with Super Steel Kenosha Section as a Student Member. welding engineer Chris Nielsen (left) and CEO Keith Trafton. RACINE-KENOSHA MAY 7 Activity: The Section members toured CNH Global plant in Racine, Wis., to study its methods for manufacturing and assembling farm tractors. District 13 Director: W. Richard Polanin Phone: (309) 694-5404

CHICAGO Shown at the May Milwaukee Section program are (from left) Scholarship Chair Craig APRIL 5 Wentzel, Joseph Chaney, Dmitri Sasic, Bobbi Bishofberger, Terry Herman, Michelle Free- Activity: The Section hosted a CWI exam. man, and Vice Chair Karen Gilgenbach. Jeff Stanczak received the District Meri- torious Certificate Award from Eric Krauss.

APRIL 16 Activity: Pete Host discussed welding and careers in welding for students at the Col- lege of DuPage in Glen Ellyn, Ill.

J.A.K. APRIL 20 Activity: The Section hosted an awards- presentation ceremony in Kankakee, Ill., hosted by Secretary Ziad Awad. Other business included preparing for the second annual Kankakee Area Career Cen- ter welding competition. Chairman John Jeff Stanczak (left) is shown with Eric Willard received an appreciation award Ziad Awad (right) is shown with John Krauss at the Chicago Section program in for his contributions to the Section. Willard, chairman of the J.A.K. Section. April.

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Shown at the J.A.K. Section program are (from left) Chairman John Willard, Vice Chair Brian Farkas discussed welding aluminum Bryce Kale, SENSE director Mike Spangler, and Secretary Ziad Awad. alloys for the Indiana Section members. were Phillip Robertson, Brandon New- ton, R. J. Corbett, Charles Ayers, and Clifton Miracle.

APRIL 12 Activity: The Indiana Section organized and judged the SkillsUSA state welding contest held at Walker Career Center in Indianapolis, Ind. Ryan Ruppel from Pike Central H. S. and Aaron Wall from Vin- cennes University were the Secondary and Postsecondary class winners, respectively.

MAY 14 Speaker: Brian J. Farkas, national sales The first-place winners in the Indiana Section’s Mid-West Team Welding Tournament are manager (from left) Phillip Robertson, Brandon Newton, R. J. Corbett, Charles Ayers, and Clifton Affiliation: Maxal, Inc. Miracle. Topic: Using GTAW and GMAW for joining various aluminum alloys Activity: This Indiana Section program was held at Ivy Tech C. C. in Richmond, Ind. Following the talk, the Indiana Sec- tion members toured the college’s new welding lab facilities.

ST. LOUIS APRIL 17 Activity: The Section hosted its annual students’ night program at Ranken Tech- nical College in St. Louis, Mo. The speakers included Ted Stegman, president of Industrial Steel Fabricators, and Glen Kayser, plant manager at Custom Fabri- cators & Coatings. The talks featured welding career opportunities and bene- Shown judging the Indiana state SkillsUSA welding contest are Gary Tucker (left) and Dick fits available in the St. Louis area. Five Alley, an AWS past president. $900 scholarships were presented to local college students. Eight outstanding students were recognized with a certificate 1 ment in New Castle, Ind. About 200 con- and a 4 ⁄2-in. grinder. Their welding in- District 14 testants representing high schools from structors were on hand to present the Director: Tully C. Parker Indiana, Kentucky, and Illinois partici- awards and give talks on why their stu- Phone: (618) 667-7744 pated in the three-day event. For the sec- dents were chosen to receive the honors. ond year, the Section hosted a Weld and INDIANA Job Fair in conjunction with the welding APRIL 8–10 contest. See more on this event on page TRI-RIVER Activity: The Section hosted its 30th An- 63. Kentucky Tech, Nelson County, took APRIL 29 nual Mid-West Team Welding tourna- first-place honors. The team members Speaker: Lloyd Benson

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Shown at the St. Louis Section students’ night program are speakers Ted Stegman (left) and Glen Kayser.

Affiliation: Airgas, sales representative The St. Louis Section honored its outstanding students and their instructors at the April (ret.) program. Topic: Cutting torch maintenance and repairs Activity: John Bockhorst, Southern In- diana Career and Vocational School, discussed the latest changes to the welding program offered at the center. The meeting was held at Evansville Armature in Evansville, Ind. District 15 Director: Mace V. Harris Phone: (651) 287-3267

NORTHWEST Shown at the November Northwest Section program are (from left) District 15 Director NOVEMBER 2007 Mace Harris, Bob Sands, Bruce Danielson, Dwight Affeldt, and Chair Dale Szabla. Activity: The Section hosted a roundtable discussion on welding certification. District 15 Director Mace Harris was the moderator. Participating were Bob Sands, a MIL specs expert; Bruce Danielson, discussing D1.1 Code provisions; and Dwight Affeldt presenting on the ASME standards.

JANUARY Activity: The Northwest Section members toured Nelson Stud Welding in Bloomington, Minn. Tour guides included Bob Shuster, Keith Zelinga, and Don Merker. Shown at the Minnesota SkillsUSA contest Shown at the January Northwest Section are postsecondary class winner Tony Nel- program are (from left) Don Merker, Keith MARCH son (left) and Colten Milford, secondary Zelinga, and Bob Shuster. Activity: The Northwest Section mem- class winner. The event was judged by members participated in and provided 20 bers of the Northwest Section in March. judges for the Minnesota SkillsUSA competition. The event involved 49 con- Central Nebraska Sections met at the testants. The postsecondary class winner Linweld store in Kearney, Neb., for a din- was Tony Nelson; Colten Milford won ner provided by Dana McDowell. The the secondary class. group then toured Jancy Engineering, Inc., in Davenport, Iowa. Jeff Hadshall, district representative, conducted the District 16 program. District 16 Director David Lan- Director: David Landon don attended the program. Phone: (641) 621-7476 CENTRAL NEBRASKA- KANSAS CITY MID-PLAINS APRIL 10 Dennis Wright (right), Kansas City Section APRIL 17 Speaker: Jason Mueller, welding instruc- chair, receives an award from Vice Chair Activity: Members of the Mid-Plains and tor Brian McKee at the April meeting.

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The Nebraska Section members posed for a group shot during their golf outing in May.

Affiliation: Johnson County C.C. Topic: Johnson County C.C. welding courses offered for railway contractors Activity: The Section held its election of officers. Dennis Wright received an appreciation award for his services as chairman. The meeting was held at Johnson County C.C. in Overland Park, Kan.

MAY 1 Speaker: David Landon, District 16 director Affiliation: Vermeer Mfg., manager, welding engineering Masterminding the Central Arkansas SkillsUSA event are (from left) Matt Fair, Tim Ryan, Topic: Lean manufacturing techniques Chairman Dennis Pickering, Bob Hlass, and Jimmy Brewer. Activity: This Kansas City Section program was held at KC Masterpiece Barbe- cue and Grill in Kansas City, Mo.

NEBRASKA MAY 17 Activity: Sixty-four Section members competed in the 14th annual golf outing held at Eagle Hills Golf course in Omaha, Neb. District 17 Director: J. J. Jones David Landon, District 16 director, dis- Phone: (940) 368-3130 cussed lean manufacturing techniques for Bill Kielhorn (left) receives his Gold Mem- the Kansas City Section members in May. CENTRAL ARKANSAS bership Certificate Award from Bryan APRIL 14–16 Baker, East Texas Section chairman. Activity: The Section members worked with representatives from United Asso- ciation of Plumbers and Pipefitters Local #155 and Lincoln Electric Co. on the state SkillsUSA welding, plate cutting, and pipe welding competitions. The participants were Matt Fair, UA business manager; Tim Ryan, UA financial secretary; Jimmy Brewer, UA field representative; Bob Hlass, Lincoln Electric; and Section Chair Dennis Pickering. The event was held at Arkansas Career Train- ing Institute in Hot Springs, Ark.

North Texas Section Chair Rob Tessier EAST TEXAS Speaker Larry Richardson (left) chats with (left) presents a speaker gift to Ernest Lev- APRIL 24 Bryan Baker, East Texas Section chairman. ert, an AWS past president . Speaker: Larry Richardson, QA director

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Barry Lawrence (left), outgoing Tulsa Sec- Tulsa Section judges for the SkillsUSA con- Shown at the Tulsa Section tour are (from tion chair, is shown with incoming Chair- test are (from left) Tim Cruse, Kenny Eden, left) Darian Erstad, incoming Chairman man Jamie Pearson. and Sam Stamper. Jamie Pearson, and Mark Hall. Affiliation: Hi-Tech Testing, Longview, Tex. Topic: The latest technology in radiographic testing Activity: Bill Kielhorn, Section secretary and treasurer, accepted his Gold Mem- bership Certificate Award for 50 years of service to the Society from East Texas Section Chairman Bryan Baker. The program was held in Longview, Tex.

NORTH TEXAS APRIL 15 Recognized for serving as trainers in the Houston Section’s Instructors Institute are (from Speaker: Ernest Levert, AWS past presi- left) Sid Tweetle, Chair John Husfeld, Jonathon Davis, and Justin Calugar. dent Affiliation: Lockheed Martin, senior staff manufacturing engineer Topic: Recent advancements in materials-joining technology Activity: The Section is active in supporting the local food bank. Rob Tessier, Sec- tion chair, presented Levert with the Sec- tion’s custom desk clock speaker gift. More than 100 members and guests attended the program. The meeting was held at Spring Creek Barbecue in Irving, Tex.

TULSA Shown during the Houston Section tour of Greens Bayou Pipe Mill on April 25 are (from APRIL 22 left) Daniel Brotsch, Tim Bailey, Martha Moreno, Daryl Wilson, Julie Theiss, Ron Theiss, Activity: The Section members toured Cristina Colon, Derek Stelly, tour guide Steve Buckles, and Tom Danowski. the Matrix Service facilities in Port of Catoosa, Okla., to study the company’s Speaker: Steve Buckles, production man- shape cutting, beveling, and welding of ager storage tanks, and tank plate rolling and Affiliation: Greens Bayou Pipe Mill beveling operations. Mark Hall and Dar- Topic: Manufacturing structural steel ian Erstad conducted the program. Barry pipe using API 2B standards Lawrence was presented an appreciation Activity: Section appreciation plaques award for his services as chairman. In- were presented to the trainers who par- coming Chair Jamie Pearson was pre- ticipated in the recent Instructors Insti- sented the District Private Sector In- tute event. Cited were Sid Tweetle with structor Membership Award. Miller Electric; Chairman John Husfeld; and Jonathon Davis and Justin Calugar with Lincoln Electric. The program was District 18 held at Brady’s Landing in Houston, Tex. Director: John Bray APRIL 24 Phone: (281) 997-7273 Activity: The Houston Section hosted its annual golf outing at Tour 18 Golf Course Speaker Steve Buckles (left) is shown with HOUSTON in Humble, Tex. About 70 members and John Husfeld, Houston Section chair, dur- APRIL 16 guests participated in the event. ing the April 16 program.

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BRITISH COLUMBIA FEBRUARY 19 Speaker: Tim Cooper, professor Affiliation: University of the Fraser Val- ley Topic: Economic and technical “fixes” for the impact of global warming effects Activity: The Section hosted a raffle of items donated by industry sponsors. The proceeds were contributed to the scholarship fund. The meeting was held at new Westminster, B.C., Canada.

MARCH 20 Speaker: Martin Gagne, manager, Sorel- metal Technical Services Affiliation: Rio Tinto Iron and Titanium Tim Cooper discussed the impacts of global Student Patrick Kerr (right) is shown with Topic: Welding ductile iron to steel warming for the British Columbia Section Northern Alberta Section Chair Matthew Activity: The British Columbia Section in February. Yarmuch during the April 16 program. members participated in a joint meeting hosted by the American Foundry Society (AFS). Eric Hasselmann, AFS vice chair, conducted the program.

APRIL 15 Activity: The British Columbia Section members toured Brenco Industries, Ltd., in Surrey, B.C. Steve Heim, president, and chairman of the Fabricators & Man- ufacturers Assn., Int’l, presented a talk on the various cutting, metal forming, and fabrication processes used in the facility, then conducted a tour of the shop areas.

NORTHERN ALBERTA MARCH 26 Steve Heim conducted a tour of Brenco In- Speaker Cal Blakney (left) is shown with Speaker: Cal Blakney, owner dustries for the British Columbia Section Matthew Yarmuch, Northern Alberta Sec- Affiliation: Edmonton Cast Iron Repair in April. tion chair, at the March 26 meeting. Co. Topic: Repair of cast iron Activity: More than 50 members and guests attended this program, held at the University of Alberta Faculty Club in Ed- monton, Alb., Canada.

APRIL 16 Speaker: Matthew Yarmuch, Section chair Affiliation: Alberta Research Council Topic: Plasma transferred arc welded overlays for wear and corrosion resistance Activity: Following the talk, Yarmuch guided the 55 attendees on a tour of the Alberta Research Council facilities in Ed- monton, Alb., Canada. Ken Nelson, a past Section chair, presented Yarmuch Eric Hasselmann (left), AFS vice chair, with a speaker gift. Student Patrick Kerr presents a speaker gift to Martin Gagne at won the door prize, a copy of Welding the joint American Foundry Society and Northern Alberta Section Chair Matthew Handbook. Fifty-five members and guests AWS British Columbia Section meeting in Yarmuch (left) accepts a speaker gift from attended the program. March. Ken Nelson at the April 16 meeting.

APRIL 25 Activity: The Houston Section members toured Greens Bayou Pipe Mill in Hous- District 19 District 20 ton, Tex. Steve Buckles, production man- Director: Neil Shannon Director: William A. Komlos ager, conducted the program. Phone: (503) 201-5142 Phone: (801) 560-2353

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Patricio Mendez (wearing a tie) and Colorado School of Mines students demonstrated orbital welding and thermite welding for the Colorado Section members.

Adam Ramirez (left), a College of San Mateo student, receives the raffle prize from Antonio De Sousa at the Santa Clara Val- ley Section program. COLORADO MAY 8 Activity: The Section members met at Colorado School of Mines in Golden, Colo., to learn about its Center for Weld- ing, Joining, and Coating Research. Prof. Patricio Mendez presented an overview of the Center, then guided a tour of the facility. Students gave presentations and demonstrations on orbital welding and thermite welding. The Section held its election of officers, chaired by Dean Shown at the Long Beach/Orange County Section program are (from left) incoming Chair Mitchell, vice chairman. Cary Chiu, Secretary Larry Gustafson, AWS President Gene Lawson, outgoing Chair Richard Hutchison, Vice Chair Winfred Sartin, and Ben Anderson of Summit Gas and Gear. District 21 Director: Jack D. Compton Phone: (661) 362-3218

LONG BEACH- ORANGE COUNTY APRIL 17 Speaker: Gene E. Lawson, AWS president Affiliation: ESAB Welding & Cutting Topic: A changing welding environment creates new opportunities Activity: Section scholarships were presented to students Josh Hurst, Brent Helmick, and Justin Nichols. Richard Hutchison, outgoing chairman, received a certificate of appreciation for his services. Cary Chiu was introduced as the Section’s incoming chairman. Ben Ander- son accepted a certificate on behalf of Summit Gas and Gear for hosting the Lou DeFreitas (left) is shown with Dale Speaker Gordon Gibbs (right) is shown meeting and providing the raffle prizes Flood, District 22 director, at the Santa with Antonio De Sousa at the Santa Clara and food. Clara Valley Section program. Valley Section program.

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Shown are the attendees at the Santa Clara Valley Section program.

Shown at the San Francisco Section pro- Frank Jackson demonstrated black- gram are Chair Tom Smeltzer (left), Artist Chris Sorensen (right) is shown with smithing techniques for the Fresno Section speaker George Vander Voort, and Vice Fred Mattern, Fresno Section treasurer. members. Chair Liisa Pine.

smithing skills. Bob Gifford described how past chairmen’s night, to be held at District 22 he built his sculpture of a fountain using Spenger’s Restaurant in Berkeley, Calif. Director: Dale Flood gas metal arc welding. For information, call Chairman Tom Phone: (916) 933-5844 Smeltzer, (707) 253-3237. FRESNO SAN FRANCISCO APRIL 17 MAY 7 SANTA CLARA VALLEY Activity: The Section members toured Speaker: George Vander Voort, director MAY 13 the Chris Sorensen Studio in Fresno, of research and technology Speaker: Gordon Gibbs Calif. Chris Sorensen creates some of his Affiliation: Buehler, Ltd. Affiliation: Sandia National Laboratories art works using scrap metal, plasma arc Topic: Studying crystal structures of met- Topic: Electron beam profiling as a tool cutting, and a welding torch. Tour high- als using color metallography Activity: The Section hosted its annual lights included demonstrations of vari- Activity: The Section displayed a new College of San Mateo night activities. ous welding and blacksmithing tech- Epson digital projector, purchased with A special recognition was given to Lou niques for building artistic metal sculp- the funds saved from reduced printing and DeFreitas by District 22 Director Dale tures. Bernard Heer, Frank Jackson, and mailing costs effected by increased use of Flood. The two presented the new Sec- Robert Rorick demonstrated their black- e-mail. September 3 was designated as tion banner.

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Member-Get-A-Member Campaign

isted are the members participating P. Hanley, Peoria — 3 M. Arand, Louisville — 16 in the 2007–2008 AWS Member- T. Nielsen, Pittsburgh — 3 J. Ciaramitaro, N. Central Florida — 16 LGet-A-Member Campaign for the T. Bridigum, Northwest — 15 period between June 1, 2007, and May 31, President’s Honor Roll J. Compton, San Fernando Valley — 15 2008. For campaign rules and a prize list, AWS Members sponsoring 1 or 2 new C. Donnell, Northwest Ohio — 15 see page 65 of this Welding Journal. Stand- Individual Members. Only those sponsor- D. Kowalski, Pittsburgh — 15 ings are as of 5/19/2008. If you have any ing 2 AWS Individual Members are listed. T. Moore, New Orleans — 15 questions regarding your member pro- T. Alberts, Southwest Virginia D. Roskiewich, Philadelphia — 15 poser points, call the Membership Depart- M. Beaton, North Texas R. Briddell, St. Louis — 14 ment, (800) 443-9353, ext. 480. C. Bridwell, Ozark H. Browne, New Jersey — 14 D. Campbell, North Texas T. Geisler, Pittsburgh — 14 Winner’s Circle D. Daugherty, Indiana H. Hughes, Mahoning Valley — 14 Members who have sponsored 20 or M. Enis, Arizona C. Overfelt, SW Virginia — 14 more new Individual Members, per year, S. Fetters, Johnstown-Altoona A. Stute, Madison-Beloit — 14 since June 1, 1999. The superscript indi- W. Galvery Jr., Long Beach/Or. County A. Wyatt, Holston Valley — 13 cates the number of times the member has C. Gotangco, New Orleans T. Buchanan, Mid-Ohio Valley — 12 achieved Winner’s Circle status. J. Hoffman, Lakeshore J. McCarty, St. Louis — 12 J. Compton, San Fernando Valley7 H. Jackson, L.A/Inland Empire R. Munns, Utah — 12 E. Ezell, Mobile5 C. Johnson, Northern Plains B. Suckow, Northern Plains — 12 J. Merzthal, Peru2 J. Johnson, Northern Plains D. Zabel, Southeast Nebraska — 12 G. Taylor, Pascagoula2 R. Key, San Antonio M. Rotary, Detroit — 11 B. Mikeska, Houston1 J. Kozeniecki, Milwaukee W. Harrris, Pascagoula — 10 R. Peaslee, Detroit1 D. Landon, Iowa D. Lynn, Ozark — 10 W. Shreve, Fox Valley1 S. Leighton, Louisville S. Robeson, Cumberland Valley — 10 M. Karagoulis, Detroit1 J. Livesay, Nashville R. Tully, San Francisco — 10 S. McGill, NE Tennessee1 J. McCarty, St. Louis D. Aragon, Puget Sound — 9 L. Taylor, Pascagoula1 J. Nieto, Corpus Christi P. Bedel, Indiana — 9 T. Weaver, Johnstown/Altoona1 R. Norris, Maine D. Vranich, North Florida — 9 G. Woomer, Johnstown/Altoona1 R. Panter, Long Bch./Or. Cty. D. Williams, North Texas — 9 R. Wray, Nebraska1 J. Reid, Boston A. Badeaux, Washington D.C. — 8 M. Haggard, Inland Empire1 F. Schmidt, Niagara Frontier W. Komlos, Utah — 8 G. Sinkule, Northern Michigan M. Legel, Maine — 8 President’s Guild T. Snider, Mobile C. Schiner, Wyoming Section — 8 Members sponsoring 20 or more new A. Sumal, British Columbia T. Smith, Utah — 8 Individual Members. J. Truitt, San Diego J. Theberge, Boston — 8 L. Taylor, Pascagoula — 144 J. Wagner, Kansas City J. Boyer, Lancaster — 7 E. Ezell, Mobile — 23 R. Wright, San Antonio G. Rolla, L.A/Inland Empire — 7 M. Yarmuch, Northern Alberta L. Smerglia, Cleveland — 7 President’s Roundtable P. Zammit, Spokane T. Strickland, Arizona — 7 AWS Members sponsoring 9–19 new W. Troutman, Cleveland — 7 Individual Members. Student Member Sponsors J. Cox, Spokane — 6 J. Compton, San Fernando Valley — 16 Members sponsoring 4 or more new B. Hallila, New Orleans — 6 J. Hope, Puget Sound — 12 AWS Student Members. S. McDaniel, Inland Empire — 6 J. Sanchez, Cuautitlan Izcalli — 9 S. Siviski, Maine — 45 E. Norman, Ozark — 6 W. Wood, Baltimore — 9 D. Berger, New Orleans — 38 R. Richwine, Indiana — 6 M. Reiter, Columbus — 36 T. Shirk, Tidewater — 6 President’s Club J. McCloud Jr., Puget Sound — 35 L. Taylor, Pascagoula — 6 AWS Members sponsoring 3–8 new G. Euliano, Northwestern Pa. — 34 B. Wenzel, San Francisco — 6 Individual Members. R. Evans, Siouxland — 34 P. Carney Jr., Lehigh Valley — 5 R. Cook, Utah — 8 D. Nelson, Puget Sound — 34 C. Daily, Puget Sound — 5 S. Christensen, Nebraska — 7 T. Zablocki, Pittsburgh — 28 W. Galvery Jr., Long Bch./Or. Cty. — 5 R. Ellenbecker, Fox Valley — 7 M. Anderson, Indiana — 26 B. Hardin, San Francisco — 5 D. Wright, Kansas City — 7 R. Hutchison, Long Bch./Or. Cty. — 23 R. Hilty, Pittsburgh — 5 A. Castro, South Florida — 6 N. Goncalo, Milwaukee — 21 R. Olesky, Pittsburgh — 5 A. Demarco, New Orleans — 5 R. Hutchinson, Long Bch./Or. Cty. — 20 T. Parker, Wheeling — 5 V. Raloff, J.A.K. — 5 G. Smith, Lehigh Valley — 20 T. Paolino, Connecticut — 5 P. Johnson, Houston — 4 J. Daugherty Louisville — 19 C. Yaeger, Northeastern Carolina — 5 K. Kotter, Utah — 4 G. Seese, Johnstown-Altoona — 19 J. Angelo, El Paso — 4 T. Lowe, Northwest Ohio — 4 B. Yarrison, York-Central Pa. — 19 J. Craiger, Indiana — 4 T. Moffitt, Tulsa — 4 J. Kacir, Detroit — 18 G. Ellar, Detroit — 4 R. Gaffney, Tulsa — 3 C. Kipp, Lehigh Valley — 18 S. Hansen, Southeast Nebraska — 4 L. Garner, Mobile — 3 D. Parker, Idaho-Montana — 18 R. Leford Jr., Birmingham — 4 C. Gilbert, East Texas — 3 D. Ketler, Willamette Valley — 17 C. Rossi, Washington, DC — 4

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Guide to AWS Services 550 NW LeJeune Rd., Miami, FL 33126 www.aws.org; phone (800/305) 443-9353; FAX (305) 443-7559 (Phone extensions are shown in parentheses.)

AWS PRESIDENT Corporate Director, Exhibition Sales EDUCATION SERVICES Gene E. Lawson Joe Krall.. [email protected] ...... (297) Managing Director [email protected] Organizes the annual AWS Welding Show and Dennis Marks.. [email protected] ...... (449) ESAB Welding and Cutting Convention, regulates space assignments, regis- 25108 Margurite Pkwy. #165 tration items, and other Expo activities. Director, Education Services Administration Mission Viejo, CA 92692 and Convention Operations John Ospina.. [email protected] ...... (462) ADMINISTRATION PUBLICATION SERVICES Executive Director Department Information ...... (275) Ray W. Shook.. [email protected] ...... (210) Managing Director AWS AWARDS, FELLOWS, COUNSELORS Andrew Cullison.. [email protected] . . . . .(249) Senior Manager CFO/Deputy Executive Director Wendy S. Reeve.. [email protected] ...... (293) Frank R. Tarafa.. [email protected] ...... (252) Welding Journal Coordinates AWS awards and AWS Fellow and Publisher Counselor nominees. Deputy Executive Director Andrew Cullison.. [email protected] . . . . .(249) Cassie R. Burrell.. [email protected] . . . . .(253) TECHNICAL SERVICES Editor Department Information ...... (340) Associate Executive Director Mary Ruth Johnsen.. [email protected] (238) Managing Director Jeff Weber.. [email protected] ...... (246) Andrew R. Davis.. [email protected] ...... (466) National Sales Director Int’l Standards Activities, American Council of Executive Assistant for Board Services Rob Saltzstein.. [email protected] ...... (243) the Int’l Institute of Welding (IIW) Gricelda Manalich.. [email protected] . . . .(294) Society and Section News Editor Director, National Standards Activities Administrative Services Howard [email protected] .(244) John L. Gayler.. [email protected] ...... (472) Managing Director Personnel and Facilities Qualification, Comput- Jim Lankford.. [email protected] ...... (214) Welding Handbook erization of Welding Information Welding Handbook Editor IT Network Director Annette O’Brien.. [email protected] . . . . .(303) Manager, Safety and Health Armando [email protected] . . .(296) Publishes the Society’s monthly magazine, Weld- Stephen P. Hedrick.. [email protected] (305) ing Journal, which provides information on the Metric Practice, Safety and Health, Joining of Director state of the welding industry, its technology, and Plastics and Composites Hidail Nuñ[email protected] ...... (287) Society activities. Publishes Inspection Trends, the Welding Handbook, and books on general welding Technical Publications Database Administrator subjects. AWS publishes about 200 documents widely used Natalia [email protected] ...... (245) throughout the welding industry. Senior Manager Human Resources Rosalinda O’Neill.. [email protected] . . . . .(451) Director, Compensation and Benefits MARKETING COMMUNICATIONS Luisa Hernandez.. [email protected] ...... (266) Director Staff Engineers/Standards Program Managers Ross Hancock.. [email protected] . . . . .(226) Annette Alonso.. [email protected] ...... (299) Manager, Human Resources Automotive Welding, Resistance Welding, Oxy- Dora Shade.. [email protected] ...... (235) Assistant Director fuel Gas Welding and Cutting, Definitions and Adrienne Zalkind.. [email protected] . . . .(416) Symbols, Sheet Metal Welding INT’L INSTITUTE of WELDING Webmaster Stephen Borrero.. [email protected] . . . . .(334) Senior Coordinator Angela [email protected] ...... (456) Welding Iron Castings, Joining of Metals and Al- Sissibeth Lopez . . [email protected] ...... (319) loys, Brazing and Soldering, Brazing Filler Met- Provides liaison services with other national and als and Fluxes, Brazing Handbook, Soldering international professional societies and standards Handbook organizations. MEMBER SERVICES Rakesh Gupta.. [email protected] ...... (301) Department Information ...... (480) Filler Metals and Allied Materials, Int’l Filler GOVERNMENT LIAISON SERVICES Metals, Instrumentation for Welding, UNS Num- Hugh K. Webster. . . [email protected] Deputy Executive Director bers Assignment Webster, Chamberlain & Bean, Washington, D.C., Cassie R. Burrell.. [email protected] . . . . .(253) (202) 466-2976; FAX (202) 835-0243. Identifies Brian McGrath . [email protected] . . . . .(311) funding sources for welding education, re- Director Methods of Inspection, Mechanical Testing of search, and development. Monitors legislative Rhenda A. Mayo... [email protected] . . . . .(260) Welds, Welding in Marine Construction, Piping and regulatory issues of importance to the weld- Serves as a liaison between Section members and and Tubing, Robotic and Automatic Welding ing industry. AWS headquarters. Informs members about AWS benefits and activities. Selvis [email protected] . . . . .(313) Welding Qualification, Structural Welding Brazing and Soldering Manufacturers’ Committee Matthew [email protected] ...... (215) Jeff Weber.. [email protected] ...... (246) CERTIFICATION SERVICES Machinery and Equipment, Robotics Welding, Department Information ...... (273) Arc Welding and Cutting Processes RWMA — Resistance Welding Manufacturing Alliance Managing Director, Certification Operations Reino [email protected] ...... (304) Manager John [email protected] ...... (222) Welding in Sanitary Applications, High-Energy Susan Hopkins.. [email protected] ...... (295) Beam Welding, Aircraft and Aerospace, Friction Managing Director, Technical Operations Welding, Railroad Welding, Thermal Spray Peter Howe.. [email protected] ...... (309) WEMCO — Welding Equipment Manages and oversees the development, in- Note: Official interpretations of AWS standards Manufacturers Committee tegrity, and technical content of all certification may be obtained only by sending a request in writ- Manager programs. ing to the Managing Director, Technical Services. Natalie Tapley.. [email protected] ...... (444) Oral opinions on AWS standards may be ren- Director, Int’l Business & Certification Programs dered. However, such opinions represent only the Priti Jain.. [email protected] ...... (258) personal opinions of the particular individuals CONVENTION and EXPOSITIONS Directs all int’l business and certification pro- giving them. These individuals do not speak on Associate Executive Director grams. Is responsible for oversight of all agencies behalf of AWS, nor do these oral opinions con- Jeff Weber.. [email protected] ...... (246) handling AWS certification programs. stitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are in- formal and should not be used as a substitute for an official interpretation.

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Nominees for National Office AWS Publications Sales nly Sustaining Members, Mem- fice of treasurer, an individual must be a bers, Honorary Members, Life member of the Society, other than a Stu- Purchase AWS standards, books, OMembers, or Retired Members dent Member, must be frequently avail- and other publications from who have been members for a period of able to the national office, and should be World Engineering Xchange (WEX), Ltd. at least three years shall be eligible for of executive status in business or industry [email protected]; www.awspubs.com election as a director or national officer. with experience in financial affairs. Toll-free (888) 935-3464 (U.S., Canada) It is the duty of the National Nominat- Director-at-large: To be eligible for (305) 824-1177; FAX (305) 826-6195 ing Committee to nominate candidates for election as a director-at-large, an individ- national office. The committee shall hold an ual shall previously have held office as Welding Journal Reprints open meeting, preferably at the Annual chairman of a Section; as chairman or Copies of Welding Journal articles may be Meeting, at which members may appear vice chairman of a standing, technical, purchased from Ruben Lara. to present and discuss the eligibility of all or special committee of the Society; or (800/305) 443-9353, ext. 288; [email protected] candidates. as District director. To be considered a candidate for the po- Interested persons should submit a let- Custom reprints of Welding Journal sitions of president, vice president, treas- ter stating which office they seek, including articles, in quantities of 100 or more, urer, or director-at-large, the following qual- a statement of qualifications, their willing- may be purchased from ifications and conditions apply: ness and ability to serve if nominated and FosteReprints President: To be eligible to hold the of- elected, and a biographical sketch. Toll-free (866) 879-9144, ext. 121 fice of president, an individual must have E-mail the letter to Gricelda Manalich, [email protected] served as a vice president for at least [email protected], c/o Gerald D. Uttrachi, one year. chair, National Nominating Committee. Vice President: To be eligible to hold the The next meeting of the National office of vice president, an individual must Nominating Committee is scheduled for have served at least one year as a director, October 2008. The terms of office for can- AWS Foundation other than executive director and secretary. didates nominated at this meeting will AWS Foundation, Inc., is a not-for-profit cor- Treasurer: To be eligible to hold the of- commence January 1, 2010. poration established to provide support for educational and scientific endeavors of the American Welding Society. Information on Honorary Meritorious Awards gift-giving programs is available upon request. Chairman, Board of Trustees he Honorary-Meritorious Awards Committee makes recommendations for the Ronald C. Pierce nominees presented for Honorary Membership, National Meritorious Certificate, TWilliam Irrgang Memorial, and the George E. Willis Awards. These awards are Executive Director, AWS presented during the FABTECH International & AWS Welding Show held each fall. Ray Shook, ext. 210, [email protected] The deadline for submissions is December 31 prior to the year of awards presentations. Send candidate materials to Wendy Sue Reeve, secretary, Honorary Meritorious Awards Executive Director, Foundation Committee, [email protected]; 550 NW LeJeune Rd., Miami, FL 33126. Descriptions of Sam Gentry, ext. 331, [email protected] the awards follow. Corporate Director, SOS William Irrgang Memorial Award is Honorary Membership Award is pre- Monica Pfarr, ext. 461, [email protected] awarded each year to the individual who sented to a person of acknowledged emi- has done the most over the past five years nence in the welding profession, or who is Director, SOS Gulf Coast Division to enhance the American Welding Soci- accredited with exceptional accomplish- Connie Bowling, ext. 308, [email protected] ety’s goal of advancing the science and ments in the development of the welding technology of welding. art, upon whom the American Welding So- 550 NW LeJeune Rd., Miami, FL 33126 This award consists of a $2500 honar- ciety sees fit to confer an honorary distinc- (305) 445-6628; (800) 443-9353, ext. 293 ium and a certificate. It is presented dur- tion. Honorary Members have full rights general information: ing the FABTECH International & AWS of membership. (800) 443-9353, ext. 689; [email protected] Welding Show held each fall. The award is administered by the American Welding National Meritorious Certificate Society and sponsored by The Lincoln Elec- Award is given in recognition of the can- tric Co. to honor the late William Irrgang. didate’s counsel, loyalty, and devotion to AWS Mission Statement the affairs of the Society, assistance in pro- George E. Willis Award is awarded each moting cordial relations with industry and The mission of the American Welding year to an individual who promotes the other organizations, and for the contribu- Society is to advance the science, technolo- advancement of welding internationally tion of time and effort on behalf of the gy, and application of welding and allied by fostering cooperative participation in Society. processes, including joining, brazing, sol- areas such as technology transfer, stan- dering, cutting, and thermal spraying. dards rationalization, and promotion of International Meritorious Certificate industrial goodwill. Award is given in recognition of signifi- The award consists of a $2500 honar- cant contributions to the welding industry It is the intent of the American Weld- ium and a certificate. It is presented dur- for service to the international welding ing Society to build AWS to the highest ing the FABTECH International & AWS community in the broadest terms. The quality standards possible. The Society Welding Show held each fall. The award awardee is not required to be an AWS welcomes your suggestions. Please con- is administered by the American Welding member. Multiple awards may be given. tact any staff member or AWS President Society and sponsored by The Lincoln The award consists of a certificate and a Gene E. Lawson, as listed on the previous Electric Co. to honor George E. Willis. one-year AWS membership. page.

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The world of nondestructive testing is expanding due to the introduction of new AWSAWS Conference Conference on on technologies. Among the technologies to be discussed are several of the new NewNew Nondestructive Nondestructive versions of ultrasonic testing (UT), including time of flight diffraction (TOFD), alternating current field measurement TestingTesting Technologies Technologies (ACFM), phased array inspection, and guided wave examination. The ASME Code, Las Vegas with Code Case No. 2235, has October 7, 2008 accepted TOFD in lieu of radiography examination for at the FABTECH Int’l & AWS Welding Show thicknesses over 4 inches. ACFM is being used to detect fatigue cracks in offshore structures, and is now being used on many structures throughout industry. Both phased array and guided wave inspection are gaining in popularity. Phased array has demonstrated high speed, thorough inspection, while the guided wave approach has been especially useful in remote application situations.

In addition, attendees will hear about a new UT system that is being used to inspect austenitic welds in LNG storage tanks. This system has been accepted as an alternative to radiographic testing by the American Petroleum Institute.

Other presentations will include the use of acoustic emission to inspect the welds in bridge construction, and an introduction to a project funded by the Center for Naval Shipbuilding Technology involving a digital radiography system that uses computed radiography techniques.

To register or to receive a descriptive brochure, call (800) 443-9353 ext. 455 (outside North America, call 305-443-9353), or visit www.aws.org/conferences Page 88 and 89:FP_TEMP 6/6/08 1:03 PM Page 89

New Nondestructive Testing Technologies Advancements in NDE at Edison Welding Institute Tuesday, October 7, 2008 • 8:50 AM – 4:00 PM Kevin M. Clear, Project Engineer – NDE Technology, Edison Las Vegas Convention Center Welding Institute, Columbus, OH Member of AWS, FMA, SME, NAM, or PMA: $345 This presentation will discuss the advancements in nonde- Nonmembers: $480 structive evaluation at Edison Welding Institute. It will provide Registration Code: W82 a brief overview of linear and matrix phased array, digital com- To register or to receive a descriptive brochure, call puted radiography, phased array eddy current, and microwave (800) 443-9353 ext. 455 (outside North America, call 305-443- inspection techniques. 9353), or visit www.aws.org/conferences Practical Applications of the Time of Flight Diffraction Ultrasonic Technique for the Examination of 9% Nickel Ultrasonic Technique Inner Shells of Large Diameter Liquid Natural Gas Storage David Dechene, NDE Level III for US Operations, Sonomatic, Tanks Baton Rouge, LA Ronald W. Kruzic, Senior Welding Engineer/Corporate NDT Originally developed in the late 1970’s for the nuclear indus- Level III, CB&I, Plainfield, IL try as a very accurate flaw-sizing tool, the time of flight diffrac- A semi-automatic, first-of-its-kind, ultrasonic examination tion (TOFD) ultrasonic technique has also gained popularity technique that is currently being utilized for the examination of over the years for its other unique abilities, such as one-scan the high nickel alloy welds of 9% Ni LNG tanks will be weld inspections, corrosion mapping, hydrogen damage described. It is currently being utilized to examine the world’s detection, and rapid screening of vessel shells, to name a few. largest LNG tanks, 190,000 m3, and will shortly be applied to a This presentation is designed to explain what TOFD is, how it 200,000 m3 storage tank. This technique takes the volumetric differs from pulse echo UT, its advantages/disadvantages, and examination of the shell welds off the critical path and places its applications for industry today. the welding operation in its place. An Introduction to Alternating Current Field Measurement Computed Radiography – Innovations for Film Quality Robert E. Cameron, Manager, Quality Assurance and Training, Results in Industrial Applications TWI North America, LCC, Deer Park, TX Terry Plasek, Western Regional Manager, Fujifilm NDT ACFM is an electromagnetic test technique used for the detec- Systems, Conroe, TX tion and sizing of surface-breaking cracks. It was initially con- This presentation addresses the evolution of computed radiog- ceived for use under water to detect flaws in offshore raphy dedicated to industrial use and applications. Discussion structures and proved to be very effective. Now ACFM is used on the improvements in systems resulting in the ability to to inspect structures both in and out of the water. ACFM has achieve results equal to or, in some cases, better than conven- the advantage, over some other NDT methods, that the surface tional wet film radiography. System specifications and exam- requires minimal cleaning. Also, ACFM can be applied to sur- ple imaging are also included. faces that are painted, or have other coatings up to about 5 mm in thickness. ACFM is used not only to detect and size sur- Eddy Current Array and Ultrasonic Phased-Array face-breaking cracks, but also to monitor crack growth. Technologies as Reliable Tools for FSW Inspection Michael Moles, Senior Technology Manager, Olympus NDT Emerging Ultrasonic Guided Wave Applications in NDT, Canada, Toronto, Canada and André Lamarre, Business Structural Health Monitoring (SHM), and Weld Inspection Development Director,Aerospace and Defense, Olympus NDT, Joseph L. Rose, Paul Morrow Professor, Engineering Science Quebec, Canada & Mechanics Department, Pennsylvania State University, Ultrasonic phased-array technology has demonstrated over University Park, PA. Dr. Rose is also Senior Scientist, FBS Inc., the years its capabilities to reliably inspect aluminum friction Feature Based Systems, College, PA. Dr. Rose’s paper will be stir welds as many aerospace manufacturers have used it presented by Michael Moles, Senior Technology Manager, during their manufacturing process. Recent developments in Olympus NDT Canada, Toronto, Canada eddy current array technology added new perspectives to the Ultrasonic guided waves have always been of interest for FSW evaluation. It is now possible to characterize the tool decades, but little used in NDT and SHM. Today, however, with penetration and minimize the presence of an oxide layer, so- significant advancements in theoretical understanding and called kissing bond. This article will summarize results of both computational efficiency, the road ahead for guided waves is technologies for the evaluation of FSW. clear. Phased array utilization has advanced guided wave applications even further. Sample problems in pipeline, air- Use of Acoustic Emission for Field Inspection of Welds for craft, and rail will be covered, along with special emphasis on In-Service Bridges newly developed phased array scanning of an entire plate Richard Gostautas, Infrastructure Group Leader, Physical from a single sensor position and weld inspection with simple Acoustics Corp., Princeton Junction, NJ single line scan at any arbitrary distance from the weld. This presentation includes a few case studies that describe and illustrate how acoustic emission monitoring was used as ® a NDE tool for condition assessment of defects and discontinuities (e.g. cracks) in welds on different types of in-service bridges. New Lit JULY:Layout 1 6/6/08 3:10 PM Page 90

NEW LITERATURE Bulletins Detail Laser Peening and Welding

welding, applications, and the vendors employed. A number of implementation include Guide for the Selection of Laser Eye successes are described for applications Protection, ANSI Z136.7 (2008) for Testing specifying lightweight, corrosion-resistant and Labeling of Laser Protective Equipment, panels that must also meet structural, CLSOs’ Best Practices in Laser Safety, and The Navy Metalworking Center has re- heat, and other requirements. Several Laser Safety Guide. Described are training leased two informative two-page bulletins photographs illustrate the welding and as- courses, including Laser Safety Officer, and Laser Peening, and Naval Applications of sembly of the sandwich panels. Advanced Concepts in Laser Safety, and a Laser-Welded Metallic Sandwich Panels. number of online training courses. Listed The laser peening technique is similar to Concurrent Technologies Corp. on one page are all of the company’s pub- shot peening but imparts compressive www.nmc.ctc.com lications with prices. Included is complete stresses much deeper into the components (717) 565-4405 membership information and details of up- with minimal surface deformation, using coming conferences. short blasts of intense laser light. The Laser Safety Products process is detailed with its benefits and Pictured in Catalog Laser Institute of America several applications using mobile laser www.laserinstitute.org peening systems. The other bulletin de- (800) 345-2737 tails innovative lightweight sandwich pan- A 16-page, full-color catalog illustrates els under consideration by the U.S. Navy and details the company’s full line of laser Updated Welding for significant weight and cost reductions safety products, literature, training courses, in the construction of Navy ships. Dis- conferences, and services. New items in- Equipment Catalog Issued cussed are the background on the devel- clude aluminum and magnetic signs at re- opment project, and the many benefits of duced prices, and updated laser safety stan- using modular panel assemblies, laser dards and manuals. A few of the new titles

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BT1B Visit our website TT1 for all sizes and models available

BSC-1PLT BT1C www.fischerengr.com ! (937)754-1750 The company’s 2008 product catalog illustrates and describes its updated complete lines of welding machines, wire feed- For info go to www.aws.org/ad-index

90 JULY 2008 New Lit JULY:Layout 1 6/6/08 3:10 PM Page 91

ers, robotic solutions, consumables, fume- Leak Detection and Safety Booklet Stresses extraction systems, automated solutions, Diagnostic Tools Pictured Importance of Standards guns, torches, and welding equipment accessories. Each section begins with a selection guide that highlights each machine’s capabilities at a glance and allows for easy comparisons. Once users have narrowed their choices, they can turn to the color-coded product pages for more detailed information on each machine, including welding process, key features, benefits, output range, input power, dimensions, and photographs. Order a copy of the catalog by phone or visit the Web site and request Bulletin E1.10.

The Lincoln Electric Co. www.lincolnelectric.com (888) 355-3213 Catalog Pictures Modular Work-Holding Fixtures

A 94-page catalog illustrates the company’s line of Amflex® modular work- A 6-page, full-color brochure illus- Safety Equipment Standards — Your holding self-aligning fixturing elements. trates and describes the company’s lines Keys to Business Success gives an overview Included are hydraulic and pneumatic fix- of leak detection products and diagnostic of the importance of using personal pro- tures, modular components, grids, force tools for industrial systems. Shown are tective and safety equipment made to rig- cartridges, tombstones, and high-density high-intensity, corded UV lamps, and orous standards. The 12-page brochure is work-holding systems for dedicated or cordless, rechargeable LED flashlights. organized in a Q & A format with three manual fixturing. Included is a variety of Featured is the Optimax™ 365 that pro- sections that pose questions with answers precision grid bases, ball elements, spring vides a pure, long-wave UV light that about U.S. standards, international stan- supports, V-block supports, locators, and makes even dirty oil leaks glow brightly. dards, and conformity assessment. In- clamping components. Detailed technical Other tools featured include the Marks- cluded is information on the U.S. stan- data with application information, design man™ ultrasonic diagnostic tool, Cobra™ dards system and the role of the Ameri- options, and mounting dimensions are series of multipurpose borescopes, and can National Standards Institute, and the provided. Pro-Alert™ electronic refrigerant leak de- growing importance of international stan- tector. Information is provided on a com- dards in global commerce. The free PDF Advanced Machine & Engineering www.ame.com plete line of fluorescent dyes used to de- version of the booklet may be downloaded (815) 962-6076 tect hydraulic fluid, engine oil, compres- from the Web site. sor oil, gearbox oil, fuel, and water leaks. CD Details Welding Int’l Safety Equipment Assn. Equipment Spectronics Corp. www.safetyequipment.org www.spectroline.com (703) 525-1695 (800) 274-8888 A CD details the company’s lines of Web Site Posts Hydraulics welding equipment and welding automa- Free Poster Pictures tion products and systems providing tech- Technology Updates nical data in an easy-to-use format. The Common Weld Flaws CD is intended for anyone buying man- A new industrial hydraulics Web site ual or automated welding equipment. All Ten of the most common weldment provides easy access for technology up- products are included including a portable problems, their likely causes, and fixes are dates, applications support, expert help, Caddy range of arc welding machines presented in a 22- × 28-in. poster format. and product information. Also featured through to heavy-duty arc welding ma- Using diagrams and concisely written ex- are free downloads of literature, training chines and ancillary equipment, torches, planations, the poster serves as a handy information, and news about the hy- components, and plasma arc cutting reference for educational welding envi- draulics industry. This in-depth resource equipment. For automated welding, the ronments and professionals too. The ten helps first-time visitors get started and CD details orbital gas tungsten arc weld- topics detailed include porous welds, find what they need. Featured is a coming, universal mechanization equipment, cracked welds, undercutting, distortion, prehensive hydraulics portfolio ranging flux handling equipment, column-and- spatter, incomplete fusion, overlapping, from accumulators to valves and re- boom equipment, resistance welding, fric- insufficient penetration, magnetic arc lated products, to dozens of catalogs, tion stir welding, and many other items. blow, and inclusions. The free poster may brochures, and interactive materials. Ex- One section spotlights the company’s abil- be ordered by calling the number below tensive product photos and helpful selec- ity to custom-design systems to suit cus- or sending an e-mail request to the fulfill- tion criteria make browsing more inter- tomers’ specific applications. ment center at [email protected]. esting and simplifies product selection.

ESAB Welding & Cutting Products Hobart Brothers Co. Bosch Rexroth Corp. www.esabna.com www.hobartbrothers.com www.boschrexroth-us.com/BRH-I (800) 372-2123 (888) 462-2789 (610) 694-8339

WELDING JOURNAL 91 Personnel JULY:Layout 1 6/6/08 3:42 PM Page 92

PERSONNEL

ESAB Names Four VPs custom-fabricated capital equipment Dulchinos Elected to solutions to major original equipment Robotic Industries Board manufacturers. John Dulchinos, president and COO District Sales Manager of Adept Technol- Named at T. J. Snow ogy, Inc., Liver- more, Calif., a T. J. Snow Co., provider of intelli- Chattanooga, gent vision-guided Tenn., has ap- robotics, has been George Learmonth Greg Stauffer pointed Robert J. elected to serve a Hosa a district sales second two-year manager, based in John Dulchinos term as a member Columbus, Ohio. of the board of di- Hosa, with 30 years’ rectors of the Ro- experience in the in- botics Industry Association (RIA). dustry, will be re- Dulchinos has served in the robotics in- Robert Hosa sponsible for servic- dustry for more than 20 years. The RIA ing the company’s represents about 270 robotics manufac- resistance welding turers, component suppliers, system inter- machine clients throughout the Midwest. ators, end users, research groups, and consulting firms. Jerry Gleisner David Abe Team Industries Designates Fiber Society Names ESAB Welding & Cutting Products, Flo- Sales VP rence, S.C., has promoted George Lear- President month to vice president of strategic ac- Team Industries, counts, North America, based in Hanover, Inc., Kaukauna, The Fiber Society, Raleigh, N.C., has Pa. Learmonth previously was director of Wis., a supplier of named Young Chung president for 2008. strategic accounts for ESAB. Greg Stauf- steel pipe and ves- Chung, with Donaldson Co., Inc., Min- fer was named vice president of sales sup- sels, has named neapolis, Minn., for 26 years, has been en- port, based in Florence, S.C. Stauffer, with Michael E. Mincks gaged in nanofiber research, polymer sci- the company for 28 years, previously vice president of ence, and nanofiber chemistry. A Fellow served as vice president of sales. Jerry sales and estimat- within the Donaldson Corporate Technol- Gleisner was appointed vice president of ing. With the com- ogy group, he is credited with being in- sales, eastern zone, based in Clayton, N.C. pany for 15 years, strumental in the development of electro- Gleisner previously served as zone man- Michael Mincks Mincks most re- spinning nanofiber air filtration and the ager for Sandvik Coromant. David Abe cently held the posi- company’s advanced Ultra-Web® air- was named vice president of sales, western tion of estimating manager. filtration technology. zone, based in Denver, Colo. Previously, Abe served as executive vice president, sales and marketing, for WIKA Instru- President Named at Airgas Obituaries ment Corp. NCN Region Dinesh Chand Agarwal Jet Edge Appoints Sales Airgas, Inc., Rad- Manager nor, Pa., has named Dinesh Chand “D.C.” Agarwal, 64, J. Samuel Thomp- died April 20. An AWS member since son president of Air- 1991, he served on the A5E Subcommitee Jet Edge, Inc., St. gas Northern Cali- on Nickel and Nickel-Alloy Filler Metals. Michael, Minn., a fornia and Nevada, He was a member of provider of ultra- one of the compa- ASM International, high-pressure wa- nies that make up its and American Soci- terjet and abrasive distribution busi- ety of Mechanical jet systems for preci- ness. He replaces Engineers, and sion cutting, has ap- Samuel Thompson Jim McCarthy, who chaired numerous pointed Robert has joined the corpo- technical sessions Bangasser corporate distributions operations department as for the annual con- rate sales manager. director of gas supply chain for the Western ference of the Na- Robert Bangasser Bangasser most re- division. Thompson, based in Sacramento, tional Association cently served as a Calif., formerly served as area vice presi- of Corrosion Engi- manufacturer’s representative providing dent for Airgas South. D. C. Agarwal neers. He received

92 JULY 2008 Personnel JULY:Layout 1 6/6/08 3:43 PM Page 93

Harry F. Prah NEW PRODUCTS — continued from page 28 Harry Frank Prah, 91, died May 19 in Indianapolis, Ind. An AWS Life Member, Weld Profile Visualization affiliated with the Indiana Section, he served as Section chairman, District 14 di- System Uses Phased Array rector, and AWS president (1985–1986). Technology He also served on the D9 Committee on Welding, Brazing, and Soldering of Sheet Metal, and on the Conference and Semi- nar Committee, and chaired the Technical Council. Prah attended East Technical High School and graduated from Fenn College in 1946 with a degree in industrial engineering. He worked as chief inspector at Bryant Heater Co. from 1941 to 1946, and served as plant engineer until 1951. In 1952 he founded Prah Engineering Co. in Indianapolis, where he served as president. He was granted a patent on testing devices, and authored articles on welding Harry F. Prah applications. Prah was active in Toastmas- ters International and Boy Scouts of America, where he guided all four of his sons to the rank of Eagle Scout. Prah and his wife, Violet, performed volunteer work at St. Vincent Hospital for many years. He is survived by his wife of 66 years, a sister, four sons, a daughter, nine grandchildren, and five great-grandchildren. The company’s scarf monitoring system provides a real-time, online, accurate his engineering degree in India in 1964, utive board in 1966, named TWI director picture of the inside and outside diameter master’s from Drexel University in 1968, of development in 1981, and became chief profiles of scarfed ERW pipes during the and MBA from Ball State University in executive in 1988. He retired from TWI in manufacturing process. At the center of 1977. Agarwal was a NACE Certified Cor- 2004. During his retirement, he served as the system is the ultrasonic phased array rosion Specialist, a registered Professional chairman of Bressingham Steam Museum transducer that electronically simulates Engineer in the state of Texas, and a Fel- and was active with the Cambridge Mu- the scanning action required to provide low of ASM International. He worked as seum of Technology. Braithwaite received the weld profile information. Next, the re- a production metallurgist at Alloy Steels the Order of the British Empire in 1991, sulting information is fed into GE’s UTxx in India for two years before joining elected a Fellow in the Royal Academy of digital flaw detection platform. In use, the Kawecki Berylco in 1968 where he made Engineering in 1999, received the IIW Ed- transducer test head assembly is mounted tantalum and niobium alloys. In 1974 he ström Medal in 2003, and was named an directly above the weld interface. The mill moved to Haynes where he held various Honorary Fellow of The Welding Institute coolant acts as the ultrasonic coupling production, technical, and marketing po- in 2004. medium. Then, the transducer test head sitions. He published more than 100 arti- uses its phased array elements to monitor cles. Agarwal worked as technical market- the inside and outside diameter of the ing manager at VDM from 1989 to 2000, Russell Stine weld as it is being cut, at a scanning rate then served as vice president of technical of up to 300 profiles/s. Plus, inspection marketing until his death. He is survived Russell “Stiney” Stine, 69, died April data are displayed in true-to-scale cross- by his wife, Madu, a son, Asheesh, and a 14, in Harrisburg, Pa. An AWS member, sectional profile at one or multiple moni- daughter, Anglee. he worked in the welding industry for 45 tor screens, and high and low limit alarms years. He served in the U.S. Army. Active provide warning of weld profile deviation. in community affairs, Stine was a life Bevan Braithwaite GE Sensing & Inspection Technologies member of the West Hanover Fire Co., www.geinspectiontechnologies.com Station #38, and a member of the Tall (717) 242-0327 Bevan Braithwaite, IIW president Cedars of Lebanon Upper Shriners Club, (1999–2002) and former chief executive of Moose Lodge, and the National Rifle The Welding Institute (TWI), died April Assoc. He was a past president of the Change of Address? 25 after a long illness. Braithwaite held an Dauphin County Fire and Police Assoc. engineering degree from Cambridge and a and the Charlton Paxtonia Lions Club. He Moving? Class 1 Welder qualification. In 1961, he was a 32nd Degree Mason and a leader of joined TWI as a scientific officer, where the Country Americans, a country and Make sure delivery of your Welding he authored seminal works on fatigue western band. Stine is survived by his par- Journal is not interrupted. Contact the strengths of structural steel, metallurgy ents, wife, Nina, four daughters, two sons, Membership Department with your for engineers, and friction welding for rail- three sisters, two brothers, ten grandchil- new address information — (800) 443- ways. He was appointed to the TWI exec- dren, and three great-grandchildren. 9353, ext. 217; [email protected].

WELDING JOURNAL 93 JULY 2008 CLASSIFIEDS:Classified Template 6/6/08 2:16 PM Page 94

CLASSIFIEDS

CAREER OPPORTUNITIES

BECOME AN AUDITOR FOR THE AMERICAN WELDING SOCIETY

The American Welding Society is currently accepting résumés from experienced auditors for contract work in our Accredited Test Facility (ATF) and Certified Welding Fabricator (CWF) Programs. Applicants must possess the following minimum qualifications: WELDERS • Certified Welding Inspector for the past five years. Oshkosh Corporation designs and • Two years of previous auditor experience. builds the toughest specialty • Auditor certification or certificate of completion for an auditor training course from a nationally or internationally recognized quality organization. trucks and truck bodies in defense, • Participate in/perform one or two monitored AWS Accredited Test Facilities and/or Certified commercial and fire and emer- Welding Fabricator audits. gency markets. As a result of con- • Attendance and participation in AWS annual auditor seminar after acceptance as an AWS auditor. tinued growth, we have immediate (This AWS annual seminar is not counted as the nationally recognized auditor training for openings in Oshkosh, WI: qualification.)

Set up, tack, and perform welding If you are interested in this exciting opportunity, please send your résumé to Frank Lopez Del Rincon on all gauges of ferrous and at the American Welding Society. non-ferrous metals. HS diploma or Phone: (800) 443-9353, ext. 211 equivalent and one year welding Fax: (305) 443-6445 experience required. Ability to read E–mail: [email protected] blueprints/welding symbols.

Competitive salaries and excellent 500 N.W. LeJeune Road benefits. Miami, FL 33126

For more information or to apply, please visit our website: www.oshkoshdefense.com AWS JobFind Post Jobs. Place Your Classified Ad Here! Find Jobs.

Contact Frank Wilson, @ Advertising Production Manager www.aws.org/jobfind

(800) 443-9353, Job categories for welders, ext. 465 engineers, inspectors, and more [email protected] than 17 other materials joining industry classifications!

94 JULY 2008 JULY 2008 CLASSIFIEDS:Classified Template 6/6/08 2:17 PM Page 95

CAREER OPPORTUNITIES

Use Your Product Photo and Promotional Literature PROGRAM DEVELOPER to Increase Your Sales in EDUCATION SERVICES October 2008 AWS Education Services is recruiting a program developer to manage the production of program content for professionals that are currently in the welding profession. Some of the top responsibilities include:

• Management of revisions and content updates of resources and instructional assets, • Research and development for new seminars/programs requested by welding professionals, • Event manager for professional services, • Collaborate with other members of the development pod on projects, • Customer service to society members.

Qualifications for the position include:

• Background knowledge or experience in the overall technical aspects of welding, • Experience in instructional design, project management and program Generate more sales leads by development, showcasing your full-color catalog • Possess excellent computer skills: MS Office Suite, MS Project, WebEx, etc., or product photo, a product • Ability to manage and direct adjunct contractors that are commissioned as description, website address, or subject matter experts, other sales literature. • Able to coordinate multiple projects and timelines, including producing high These showcases reach quality work under tight deadlines, working independently and as a team, 70,000 qualified buyers. Its your • Excellent communication skills, best exposure for just pennies • Ability to multi-task several projects and programs, per contact. • Demonstrate a high degree of organization, consistency and detail in all asset Closes August 15, 2008 and program/project management, • Operate within the position’s expectations as defined by the managing director Call our sales team at: of education services. 1-800-443-9353 Rob Saltzstein at ext. 243 Please submit your electronic resume to Dennis Marks at [email protected]. [email protected] Lea Garrigan-Badwy

at ext. 220 500 N.W. LeJeune Road Garrigan @aws.org Miami, FL 33126

Welding Engineers 2008 Fabtech/AWS Show Preview Issue of Welding Journal Career opportunities for Welding Engineers at Helix ESG. This position monitors daily Now is the time to plan your progress of ongoing production on advertising for our biggest issue of the the vessels/work site and provide technical input and cost estimates year with the most readership. for the project. Get your company’s name exposed to Position requirements: our many thousands of readers. MTS/HTS, Metallurgy Degree or equivalent education related to 1-800-443-9353 welding/NDT. Possession of EWE Rob Saltzstein at ext. 243 or IWE. Qualified in at least two [email protected] NDT methods, preferably RT and UT. Minimum of 5 years experi- Lea Garrigan-Badwy ence. Willing to work offshore. at ext. 220 Garrigan @aws.org To apply, please email your resume to [email protected].

WELDING JOURNAL 95 JULY 2008 CLASSIFIEDS:Classified Template 6/9/08 1:54 PM Page 96

EQUIPMENT FOR SALE OR RENT

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SUPPLEMENT TO THE WELDING JOURNAL, JULY 2008 Sponsored by the American Welding Society and the Welding Research Council

Liquation of Mg Alloys in Friction Stir Spot Welding

The susceptibility of Mg alloys to liquid formation and cracking in FSSW and methods to test and explain the susceptibility of Mg and Al alloys are demonstrated

BY Y. K. YANG, H. DONG, H. CAO, Y. A. CHANG, AND S. KOU

ABSTRACT. The use of friction stir spot ing solidification were calculated. They in- Welding Institute in 1991 (Ref. 1). It has welding (FSSW) to join Al alloys in auto- dicated little liquation-causing constituent been widely used for welding soft materi- mobiles (e.g., by Mazda Motors) is ex- in 6061 Al but much more in AZ91E Mg, als such as Al and Mg alloys since then. In pected to extend to Mg alloys in view of AM60 Mg, and AZ31 Mg and with a much FSW the pin at the bottom of a rotating their increasing use to further reduce the lower liquation temperature. Most Mg al- cylindrical tool is plunged into a rigidly vehicle weight. FSSW is considered a loys including these three have Al as the held workpiece and traversed along the solid-state welding process, but liquation major alloying element, thus providing γ joint to be welded. Welding is achieved by (liquid formation) and cracking have been (a Mg-Al compound) to react with α (the plastic flow of frictionally heated material reported recently in Mg alloys in FSSW. In Mg-rich phase) and cause liquation by the from ahead of the pin to behind it. In fric- the present study, liquation in Mg alloys eutectic reaction α + γ → L at a low tem- tion stir spot welding (FSSW), as illus- was investigated using as-cast AZ91E Mg perature (≤ 437°C). The effect of heat trated in Fig. 1, the rotating tool is also (~Mg-8.6Al-0.6Zn, a widely used Mg treating before welding on liquation in plunged into a rigidly held workpiece but alloy) as an example and 6061-T6 Al (~Al- FSSW was discussed. without being traversed along any direc- 1Mg-0.6Si, an Al alloy widely welded by tion. Welding is achieved by plastic flow of FSSW) as a reference for comparison. Introduction frictionally heated material around the With the same welding schedule, liquation pin. A keyhole is left in the workpiece occurred in AZ91E Mg but not 6061 Al. A Since magnesium (Mg) is about one- after the tool is withdrawn at the end of simple test with an augmented torque to third lighter than aluminum (Al), the use FSW or FSSW. FSSW has recently re- amplify the difference in the liquation sus- of Mg alloys in automobiles is expected to placed resistance spot welding in making ceptibility between different alloys was rise rapidly in view of the increasing de- aluminum rear doors in Mazda RX8 pas- demonstrated. It showed no liquation in mand to reduce the vehicle weight in order senger cars. 6061 Al but severe liquation and cracking to improve the fuel efficiency and reduce In FSW the tool travels along the joint in AZ91E Mg, including formation of eu- air pollution. The gas tungsten arc welding and the heat input is distributed along the tectic liquid films, cracking along liquated (GTAW) process can join Mg alloys satis- joint. Liquation, that is, formation of liquid, grain boundaries, removal of liquated ma- factorily, but this process is impractical for is unlikely to occur in FSW. Cao and Kou terial by the tool, and a mirror-like weld the automotive industry. The gas metal arc (Ref. 2) found no liquation in FSW of 2219 top surface. The microstructural evolution welding (GMAW) process is much more Al. However, in FSSW the tool remains at leading to liquation in FSSW was pre- useful, but severe spatter and porosity one spot, where the heat input dwells. Thus, sented. Liquation made the torque fluctu- often occur in GMAW of Mg alloys. Thus, liquation is much more likely to occur. ate and fail to show a clear peak as the ro- solid-state welding is an attractive alterna- Gerlich, Yamamoto, North et al. (Refs. tating tool shoulder reached and tive for joining Mg alloys. 3–7) have recently conducted tempera- penetrated the workpiece surface. The Friction stir welding (FSW) is a solid- ture measurements in FSSW. They em- heat input, determined from the torque state welding process invented by The bedded thermocouples in a stationary and the axial force, was much less with alloy-steel tool to measure temperatures AZ91E Mg than 6061 Al and thus not why in a rotating workpiece at the surfaces of AZ91E Mg liquated more severely. A the tool shoulder and pin. Temperatures method to explain the liquation suscepti- KEYWORDS approaching or exceeding the liquation bility was thus proposed. The curves of temperature have been measured in Mg temperature vs. fraction solid (T-fS) dur- Cracking alloys including AZ91 Mg extrusions and Friction Stir Welding AM60 Mg sheets prepared by thixomold- Y. K. YANG and H. CAO are graduate students Friction Stir Spot Welding ing (a casting process), wrought AZ31 Mg and Y. A. CHANG and S. KOU are professors, Liquation sheets (Refs. 4, 5), and aerospace Al alloys Department of Materials Science and Engineer- Magnesiun Alloys including 2024 Al and 7075 Al (Ref. 6). ing, University of Wisconsin, Madison, Wis. H. Solid-State Welding Microstructural evidence of liquation was DONG is lecturer, School of Materials Science and Engineering, Dalian University of Technology, observed in the resultant welds. Thus, li- Dalian, China. quation can occur in FSSW even though

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produced by dynamic recrystallization used are listed in Table 1. A caused by the intense plastic deformation For both materials the workpiece was associated with the movement of material 3.1 mm thick and 64 × 44 mm in area. Spot- around the pin and friction heating (Refs. on-plate welding was conducted, which is 8, 9). FSSW is expected to be similar in equivalent to lap welding two pieces of this respect. The presence of liquid films 1.5-mm sheets. The tool, prepared from can interfere with plastic deformation. H13-steel, had a shoulder of 10-mm diam- More importantly, it can weaken the stir eter and a threaded pin of 4-mm diameter zone and cause it to crack under the at the top but tapered down at 10 deg torque of the tool. A liquid-penetration- along its 1.8-mm length. This tool will be induced (LPI) cracking mechanism of the called the 10-mm-shoulder tool hereafter. following sequence was proposed by Ya- The rotation speed was 1000 or 1200 mamoto et al. (Refs. 4, 5) for cracking in rev/min, counterclockwise when viewed B AZ91 Mg during FSSW: 1) formation of from above. The plunge rate was about 0.2 liquid eutectic films in the periphery of the mm/s and the dwell time 4 s. stir zone, 2) engulfment of liquid eutectic films by the growing stir zone, 3) penetra- Welds Made with Augmented Torque tion of the α (Mg) grain boundaries in the stir zone extremity by the liquid eutectic, To amplify the difference in the liqua- and 4) crack propagation along the li- tion tendency between different alloys, a quated grain boundaries under the torque liquation-susceptibility test was adopted of the rotating tool. Even without cracking, in which the torque was augmented by C the eutectic liquid films become brittle using a relatively large tool for FSSW. This after solidification and can thus reduce the is similar to amplifying solidification ductility and strength of the weld. Kou and cracking in fusion welds in Varestraint coworkers (Refs. 10–16) have shown liqua- testing (Ref. 19), in which an augmented tion-induced cracking in the partially tensile strain is applied during welding to melted zone (PMZ) of Al arc welds and the cause the solidifying weld metal to crack. severe loss of ductility and strength of the The tool for welding was an H13-steel PMZ even in the absence of cracking. Var- tool, with a shoulder of 15-mm diameter ious liquation mechanisms in Al arc welds and a threaded pin of 5.5-mm diameter and have been discussed by Kou (Ref. 17). 5.1-mm length beyond the bottom of the Mg is very similar to Al in many ways, shoulder. This tool, shown in Fig. 2, will be called the 15-mm-shoulder tool hereafter. It such as low density, low melting point, a soft was originally designed by Friction Stir Fig. 1 — Friction stir spot welding (FSSW). A — material weldable by FSSW with an alloy- Link, Inc., Menomonee Falls, Wis., for FSW Plunging; B — stirring; C — withdrawing. steel tool, etc. Thus, one may assume that of 6-mm-thick Al alloys. However, it was welding schedules good for common Al al- found ideal for testing and comparing the li- loys can automatically be applied to Mg al- quation tendency in FSSW. As will be shown loys. However, as will be shown in the pre- FSSW has been considered as a solid-state subsequently, at a 1000-rev/min tool rota- sent study, Mg alloys can be much more tion speed, significantly different extents of welding process. However, 6061 Al, a susceptible to liquation in FSSW than 6061 liquation can be easily induced in different common Al alloy widely welded by FSW Al, and a welding schedule good for 6061 Al alloys for comparing the liquation suscepti- and FSSW, was not found to liquate in may in fact cause liquation in Mg alloys. bility. A workpiece 6 mm and thicker can be FSSW (Ref. 7). The present study investigates the sus- used, depending on availability. The Gerlich (Ref. 7) determined the strain ceptibility of Mg alloys to liquation in FSSW AZ91E Mg workpiece available was 51 × 44 rate of the material adjacent to the rotat- using as-cast AZ91E Mg as an example and × 9.4 mm and the 6061 Al workpiece was 51 ing tool based on EBSD (electron back- 6061 Al as a reference for comparison. × 51 × 9.7 mm. scattered diffraction). In both the 2024 Al The tool rotation speed was 1000 and 7075 Al, the stain rate dropped Experimental Procedure rev/min, counterclockwise when viewed sharply above a high rotation speed, e.g., from above. The plunge rate was 0.15 1500 rev/min. This was attributed to tool Welds Made without Augmented Torque mm/s and the dwell time 4 s. After each slippage caused by liquation. weld was made, the tool was plunged into Liquation, if it occurs in FSSW, can in- 6061 Al was welded in the as-received a separate piece of 6061 Al to clean off the terfere with plastic deformation, degrade condition of T6, which stands for solution AZ91E Mg stuck to the tool during weld- the weld quality, and even cause cracking. heat treating and artificial aging (Ref. 18). ing. Unlike AZ91E Mg, 6061 Al did not The high plasticity of the material in FSW AZ91E Mg was welded in the as-cast con- stick to the tool after welding. has been attributed to the very fine grains dition. The compositions of the alloys Measurements of Torque and Axial Force

Table 1 — Compositions of Workpiece Materials (wt-%) To measure the torque and axial force during FSSW, a HAAS TM1 CNC milling Si Cu Mn Mg Cr Zn Ti Fe Al machine (5.5 kW or 7.5 hp) equipped with 6061 Al 0.62 0.28 0.08 0.89 0.19 0.02 0.01 0.52 balance a Kistler Type 9271A dynamometer was AZ91E Mg — — 0.24 balance — 0.65 — — 8.60 used. The dynamometer was cylindrical in AZ31 Mg* balance 1.0 3.0 AM60 Mg* 0.5 balance 6.0 shape, and it allowed both the moment acting about its axis and the force parallel to its axis to be measured during FSSW. *Compositions taken from Ref. 7.

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Fig. 2 — Tool with a 15-mm-diameter shoulder for FSSW with augmented torque (tool with a 10- D mm-diameter shoulder not shown).

The dynamometer allowed torque measurements in the range of –100 to +100 Nm with a 0.02 Ncm threshold and –1.5 pC/Ncm sensitivity for the torque and force measurements in the range of –5 to +20 kN with a 0.02 N threshold and –1.8 pC/N sensitivity for the axial force. A computer-based data-acquisition system was used to collect the data at 250 Hz and display in real time the curves of torque vs. C time and axial force vs. time.

Examination of Weld Microstructure

The resultant welds were cut vertically A through the meridian plane, mounted, and polished. Welds of 6061 Al were etched with a solution of 0.5 vol-% HF in water. Welds of AZ91E Mg were etched with an acetic-picric solution consisting of 10 mL acetic acid, 4.2 g picric acid, 10 mL water, and 70 mL ethanol in order to re- veal more clearly the fine as well as coarse γ-phase in the SEM image of the base B metal. In all other cases, AZ91E Mg welds were polished with a water-based polish- Fig. 3 — Liquation in weld of as-cast Fig. 4 — Liquation in weld of as-cast AZ91E Mg. A ing suspension during the final polishing AZ91E Mg. A — Vertical cross section; B — — Vertical cross section; B — optical micrograph stage and thus etched automatically by the optical micrograph showing striations below showing striations below bottom of keyhole; C — op- water in the suspension during polishing. bottom of keyhole; C — SEM image show- tical micrograph showing striations around bottom of Both optical microscopy and scanning ing evidence of liquid eutectic films; D — keyhole; D — SEM image showing eutectic film in the electron microscopy (SEM) were used, SEM image of base metal; E — weld sur- area circled in A; E — weld surface. 10-mm-diameter face. 10-mm-diameter shoulder, 1200- shoulder, 1000-rev/min rotation speed. the latter with the secondary electron rev/minrotation speed. mode at 15 kV and a 15-mm working distance. The composition of the intermetallic-compound particles in the alloy was determined by energy dispersive thick workpiece with the 10-mm-shoulder section of AZ91E Mg made with 1200 spectroscopy (EDS) to help identify them. tool at 1000- or 1200- rev/min rotation rev/min. The optical micrograph in Fig. 3B Photos of the cross sections of the welds speed, 0.2 mm/s plunge rate, and the 4-s shows that dark-etching striations are pre- were taken with digital cameras. dwell time. Liquation was observed in the sent near the bottom of the keyhole. As re- case of AZ91E Mg but not 6061 Al, as will vealed by EDS, these striations are richer Results and Discussion be described as follows. Thus, AZ91E Mg is in Al than the lighter-etching surrounding more susceptible to liquation in FSSW than areas. This suggests that the striations Welds Made without Augmented Torque 6061 Al, and a welding schedule good for could have been the thin liquid films that 6061 Al can cause liquation in AZ91E Mg. partially dissolved (solutionized) in the α These welds were made on the 3.1-mm- Figure 3A shows the vertical weld cross matrix. The SEM image in Fig. 3C shows

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shows the SEM image of the base metal The microstructure of the stir zone near far away from the keyhole. Both coarse the weld top surface is shown by the SEM and fine γ are found in the eutectic be- image in Fig. 5C. No signs of liquation are tween α dendrite arms (Ref. 20). The for- evident. No large Fe-rich particles similar to mer grows from the liquid during casting. those in the base metal (Fig. 5B) are present The latter grows as precipitation from the here, suggesting they have been broken up supersaturated interdendritic α (Ref. 21). by stirring. The grains in the stir zone are EDS showed that the coarse γ contained much smaller than those in the base metal, about 57 wt-% Mg, 37 wt-% Al, and 4.5 suggesting dynamic recrystallization of new wt-% Zn. The weld top surface (the top small grains in the stir zone. Figure 5D surface of the stir zone in contact with the shows the weld top surface. No evidence of tool shoulder during FSSW) is shown in liquation can be seen. Fig. 3E. No evidence of liquation is visible on the weld top surface. AZ91E Mg Liquation still occurred even when the rotation speed was reduced to 1000 Evidence of severe liquation was ob- rev/min. The vertical cross section of the served, including formation of liquid eu- resultant weld is shown in Fig. 4A. Figure tectic films, cracking along liquated grain 4B and C shows dark-etching striations boundaries, removal of liquated material by below and around the bottom of the key- the tool, and a mirror-like weld top surface. hole. Figure 4D shows a eutectic film in Figure 6 shows the AZ91E Mg spot the stir zone near its periphery, in the area weld. Figure 6A is the vertical cross sec- marked by the circle in Fig. 4A. Thus, li- tion of the weld. The pin and the shoulder quation occurred near the stir-zone pe- penetrated about 5.6 and 0.5 mm, reSpec- riphery during FSSW. The weld top sur- tively, below the workpiece surface. Fig- face in Fig. 4E again shows no evidence of ure 6B is an optical micrograph showing liquation. cracking across in the stir zone and removal of the liquated material from the Welds Made with Augmented Torque top of the stir zone. The liquated material stuck to the tool shoulder and was re- These welds were made on the 9.7-mm moved by it when the tool was withdrawn 6061 Al and 9.4-mm AZ91E Mg with the at the end of FSSW. The small and large 15-mm-shoulder tool at 1000-rev/min ro- rectangles indicate the locations of Figs. 7 tation speed, 0.15-mm/s plunge rate, and and 8A to be shown subsequently. The 4-s dwell time. The tool shoulder was in- weld top surface is mirror-like as shown in creased (from 10-mm diameter) to in- Fig. 6C. This is evidence of liquation in the crease the torque and thus amplify the dif- stir zone during FSSW. ference in the liquation tendency between Figure 7 is a SEM image taken in the different alloys. The welds, as will be small rectangle in Fig. 6B. It shows evi- shown as follows, revealed no evidence of dence of liquid eutectic films near the pe- liquation in 6061 Al but severe liquation riphery of the stir zone during FSSW. Sev- and cracking in AZ91E Mg. eral long eutectic films are present in the lower right quarter of the image. A film is 6061 Al enlarged by the inset. The film is normal eutectic (α + γ, that is, composite-like) No evidence of liquation was observed. where it is thick but divorced eutectic (γ Figure 5 shows the 6061 Al spot weld. The plus an α that is connected to the sur- vertical cross section of the weld is shown rounding α matrix) where it is thin. The rein Fig. 5A. The workpiece surface before crystallized grains in the α dendrites are welding is indicated by the two short hori- somewhat visible. In the lower-right cor- zontal broken lines in the photo. The pin ner of Fig. 7, coarse γ particles are visible length was 5.1 mm, and the pin and shoul- between α dendrites. In the upper-left half der penetrated about 5.9 and 0.8 mm, re- of the same figure, however, only a eutec- α γ Fig. 5 — No liquation in weld of 6061-T6 Al. A — spectively, below the workpiece surface. tic consisting of dark plus thin is visible Vertical cross section; B — SEM image showing The base metal microstructure far away between α dendrites (which tend to be de- base metal microstructure; C — SEM image show- from the keyhole is shown by the SEM formed). This eutectic formed as a result ing microstructure near weld surface; D — weld sur- image in Fig. 5B. The particles are Fe-rich of liquation during FSSW. face. 15-mm-diameter shoulder, 1000-rev/min ro- with 20 to 30 wt-% Fe as shown by EDS. Further evidence of liquation and tation speed. These are the Fe-rich intermetallic com- cracking in the AZ91E Mg spot weld is pounds commonly present in 6061 Al shown by the SEM images in Fig. 8. Figure (Ref. 14). Fe is often present in Al alloys 8A is a SEM image taken in the large rec- the evidence of liquid eutectic films in the as an impurity and it forms Fe-rich parti- tangle in Fig. 6B. AN α dendrite (marked periphery of the stir zone, with penetra- cles because of its very low solubility in Al. with α) that is deformed but still dis- tion of the liquid eutectic into some grain The holes along the grain boundary are cernible is visible just to the left of point 2 boundaries near the films. The eutectic caused by etching, which was heavy in near the mid bottom of the micrograph. films are different in morphology from the order to bring out the grain structure in More dendrites are visible in the lower- eutectic in the base metal. Figure 3D the base metal of 6061 Al. right corner of the micrograph.

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Figure 8B is an image of the base metal taken at point 1 in Fig. 8A. Microsegrega- B tion (that is, coring) of Al and Zn to the interdendritic areas occurs during casting as indicated by the light gray α in the dendrite arms, the dark gray α and white γ in the interdendritic areas. Both coarse and fine γ are present. Figure 8C is an image taken at point 2 in Fig. 8A. In the dark interdendritic areas there is no more fine γ (Fig. 8B) — only small grains with thin light grain boundaries. Perhaps, there was enough deformation of the interdendritic α to cause recrystallization. When the eutectic γ temperature TE was reached, the fine re- acted with α to form liquid eutectic and penetrated the grain boundaries. Upon cooling, the liquid eutectic along the grain boundaries solidified as thin solid eutectic. In fact, as can be seen in the lower- right corner of Fig. 7, similar small grains with thin light grain boundaries and without fine γ are present farther away from the stir zone than the long eutectic films. A As mentioned previously, Yamamoto et C al. (Refs. 4, 5) proposed that the liquid eutectic films in the stir-zone periphery of Fig. 6 — Liquation and cracking in weld of as-cast AZ91E Mg. A — Vertical cross section; B — evi- AZ91 Mg were engulfed by a growing stir dence of liquation shown by cracking (small rectangle shown in Fig. 7 and large one Fig. 8A) and re- zone and that the liquid eutectic pene- moval of liquated material by tool (black area at top of stir zone); C — evidence of liquation shown by mirror-like weld top surface. 15-mm-diameter shoulder, 100- rev/min rotation speed. trated grain boundaries to cause cracking along the grain boundaries under the torque of the rotating tool. However, it is not clear if the liquid eutectic penetrated the grain boundaries here after the liquid eutectic films had formed first and then been engulfed by a growing stir zone. Figure 8D is an image taken at point 3 in Fig. 8A. The α dendrite arms and the dark interdendritic areas are both severely elongated along the direction of stirring. Because of the friction heat produced by stirring, the peak temperature should be higher here than at point 1, which is already above TE. Some fragments of the coarse γ particles might have disappeared after reacting with the interdendritic α and causing further liquation above TE. Upon cooling, the liquid eutectic along the grain boundaries solidified as solid eutectic. It is interesting to note that the small grains in the elongated interdendritic areas are similar to those in the much less deformed interdendritic areas at Point 2 — Fig. 8C. Figure 8E is an image taken at point 4 in Fig. 8A. It is similar to that at point 3 — Fig. 8D. However, the dark liquated area is now wider, suggesting more liquation here than Fig. 7 — SEM image of weld of as-cast AZ91E Mg (small rectangle in Fig. 6B) showing evidence of at point 3. Few γ particles are left in the eutectic liquid films during FSSW. Film enlarged in inset. 15-mm-diameter shoulder, 1000-rev/min ro- upper-left half of the image. Along the grain tation speed. boundaries in the interdendritic areas, solidified eutectic is visible (α + γ with α connected to the dark interdendritic α). This in- occurred along liquated grain boundaries ble. The dendrite arms and interdendritic dicates the presence of liquid eutectic along during FSSW. areas have mixed with each other to the the grain boundaries. A crack runs along Figure 8F shows an image taken at extent that they are no longer distinguish- the grain boundaries, suggesting cracking point 5 in Fig. 8A. No γ particles are visi- able. Solid eutectic is present along the

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WELDING RESEARCH γ F E 8A. No particles are visible. Fine grains caused by dynamic recrystallization are present in the α phase both in the dendrites (not clear) and in the interdendritic areas (clear). However, grain-boundary eutectic is present only in the latter.

Microstructural Evolution Leading to Liquation during FSSW

Before proceeding with the microstruc- G tural evolution, binary Mg-Al and ternary D Mg-Al-Zn phase diagrams are shown first. Figure 9A shows the Mg-rich side of the binary Mg-Al phase diagram (Ref. 22). At the room temperature alloy Mg-8.6Al consists α γ of an (Mg) matrix and (Mg17Al12) particles embedded in it. The eutectic reaction α γ → (Mg) + (Mg17Al12) LE occurs at the eutectic temperature TE of 437°C, where LE is the liquid eutectic. Figure 9B shows a B C vertical section (solid lines) of a calculated Mg-Al-Zn ternary phase diagram along which the Al/Zn ratio equals 8.60/0.65 (in wt-%). The vertical section, which is also called an isopleth, includes AZ91E Mg (Mg-8.60Al-0.65Zn if its 0.24 wt-% Mn is ignored as can be seen in Table 1). A calculated binary Mg-Al phase diagram (broken lines) is included for comparison. These A two phase diagrams were calculated using the thermodynamic computer code Pandat (Ref. 23) and the database of Mg alloys (Ref. 24). The difference between the two calculated phase diagrams is very small. As shown in Table 1, AZ31 Mg is Mg-3.0Al. AZ91E Mg is approximately Mg-8.6Al if Zn (0.65%) and Mn (0.24%) are ignored. Likewise, AM60 Mg is approximately Mg- 6.0Al if Mn (0.5%) is ignored. Thus, the binary Mg-Al phase diagram can be used as an approximation for the vertical section of a ternary Mg-Al-X phase diagram if the content of solute X is small. The microstructural evolution leading to constitutional liquation in Mg alloys during FSSW is shown in Fig. 10, based on the weld microstructure in AZ91E Mg shown in Fig. 8. Figure 10A is a schematic sketch of the vertical cross section of a weld of alloy C0 made by FSSW. Alloy C0 γ Fig. 8 — SEM images of weld of as-cast AZ91E Mg. A — Vertical cross section (large rectangle in has an abundant and a relatively low TE Fig. 6B); B — base metal at point 1 in A; C — liquation at point 2; D — deformation and more li- as most Mg alloys. Figure 10B shows a quation at point 3; E — cracking at point 4; F — liquation at point 5; G — liquation at Point 6. 15- phase diagram that includes the alloy. It is mm-diameter shoulder, 1000-rev/min rotation speed. either a binary Mg-Al phase diagram (Fig. 9A) if the alloy is close to a binary Mg-Al alloy, or a vertical section of a ternary Mg- Al-X phase diagram if the alloy is close to grain boundaries. It seems that if the ma- of the α phase at the solidus temperature, a ternary Mg-Al-X alloy (e.g., Fig. 9B). terial is homogeneous in this area, then that is, by α→L. Upon cooling to the eu- The microstructural evolution at a lo- there probably is no γ present to react with tectic temperature the liquid remaining at cation (point P) heated up to a peak tem- α and cause liquation by the eutectic reac- the grain boundaries can become liquid perature of TE during FSSW is illustrated α γ→ tion + L. If this is true, liquation eutectic and solidify as solid eutectic. in Fig. 10C. At the room temperature T1 near the weld surface could have occurred Figure 8G is an SEM image taken at a alloy C0 in its as-cast condition consists of not by the eutectic reaction but by melting location similar to that at point 6 in Fig. an α matrix and γ particles embedded in it.

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The α phase is shown in two different col- by the difference in the heat input or the ors — light gray for the dendrite arms and real susceptibility to liquation. The heat dark gray for the interdendritic area. Dur- input during FSSW of a given alloy can be ing casting solute microsegregation causes affected significantly by its mechanical the liquid to solidify first as α lower in Al properties such as the strength. Since the (< C0) in the dendrite arms and finally as temperature and hence strength vary sig- α γ higher in Al (up to CSM) and as in the nificantly within the stir zone, it is hard to interdendritic areas (similar to Fig. 8B). discuss the heat input based on the Because of the high heating rate during strength. An easier way is to analyze the FSSW, γ does not have enough time to dis- torque and the axial force during FSSW. α solve in the phase upon heating to T2 Figure 11 shows that both the torque even though they should do so under the Mz of the rotating tool and the axial force equilibrium (very slow heating) condition Fz vary with time t and from alloy to alloy. according to the phase diagram — Fig. The penetration period lasts for about 42 10B. This is because the solid-state diffu- s and is followed by a 4-s holding period sion required for γ dissolution to occur is before tool withdrawal. From the torque very slow in view of the very small solid dif- curve of 6061 Al (Fig. 11A), it can be seen fusion coefficient (on the order of 1 × 10–8 that the rotating tool shoulder reaches the A cm2/s). The α phase has been deformed by workpiece surface at about 33.5 s. So, the stirring and perhaps some small grains average plunge rate of the 5.1-mm-long have formed by dynamic recrystallization. pin is about 0.15 mm/s (5.1 mm ÷ 33.5 s), Upon further heating to the eutectic which is identical to the 0.15 mm/s plunge γ temperature TE, the remaining particles rate used in the experiment. The shoulder start to react with the surrounding α ma- plunge lasts for about 8.5 s (42 – 33.5 s). As trix and cause liquation by the eutectic re- mentioned previously, the shoulder pene- α γ→ action + LE, where LE is the liquid trated only about 0.8 mm below the work- eutectic — Fig. 10C. This liquation mech- piece surface instead of 1.3 mm (8.5 s × anism is the so-called “constitutional li- 0.15 mm/s). This difference probably can quation” originally observed in fusion be accounted for by the very slight work- welds by Pepe and Savage (Refs. 25, 26). It piece distortion (the resultant workpiece requires a high heating rate, which usually bent downward slightly in the area under exists in welding, in order to have γ remain the keyhole) and the flexibility in the α at TE to react with and cause liquation. milling machine system in view of the The liquid eutectic penetrates the grain much (about 7 times) larger cross- boundaries and solidifies as solid eutectic sectional area of the shoulder than the pin. along the grain boundaries upon cooling. For 6061 Al, a peak torque of about 23 The microstructural evolution at a loca- Nm starts to show up at 33.5 s when the ro- tion (point Q) heated up to T3 (> TE) is il- tating tool shoulder reaches the workpiece lustrated in Fig. 10D. Here, α is severely surface. During the last 4-s holding period, elongated in the direction of stirring, γ the torque decreases significantly. Initially breaks up and more liquation occurs. Since (t = 0 s), the torque rises quickly and then bonding between grains can be severely more slowly as the adjacent workpiece weakened by the presence of liquid, crack- material is heated up and softened by the ing can occur along liquated grain bound- friction heat produced. It then increases aries under the shear force caused by stir- steadily as the tool pin penetrates deeper ring — Fig. 8E. Upon cooling, the liquid into the workpiece. As the tool shoulder B eutectic LE forms solid eutectic SE along the catches the expelled metal (Fig. 1A), the grain boundaries (similar to Fig. 8D, E). torque rises quickly again but with fluctu- Fig. 9 — Mg phase diagrams. A — Binary Mg-Al The microstructural evolution at a lo- ation. The fluctuation is not caused by li- phase diagram (Ref. 22); B — vertical section (solid cation (point R) further up in the stir zone quation because of the absence of liqua- lines, also called isopleth) of Mg-Al-Zn ternary where the material is well mixed is illus- tion — Fig. 5. This is likely to be caused phase diagram at Al/Zn = 8.60/0.65, with a binary trated in Fig. 10E. Here, the peak temper- by the material expelled by the tool but en- Mg-Al phase diagram (broken lines) included for comparison. Both phase diagrams in B calculated ature during FSSW is T4 (> T3 > TE). The trapped between the rotating shoulder α using Pandat of CompuTherm LLC (Ref. 23) and dendrites and the interdendritic areas and the stationary workpiece surface, Mg database (Ref. 24). are well mixed and indistinguishable. which tended to switch back and forth be- Upon cooling, the liquid eutectic LE forms tween rotating and stopping. solid eutectic SE along the grain bound- For AZ91E Mg (Fig. 11B) the torque aries (similar to Fig. 8F). curve is far below that of 6061 Al, with a liquid cools and solidifies, the torque and maximum torque of only about 10 Nm. No hence temperature increase, and liquid Torque and Axial Force clear peak starts to show up in the torque forms again to repeat the cycle. curve when the rotating tool shoulder As shown in Fig. 11, both alloys show two For a given alloy the tendency to li- reaches the workpiece surface at 33.5 s. peaks in the curve of axial force Fz vs. time quate during welding increases with the The absence of a clear peak torque and t. The axial force rises quickly initially but heat input (Ref. 17). Thus, knowing the the fluctuation of the torque are likely to decreases as the adjacent workpiece mater- heat input in FSSW can help determine be caused by liquation. It is likely that ial is heated up and softened. This results in whether the difference in the extent of li- when liquid forms, the torque and hence a first peak of about 8 kN in 6061 Al and 7 quation between different alloys is caused temperature tend to decrease. When the kN in AZ91E Mg. The axial force rises

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t B QFvdt= fzz∫ A 0 (2) Both the rotation speed Ω and the plunge rate vZ are often held constant during FSSW. For both materials in the pre- Ω sent study, = 1000 rev/min and vZ = 1.5 × –4 Ω 10 m/s. Thus, for constant and vZ, the total heat input Q due to both tool rotation and plunge in FSSW is as follows: ⎛ πΩ⎞ t t =+=2 + QQΩ Q⎜ ⎟ ∫∫ Mdt v F dt Fz⎝ 60 ⎠ zz 00 (3) The first integral on the right-handside of Equation 3 is the area under the MZ-t curve. Likewise, the second integral is the C area under the FZ-t curve. As shown in Table 2, the heat input QΩ due to tool rotation is 67.5 kJ with 6061 Al and 32.3 kJ with AZ91 Mg. The heat input QF due to tool plunge is 35 J with 6061 Al and 51 J with AZ91E Mg. Thus, in FSSW QF is much less than QΩ. The total heat input Q is 67.5 kJ with 6061 Al and 32.3 kJ with AZ91E Mg, this is consistent with the much lower heat input with AM50 than with 6061 Al observed by Su et al. (Ref. 28). D Thus, the much higher liquation susceptibility of AZ91E Mg in FSSW than 6061 Al cannot be explained by a higher heat input with AZ91E Mg.

Explanation for Liquation Susceptibility in FSSW

A method to explain the liquation susceptibility of an alloy in FSSW is proposed E below.

T-fS Curves and Phase Diagrams

The curve of temperature vs. fraction solid (T-fS) during solidification shows the eutectic temperature and the amount of the eutectic in an as-cast alloy. The phase dia- Fig. 10 — Microstructural evolution leading to liquation in FSSW of an alloy with a low eutectic tem- gram also helps identify the liquation-caus- perature like most Mg alloys. A — Vertical weld cross section; B — phase diagram; C — point P in A ing constituent in the alloy, for instance, an (similar to Fig. 8C); D — point Q (similar to Fig. 8D); E — point R (similar to Fig. 8F). Recrystal- intermetallic compound in a wrought alloy lized grain boundaries in α dendrites (lighter α) not shown. or a eutectic in an as-cast alloy. In any case, the more abundant the liquation-causing constituent and the lower the liquation temperature, the greater the liquation suscepti- quickly again as the tool shoulder ap- Then the contribution of rotation to the bility is. proaches the workpiece surface. This re- heat input QΩ (in Joules) is as follows Figure 12 shows the T-fS curves of AZ31 sults in a second peak of about 10 kN in 6061 (Ref. 27): Mg, AM60 Mg, and AZ91E Mg during so- Al and 15 kN in AZ91E Mg. For 6061 Al, lidification. The compositions of these Mg t ⎛ πΩ⎞ the much lower second peak might be re- = 2 alloys are shown in Table 1. For comparison, QMΩ ∫ ⎜ ⎟ dt lated to its known excellent extrudability. z ⎝ 60 ⎠ the T-fS curve of 6061 Al is also included as The axial force fluctuated during the same 0 (1) a reference. They were calculated based on period of time when the torque fluctuated. Likewise, let Fz be the axial force (in N) the Scheil model using Pandat (Ref. 23) and and vz the plunge rate (in m/s). Then, the the solidification databases of Al alloys Heat Input during FSSW contribution of tool plunge to the heat (Ref. 29) and Mg alloys (Ref. 24). The T-fS input QF (in Joules) is as follows (Ref. 28): curve for AZ91E Mg has also been calcu- Ω Let Mz be the torque (in Nm), the ro- lated by Ohno et al. (Ref. 21) using Pandat tation speed (in rev/min), and t time (in s). and the Mg-alloy database (Ref. 24).

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A B

Fig. 11 — Tool torque and axial force measured during FSSW. A — 6061 Al; B — AZ91E Mg. Area under each curve proportional to heat input generated by either rotation (MZ) or plunge (FZ) of tool. 15-mm-diameter shoulder, 1000-rev/min rotation speed.

Figure 13 shows the solidus projections Mg should have a significantly greater ten- of the ternary phase diagrams of Al-Mg-Si dency to liquate than 6061 Al. The evi- (Ref. 30) and (Mg+0.2Mn)-Al-Zn (Ref. 21) dence of liquation, cracking, removal of li- on the composition (horizontal) plane. The quated material by the tool, and a solidus temperature TS and the line of solid- mirror-like weld surface shown in Figs. 6 solubility limit are shown as a function of and 7 all confirm the liquation susceptibil- composition. ity of AZ91E Mg.

6061 Al Other Mg Alloys

As shown by its T-fS curve in Fig. 12, Al is the most common alloying ele- 6061 Al does not have much liquation- ment in Mg alloys, and most Mg alloys con- causing constituent even in the as-cast tain Al as a major alloying element, such as condition. Even less or none is left after AZ91 Mg, AM60 Mg, and AZ31 Mg, the T6 heat treating. As shown in Table 1, where the first alphabet “A” stands for Al the composition of the 6061 Al used is Al- and the first digit for its content (in wt-% 0.89 Mg-0.62Si-0.52Fe-0.28Cu 0.19Cr and rounded to the closest whole num- 0.08Mn. Fe can be neglected because Fe- ber). As already shown by the Mg-Al rich particles (Fig. 5B) do not cause liqua- phase diagram in Fig. 8A, the eutectic re- →α γ tion in 6061 Al (Ref. 14). action L (Mg) + (Mg17Al12) occurs at the eutectic temperature 437°C. Conse- AZ91E Mg quently, Mg alloys containing Al tend to liquate at a very low temperature near or According to its T-fS curve shown in even below 437°C. Fig. 12, AZ91E Mg reaches the eutectic Figure 12 shows that the Mg alloys reaction L →α+ γ at 432°C and a frac- have a much lower eutectic temperature tion solid of 0.85, the effect of the low Mn and much more eutectic than 6061 Al. The content in this alloy on the curve being eutectic temperature and the amount of negligible. Thus, the AZ91E Mg has a eutectic are 541°C and 1% for 6061 Al, rather high fraction of eutectic of about 432°C and 15% for AZ91E Mg, 436°C and 15% and a very low eutectic temperature 8% for AM60 Mg, and 413°C and 4% for of 432°C, which is 109°C lower than the AZ31 Mg. lowest eutectic temperature of 6061 Al Thus, it is not surprising that Ya- 541°C. This clearly suggests that AZ91E mamoto et al. (Ref. 4) observed liquation

Table 2 — Heat Inputs in FSSW Fig. 12 — T-fS curves during solidification explaining why Mg alloys are much more liquation susceptible than 6061 Al. Eutectic temperatures and con- Heat Input Heat Input Total Heat ∫ M dt ∫ Fz dt z tents: 541°C and 1% for 6061 Al, 432°C and 15% from Rotation from Plunging Input Q (J) (Nm s) (kN s) for AZ91E Mg, 436°C and 8% for AM60 Mg, and Q Ω (J) QF (J) 413°C and 4% for AZ31 Mg. Curves calculated 6061 Al 67512 35 67547 644.7 232.9 based on Scheil model of multicomponent alloys AZ91E Mg 32285 51 32336 308.3 338.3 using Pandat of CompuTherm LLC (Refs. 21, 23).

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Effect of Heat Treating on Liquation used in the as-cast condition, thus provid- A Susceptibility γ ing (a Mg17Al12 compound containing other alloying elements, e.g., Zn) to react In the binary phase diagram in Fig. 9A, with α (Mg) and cause liquation upon the vertical projection of the solidus line heating by the eutectic reaction α + γ→L on the horizontal (composition) axis is a at a low eutectic temperature TE (e.g., line segment. The projection of the solidus ≤ 437°C). plane of a ternary phase diagram on its 2) The susceptibility of these Mg alloys horizontal (composition) plane, called the to liquation in FSSW is promoted by 1) a solidus projection, is indicated by a shaded liquation-causing constituent γ and a low area like one of those in Fig. 13. The bro- TE, and 2) the heat input dwelling at one ken lines within each shaded area indicate spot (instead of spreading along the joint how the solidus temperature varies with path as in FSW). the composition. 3) Although Mg is very similar to Al in For 6061 Al, as shown by the solidus being light, soft and weldable by FSSW projection in Fig. 13A, constitutional li- with an alloy-steel tool, a welding schedule quation can occur if liquation-causing good for an Al alloy widely welded by B constituents are present. Some 6061 Al FSSW such as 6061 Al may, in fact, cause alloy contains Si-rich particles (Ref. 14), liquation in Mg alloys. It is essential to and liquation can occur by the eutectic re- keep the heat input as low as possible and action α + Si → L at 577°C or by the eu- check the weld on liquation and cracking. α → tectic reaction + Mg2Si + Si L at 4) A liquation-susceptibility test with 555°C (Ref. 31). Based on the approxi- an augmented torque in FSSW to amplify mate composition of ternary Al-0.9Mg- the difference in liquation between differ- 0.6Si alloy as an approximation and the ent alloys has been demonstrated, provid- ternary Al-Mg-Si solidus projection ing not only a simple reliable method for shown in Fig. 13A, it is possible to dissolve susceptibility testing but also a tool for all liquation-inducing constituents com- more clearly examining and understand- pletely by heat treating at a temperature ing liquation. below the solidus temperature 595°C. 5) The MZ-t (torque vs. time) curve can Such a 6061 Al can liquate by melting be used to diagnose liquation in real time when the solidus temperature 595°C is during FSSW. A curve fluctuating and reached, which is rather high and unlikely lacking a clear peak as the rotating tool to reach in FSSW. shoulder reaches and penetrates the work- Fig. 13 — Solidus projections showing solidus tem- As already shown, constitutional liqua- piece surface indicates likely liquation. perature TS and line of maximum solubility. A — tion occurs in AZ91E Mg in FSSW. Based 6) A method for explaining the liqua- Ternary Al-Mg-Si in Al (α) corner (Ref. 30); B — on the approximate composition of Mg- tion susceptibility in FSSW has been ternary (Mg+0.2Mn)-Al-Zn in (Mg+0.2Mn) cor- 8.6Al-0.65Zn-0.2Mn and the ternary demonstrated, with the T-fS (temperature ner (Ref. 21). (Mg+0.2Mn)-Al-Zn solidus projection vs. fraction solid) curve to indicate TE and shown in Fig. 13B, it is possible to dissolve estimate the eutectic content, with the γ completely by heat treating at a temper- phase diagram to identify the liquation- in FSSW of thixomolded AZ91 Mg and ature near but below the solidus tempera- causing constituent and determine the effect of heat treating, and with the M -t AM60 Mg. Liquation was also observed in ture 475°C. This can raise the liquation Z wrought AZ31 Mg. The extents of liqua- curve to check the heat input. temperature from the eutectic tempera- tion were less in wrought AZ31 Mg and 7) Formation of liquid eutectic films, ture 432°C to the solidus temperature thixomolded AM60 Mg than in thixo- cracking along liquated grain boundaries, molded AZ91 Mg. This, in fact, is consis- 475°C. However, this is still significantly removal of liquated material by the tool, (72°C) lower than the liquation tempera- tent with the T-fS curves in Fig. 12, which and a mirror-like weld top surface have show less eutectic in the former two Mg al- ture of 6061 Al (541°C), thus suggesting been observed in AZ91E Mg but not in loys. The fact that wrought AZ31 Mg also that a heat treated AZ91E Mg can still be 6061 Al, thus confirming the liquation sus- liquated during FSSW suggests that some more susceptible to liquation. Unfortu- ceptibility of AZ91E Mg in FSSW (indi- liquation-causing constituent still re- nately, many Mg alloys are used in the as- cated by the liquation`-susceptibility test) mained after heat treating. cast condition. regardless of its much lower heat input However, with a similar tool and within A more effective way to reduce the (indicated by the torque measurement). a wide range of welding conditions includ- chance of liquation and cracking is to keep 8) The microstructural evolution leading ing conditions similar to those used for the the heat input as low as possible (e.g., by to liquation in FSSW has been presented three Mg alloys, no liquation was observed using a low rotation speed or a small tool) for alloys with a liquation-causing con- γ in 6061 Al (Ref. 7). The higher thermal if welding can be achieved. The weld mi- stituent and a low TE like most Mg conductivity of Al alloys can also help con- crostructure can be examined to make alloys. duct heat away from the welding spot into sure no liquation or cracking has occurred. 9) When comparing different alloys in the bulk workpiece and thus reduce the the liquation susceptibility in FSSW, it is chance of liquation due to over heating. Conclusions desirable to check the heat input in weld- Thus, it is shown that a welding schedule ing each alloy, which can be determined good for a common Al alloy widely used in 1) Most Mg alloys (e.g., AZ91 Mg, from the MZ-t curve, because the extent of welding such as 6061 Al may cause liqua- AM60 Mg, and AZ31 Mg) have Al as a liquation in a given alloy increases with in- tion in Mg alloys. major alloying element and they are often creasing heat input.

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10) Heat treating as-cast Mg alloys be- gineering, University of Toronto, Toronto, 24. PanMagnesium — Thermodynamic fore welding may reduce liquation in Ont., Canada. Database for Magnesium Alloys, Com- FSSW by reducing γ, but a more effective 8. Murr, L. E., Liu, G., and McClure, putherm LLC, Madison, Wis., 2001, pro- way is to keep the heat input as low as pos- J. C. 1997. Dynamic recrystallization in vided by R. Schmidt-Fetzer, Technical sible if there is still enough stirring to friction-stir welding of aluminum alloy University of Clausthal, Institute of Met- achieve sufficient bonding. 1100. Journal of Materials Science Letters allurgy, Clausthal-Zellerfeld, Germany. 16: 1801–1803. 25. Pepe, J. J., and Savage, W. F. Acknowledgments 9. Murr, L. E., Li, Y., Trillo, E. A., 1967. Effects of constitutional liquation in Nowak, B. M., and McClure, J. C. 1999. 18-Ni maraging steel weldment. Welding This work was supported by the Na- A comparative study of friction-stir weld- Journal 46(9): 411-s to 422-s. tional Science Foundation under NSF ing of aluminum alloys. Aluminum Trans- 26. Pepe, J. J., and Savage, W. F. 1970. FRG Grant No. DMR-0605662 and NSF actions 1: 141–154. Weld heat-affected zone of the 18Ni Grant No. DMR-0455484. The authors 10. Cao, G., and Kou, S. 2006. Pre- maraging steels. Welding Journal 49(12): would like to thank 1) John F. Hinrichs of dicting and reducing liquation-cracking 545-s to 553-s. Friction Stir Link, Inc., Menomonee Falls, susceptibility based on temperature vs. 27. Pew, J. W., Nelson, T. W., and Wis., for suggesting the topic of liquation fraction solid. Welding Journal 85: 9-s to Sorensen, C. D. 2007. Torque based weld in FSSW for study, 2) Prof. Thomas H. 18-s. power model for friction stir welding. Sci- North of University of Toronto, Toronto, 11. Cao, G., and Kou, S. 2005. Liqua- ence and Technology of Welding and Join- Canada, and his former graduate student tion cracking in full-penetration Al-Si ing, vol. 12, pp. 341–347. Adrian P. Gerlich (now assistant profes- welds. Welding Journal 84: 63-s to 71-s. 28. Su, P., Gerlich, A., North, T. H., and sor, University of Alberta, Edmonton, Al- 12. Huang, C., and Kou, S. 2004. Li- Benddzsak, G. J. Energy generation and berta, Canada) for sharing their publica- quation cracking in full-penetration Al- stir zone dimensions in friction stir spot tions on FSSW, (3) Prof. Rainer Cu welds. Welding Journal 83: 50-s to 58-s. welds. SAE Technical Series, 2006-01- Schmid-Fetzer of Technical University of 13. Huang, C., and Kou, S. 2004. Liqua- 0971. Clausthal for the Mg database, 4) Prof. tion cracking in full-penetration Al-Mg-Si 29. PanAluminium — Thermodynamic Frank Pfefferkorn of University of Wis- welds. Welding Journal 83: 111-s to 122-s. Database for Commercial Aluminum Al- consin-Madison and his graduate student 14. Huang, C., and Kou, S. 2002. Li- loys, Computherm LLC, Madison, Wis. Axel Fehrenbacher for assistance in the quation mechanisms in multicomponent 53719, 2001. torque and axial-force measurements, and aluminum alloys during welding. Welding 30. Philips, H. W. L. 1959. Annotated 5) the reviewers for helpful comments. Journal 81: 211-s to 222-s. Equilibrium Diagrams of Some Aluminum 15. Huang, C., and Kou, S. 2001. Par- Alloy Systems, The Institute of Metals, References tially melted zone in aluminum welds — London, pp. 21–86. solute segregation and mechanical behav- 31. Mondolfo, L. F. 1976. Aluminum 1. Thomas, W. M., et al. Friction stir ior. Welding Journal 80: 9-s to 17-s. Alloys Structure and Properties, pp. butt welding. International Patent Appli- 16. Huang, C., and Kou, S. 2000. Par- 717–857, Boston, Mass., Butterworth. cation No. PCT/GB92, Patent Application tially melted zone in aluminum welds — li- No. 9125978.8, Dec. 6, 1991. quation mechanism and directional solid- 2. Cao, G., and Kou, S. 2005. Friction ification. Welding Journal 79: 113-s to stir welding of 2219 aluminum: behavior 120-s. θ 17. Kou, S. 2003. Welding Metallurgy, of (Al2Cu) particles. Welding Journal 84: 1-s to 8-s. 2nd edition, John Wiley and Sons, New 3. Gerlich, A., Su, P., and North, T. H. York, N.Y., pp. 303–339. 2005. Peak temperatures and microstruc- 18. The Aluminum Association. 1982. tures in aluminum and magnesium alloy Aluminum Standards and Data. p. 15, friction stir spot welds. Science and Tech- Washington, D.C., The Aluminum nology of Welding and Joining Vol. 10, (6): Association. 647–652 19. Savage, W. F., and Lundin, C. D. 4. Yamamoto, M., Gerlich, A., North , 1965. The Varestraint test. Welding Journal REPRINTS REPRINTS T. H., and Shinozaki, K. 2007. Mechanism 44: 433-s to 442-s. of cracking in AZ91 friction stir spot 20. Cao, G., and Kou, S. 2007. Real- welds. Science and Technology of Welding Time monitoring of hot tearing in AZ91E To order custom reprints and Joining Vol. 12, (3): 208–216. magnesium casting. Transactions of the of 100 or more of articles in 5. Yamamoto, M., Gerlich, A., North American Foundry Society, vol. 115, paper the Welding Journal, T. H., and Shinozaki, K. 2007. Cracking in 07-034. the stir zones of Mg-alloy friction stir spot 21. Ohno, M., Mirkovic, D., and call FosteReprints at welds. Journal of Materials Science Vol. 42, Schmid-Fetzer, R. 2006. Liquidus and (219) 879-8366 or pp. 7657–7666. solidus temperature of Mg-Rich Mg-Al- (800) 382-0808 or 6. Gerlich, A.,Yamamoto, M., and Mn-Zn alloys. Acta Materialia 54: North, T. H. 2007. Local melting and 3883–3891. Request for quotes can be cracking in Al 7075 and Al 2024-T3 fric- 22. ASM International. 1986. Binary faxed to (219) 874-2849. tion stir spot welds. Science and Technol- Alloy Phase Diagrams, Vol. 1, p. 106, Ma- You can e-mail ogy of Welding and Joining, in press. terials Park, Ohio, ASM International. FosteReprints at 7. Gerlich, A. P. 2007. Local Melting 23. Pandat — Phase Diagram Calcula- and Tool Slippage during Friction Stir tion software package for Multicompo- [email protected]. Welding of Aluminum Alloys. PhD thesis, nent Systems. 2001. CompuTherm LLC, Department of Materials Science and En- Madison, Wis.

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WELDING RESEARCH Experimental and Numerical Analysis of the Friction Welding Process for the 4340 Steel and Mild Steel Combinations A model was developed that can be used as an industrial tool to predict evolution of temperature, stress, strain, and final geometry of the welded parts

BY S. A. A. AKBARI MOUSAVI AND A. RAHBAR KELISHAMI

ABSTRACT. During friction welding, ical energy to thermal energy at the inter- stress and strain distributions during the temperature, stress, strain, and their vari- face of the workpieces. In order to model welding process. Fu et al. (Ref. 3) simu- ations govern welding parameters, and the friction welding process, a combina- lated deformation and transient tempera- knowledge of them helps determine opti- tion of thermal effects and plastic defor- ture during the process by the finite ele- mum parameters and ways to improve the mation is needed. ment method. Alvise et al. (Ref. 4) design and manufacture of welding ma- The friction welding process is a solid- simulated the two-dimensional inertia chines. The finite element method was state joining process that produces a weld friction welding process for two dissimilar used for the coupled thermomechanical under the compressive force contact of materials, though the names of the mate- problem, and the Johnson-Cook equation one rotating and one stationary work- rials modeled were not reported. Re- was used to define material properties. piece. The heat is generated at the weld in- cently, Sahin (Ref. 5) introduced a friction The variations in temperature, deforma- terface because of the continuous rubbing subroutine in his visual basic program to tion, stress, strain, and strain rate during of contact surfaces, which, in turn, causes model the shape of the upset in the con- continuous welding were systematically a temperature rise and subsequent soften- tinuous friction welding process. investigated and analyzed. The calculated ing of material. Eventually, the material at In this study, friction welding experi- results of temperature distribution were in the interface starts to flow plastically and ments were carried out for 4340 and mild good agreement with the infrared de- forms an upset. When a certain amount of steel combinations. The various materials tected ones. The numerically calculated upsetting has occurred, the rotation stops were used to validate the simulation re- results for the shape of the welded joint and the compressive force is maintained sults. All of the experiments performed also showed an excellent fit with the ex- or slightly increased to consolidate the were modeled using the ABAQUS code perimental observations. The effects of weld. Friction time, friction pressure, forg- and under similar conditions. The physical initial and final pressure on internal para- ing time, upset time, forging pressure, and parameters such as temperature, stress, meters are discussed. Moreover, the met- rotation speed are the most important op- strain, and strain rate fields for a friction allographical examinations, hardness, and erational parameters in the friction weld- welded joint of a few materials in bar form tensile tests of the samples were carried ing process. were calculated under given boundary out. In addition, in this study, the opera- Few attempts have been carried out in conditions. Variable thermal and mechan- tional parameters of the friction welding the literature to simulate the friction weld- ical properties of the welded material process are related to the physical para- ing process. In these studies, only one or were taken into account. The simulation meters of the process. two of the operational parameters were results were validated against the experi- discussed. Most of the simulations were ments. An infrared detector was used to Introduction performed for the stir and inertia friction measure the temperature at the contact welding processes. Only a few efforts were surface of the weldment. The infrared de- Friction welding is a complicated met- reported in the literature for the continu- tector results are compared with the sim- allurgical process, accompanied by a se- ous friction welding process. Vairis et al. ulated values. The observed shape of the ries of physical phenomena: frictional (Ref. 1) simulated linear friction welding welded joint is also compared with the heat generation, plastic deformation, of titanium bars. He predicted the tem- simulated one. In all the tension tests car- cooling of high-temperature metal, and perature rise in the initial phase of the ried out, the samples were broken from solid-state phase variation. In the contin- process. Sluzalec (Ref. 2) used the finite their base metals and not the welds. The uous-drive friction welding processes, the element method (FEM) to determine the metallographical examinations of the thermomechanical behavior at the inter- specimens were also performed. More- face is obviously critical to the quality of over, in this study, the operational para- the welded joint. Fiction welding is a KEYWORDS meters of the friction welding process are process in which the heat for welding is related to the physical parameters of the produced by direct conversion of mechan- Friction Welding process. Finite Element Method S. A. A. AKBAR MOUSAVI and A. RAHBAR Experimental Samples KELISHAMI are with the School of Metallurgy Mechanical Properties and Materials Engineering, University College of Engineering, University of Tehran, Tehran, Iran. Experiments were carried out to fric- E-mail Mousavi at [email protected]. tion weld the samples with 20-mm diame-

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ters and 100-mm lengths. The operational B A parameters of the process for the similar and dissimilar materials welded are tabulated in Table 1.

Materials

In this investigation, Grade 4340 steel and mild steel were used. The chemical compositional ranges, and mechanical and physical properties for the materials used in this study are given in Tables 2–4, respectively. The typical final shape of mild steel to mild steel bars and 4340 steel to mild steel bars obtained from the experiments is shown in Fig. 1A and B, respectively. Fig. 1 — The final shape of the following friction welds: A — Mild steel to mild steel; B — 4340 steel to Comprehensive information about the mild steel. numerical and experimental phases of other materials can be found in Rahbar (Ref. 6). Modeling

In this investigation, the continuous Table 1 — Friction Welding Parameters of the Various Experiments Performed friction welding process of Grade 4340 steel and mild steel was numerically simu- Materials Initial Pressure Final Pressure Friction Time Rotation Speed lated by the ABAQUS 6.4-11 Pro com- (MPa) (MPa) (s) (rev/min) mercial software code (Ref. 7). The objec- 4340 Steel–4340 Steel 80 100 7 3000 tive of the study was to consider the Mild Steel–Mild Steel 20 30 6 3000 variations of temperature, deformation, 4340 Steel–Mild Steel 50 75 6 3000 stress, strain, and strain rate during the process. Moreover, in this study, the operational parameters of the friction welding process are related to the physical para- Table 2 — Composition Ranges of the Materials Used in This Study meters of the process.

Grade C Mn Si P S Cr Mo Ni Johnson-Cook Constitutive Equation min. 0.38 0.6 0.15 — — 0.7 0.2 1.65 4340 Steel max. 0.43 0.8 0.30 0.035 0.04 0.9 0.3 2.0 In the friction welding process, contin- min. 0.03 0.2 — — — — — — uous rubbing of contact surfaces gener- Mild Steel max. 1.25 16 0.5 0.05 0.05 — — — ates the heat at the weld interface. The temperature of the material increases with heat and therefore subsequent softening of the material occurs. The material at the interface starts to flow plastically and Table 3 — Mechanical Properties of the Materials Used in This Study forms an upset collar. Therefore, the type Tensile Yield Strength of equation that can be used to describe Elongation Rockwell C Strength 0.2% Proof the material behavior during the process Grade (% in 50 mm) (HRC) (MPa) (MPa) must include the effect of temperature as min. max. min. min. well as strain and strain rate. Therefore, 4340 Steel 744.6 473.2 22 39 the Johnson-Cook equation (Ref. 8) is Mild Steel 420 350 15 26 used in which the von Mises yield stress is defined as a function of strain, strain rate,

Table 4 — Physical Properties of the Materials Used in This Study Mean Coefficient of Thermal Elastic Thermal Expansion Conductivity Specific Density μ Heat Grade3 Modulus ( m/m°C) (W/m.K) (kg/m ) (GPa) 0°–100°C 0°–100°C 0°–315°C 0°–538°C at 100°C at 500°C (J/kg.K) 7700– 4340 Steel 190–210 17.2 17.8 18.4 16.2 21.5 500 8300 7800– Mild Steel 200 9.5–12.6 11.7 12.8 44 470 8000

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Fig. 2 — Initial configuration of the simulation of two bars before welding. Fig. 3 — The final shape of the weld between stainless steel and mild steel.

Fig. 4 — The final shape of the weld between mild steel and mild steel. Fig. 5 — The “centerline” path upon which the analysis carried out in this paper is based.

and temperature, i.e., coupled temperature-displacement equa- rotation stopped and the compressive tions were employed. The C3D8RT ele- force was maintained or slightly increased ⎛ ⎞ ⎛ ° ⎞ ment type was used. A proper contact al- to consolidate the weld. The boundary σ=A+Bεn ×1+c.lnε ⎝ ⎠ ⎝ p ⎠ gorithm was employed in the model. The condition is defined so that the materials general contact algorithm is used in mod- positioned in the right-hand side of the ×⎛ −°m ⎞ ⎝1T ⎠ (1)eling the friction welding process due to paper are fixed, and the materials suited in the following reasons: the left-hand side of the paper are rotat- ε ε where is the equivalent plastic strain, °p • During the friction welding process, ing. According to this, the centerline is the plastic strain rate, T° is the homolo- more than two surfaces can take part in nodes could only move in the “z” axis and gous temperature contact. not in “x” or “y” axis. The initial and final • The edge of the materials must be in- pressures are applied to the fixed bar. The ⎛ ⎞ cluded during the contact procedure. T− T initial pressure is applied during the weld- ⎜ room ⎟ , In addition, an algorithm was written ing time in which its values are increased ⎝⎜ T− T⎠⎟ and coded into the software to express the to the final pressure during the braking melt room contact definition of the process. Two-step time while the rotating speed decreases to and T is the absolute temperature. A, B, n, modeling was used in order to suitably ex- zero. The adaptive mesh type was used to c, and m are five constants. The expression press the process. In the first step, rotating adjust with the grain refinement during in the first set of brackets gives the stress and transition speeds were applied to the the contact deformation process. Thermal ε as a function of strain for °p =1 and T°=0. left bar and when a certain amount of up- effects are assumed to be adiabatic. The expressions in the second and third setting had occurred, the second step, the set represent the effects of strain rate and temperature, respectively. The Johnson- Cook parameters for the materials used in this study are tabulated in Table 5. Table 5 — The Johnson-Cook Parameters for the Materials Used in This Study (Ref. 7)

The Finite Element Modeling of the Material A B n C M Friction Welding Process (MPa) (MPa) Mild Steel 310 350 0.3 0.02 0.5 In this analysis, the eight-node element 4340 Steel 792 510 0.26 0.014 1.03 was used. The modeling was performed 3D with reduced integration points and

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Figure 2 shows the initial configuration of the process. The final configuration of the friction welding of 4340 steel bar to mild steel bar is shown in Fig. 3. The left- hand side of the model in Fig. 3 is the 4340 steel bar. The final shape of the mild steel C B A bar to mild steel bar is depicted in Fig. 4. Comparing Figs. 1 and 3 shows that simulation is relatively successful in modeling the out shape of the weld. The thin edge of the upset produced in experimental results could not be achieved due to the lim- itation of element size and type and avoidance of more complexity.

Validation of the Simulation Results

The sizes of upseting occurring during the friction welding process were compared with the corresponding simulation D results. The results are tabulated in Table 6. Validation of temperature results are described in the Hardness Distributions Fig. 6 — Metallographic images of the interface of a mild steel to mild steel friction weld: A — Initial section of this paper. mild steel structure before welding; B — the microstructure obtained after welding in the HAZ; C — the To analyze the simulation results, a typ- microstructure achieved in the fusion zone; D — temperature profile. ical “centerline” path similar to what is shown in Fig. 5 is chosen. The path has 150 mm length and includes the weld zone, the heat-affected zones (HAZ), and parts of both base metals. The path starts at 50 mm the metallographic images of the 4340 sion zones (which have a finer grain size). from the left bar end to 50 mm from the steel to mild steel samples before and after The hardness is decreased in the HAZ due right bar end. It covers all the changes that welding, respectively. to temperature softening and coarser might occur during the friction welding grain size structure produced (see typical process. The Tensile Tests temperature profile in Fig. 6D and microstructure in Fig. 6B). In the experi- Microstructures Experiments were also conducted to ments and the simulations, the bars were measure the weld strength of the samples. fixed at the right-hand side and rotating at The metallographic images of the mild Figure 8A shows the tensile test of mild the left-hand side of the figure. This pro- steel to mild steel samples before and after steel before the weld, and Fig. 8B depicts duces some rigidity at the bar ends and welding are shown in Fig. 6A–C. Figure the tensile strength of the weld after the causes the increase of hardness at a dis- 6B, C shows the fine grain size structure friction welding process. The two figures tance far away from the weld centerline. produced at the HAZ and the weld zones, are similar showing the rupture occurs in The increase in hardness away from the respectively. After cooling and applying the mild steel base bars and not at the weld joints, which is due to fixing the bars dur- the subsequent pressure, the process of re- zone. ing the test, is shown in Fig. 9. crystallization and growth takes place that Hardness Distributions results in a fine grain structure — Fig. 6C. The Temperature Distributions The fusion zone has finer grain than the The study was also conducted to find HAZ. Typical temperature profile ob- Friction causes the increase in temper- the hardness distributions across the tained from the simulation is shown in Fig. ature at the interface. The highest tem- joints. Figure 9 shows the typical hardness 6D. Figure 6D shows a very high temper- perature is obtained at the weld centerline distributions (in Vickers) for the friction ature is produced at the collision zone. In and the temperature decreases with dis- welded joints of 4340 steel-mild steel. addition, it will be shown later in the sec- tance away from the weld centerline. Fig- Maximum hardness is obtained at the fu- tion titled Plastic Strain Distributions that ure 10A shows the temperature distribu- the very high plastic strain is produced at the collision zone. High-temperature and plastic strain with fast cooling results in a Table 6 — Comparison of Upsetting Thickness between Simulations and Experiments fine grain structure at the contact zone. According to the Hall-Petch equation, the Materials Size of Upsetting Size of Upsetting Comparison material strength depends on the grain (Simulation) (Experiments) (% Error) size, and smaller grains produce the (mm) (mm) higher strengths (strength test results are Mild Steel-Mild Steel 1.9 2 5 described in the next section). 4340 Steel-4340 Steel 1.8 2 10 Similar trends are seen in friction weld- 4340 Steel-mild Steel 2.3 2.2 4.5 ing of other samples. Figure 7A, B shows

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A B

Fig. 7 — Metallographic images of the interface of 4340 steel to mild steel: A — The initial 4340 steel structure before welding; B — the microstructure achieved after welding in the fusion zone of 4340 steel-mild steel friction weld sample (initial mild steel structure is shown in Fig. 6A).

A B

Fig. 8 — Stress-strain graphs: A — The mild steel specimen; B — the mild steel to mild steel weld.

tions for friction welding of 4340 steel to hand sides of the figures and the initial and steel bars, respectively. The peak plastic mild steel material bars, and Fig. 10B final pressures are applied to the fixed strain is obtained at the centerline. The shows profiles for friction welding of mild bars. The maximum temperatures mea- figures show that the plastic strain de- steel to mild steel bars. The graphs are sured by the infrared detector for the 430- creases with distance from the centerline. drawn based on the normalized tempera- mild steel and mild steel-mild steel com- In the heat-affected zone, the plastic ture. The normalized temperature is the binations were 1425° and 1480°C, strain increases slightly due to the increase ratio of actual temperature to the melting respectively. The corresponding simula- of temperature. The temperature de- point temperature in °C. The data on the tion results predicted were 1440° and creases further at distances away from the figures show the ratio of actual tempera- 1520°C, respectively. heat-affected zones. ture to the melting temperature for some critical points. The figures clearly show The Plastic Strain Distributions The Von Mises Stress Distributions that the welding zones consist of two heat- affected zones and a center zone. Higher The transient temperature produced in Figure 12 shows the von Mises stress temperature is obtained for the friction the friction zone causes the variations of profiles for the two samples. In Fig. 12A, welding of 4340 steel to mild steel materi- all the physical parameters during the fric- the von Mises stress profiles for friction als. The heat-affected zone peak temper- tion welding process. The plastic strain welding of 4340 steel to mild steel are ature is found to be lower in the right-hand distributions are similar in shape to the shown and in Fig. 12B, profiles for friction sides of Fig. 10A and B than it is in the left- temperature distributions. Figure 11A welding of mild steel to mild steel are de- hand side of Fig. 10A and B. The differ- shows the plastic strain distributions for picted. The asymmetry in the von Mises ence is attributed to positioning the fixed friction welding of 4340 steel to mild steel stress profiles seen in Fig. 12A in compar- bar to the right-hand side of the figures materials, and Fig. 11B depicts profiles for ison with Fig. 12B is attributed to welding and suiting the rotating bar in the left- the friction welding of mild steel to mild dissimilar materials (i.e., 4340 steel to

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A B

Fig. 9 — Typical hardness distributions of the 4340 Fig. 10 — Normalized temperature profiles for friction welding of the following: A — 4340 steel to mild steel-mild steel and A12017-A12017 samples. steel materials; B — mild steel to mild steel materials.

A B A

Fig. 11 — The plastic strain distributions for friction welding of the following: A — 4340 steel to mild steel materials; B — mild steel to mild steel materials. B A B

Fig. 13 — The strain rate distributions for friction Fig. 12 — Von Mises stress distributions for friction welding of the following: A — 4340 steel to mild steel welding of the following: A — 4340 steel to mild steel materials; B — mild steel to mild steel materials. materials; B — mild steel to mild steel materials..

mild steel bars). In addition, the 4340 steel distance from the weld centerline, the von increases and the yield stress at tempera- has more strength than the mild steel and Mises stress is found to be similar to the von ture decreases which, in turn, reduces the therefore the von Mises stress in the right Mises stress of material at room tempera- von Mises stress — Fig. 12A, B. side of Fig. 12A is higher than that in the left ture, since the effects of temperature and At a closer distance to the weld center- side of the figure. In addition, a special pat- deformation on the material are negligible. line, the increase of temperature produces tern and characteristic exist in both figures At a closer distance to the weld centerline, more plasticity while the rest of the mater- and are described as follows: At a very far in the heat-affected zone, the temperature ial resists against the deformation which, in

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Fig. 14 — Effects of initial pressure on von Mises stress for constant final Fig. 15 — Effects of initial pressures on plastic strains for constant final pres- pressure on 4340 steel to mild steel. sure — 4340 steel to mild steel.

Fig. 16 — Effects of final pressures on von Mises stress for constant initial Fig. 17 — Effects of final pressures on equivalent strain profiles for constant pressure — 4340 steel to mild steel. initial pressure on 4340 steel to mild steel.

turn, increases the von Mises stress. At the ing process. The most deformation oc- creasing from zero to a minimum value and weld centerline, where the two surfaces are curred in the interface as a result of high reaching again at x = 0; to rise to a maxi- in contact with each other, the von Mises transient temperature and subsequent ma- mum positive at the heat-affected zone. stress reduces and the peak plastic strain in- terial flowing. Figure 13A shows the strain This variation of the strain rate is seen in creases due to temperature softening pro- rate distributions for friction welding of modeling of all samples. The strain rate ap- duced at the weld centerline. At distances 4340 steel to mild steel materials, and Fig- proaches zero at a far distance since no de- away from the weld zones due to resistance ure 13B illustrates the strain rate distribu- formation occurred at distances away from of the material against the deformation, the tions for friction welding of mild steel to the weld and HAZ zones. More fluctuation von Mises stress increases. The von Mises mild steel materials. Different strain rate of the strain rate was observed in the mate- stress obtained for the friction welding of patterns are obtained for friction welding of rial’s left-hand side than in the right-hand 4340 steel to mild steel is found to be higher 4340 steel to mild steel and for mild steel to side. The reason is attributed to fixing of the than that of mild steel to mild steel materi- mild steel materials, respectively. In gen- right-hand-side bar and rotation of the left- als. This matter is attributed to friction eral, the strain rate of the order of 101 ob- hand-side bar. The strain rate fluctuations welding of two dissimilar materials, which in served for friction welding of 4340 steel to are increased with the bar rotation velocity. turn produces more resistance to deforma- mild steel materials compared to the strain tion due to the materials’ yield stress varia- rate of the order 1 obtained for friction Effects of Initial Pressure on Internal tions at temperatures. welding of mild steel to mild steel materials. Parameters Strain rate variations for the mild steel to The Strain Rate Distributions mild steel friction weld are wider than those Effects of Initial Pressure on Von Mises for the 4340 steel to mild steel friction weld. Stress The strain rate is an important physical However, the figures show that the strain parameter in plasticity. Therefore, the rate is zero at the weld interface due to tem- Figure 14 shows the effects of initial analysis was carried out to consider the perature softening and might be positive pressure on the von Mises distributions strain rate distributions in the friction weld- and negative in the heat-affected zone, defor friction welding of mild steel to mild

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Fig. 18 — The experimental welding window. Fig. 19 — The numerical welding window.

steel bars when the final pressure is kept tial pressure, which in turn causes an in- sure on changing the effective strain constant. Three initial pressures were cho- crease in pressure and plasticity at the profiles. sen — 0.8 (in yellow), 1.2 (in green), and 1 contact surface. (in red) — times the initial pressure from The Proposed Experimental and Physical Table 1. The numbers in the figures show Effects of Final Pressure on Internal Welding Windows Parameters the magnitude of von Mises stresses for that point. The simulation results show It is possible to draw a welding window Effects of Final Pressure on Von Mises based on the experimental parameters. that all the diagrams follow similar pat- Stress terns. Simulation results show that the von The two most important experimental pa- Mises stress increases with the initial pres- rameters are the rotational velocity and Figure 16 shows the effects of final the initial pressure. It was found previ- sure. Increase of pressure to the ratio of pressure on the von Mises stress distribu- 1.2 causes the von Mises stress to increase ously that the initial pressure is more im- tions for friction welding of mild steel to portant than the final pressure. Figure 18 about 50 MPa. The figure shows that the 4340 steel bars when the initial pressure is initial pressure does not affect the von shows the welding window for the 4340- kept constant. Three final pressure ratios mild steel combinations. In any welding Mises stress for the fixed bar (see the of 1.8, 2, and 2.2, to the defined final pres- right-hand sides of the profiles in Fig. 14). window, minimum values of pressure and sure in Table 1, were selected for simula- rotational velocity are required in order to Moreover, the magnitude of von Mises tions. Figure 16 also shows the von Mises stress at the contact surface (fusion zone) produce the weld. If the initial pressure stress along the rods. and rotational velocity are below these increases with initial pressure. This matter Simulation results show that the final is attributed to more hardening occurring limits, there would not be enough plastic pressure does not significantly affect the deformation to consolidate the weld. in the fusion zones by increasing the initial von Mises stress obtained at the fusion pressure. In addition, Fig. 14 shows that Moreover, there exists maximum pressure zone and on the fixed bar. However, the and rotational velocity. If the initial pres- the initial pressure of 16 MPa (0.8 P) is not von Mises stress increases slightly in the sufficient to produce deformation and sure exceeds a threshold limit, it may re- rotating bar with the final pressure. In sult in cracking and distortion of the ma- plasticity. It is also implied that the initial other words, the HAZ von Mises stress in- pressure is an important parameter that terials. If the rotational velocity exceeds a creases in the rotating bar with the final threshold limit, it produces more heat at helps with plasticity similar to rotational pressure. Comparison between Figs. 14 velocity. the temperature and more softening and and 16 reveals that initial pressure is a may produce melt at the interface and, Effects of Initial Pressure on Plastic Strain more important parameter than final therefore, there would be no weld in the pressure in affecting the von Mises stress. interface. Figure 15 shows the effects of initial Effects of Final Pressure on Equivalent It is also possible to draw the numeri- pressure on the plastic strain profiles for Strain cal welding window based on the numeri- friction welding of mild steel to 4340 steel cal parameters. It was found from this bars when the final pressure is kept con- Figure 17 shows the effects of final study that the most influential numerical stant. The highest plastic strains occurred pressure on the equivalent strain distribu- parameters are the von Mises stress and at the contact zones. Simulation results tions for friction welding of mild steel to the effective strain. Figure 19 shows the show that the plastic strain at the contact 4340 steel bars when the initial pressure is numerical welding window for the 4340- zone increases with the initial pressure. kept constant. mild steel combinations. In the numerical The numbers in the figure show the mag- The simulation results show that the ef- welding window, it is not possible to draw nitude of plastic strain at the fusion zones. fective strain distributions are not affected a line of minimum and maximum von In addition, the figure shows that the fu- by the final pressure. Comparison be- Mises and effective strain similar to what sion zones shift toward the fixed bar (to tween Figs. 14 and 17 reveals that initial can be drawn for the initial pressure and the right-hand side) by increasing the ini- pressure is more effective than final pres- rotational velocity welding window. This

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may be attributed to more dependency on tained. That means this model can be used equivalent strain distributions. variables such as the von Mises and effec- as an industrial tool to predict evolution of • The experimental and numerical weld- tive strain to those of initial pressure and temperature, stress, strain, and final ing windows are proposed to determine rotational velocity. The numerical welding geometry of the welded parts. the operational and numerical parame- window shows the welding window bound- The following conclusions can be ters to produce the weld. aries. As long as the numerical values of drawn from this study. von Mises and effective strain obtained • Simulation results predict a high value References from any operational parameters used are of plastic strain produced at the weld inside the window, we can suggest that centerline due to increasing the tem- 1. Vairis, A., and Frost, M. 2000. Mod- welding may occur. perature. eling the linear friction welding of tita- The numerical welding window makes it • Similar trends to those obtained with nium blocks. Journal of Material Science possible to find the required essential oper- the plastic strain distributions are ob- and Engineering A292: 8–17. ational parameters for friction welding of tained for the temperature distribu- 2. Sluzalec, A. 1988. Thermal effects in any combinations. This proposal may help tions. friction welding. International Journal of in reducing lots of trial and error experi- • The peak von Mises stress is produced at Mechanical Science 32(6): 467–478. ments carried out to produce the weld for distances away from the weld centerlines. 3. Fu, L., and Duan, L. 1988. The cou- any similar and dissimilar combinations. • The von Mises stress reduces in the fu- pled deformation and heat flow analysis sion zone due to temperature softening. by finite element method during friction Conclusions • The von Mises stress obtained for fric- welding. Welding Journal 77(5): 202-s to tion welding of 4340 steel to mild steel 207-s. Numerical calculations and experi- is found to be higher than that achieved 4. Alvise, L. D., and Massoni, E. 2002. ments were performed to analyze the con- for friction welding of mild steel to mild Finite element modeling of the inertia tinuous friction welding process, which is steel materials. This is attributed to fric- friction welding process between dissimi- a typical process with a high temperature, tion welding of two dissimilar materials, lar materials. Journal of Materials Process- large deformation, and transient opera- which in turn produces more resistance ing Technology, 125-126: 387–391. tion. The mathematical model of continu- to deformation, and is also due to the 5. Sahin, M. 2004. Simulation of fric- ous friction welding is presented. The cou- materials yield stress variations at tem- tion welding using a developed computer pled effects of the mechanics and heat peratures. program. Journal of Materials Processing transfer are taken into account in the • A very fine grain structure is produced Technology. 153-154: 1011–1018. model. The distributions of temperature, at the weld zone, which in turn causes 6. Rahbar Kelishami, A. 2005. Ther- deformation, von Mises stress, strain, and the higher strength according to the momechanical analysis of friction welding strain rate during the continuous friction Hall-Petch relation. by finite element method and its metallur- welding process were numerically ana- • The results of the tensile test predict gical relations, MSc thesis, Tehran, Iran, lyzed. The simulation results of tempera- that the weld zone is stronger than the University of Tehran. ture were in good agreement with the ex- base metals since the rupture occurred 7. ABAQUS 6.4 Pro11 software, Help, perimental points. The shape of the upset outside of the welding area. 2005. collar obtained from the simulations also • The shape of the upsetting obtained 8. Johnson, R. G., and Cook, W. H. fits excellently with those experimentally from the simulation is similar to that 2004. A constitutive model and data for observed. With the finite element method achieved from the experiments. metals subjected to large strains, high (FEM) used in this paper, distribution of • The initial pressure is a more effective strain-rates and high temperature. Proc. of welding temperature, flow stress, and parameter than the final pressure on the 7th Int. Symp. Balestics, The Hague, plastic strain and strain rate can be ob- changing the von Mises stress and The Netherlands, pp. 541–547.

Call for Papers

2008 World Standards Day Competition

Sponsored by the Standards Engineering Society (SES), the theme for this year’s paper competition, “Intelligent and Sustainable Buildings,” recognizes the critical role of standards and conformity assessment programs in ensuring safety requirements; facilitating coordination among contractors, builders, engineers, and architects; and incorporating new technologies in design and construction. The competition invites papers that use specific examples to show ways that standards and conformity assessment programs are used for intelligent and sustainable buildings. All paper contest submissions must be received with an official entry form by midnight on August 29, 2008, by the SES Executive Director, 13340 SW 96th Avenue, Miami, Florida, 33176. For details on the winners’ recognition, cash awards, judging, and rules, go to www.ses-standards.org and follow the link for WSD Paper Competition 2008.

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WELDING RESEARCH A Friction-Based Finite Element Analysis of Ultrasonic Consolidation

In this study, the contribution of friction to the bonding mechanism in ultrasonic welding is explored, and offered are the distributions of temperature and plastic deformation caused by the friction stress

BY C. ZHANG AND L. LI

ABSTRACT. Surface bond formation in fective implementation of MMCs in new consolidation of metals and alloys began ultrasonic consolidation is a complicated and existing applications. only recently with the development of thermal-mechanical coupled process. As a joining method, ultrasound bond- emerging new technologies that employ Friction and plastic flow are used to simu- ing is arguably the least understood. How- ultrasonic welding in ultrasonic consolida- late the bond interface behavior. This ever, realization of the full potential of ul- tion. The weld strength of UC was mod- paper focuses on the contribution of fric- trasonic bonding will require a greater eled and an empirical model was derived tion to the bonding mechanism in ultra- understanding of the mechanisms for on the basis of the theory of surface and sonic welding. Based on a 3-D thermome- bond formation. No systematic simulation volume effects by Kong et al. (Ref. 10). A chanical quasi-static finite element model, results and analysis have been published 2-D spot-welding model for the mechani- the distributions of temperature and plas- on ultrasonic bonding, especially those of cal field was also constructed, and the vari- tic deformation caused by the friction the interface between the top layer of the ation of friction coefficient during the stress are presented. Temperature and foil and the substrate that is believed to be process was measured and studied in de- plastic deformation are found to vary with the most important region where bonding tail by Gao and Doumanidis (Ref. 11). vibration cycles. A saturation phenome- occurs. Most research of UC assumes that Their results pointed out the role of fric- non is identified that after a certain num- friction and plastic flow can be studied to tion and pressure in the formation of the ber of vibration cycles, the plastic defor- understand the most fundamental phe- elastic strain field at the bond region. mation at the bond interface reaches a nomena at the interface in ultrasonic However, since the heat equation was not steady state. welding (Refs. 2, 4–9). The friction is at- included in their analysis, the results did tributed as the shear effect on bonding, not include any thermal effect. Introduction while plastic deformation is attributed as This paper attempts to present the ef- the process in which the bond forms. Dif- fect of friction on the bonding interface by The ultrasonic consolidation (UC) fusion is also suggested as a possible applying Coulomb’s law of friction, and process is designed to continuously weld process for bond formation; however, the assumes that, under the vibration load, the layers of metal foil to previously deposited relatively low temperature and short time interface material will go through the lo- layers, during which the profile to each during the rapid bonding process seem to calized elastoplastic deformation under layer is created by contour milling, to build make diffusion insignificant for bond the friction heating process. up a 3-D structure. As with ultrasonic formation. During ultrasonic consolidation, the welding, most commercially available behavior of the bonding interface can be metal foils, such as aluminum, titanium, Coupled Physical Phenomena in described as follows: 1) The sonotrode vi- magnesium, copper, and steel, can be used Ultrasonic Consolidation brates at a fixed frequency transversely to in the UC process (Refs. 1, 2). the direction of sonotrode travel (Fig. 1) One area that will benefit from an im- The bond formation between the foil and a constant pressure is applied through proved understanding of ultrasonic bond- and substrate in UC is still unknown to re- the sonotrode; 2) the friction at the con- ing is the fabrication of metal matrix com- searchers because of the complicated in- tact surface area will break the surface posites (MMCs). Continuous fiber- teractions of vibration, deformation, fric- contaminants, such as oxides, so as to reinforced MMCs are typically produced tion-like shear, localized thermal effect, build an intimate contact condition; 3) the using diffusion bonding or casting, and oxides/contaminants dispersion on ultrasonic vibration generates a localized whereas discontinuously reinforced the interface. The modeling of ultrasonic elevated-temperature zone at the contact MMCs are typically produced using pow- surface, which will dramatically reduce the der metallurgy or pressure-assisted cast- critical shear stress; and 4) shear strain in ing methodologies (Ref. 3). The appropri- KEYWORDS turn will generate heat and affect the fric- ate design and application of MMCs tion conditions. Therefore, the ultrasonic depends on how easily they can be fabri- Numerical Model consolidation is a continuous process in cated. The ability to model their proper- Ultrasonic Consolidation (UC) which the generation of strain in the me- ties accurately is one of the keys to the ef- Friction chanical field and temperature in the ther- Thermal-Mechanical Analysis mal field are interactive. Thus, the UC Plastic Strain process constitutes a typical coupled-field C. ZHANG is a PhD student and L. LI (lei- Bond Formation problem. [email protected]) is a faculty member with the De- The analysis strategy for ultrasonic con- partment of Mechanical & Aerospace Engineering solidation as a coupled-field problem is at Utah State University, Logan, Utah. outlined in Fig. 2. It can be seen that in the

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Fig. 1 — Schematic of ultrasonic consolidation process based on Ref. 12. Fig. 2 — Diagram showing the process parameters, mechanical properties, and possible interactions (couplings) between thermal and mechanical mechanisms for ultrasonic consolidation (Ref. 13).

A B

C Two routes are be- nonlinear model has been developed and lieved to couple the a dynamic finite element analysis has been mechanical and ther- conducted based on the ANSYS package. mal fields in ultrasonic consolidation: Theoretical Background 1) The thermal field affects the mechanical In the ANSYS mechanical analysis, the field, because most of stress and strain relationship is as follows: the material mechanical properties, such as {}σε = [D ]{ el } ()1 modulus of elasticity, yield strength, and friction coefficient, are temperature sen- {}εεεεel = { } – { pl } – { th } () 2 sitive; and 2) the mechanical field (the friction force) gener- Fig. 3 — 3-D coupled-field model for ultrasonic consolidation σ ates heat, which where { } is stress vector, [D] is elastic changes the thermal stiffness matrix, which is a function of tem- εel ε field. During simula- perature, { } is elastic strain vector, { } εpl tion, these varying is total strain vector, { } is plastic strain εth mechanical field the strain and stress are material properties and quantities at the vector, and { } is thermal strain vector. determined by the pressure load, fiction last time step must be determined for cal- The bilinear von Mises yield criteria are force, and temperature-dependent mater- culating the state at the current time step. used in this model. If the von Mises equiva- ial properties. In the thermal field, the tem- lent stress is less than the material yield perature is assumed to be mainly influ- Finite Element Analysis strength at temperature, the stress state is enced by the heat generated by friction. elastic and no plastic strain is computed. If The fiction coefficient and material me- For the purpose of understanding the the stress exceeds the material yield chanical properties vary with temperature, role of friction in UC and its contribution strength, the plastic strain εpl is calculated by which in turn affect the heat generation. to the bond formation, a 3-D coupled-field

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Fig. 4 — Schematic of Al-Al friction coefficient measurement on a Gleeble Fig. 5 — Al-Al friction coefficient varying with temperature (Ref. 13). 1500D.

pl ⎧∂Q ⎫ Table 1 — Element Types and Functions {}dελ = ⎨ ⎬ ()3 ⎩∂σ ⎭ Name Description Function where λ is the plastic multiplier (which de- Solid92 3-D 10-node tetrahedral structural solid element A termines the amount of plastic straining) Solid227 3-D 10-node coupled-field solid element B and Q is the yield function. As the mater- Conta174 & Targe170 surface-to-surface contact element pair both A and B ial yields, the yield surface changes due to the bilinear isotropic (work) hardening. A — mechanical analysis; B — thermomechanical analysis To find out the effect of sonotrode’s cyclic motion, a transient dynamic analysis is conducted on the model. The governing dynamic equation is as follows for a linear Table 2 — Temperature-Dependent Mechanical Properties of AL 3003-H18 structure (Ref. 14): ⎪⎧∂2u ⎪⎫ ⎧∂u ⎫ Temp. Modulus of Elasticity Yield Strength Yield Strength (Ref. 15) []M ⎨ ⎬ + [C ] ⎨ ⎬ + [KKu]{ } 2 ∂t (°C) (GPa) (MPa) (MPa) ⎩⎪ ∂t ⎭⎪ ⎩ ⎭ = {Fa } (4) 25 53.2 227.3 185 50 28.8 197.3 — where [M] is the structural mass matrix, [C] 100 26.8 131.2 145 is the structural damping matrix, [K] is the 150 22.7 70.0 — structural stiffness matrix, {∂2u/∂t2} is the 200 16.9 68.3 62 nodal acceleration vector, {∂u/∂t} is the 250 16.4 32.9 — nodal velocity vector, {u} is the nodal dis- 300 14.5 29.0 17 a 350 13.3 26.5 — placement vector, and {F } is the applied load vector. The nonlinear analysis in this model is proceeded by updating these ma- trixes computed from the temperature- dependent material properties and con- Table 3 — Nominal Chemical Composition of AL 3003-H18 (wt-%)(Ref. 15) ducting a linear analysis for each step. Al Cu Fe Mn Si Zn In the ANSYS thermal module, conduction heat flow is included in the FEM 96.7–99.0 0.050–0.200 ≤ 0.700 1.00–1.50 ≤ 0.600 ≤ 0.100 model and the governing equation is as follows: ⎛ ∂T ⎞ ρc⎜ + (vT⋅∇ )⎟ = q + ∇ ⎝ ∂t ⎠ Table 4 — Thermal Properties of AL 3003-H18 (Ref. 15) ⋅⋅∇ ((K )T )()5

CTE Specific Heat Thermal Conductivity where ρ is density, c is specific heat, T is (μm/m–°C) (J/g–°C) (W/m–K) → temperature, t is time, v is velocity. vector 25.1 0.893 155 for mass transport of heat, q is heat gen-

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Fig. 6 — Flowchart of finite element analysis for UC. Fig. 7 — Distribution of temperature (°C) at the 1500th vibration cycle. A — Front view; B — top view; and C — side view.

. eration rate per unit volume, K is conduc- the element nodal force, [Ct] is the ele- same as the experimental setup: 355.6 × tivity vector, and ∇ = ∂/∂x + ∂/∂y + ∂/∂z. ment specific heat matrix, [Kt] is the ele- 355.6 × 12.7 mm and 146.1 mm (diameter) In the ANSYS thermomechanical cou- ment diffusion conductivity matrix, {T} is × 25.4 mm (thickness). Compared with the pled analysis, the thermal-structural cou- the temperature vector, {Q} is the sum of baseplate and sonotrode, the aluminum pled finite element matrix equation de- the element heat generation load and ele- foil is much smaller (25.4 mm width and 0.1 rived from the stress equation of motion ment convection surface heat flow vectors, mm thickness). Since this model has two and the heat flow conservation equation [Kut] is the element thermoelastic stiffness symmetrical planes (Plane X = 177.8 mm ∫ T β ∇ T coupled by the thermoelastic constitutive matrix (= – vol[B] { }{ {N} }d{vol}), and Plane Y = 177.8 mm) and the large dif- equations is as follows (Ref. 14): [B] is the strain-displacement matrix, [Ctu] ference in dimensions exists between the is the element thermoelastic damping ma- foil and baseplate/sonotrode, a UC model ⎡[M ] [0]⎤ ⎧{u}⎫ ⎡[C] [0] ⎤ ⎧{u}⎫ trix (= –T [Kut]T), T is the absolute refer- with quarter size has been built and shown + o o ⎢ ⎥ ⎨ ⎬ ⎢ tu t ⎥ ⎨ ⎬ ence temperature (= T + T ), T is the in Fig. 3B. This model is used to simulate ⎣[0] [0] ⎦ ⎩⎪{T}⎭⎪ ⎣⎢[C] [C]⎦⎥ ⎩⎪{T}⎭⎪ ref off ref reference temperature. the bonding of the first layer. Because the ⎡[K] [Kut ] ⎤ ⎧{u}⎫ ⎧{F}⎫ foil is very thin and the sonotrode has a + ⎢ ⎥ ⎨ ⎬ = ⎨ ⎬ (6) Finite Element Model roughened surface, it is assumed that a no- ⎢[0] [K t ] ⎥ ⎩{T}⎭ ⎩{Q} ⎭ ⎣ ⎦ slip condition exists between the top sur- where [M] is the element mass matrix, [C] Figure 3A shows the 3-D UC model face of the foil and the sonotrode. The fric- is the element structural damping matrix, with the sonotrode located at the center of tion is assumed to occur between the [K] is the element stiffness matrix, {u} is the baseplate. The dimensions of the base- bottom surface of the foil and the substrate. the displacement vector, {F} is the sum of plate and cylindrical sonotrode are the The 3-D coupled-field meshed model (Fig.

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3C) involving the sonotrode that is in close on the local temperature contact with and vibrates against the sub- and are input to the strate has been developed. The meshing model for each step. around the contact area is refined following a meshing study. The type of elements used Boundary and Initial in simulation and their functions are listed Conditions in Table 1. The number of total nodes and elements is 14722 and 10251, respectively. The UC process parameters, including pres- Material Properties sure load (1800 N), preheating temperature Tensile tests have been conducted on (150°C), vibration ampli- the Gleeble 1500D thermal-mechanical tude (16 μm), and vibra- simulator for measuring the temperature- tion frequency (20 kHz), dependent mechanical properties of alu- are incorporated in the minum foil (Al 3003-H18) used in this model as boundary condi- study. The dimensions of test samples are tions. The pressure load 22.0 × 10.1 × 0.1 mm, and the tensile load and vibrational displace- rate is 1.2 mm/min. Specimens were heated ment are applied to the to various temperatures and held for 3 min interface of foil and base- for thermal equilibrium, and tensile pulled. plate. A triangle wave is The results are listed in Table 2. It is seen used to approximate the that the properties of aluminum material Fig. 8 — Average temperature at the contact surface as a function of the sinusoidal waveform of vibration cycle. are very sensitive to the temperature. At the ultrasonic vibration. the preheating temperature (150°C), the The measured contact mechanical properties decrease to the half area under 1800 N is 4.7 or even less of those at room temperature. mm along the direction of The measured yield strength data of alu- the sonotrode’s moving, on each node; and 5) conduct a mechani- minum foil are different, but close to those and the sonotrode’s speed in UC process cal analysis and output the plastic results. from the reference. The composition and is 28 mm/s. For a given point underneath A flowchart that outlines the analysis pro- thermal properties for Al 3003-H18 are the sonotrode, the maximum time of con- cedures is given in Fig. 6. A further sim- shown in Tables 3 and 4. tact is approximately 0.16 s, or about 3000 plification involves that the plastic defor- Coulomb’s law of friction is used to cycles of vibration. Therefore, we assume mation is assumed to have no effect on the simulate the friction-like shear force on a stationary sonotrode in the model, and friction heat generation, and that no plas- the bonding interface. Since the pressure the maximum number of cycles to be mod- tic heat is generated in the entire process. is constant in the process, the friction co- eled is 3000. efficient is the only factor determining the A fixed boundary condition for dis- Simulation Results magnitude of friction. Experiments for placement is applied to the baseplate’s measuring the Al-Al friction coefficient bottom surface and all corners except the Effect of Friction on Temperature have been designed and conducted on the surface contacting the sonotrode. Sym- Gleeble 1500D. Figure 4 shows the device metrical boundary conditions are used on setup. The fixed anvil is covered with foil two symmetrical planes. A uniform initial Figure 7 shows the coordinate plane of Al 3003-H18 and another foil is put be- preheating temperature is applied to the projections of temperature distribution on tween them. A normal force (N) is applied parts around the bonding surface, includ- the contact surface (bond interface) at the on the top anvil. When a certain uniform ing the sonotrode, baseplate, and foil. No 1500th vibration cycle. With friction heat, temperature is achieved by the heating convective heat loss from baseplate and a uniform peak temperature state exists and controlling system of the Gleeble, the sonotrode to air is assumed because the on the contact surface, and the tempera- middle foil is pulled out at a certain rate UC device is in an enclosed space in which ture decreases away from the contact sur- (sliding speed). The sliding speeds be- there is no significant air flow. The radia- face into the substrate. The temperature tween 1 and 1000 mm/s are tested. The tion heat loss is also ignored due to the low distribution shows a cylindrical symmetry friction occurs on the top and bottom sur- temperature range. about the center of the contact surface. faces of the foil pulled out. Therefore, the The average temperature due to fric- Al-Al friction coefficient at the testing tion at the contact surface increases temperature can be calculated by μ = Methodology of Finite Element Analysis rapidly with the number of vibration cycles F/2(N + W), where F is the measured for UC in the initial period of bonding. As the pulling force, and W is the top anvil’s welding time is longer (higher number of weight and pressure. Friction coefficient Because of the limit of capability of the cycles), the temperature rise slows down, of Al-Al varying with temperature is ANSYS thermomechanical coupled ele- and seems to approach a steady state — shown in Fig. 5. There is no significant ef- ment, no plastic results can be obtained Fig. 8. The increase of interface tempera- fect of sliding speeds, in the range tested, from the thermoelastic equation. There- ture is influenced by qfriction – qloss, where on the friction coefficient. fore, the strategy for simulation involves qfriction is the friction heat generation rate, κΔ The model in this paper has included calling appropriate analysis modules: 1) qloss = T is the heat dissipation rate by the material nonlinear effects by using the Conduct a thermoelastic analysis using conduction. At the beginning of UC bond- data in temperature-dependent mechani- the thermomechanical coupled element ing, the rate of friction heat generation is cal properties tables above. In the tran- for friction heat generation; 2) output the much higher than that of heat loss, be- sient dynamic analysis, the mechanical temperature data for each node; 3) cause initially the temperature difference properties for different locations on the change the element type to the mechani- (ΔT) is low. As the temperature becomes contact surface are different depending cal element; 4) apply the temperature load higher due to friction heating, two com-

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A B

C D

Fig. 9 — Distribution of plastic strain as a function of location and vibration cycle.

peting factors become significant: On the around the contact surface where the bration waves in Ref. 9. one hand, the decrease of Young’s modu- bonding process happens — Fig. 9A. Fig- A similar plastic strain distribution can lus (Table 2) and friction coefficient (Fig. ure 9B shows the von Mises strain distrib- be seen along path A-C (the depth direc- 5) will slow down the fiction heat genera- utions along path A-B (the vibration dition). In Fig. 9C, a small region close to tion; on the other hand, the greater tem- rection) as a function of the number of point A has a plastic strain level higher perature difference enhances faster heat vibration cycles. At the beginning of bond- than 1 after 500 vibration cycles. The depth dissipation. Therefore, the temperature ing (50th cycle), the plastic strain is rela- direction plastic strain in all other regions increase slows down. A balance between tively small. The highest plastic strain oc- along path A-C is lower than 0.1. Since the qfriction and qloss can be achieved eventu- curs at the edge of the contact surface near depth direction plastic strain is the easiest to ally, giving rise to qfriction – qloss = 0, i.e., a point B. By the 350th cycle, the plastic measure experimentally, it will be used for thermal steady state. Physically, if the heat strain in the center of the contact surface verification of the model later. loss is faster than the friction heat genera- exceeds the level of plastic strain at the Path A-D is perpendicular to the tion and the interface temperature de- edge. After the 500th vibration cycle, the sonotrode vibration; therefore, there is no creases, the higher values of Young’s mod- value and distribution of plastic deforma- waveshape deformation distribution (Fig. ulus and friction coefficient at the lower tion reach a steady state, when there is no 9D) as seen along path A-B. A steady in- temperature will automatically increase change in von Mises strain with further increase of plastic strain levels can be seen the qfriction until a new dynamic heat bal- crease of the vibration cycle. The maxi- as the number of cycles increases. The ance is achieved. mum plastic strain is located at point A, steady-state strain distribution indicates a the center of the contact surface. A wavy- peak level close to point A. Effect of Friction on Plastic Deformation shaped plastic strain distribution caused The evolution of the average von Mises by the cyclic vibration is apparent. The plastic strain on the contact surface as a Three paths (A-B, A-C, and A-D) have reason for such characteristic wave shape function of time (or vibration cycle) is been selected to show the three-dimen- distribution of deformation has been stud- shown in Fig. 10. It has the same trend as sional distributions of von Mises strain ied and explained by superposition of vi- the temperature vs. vibration cycle in Fig.

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A B

Fig. 10 — Average plastic strain at the contact surface as a function of vi- Fig. 11 — Schematic of preferment deformation in substrate’s height (Ref. 13). bration cycle.

A B

Fig. 12 — A — 3-D coupled-field model for validation; B — distribution of Fig. 13 — Comparison of experimental measurements and simulation results z-directional plastic strain for an eight-layer deposit. for the average z-direction compressive plastic strain (Ref. 13).

8. The average plastic strain also ap- ered in addition to the friction heat. conducted. In UC, the height of deposit is proaches a “steady state” at the 1000th vi- One important experimental observa- smaller than the sum of foil layers’ origi- bration cycle when the contact surface av- tion in UC is that the strongest bonding is nal thickness, and the relative ratio is erage temperature is close to the steady only achieved with an optimized travel ve- changing with the number of layers. Fig- state. The time to reach the steady state locity of the sonotrode. Too fast travel ve- ure 11 shows the difference of substrate’s for the average plastic strain is later than locity does not provide enough dwell time height before bonding (A) and after bond- that for the three paths defined in Fig. 9. (or number of vibration cycles) for bonding (B). Thus, the z-directional compres- In the initial period when the tempera- ing; while too slow a travel velocity does sive equivalent plastic strain can be de- ture is increasing, the yield strength of ma- not result in good bonding either. The fined as follows: terial in the contact area decreases. When evolution of temperature and plastic the von Mises stress at any location strain obtained in this study can help pl ()HHab− εzeq, = ()7 reaches the yield condition at certain spe- quantitatively understand the phenom- Hb cific temperature, the material yields and ena, and provide control strategies for plastic deformation occurs. When the fric- stronger bonding. Samples of various numbers of layers tion heat generation on the interface bal- are made on the UC machine with the same ances the heat loss and the average tem- FEM Model Validation process parameters used in the simulations. perature approaches the steady state, the The sample heights after UC bonding are increase in plastic deformation stops and Definition of Z-Directional Compressive measured with a precision height gauge a similar steady state is also achieved. The Equivalent Plastic Strain in Experiment with a 0.001-mm resolution. The sub- number of cycles to reach this steady state strate’s height before bonding is calculated may decrease (or the time may be shorter) An experimental validation of the fi- by 0.1 mm (foil thickness) × 8 (layer’s num- when plastic deformation heat is consid- nite element results shown in Fig. 9C was ber). Thus, the z-directional compressive

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equivalent plastic strain from the experi- may also contribute to the error. 2. Daniels, P. C. 1965. Ultrasonics. Ultra- ment can be calculated by Equation 7. sonic welding 3(4): 190–196. Conclusions 3. Rawal, S. 2001. Metal-matrix composites Definition of Z-Directional Compressive for space applications. JOM 53(4): 14–17. Equivalent Plastic Strain in Simulation 4. Jones, J., and Meyer, F. 1958. Ultrasonic 1. A friction-based dynamic, coupled- welding of structural aluminum alloys. Welding field, finite element model has been de- For the purpose of finite element Journal 37(3): 81-s to 92-s. veloped for ultrasonic consolidation. The 5. Joshi, K. 1971. The formation of ultra- model validation, a new finite element friction heat flux at the bond interface in- sonic bonds. Welding Journal 50(12): 840–848. model is developed to incorporate a rec- creases quickly in the initial period of 6. Kong, C. Y., Soar, R. C., and Dickens, P. tangular substrate 12.2 mm long and 5.0 bonding and approaches a steady state. M. 2005. Ultrasonic consolidation technique mm wide — Fig. 12A. The same simula- The peak temperature develops at the for embedding sma fibers with aluminum mation strategy is applied to the new simula- trices. Composite Structures 66: 421–427. bond interface due to friction heating. tion with various buildup layers. A cut sec- 7. Doumanidis, C., and Gao, Y. 2002. Me- 2. The plastic strain is believed to con- tion plane parallel to the vibration chanical modeling of ultrasonic welding. Weld- tribute to bond formation of the ultrasonic direction and located at the center of the ing Journal 83(4): 140-s to 146-s. consolidation. Similar to the temperature substrate is chosen for extracting the z- 8. de Vries, D. 2004. Mechanics and mech- field, the plastic strain field also ap- anisms of ultrasonic metal welding. PhD thesis, directional plastic strain. Figure 12B proaches a steady state after a certain The Ohio State University, Columbus Ohio. shows the distribution of z-directional number of vibration cycles. The peak level 9. Zhang, C., and Li, L. 2006. A study of dy- plastic strain in the cut section for the of the plastic strain is located near the cen- namic mechanical behavior of substrate in ul- eight layers of the substrate. The average ter of the contact surface between the top trasonic consolidation. The 17th Solid Freeform value is calculated and defined as the z-di- foil and substrate. The plastic strain has a Fabricaion Symposium, Austin, Tex.. rectional compressive equivalent plastic 10. Kong, C. Y., Soar, R. C., and Dickens, P. characteristic waveshape distribution that strain in simulation. M. 2005. A model for welding strength in ultra- is caused by the superposition of vibration sonically consolidated components. Proceed- Comparison waves. ings of the Institution of Mechanical Engineers, 3. The model has been reasonably ver- Part C: Journal of Mechanical Engineering Sci- Figure 13 shows the comparison of z- ified by experimental measurement. The ence 219(1): 83–91. 11. Gao, Y., and Doumanidis, C. 2002. Me- directional compressive equivalent plastic results are able to provide insights for understanding the mechanisms of bond for- chanical analysis of ultrasonic bonding for rapid strain between experiment measurement prototyping. Journal of Manufacturing Science and finite element simulation. It can be mation for ultrasonic consolidation, and for guiding experimental design for and Engineering, Transactions of the ASME seen that the finite element model in this 124(2): 426–434. paper is able to correctly predict the trend stronger ultrasonic bonds. 12. White, D. R. 2003. Ultrasonic consoli- and magnitude of the experimental data. dation of aluminum tooling. Advanced Materi- Acknowledgment The error may be very likely due to the als & Processes 161(1): 64, 65. omission of contribution of plastic heat 13. Zhang, C., and Li, L. 2007. Effect of fric- This work was supported by the Na- flux to plastic strain. Another error source tion on ultrasonic consolidation. Proceedings of tional Science Foundation through DMII- is the use of solid substrate in the valida- the 2007 International Manufacturing Science 0522908. tion model instead of the true substrate and Engineering Conference, ASME (paper number MSEC2007-31202). that actually has a layered structure and References different mechanical properties. When 14. ANSYS, Inc. Release 11.0 Documenta- tion for ANSYS. the temperature increases, the tendency 1. Welding Handbook 1991. Welding for microstructure change, such as recov- 15. Metals Handbook, Vol. 2. Oct. 1990. process. Vol. 2, pp. 783–812. R. L. O’Brien, ed. ASM International, 10th edition. ery, which is not included in the model, Miami, Fla.: American Welding Society.

Call for Papers 15th International Conference on the Joining of Materials

The 15th International Conference on the Joining of Materials (JOM-15) and the 6th International Conference on Education in Welding (ICEW-6) Conference and Exhibition organized by the JOM Institute and supported by Dansk Metal, Danish Welding Society, and DSL FORCE Technology, will be held May 3–6, 2009, Helsingør, Denmark. A full technical program on welding technology and education and training will be conducted. The main topics are listed below. 1) Recent developments in joining technology — welding, soldering, brazing, and projects, with the emphasis on industrial applications, 2) Welding quality — properties and environmental considerations, 3) Welding management and qualification of welding personnel. The organizers cordially invite you to send a title of your presentation and a short abstract by October 15, 2008. Notification of acceptance and author’s guidelines will follow after review of the abstracts by December 2008. Full papers must be received by February 2009. Please send your name, address, title, and abstract to Alan Parnes (Dansk Metal);. e-mail [email protected]. For further information about the conference, contact JOM, Gilleleje Strandvej, 28 DK-3250 Gilleleje. Denmark. Telephone: +45 48355458, e-mail jom [email protected].

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