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Circle No. 3 on Reader Info-Card • SPECIAL EMPHASIS: WELDING EDUCATION AWS Web site: http'd/www.aws.org

Feature Articles Monthly Columns

• Program Answers Industry's Call for Entry-Level Welders Press-Time News ...... 7 M. R. Johnsen Manufacturers and educators collaborate in a unique program designed to attract individuals to the welding Washington Watchword ...... 9 profession and satisfy the need for entry-level welders/29 Editorial ...... 10 A Wise Method for Assessing Arc Welding Performance and Quality D. D. Harwig Commentary ...... 12 A systematically developed database of welding parameters for specific applications shows promise for eliminating time-consuming and costly trial-and-error methods that many engineers traditionally use/35 CyberNotes ...... 14 • Training Welders in Mexico A. H. Price Conferences ...... 16 Understanding and accepting cultural differences goes a long way in ensuring training success/41 News of the Industry ...... 18 • Who Will Become a Welder? W. Western New Products ...... 22 A veteran instructor identifies personality traits of those inclined to be welders and uses them to define an approach to instruction that offers the greatest chance of success/45 Welding Workbook ...... 51

• Training for the Future Navy Joining Center ...... 55 D. Landon What starts as an industry in-house training program expands into a work-study course for students from a local high schooV48 Coming Events ...... 56 Welding Research Supplement Brazing Q&A ...... 60 New Literature ...... 62 A New Ferritic-Martensitic Stainless Steel Constitution Diagram M. C. Balmforth andJ. C. Lippold Stainless Steel Q&A ...... 64 The comparison of new equivalency formulae to existing formulae show improved accuracy in predicting microstructure of ferritic and martensitic stainless steel welds/339-s Personnel ...... 66

A Martensite Boundary on the WRC-1992 Diagram -- Part 2: The Effect of Manganese Society News ...... 67 D.J. Kotecki A modification to the WRC-1992 Diagram that takes into account martensite formation will allow the use of one Guide to AWS Services ...... 92 diagram for FN prediction and dissimilar metal joining/cladding situations/346-s WeldingJournal Index ...... 94 The Stress-Relief Cracking Susceptibility of a New Ferritic Steel -- Part 1: Single-Pass Heat-Affected Zone Simulations Classifieds ...... 108 J. G. Nawrocki, et al. Under different heat inputs and postweld heat treatments, a new alloy is tested against a standard alloy used in Welding Consultants Directory .. 110 high-temperature applications/355-s Advertiser Index ...... 113 Control for Weld Penetration in VPPAW of Aluminum Alloys Using the Front Weld Pool Image signal Peer Review ...... 114 B. Zheng, et ai. A model is developed of the relationship between the bottom diameter of a keyhole and the size of the keyhole weld pool as recorded with an image sensing system/363-s

Welding Journal (ISSN 0043-2296) is the official monthly publication of the American Welding Soci- ety. Editorialand advertisingoffices are locatedat 550 N.W. LeJeuneRd., Miami, FL 33126; telephone (305) 443-9353. Printed by R. R. Oonnelley& Sons Co., Senatobia, Miss. Subscriptions: $90.00 per year in the United Statesand possessions,foreign countries $130.00. Singlecopies: members$6.00, nonmembers $8.00. Periodicals postage paid at Miami, Fla., and additional mailing offices. POST- MASTER: Send address corrections to Welding Journal, 550 N.W. LeJeune Rd., Miami, FL 33126. Starred (*) items excludedfrom copyright. Readersof the WeldingJournal may make copies of articles for personal,archival, educational or researchpurposes, and which are not for sale or resale. Per- mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. WELDING JOURNAL I $ RE OF THE G I~\IDU

mini in i| w~ I N TER NA TI 0 NA L May 6-10, 2001 Filling the entire International Exposition (I-X) Center Cleveland, Ohio

presented by AmericanWelding Society International Welding and Fabricating Exposition and Annual Convention and lUL=mUF,,'~,,]~IVl

~r~JA i,Wllllr4 PRECISION Visit us at www.aws.org or METLALFORMING www.metalforming.com New Recycling Process Uses Lasers to Separate Aluminum

A newly developed recycling process employs lasers to iden- Aluminum is now the third most-used material in cars and tify and recover metals from scrap lasers, according to the Auto trucks, and nearly 90% of automotive aluminum is recovered Aluminum Alliance, in conjunction with the U.S. Department and recycled. While this aluminum represents less than 10% of of Energy. The lasers can distinguish between cast and wrought the average motor vehicle by weight, it accounts for about half alloys, as well as separate wrought alloys from each other at of the vehicle's value as scrap. commercially viable rates. "The techniques we're exploring will allow us to recapture During the process, which uses a technique called laser- more of the value and performance capability of the many high- induced breakdown spectroscopy, a laser is used to clean the quality aluminum alloys that are used in our vehicles," said Jim surface of the particle by laser ablation, and then a laser pulse Quinn, staff engineer, General Motors Corp., and chairman of hits the same spot as it moves down a conveyor belt. The second the U.S. Automotive Partnership, Automotive Metals, United laser pulse vaporizes a small amount of material from the States Council for Automotive Research (USCAR). metal's surface, which creates a small, highly luminescent plume Huron Valley Steel Corp., a metals processing firm in of plasma. To quantitatively determine the metal's chemical Belleville, Mich., is evaluating the new method. The Auto Alu- makeup, the plume is analyzed using optical emission spec- minum Alliance is working with the company as part of a one- troscopy. Once verification is made, the scrap is sorted by alloy year agreement launched August 24. The Auto Aluminum Al- on a piece-by-piece basis. Up to now, such alloys were sorted liance is an interindustry collaborative research effort between manually, a costly, slow process. It is estimated the first com- USCAR and The Aluminum Association, Inc. mercial sorting center will be able to analyze and sort 100 million lbs of aluminum per year. Praxair Forms Metals Rofin-Sinar Appoints Board Director Technologies Business and New Presidents for Subsidiaries

Praxair, Inc., Danbury, Conn., recently formed Praxair Met- In connection with its recent acquisition of Baasel Lasertech als Technologies, a separate business dedicated to the commer- Group, Rofln-Sinar Technologies, Inc. (Hamburg, Germany, and cialization of technologies and services for the global metals in- Plymouth, Mich.), appointed Carl E Baasel to its board of directors. dustry, including the company's patented CoJet TM system. He will keep his position as managing director of Carl Baasel The new business will develop and market technology for li- Lasertechnik GmbH, Stamberg, Germany, and will serve as a board censing, process control software and technical services in energy member of several subsidiaries of the newly formed ROFIN Group. conservation, product quality and productivity to steel, alu- The Acton, Mass., operation, formerly known as A-B Lasers, minum and other metals customers around the world. Inc., has been renamed Rofin-Baasel, Inc., and is headed by Dr. Michael J. Douglas, vice president, Praxair Metals Technolo- Walter Volkmar. It will concentrate on manufacture and sale of gies, will head the new business. He will report to Dennis H. Reil- turnkey standard and customized laser marking systems. ley, president and chief executive officer. Lou Molnar has been named president of Rofin-Sinar, Inc., Plymouth, Mich.

Valley National Gases Acquires Manitowoc Acquires Titan Welding Supply Marinette Marine

Valley National Gases, Inc., Wheeling, W.Va., recently pur- The Manitowoc Co., Inc., a diversified manufacturing com- chased Titan Welding Supply, Ltd., Willoughby, Ohio. Titan pany with operations in food service equipment, lattice-boom provides welding supplies, propane and industrial, medical and cranes and marine services, recently purchased the stock of specialty gases. Combined annual sales are approximately $1.5 Marinette Marine Corp. for approximately $48 million as part million. of an all-cash transaction. Valley National Gases is a packager and distributor of indus- Marinette operates one of the largest shipyards on the U.S. trial, medical and specialty gases, welding equipment and sup- Great Lakes. It is located in Marinette, Wis., just across Green plies, propane, and fire protection equipment. It operates 59 lo- Bay from Manitowoc's shipbuilding facility. It is currently cations in ten states. It has seven production and distribution under contract to build six oceangoing buoy tenders for the U.S. centers in the mid-Atlantic and midwestern regions of the Coast Guard, as well as two 269-ft APL barracks barges for the United States. The company has completed six acquisitions dur- U.S. Navy. It currently employs more than 800 people. A pri- ing the last 12 months, adding approximately $14 million in an- vately held corporation, Marinette has revenues of approxi- nual sales. mately $100 million.

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PATENTED THROUGHOUT THE WORLD Circle No. 16 on Reader Info-Card BY HUGH K. WEBSTER AWS Washington Government Affairs Office Was,word

intentionally conceal product defects that result in death or Regulatory Reform Law Adopted grievous bodily injury. This legislation is a direct result of the For the first time since 1996, a new law has been enacted Firestone tire matter. aimed at reforming the federal regulatory system. The Truth in Regulating Act is designed to give Congress a means of verifying certain claims made by federal agencies in connection with Skilled Worker Visa Legislation Approved proposed and final rules. Specifically, the Act gives Congress the authority to direct the General Accounting Office to review and Congress and the President have once again approved analyze cost-benefit analyses of federal regulations. In legislation that will increase the number of visas available for connection with such a review, the GAO would also examine "highly skilled" foreign workers. Pushed by the technology other data or assumptions underlying these regulations. industry, but applicable to all industry sectors, this new law The impetus for the Truth in Regulating Act is an increasing increases the number of H-1B visas to 195,000 for each of the distrust by Congress of claims by federal agencies regarding the next three fiscal years. If this legislation had not been passed, regulations they impose, particularly with respect to the the number for this fiscal year 2001 would have been 107,500, expected burden these rules may impose. There has also been dropping precipitously to 65,000 for subsequent years. frustration at the reluctance of federal agencies to disclose all underlying assumptions of regulations, including research studies. High Court Hears Argument Some have questioned the effectiveness of this new law. In 1996, a similar law was enacted Efforts at bringing in Regulations Case giving Congress the authority to review and The U.S. Supreme Court recently heard disapprove federal agency rules. Since then, some federal reform to oral arguments in a potentially ground- Congress has not reviewed a single regulation. breaking case regarding the regulatory authority of federal agencies. Last year, a the area of products federal appeals court in the District of National Standards Policy Columbia declared part of the Clean Air Act Hearing Held unconstitutional because it gave the liability once again Environmental Protection Agency The House Technology Subcommittee unfettered discretion to adopt any recently held a hearing titled, "The Role of regulations it wished without any discernible Standards in Today's Society and in the have failed at the standard. The EPA has appealed that ruling Future." Witnesses from government, to the Supreme Court. Also at issue is a industry and the nonprofit sector discussed decision by the same appellate court to the the importance of standards to the federal level. effect the EPA need not undertake a formal competitiveness of American industry in cost/benefit analysis when promulgating international markets. They emphasized the anti-smog regulations. Like the other issue, need for these three elements to cooperate this one has potential implications for all in the international standards arena. This hearing also federal agencies. addressed the National Standards Strategy recently developed and approved by the American National Standards Institute. This strategy establishes a framework with which to use the Web Site Offers Federal Register standards process to improve U.S. competitiveness overseas. Assistance A new nonprofit Web site has been established designed to Product Liability Reform Effort Fails Again assist those who regularly peruse the Federal Register to monitor federal regulatory activity. RegRadar.org, owned and Efforts at bringing some federal reform to the area of operated by the Mercatus Center at George Mason University, products liability once again have failed at the federal level. an educational and research organization that studies and Supporters had changed their strategy in recent months, comments on regulations, aims to be a one-stop site for advocating legislation targeted at specific issues rather than monitoring planned, proposed, pending and final federal pushing for a comprehensive reform package. While there was regulations. initial optimism that this approach might be successful, it has not been. In fact, Congress ended its year by approving Contact the A WS Washington Government Affairs Office at 1747 legislation, signed by the President, that would impose criminal Pennsylvania Ave. N. W., Washington, DC 20006; telephone (202) penalties on transportation industry executives who 466-2976; FAX (202) 835-0243. WELDING JOURNAL ] 9 AMERICAN WELDING SOCIETY A Society Officers of the Members... President -- L. W. Myers As I approach my year as president of the American Welding Society, I am Vice President -- R. L. Arn humbled by the breadth and depth of talent this society represents. Our mem- Teletherm Technologies, Inc. bership spans the entire scope of our industry. It includes the skilled craftsmen that apply the welds, the engineers who design those welds, the managers who Vice President -- E. D. Levert supervise the people and processes used to produce the products. It includes Lockheed Martin Missiles and Fire Control the people who produce the welding equipment, filler metals and supplies that ultimately go into the products that are made and the sales personnel who sell Vice President -- T. M. Mustaleski them. The American Welding Society also includes the research and develop- Lockheed Martin Energy Systems ment engineers and scientists who give us new and improved joining processes and welding educators at all levels who pass welding knowledge on to the Treasurer -- N. A. Hamers next generation. The members of the American Welding Society span industry DaimlerChrysler from the shop floor welder to the presidents and CEOs of major corporations. The strength of our society comes from that diverse and talented member- Executive Director -- E G. DeLaurier, CAE ship, and together we've formed one of the most internationally respected and admired professional societies in existence today. Our society treats the con- Directors tributions of all its members with equal respect. And any member, whether a shop floor welder or the president of a company, can rise up through the ranks O. AI-Erhayem (At Large), JOM Institute of our local Section, District and national leadership positions to become the J. M. Appledorn (Dist. 18), The Lincoln Electric Co. president of our society. The strength and diversity of our membership helps B. J. Bastian (At Large), BenmarAssociates to produce the volunteer leaders who have propelled our society into being H. J. Bax (Dist. 14), Cee KaySupply one of the leading voices of the international welding community. The volunteer leaders of the American Welding Society, however, have not worked M. D. Bell (Dist. 22), Preventive Metallurgy alone. H. E. Bennett (Dist. 8), BennettSales Co. During my years serving our society on a national level, I have come to B. A. Bernstein (Dist. 5), TechniWeldLab respect and admire the dedicated service of our professional staff. While we, S. W. Bollinger (Past President), Consultant. the members and volunteer leadership of AWS, set the direction of the soci- C. B. Bottenfield (Dist. 3), DresselWelding Supply ety, it is our dedicated staff who carry out the daily tasks that make the publi- J. C. Bruskotter (Dist. 9), ProjectSpecialists, Inc. cations and programs of our society work. Whether they serve as secretaries of our technical committees, as the publishers of the codes and standards those C. E Burg (Dist. 16), AmesLaboratory committees produce, as the publishers of the award-winning Welding Journal S. C. Chapple (Dist. 11), MidwayProducts Group or keep track of our CWI program and the many other international certifica- G. R. Crawmer (Dist. 6), GE PowerGeneration Engineering tion programs AWS administers, I have found our staff to be both dedicated A. E Fleury (Dist. 2), A. E Fleurs& Associates to and enthusiastically engaged in the programs of the society. Since the vol- J. R. Franklin (At Large), SellstromMfg. Co. unteer leadership changes each year, it is the work of the staff and its leadership to keep our programs moving forward through those changes. J. D. Heikkinen (Dist. 15), SpartanSauna Heaters, Inc. In their wisdom, the founders of our society established a system in which J. L. Hunter (Dist. 13), MitsubishiMotor Mfg. of America,Inc. our society is strengthened by a diverse and changing leadership, one where all M. D. Kersey (Dist. 12), The LincolnElectric Co. of the people engaged in our industry have the opportunity to give something N. R. Kirseh (Dist. 20), NortheasternJunior College back by serving as volunteer leaders for our local, district and national activi- D. J. Kotecki (At Large), The Lincoln Electric Co. ties. They also gave us a staff organization that keeps the wheels of that soci- R. C. Lanier (Dist. 4), Pittcommunity College ety turning as that volunteer leadership changes. The leadership of our society is made up of the members, who by the work of the dedicated staff, together G. E. Lawson (At Large), ESABWelding & CuttingProducts create services for the members. V. Y. Matthews (Dist. 10), The LincolnElectric Co. Don't sit on the sidelines, get G. H. Putnam (Dist. 1), Thermal Dynamics involved in your society. We need O. E Reich (Dist. 17), TexasState Technical College at Waco people like you to fill the many E R. Schneider (Dist. 21), Bob SchneiderConsulting Services Section, District and national leader- T. A. Siewert (At Large), NIST ship positions that make our Society as diverse and strong as it is. The R. J. Zabernik (Dist. 7), The LincolnElectric Co. founders of our society gave you that R. J. Teuscher (Past President), SpringsFabrication. Inc. opportunity. Take advantage of it. We P. E Zammit (Dist. 19), BrooklynIron Works, Inc. need the breadth and depth of your experience to carry us into the future.

Richard L. Arn A WS Vice President 10 I DECEMBER 2000 Lincoln Electric. NASCAR Officially Licensed welding equipment.

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The Lincoln Electric Company, Cleveland, Ohio U.S.A. 888/355-3213 www.lincolnelectric.com Circle No. 23 on Reader Info-Card /IIIL~ ~"fi~[~(i{] lilt' L,Ilt'i~ill ~.lel:ti~e, CI; WELDING JOURNAL Editorial Staff Publisher Jeff Weber Com t-t Editor Andrew Cullison Features Editor Mary Ruth Johnsen Managing Editor Going to the Max Christine Tarafa Associate Editor Susan Campbell It's official. Our new show has a new name and identity. Welcome to MAX Assistant Editor International presented by the American Welding Society and the Precision Doreen Yamamoto Metalforming Association. Where we were once in the category of one of the Production Coordinator top 200 trade shows in America, according to Tradeshow Week Magazine, this Zaida Chavez new association places us as one of the top 50 trade shows. Essentially overnight, our entire presence has doubled. For example, at our Peer Review Coordinator upcoming show at the I-X Center in Cleveland, May 6-10, MAX International Doreen Kubish will fill the entire exhibit hall. More than 800,000 gross sq ft will be filled with Contributing Editor welding, stamping, forming, shaping and cutting equipment of all types and Bob Irving sizes along with the accessories to make operations more efficient and pro- Publications, Expositions, ductive. More than 1200 exhibitors are expected. Marketing Committee We will present a totally integrated manufacturing environment from which G. D. Uttrachi G.M. Nally an attendee can gather all the information needed to improve and enhance Committee Chairman Consultant operations limitlessly. ESAB Welding & Cutting We anticipate a crowd of 30,000 to 40,000 attendees. In surveys taken at R. G. Pall past AWS Welding Shows, some 80% of attendees wanted to see more metal- G. O. Wilcox J. E Nissen Co. Vice Chairman working equipment. Now they'll get their chance. PMA is the most respected Thermadyne Industries S. Roberts association of metalworking equipment manufacturers in the world. With Whitney Punch Press J. Weber friends like that, and the depth of representation we have in the welding indus- Secretary J. E Saenger, Jr. try, MAX International will become the driving force at the core of industry. American Welding Society Edison Welding Institute Because there are so many more things to see and do, the show is going to P. Albert R.D. Smith last longer. Instead of being three days, it will start on Sunday and last through Krautkramer Branson The Lincoln Electric Co. Thursday, or five days. And the timing couldn't be better. Attendees will like R. L. Arn P.D. Winslow, Ex Off. how much they can save on airfare by flying in on a Saturday, hitting the key Teletherm Technologies, Inc. Hypertherm exhibits on Sunday and Monday and catching the red-eye home Monday night. T. A. Barry E.D. Levert, Ex Off. That only means one day of work to catch up on and airfare savings, too. Miller Electric Mfg. Co. Lockheed Martin Missiles and Fire Control Also, be aware that even though we are working together with the Precision C. E. Boyer Metalforming Association, our show will stay unique. We are collaborating not ABB Robotics L.G. Kvidahl, Ex Off. Ingalls Shipbuilding combining. So, you will find all the traditional welding and cutting equipment, T. C. Conard services, accessories and supplies on our side of the hall -- where you expect ABICOR Binzel N. Hamers, Ex Off. it to be. However, your admission to the welding show, also gives you direct DaimlerChrysler D. L. Doench access to PMXs exhibits. Hobart Brothers Co. S.W. Bollinger, Ex Off. MAX International is where the next generation of technology, innovation Consultant and knowledge will be introduced, not only on the show floor but in meeting J. R. Franklin Sellstrom Mfg. Co. J.C. Lippold, Ex Off. rooms and conferences. Your universe of information just expanded, too. The Ohio State University Certainly you'll be able to attend seminars, sessions and conferences on the N. R. Helton topics with which you're familiar, but now you'll have access to leading edge Pandjiris, Inc. W. Gaskin, Ex Off. technology throughout the entire Precision Metalforming Association V. Y. Matthews range of manufacturing. You'll gain The Lincoln Electric Co. L.W. Myers, Ex Off. the best of every discipline. Consultant If you haven't already, now is the T. C. Myers DovaTech Ltd. F.G. DeLaurier, CAE, Ex Off. best time to make plans to attend in American Welding Society May. Don't miss this opportunity to be a part of the inaugural MAX Advertising International. Director of Sales Advertising Sales Representatives Rob Saltzstein Blake and Michelle Holton 1-800-644-5563 Advertising Production Manager Colleen Beem Subscriptions Tom L. Davis Nancy Batista Managing Director, Convention and Expositions American Welding Society 550 N.W. LeJeune Rd., Miami, FL 33126 (800) 443-9353 Copyright © 2000 by American Welding Society in both printed and electronic 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 intended for use without independent, substantiating investigation on the part of potential users. 12 I DECEMBER 2000 A warehouse of changes at Nauonal-- Standard.

A recent merger has made National-Standard a stronger, more. efficient company. N-S CopperFree and SATIN GLIDE solid wires are still in continuous production. Our ready-to-ship inventory has never been bigger. Our trademark strengths remain unchanged. We still make the best MIG wire in the world. We still are supported by an outstanding distribution system. And our innovative bulk packaging sets the standard for the industry. See the new National-Standard in action. Call us today. 0 National-Standard Welding Products Division Niles, Michigan Ph: 800-777-1618 Fax: 616-683-9276 www.nationalstandard.com

Welding wire to robotic standards

Circle No. 26 on Reader Info-Card

OS-O000 A collection o)~industry news from the lnternet ! BY MARY RUTH JOHNSEN, Features Editor

Structural Steel Site Details Hazardous Material Storage Fabrication Information

Safety Storage, • m_, ~ HOM[ ~ODUCIS kiOUO$SI N[~ (o NIACI Max Weiss Co. The Web site for this Inc. Scroll-down m~uEs~ ~fo O Milwaukee, Wis. company highlights menus at the bottom the company's experience in rolling and of each page make it sro.A~E,.~F£TY Safetv Storaae forming structural steel sections for ar- easy to navigate HAZMAT chitectural and industrial applications. around the site for MODUL~ ~'MAT ~r~JotmE~mcmt The site details its operations, which in- this Hollister, Calif., OeUM STO~GF based manufacturer sPJ~ CONTAJNM~N T clude welding and fabricating, hot form- CUSTOMEHGIN~FRED ing and forging, and blacksmithing and of prefabricated, re- ACCESSO~S machining services, including turning, locatable steel build- milling, drilling and punching. ings for the storage, The site has an extensive photo handling and use of gallery that includes pictures of the com- chemicals and haz- pany's facilities and operations, as well ardous materials. as client project photos. The site also The site includes a detailed informa- lists affiliations the company has with i Select e Cotegory organizations such as the American tion request form. Welding Society and includes links to Visitors can submit a those organizations' Web sites. Visitors summary of their applications, the time The site also includes detailed prod- can also request information via an elec- when the product would be needed, a list uct information, which is provided by tronic form. of the materials that need to be stored product category and for some specific and outline requirements for materials industries. http://www.maxweiss.com handling, temperature control and code/regulatory requirements, as well as http://www.safetystorage.com other information. Tailor-Made Cables Highlighted

Site Profiles Microjoining Applications and Solutions Eiocab. Based in Kitchener, Canada, with production facilities in Canada and Germany, this company manufactures MicroJoin, Inc. A drop-down menu and more. For instance, in answer to the tailor-made cables for applications bar plus a search feature makes it easy to question on which electrode to use, the ranging from automation and robotics navigate around this Web site. The site site offers the following: to transportation and medical equip- details the company's products and ser- "The first thing to remember is to use ment. The heart of the company's Web vices regarding resistance welding and resistive electrodes for conductive mate- site is an easy-to-use questionnaire that integrated hot bar bonding systems for rials and conductive electrodes for resis- asks customers to define their specifica- solder reflow, anisotropic conductive tive metals. If neither the electrode nor tions or problems. It includes a checklist film and heat seal bonding processes. the weldment is highly resistive, current that asks questions regarding tension re- Visitors are self-guided through pho- from the welding machine passes easily sistance, high-flex performance, chemi- tos and informational tables along three through the weldment and not enough cal and thermal jacket durability and re- paths -- applications, processes and heat is generated to make a weld. quired cable diameter. At the click of a products -- to select the technology and "On the other hand, if both the elec- mouse, the information is sent to one of system they need. trode and weldment have too much re- the company's product engineers. The site includes a company profile, sistance, their interface will become too The site also includes a listing of arti- information on how to contact a sales hot. This causes the weldment to spatter, cles dealing with cable applications and representative, a list of company clients discolor or destroy. solutions, with links to the publications. and the industries they belong to and "If the electrode is conductive, how- Other information provided includes the press releases. Copies of the company's ever, and the material to be welded is re- standards to which the company's prod- newsletter, The Joule, can be down- sistive, current will easily pass through ucts are manufactured, the trade shows loaded in PDF format. the electrode and the electrode will re- it will be attending, a map and informa- A detailed Frequently Asked Ques- main cool. The weldment will resist the tion regarding sales representatives. tions section explains what resistance current and generate enough heat to welding is, the differences between resis- make a good weld." tance welding and resistance brazing, of- http://www.elocab.com fers help on how to select a power source, http :/ /vwv.microjoin.com

14 I DECEMBER 2000 Introducing Our New Welding Products

152T 155T Two Stage Regulator Two Stage Regulator

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152L 152S Line Regulator Station Regulator

153M 196 Manifold Regulator Duat-Flowmeter Regulator SO 9001 CERTIFIED " UL LISTED PRODUCTS GENERICO products are produced, assembled, and tested by an experienced and dedicated work force that is committed to the highest standards of product integrity Balloon Regulator / and excellence consistent with our ISO 9001 certification and UL listed products. \ T" )UR MAIN EMPHASIS IS ON VALUE

230HGMYA THE HIGHEST QUALITY AT THE LOW PRICES! Mylar Balloon Gas Saver Regulator Quality and price must speak for themselves, so we encourage your inquiry. See for yourself why - the world over - more and more professionals are using GENERICO products. rilE BEST WARRANTY IN THE BUSlNES~ Flashback Arrestor TWO YEAR "OVER THE COUNTER REPLACEMENT" WARRANTY All GENERICO manufactured welding apparatus and equipment is warranted to be free from defective material and workmanship for a period of two years from the date of purchase. 162L 3ROAD PRoDUcT SELECTIOI~ Regulators Welding Apparatus Welding Accessories • Single Stage • Torch Handles • Electrode Holders • Two-Stage • Cutting Attachments • Ground Clamps • Station • Cutting Torches • Cable Connectors, • Line • Machine Torches Lugs & Splicers • Manifold • Air Torches • Chipping Hammers Air Torch MC200 • Flowmeter & Flow Gauge • Welding & Heating Nozzles • Magnetic Holders • Piston • Cutting Tips * Tip Cleaners & Drills • Balloon • Flashback Arrestors • Spark Lighter • Check Valves • Welding Goggles

Tweco Electrode Holder Ground Clamp GENSTAR TECHNOLOGIES CO., INC. PRODUCTS ALSO AVAILABLE FROM 4525 Edison Ave • Chino, CA 91710 THE FOLLOWING WHOLESALERS: Tel: (909) 606-2726 • Fax: (909) 606-6485 • UnitedAmerican Sales, Inc (U.AS.) Wilmington,OH 800-421-7081 Website: www genstartech corn • WestgateSales Corp., Oakland, NJ 201-337-0024 • Doyle'sSupply, Inc, Decatur,AL 800-633-3959

20-1710~5 -~_ Circle No. 17 on Reader Info-Card Welding Goggle Filter Plate "Pros Who Know... Go GENERICO "" Aws

AWS D I. I CODE WEEK The #1 selling welding code now comes alive in a five-day seminar that begins with a roadmap of D1.1:2000, Structural Welding Code -- Steel This is your opportunity to learn from an expert AWS instructor and ask your toughest questions about DI.1. Code week continues with corresponding subjects geared toward engineers, supervisors, planners, welding inspectors and welding technicians. Since your work is based on a reputation for reliability and safety, you want the latest industry consensus on prequalification. If you want to improve your competitive position by referencing the latest workmanship standards, inspection procedures and acceptance criteria, you won't want to miss this seminar! Each day will be in-depth and intense.

(Day 1, Monday) D I. I Road Map (Day 4,Thursday) Fabrication Houston, Tex.-- January 29, 2001 San Francisco, Calif. -- March 5, 2001 Houston, Te~ -- February 1, 2001 San Francisco, Calif. -- March 8, 2001 St. Louis, Mo. -- April 9, 2001 Chicago, Ill. -- July 16, 2001 St. Louis, Mo.- April 12, 2001 Chicago,Ill.- July 19, 2001 Las Vegas, Nev. -- September 17, 2001 Atlanta, Ga. -- November5, 2001 Las Vegas, Nev.-- September 20, 2001 Atlanta, Ga. -- November8, 2001 (Day 2, Tuesday) Design of Welded (Day 5, Friday) Inspection Connections Houston, Tex.-- February 2, 2001 San Francisco, Calif. -- March 9, 2001 Houston, Tex.-- January 30, 2001 San Francisco, Calif. -- March 6, 2001 St. Louis, Mo. -- April 13, 2001 Chicago,I11. -- July 20, 2001 St. Louis, Mo. -- April 10, 2001 Chicago,Ill. -- July 17, 2001 Las Vegas, Nev. -- September 21, 2001 Atlanta, Ga. -- November9, 2001 Las Vegas,Nev. -- September 18, 2001 Atlanta, Ga. -- November6, 2001 Prices (Day 3, Wednesday) Qualifications Member Nonmember (One-day seminar) $345 $420 Houston, Tex. -- January 31, 2001 San Francisco, Calif. -- March 7, 2001 (Entire week) $795 $870 St. Louis, Mo. -- April 11, 2001 Chicago,Ill. -- July 18, 2001 Las Vegas,Nev. -- September 19, 2001 Atlanta, Ga. -- November7, 2001 UPCOMING CONFERENCES

AWS 5th ROBOTIC ARC WELDING including preheat and peening. Other areas covered include the CONFERENCE AND EXHIBITION best use of ultrasonics and Charpy tests, plus the lowdown on February 5-6, 2001 -- Orlando, Fla. new test options. This intense day-and-a-half program covers This conference is aimed at welding engineers and technicians, cracking in steels, aluminum, stainless steels and titanium. manufacturing specialists, managers and all others concerned with the latest developments in the fast-changing field of arc THE CUTTING OF PLATES CONFERENCE welding robotics and associated topics. Particular emphasis is July 17-18, 2001 m Chicago, II. given to case studies of actual applications in motorcycle, ship For decades, the only plate cutting method was oxyfuel cutting. and heavy equipment manufacturing, and on criteria used in It is still used, but we are seeing much more plasma cutting, high- robot selection. Other areas covered include the impact of the definition plasma cutting, water jet cutting and both CO 2 and Internet, fixturing, off-line programming, remote monitoring, YAG laser cutting. Many companies are in a turmoil deciding computer interfaces with welding cells and metal arc welding. A which way to go. This conference will provide engineers with an special activity is a luncheon featuring a keynote speech on the understanding of this whole matter. They will gain knowledge present status of robotic welding. about the cost of equipment, the payback, cutting performance, and they will return home with valuable information that can be WELD CRACKING: implemented profitably into their company's production lines. CAUSES AND CURES CONFERENCE This conference will cover mostly steel, but there will be some June 7-8, 2001 -- Houston, Tx. mention of stainless and aluminum. Topics covered: laser Hydrogen-induced cracking isn't the only culprit that engineers cutting, plasma cutting, high-definition plasma cutting, water jet and QC professionals need to be on the alert against. AWS cutting, innovations in oxygen cutting. experts will identify other, often unknown or overlooked cracking scenarios, along with the best use of counteroffensives,

F or further information contact: Conferences, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126, Telephone: (800) 443-9353 ext. 223 or (305) 443-9353 ext. 223, FAX: (305) 443-1552. Visit the Conference Department homepage Ihttp://www.aws.org for upcoming conferences and registration information.

16 I DECEMBER 2000 E

Think of Us '....

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: .. :2 ...... " Industry General Tool Awarded Contract to Build Friction Stir Welding Machines

Lockheed Martin Space Systems, Michoud Operations, New Orleans, La., recently awarded a multimillion dollar contract to General Tool Co. (GTC), Cincinnati, Ohio, to design and build three friction stir welding machines. The machines, the largest ever built, will be used to weld the large 2195 aluminum-lithium alloy panels that form the external fuel tank for the space shuttle. The first machine is scheduled for delivery in July 2001, with the other two machines scheduled for delivery in September 2001. GTC will also install the machines and assist Lockheed Martin during the training phase of the project.

Acute Technological Services Moves into New Facility Acute Technological Systems recently moved into this new facility in Acute Technological Services, Inc., Houston, Tex., recently Houston, Tex. moved into a 27,000-sq-ft facility on the west side of the city. The company, which primarily focuses on the offshore industry, pro- Oerlikon welding consumables. vides welding engineering consulting, testing and specialty fabri- Housed in the new facility are several orbital gas metal arc cation services. It also serves as the U.S. stocking agent for welding stations, as well as stations for gas metal arc, shielded metal arc and submerged arc welding.

Air Liquide America Announces Plan to Improve Profitability

Air Liquide America Corp., Houston, Tex., recently announced a plan to improve profitability in the United States. The plan concentrates on the company's small- and medium-size industries (merchant) business segment, which represented 43% of its total U.S. sales of $1.4 billion in 1999. The plan is expected to improve operating margins by five points while reducing capital employed by about $100 million within two years. Key components of the plan follow: • Air Liquide America will divest its retail outlets. • The company will continue to manufacture and distribute industrial welding gases, but it will service its small and retail cylinder gas customers through a new distributor network called ALNET. It will continue to service large cylinder customers, con- centrating on selling welding and cutting gases to this market, but hard goods will be provided through ALNET. • The company will no longer directly resell welding hard goods once the divestitures are complete. The products will be available to all Air Liquide America customers through ALNET. The company expects the transition to be completed in the tg second quarter 2001. No interruption of service is expected.

Project to Develop Lower Cost Linear • auxiliary board fi~r 4-quadrant Friction Welding Machine converters, parallel SCRs and • fused power sequence reversing controllers transformer • regulator board (or battery charging An international project is working to reduce the cost of linear friction welding equipment. The project has a budget of 1.25 and electr~,-cbemical p~wer supplies variable frequency and 12-pulse firing boards million Euro and is partly funded through the European also available! Community's CRAFT initiative. Enerpro Inc., 5780 Thomwood D~ , Go~eta, CA 98117 Black Equipment is coordinating the project, which is being In CA 805/683-2114 Fax 805/964-0798 managed by TWI, both from the United Kingdom. Klaus Raiser www.enerpro.thomasrwister.com enerpro@aoLcorn and Harms & Wende from Germany, Dartec and ABB Alstom

Circle No. 12 on Reader Info-Card 18 I DECEMBER 2000 Power from the U.K., Deltamatic of Italy and Technische Universit~it Graz from Austria are the other members of the con- sortium. In linear friction welding, two surfaces are rubbed together in IS THE LACKOF A CWl an oscillating fashion. A variety of complex shapes can be joined and the process has been applied to a wide range of alloys, KEEPING YOU FROM including titanium, stainless steel, aluminum and intermetallics. However, high capital costs have hindered its use in industry. REACHING THE NEXT LEVEL? TWI LinFric 'M has trademarked a prototype machine, which NO PROBLEM. incorporates ways for more efficient use of power sources and stored energy concepts, which should lead to reductions in equipment price.

Street Rod Project Concludes First Phase

The first phase of the Miller Electric Mfg. Co. traveling street rod seminar series concluded with installation of a stainless exhaust system at the Good Guys 7th Southeastern PPG Nationals in Charlotte, N.C., in October. Since May, the company has held a series of hands-on seminars and demonstrations at regional and national street rod shows. In 2001, the seminars will continue at street rod shows and will focus on additions to the 1931 Ford Coupe's interior. Miller Electric district managers Wayne Reece and Jim Ne will demonstrate how to install power windows, air conditioning, a motorized trunk and flush-mounting doors.

The Hobart Institute offers two-week courses Wayne Reece demonstrates installing steel inserts into the street rod to help you prepare for the Certified Welding at the Street Rod Nationals in Louisville, Ky. Inspector and Educator exams. While a very high percentage of our students pass, those who As work on the car progresses, seminar attendees learn about don't can retum within six months free of charge: the different types of welding and plasma cutting equipment required during every step of construction. They can also ask REGISTER NOW FOR ONE OF THESE questions about their own projects and try out equipment. UPCOMING TWO-WEEK SESSIONS: For more information regarding the street rod project, con- NOVEMBER 6 • DECEMBER 4 ° JANUARY 15 tact Wayne Reece at (502) 239-4488. MARCH 12 • APRIL 16 ° JUNE 4 • JULY 23 INEEL Researchers Create Strong Magnets Call 1-800-332-9448 with Miniscule Structure or visit www.weldingAgg

Researchers at the Department of Energy's Idaho National Engineering and Environmental Laboratory (INEEL) recently discovered a way to make magnets used in computer hard drives and motors more powerful and durable while cutting their manufacturing costs. Scientist Dan Branagan discovered slight changes to the standard format for these magnets produces stronger magnets that can withstand high manufacturing temperatures. High heat usually transforms these rare earth magnets into worthless hunks of HOBARTINSTITUT] metal. Branagan worked in collaboration with researchers from OFWELDING TECHNOLOGY 1.~ Ames Laboratory in Iowa and Brookhaven National Laboratory in New York. *Some restrictions apply Please contact the Hobart Institute for details. © 2009 Hobart Institute of Welding Technology Magnets are a composite of thousands of miniature magnetic State of Ohio Registration No. 70-12-0064HT fields. Tiny crystals, or grains of metal, form a magnet. Circle No. 18 on Reader Info-Card WELDING JOURNAL I 19 ARONSON POSITIONERS POSITIONING Made Easy

Now you can get Aronson positioning quality at a popu- lar price. Koike Aronson engineered in the accuracy, safety and reliability you've come to expect, but at a lower cost. MD (metric designed) two-ax positioners provide y with full continuous 3 bi-directional rotatiol and 135o tilt from horizontal. And, they're rated for full-load, non-stop us • 4 models to choos ...... • 1000 to 5000 kg capacities These tiny grains of metallic glass form powerful magnets more tem- • solid state variable speed rotation; dynamic braking perature resistant than most rare earth magnets. • anti-friction bearings for greater life and efficiency Your Koike Aronson distributor has all the details. Alignment of the grains affects the strength of the magnet. At INEEL, they form magnets composed of grains so tiny each one --~ KOIKEARONSON is too small to host more than one direction of magnetic field. 635 West Main Street The researchers found adding extra elements to the mix of rare Arcade, NY 14009 earth elements improves temperature resistance and magnetic field strength. The extra elements improve the magnet by forming nonmetallic compounds. The researchers also added another important step, creating a metallic glass. Circle No. 22 on Reader Info-Card mtrooucine. Thl Industry Notes • Ford Motor Co., recently named BOC Gases, Murray Hill, SNAKEHUGGEI N.J., as one of its Top 33 Industrial Materials Suppliers. The DELlUmmzv)L company received the highest performance rating of any industrial gases supplier in Ford's supplier evaluation program and has won Ford's Q1 certification for quality, service and customer satisfaction. J~~i~ii I • Cincinnati Thermal Spray, Inc., Cincinnati, Ohio, recently developed and filed for a patent on a process that enables fused coatings to be applied reliably and economically to noncylindri- IOt ~ ~L£(-.Lk~ '~ cally shaped parts. Usual practice for irregularly shaped parts is to fuse them in a protective atmosphere furnace. The company's 6 invention eliminates the need to perform the fuse operation in a heat treat furnace with a protective atmosphere. • Sellstrom Mfg. Co., Palatine, I11., recently acquired an

equity interest in XELUX TM and will be marketing the European company's autodarkening filter in the United States. XELUX produces waterproof, solar-powered, lightweight, autodarkening welding helmets, as well as several models of manually variable filters.

Correction

! Please note that in the article titled Welding a Pathway to the Stars in the October 2000 Welding Journal, Figs. 2 and 4 were ' ~,,:!~e'," I.'c tp .SN.~r';'E ~L','2:~DE,q ,',o'r? switched. Also, CWI Services, an inspection and testing consulting business owned by CWI Lawrence E. Smetana, is located in Bloomingdale, II1., not Bloomington, as mentioned in the article. I. HUGGER,o The Welding Journal regrets the errors. Toll FnH~(I~F WIELt~GR le;~7)9~:;.~.,,4 ? i::~: )~11 ~,[~ , ,~'~ ~,, ,~ m~ ...... 2o I DECEMBER 2000 Circle No. 35 on Reader Info-Card ¸¸¸¸!ii~i!iiiii~!~!!iiiiiiiiii!~!~ili~i~ii~iii!i~i~i~ii~i~ii!i!i~ii!~iiii~i i~¸¸¸z ~i!ill ~ ii ~i ~

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0 TIG PRODUCT Industry Standard Air-Cooled & Water-Cooled Torches 0 TUNGSTEN GRINDER Patented Wet Grinder 0 TUNGSTEN ELECTRODES Meets AWS Specifications A BI C OR BINZE[ CALL NOW The World Leader!

FOR MORE INFORMATION Alexander Binzel Corporation 650 Research Drive, Suite 110 800.542.4867 Frederick, MD 21703-8619

Circle No. 1 on Reader Info-Card Modular Tool Changer Makes Maintenance Easy

The SW-150A modular tool changer has four easy-to-change modules: an air- Products actuated locking mechanism with ball- For more information, circle number on locking technology and position sensing Reader Information Card. proximity sensors; rhodium-plated, con- ical mating contacts that resist damage Robotic Welding Cell Boosts Productivity

The System 10 is a compact, preengineered robotic welding cell with a two-fixed- table welding workstation designed for small- to medium-sized parts that can be welded without reorientation. Features of the welding cell include a Fanuc Robotics ArcMate 50iL 3-kg, 6-axes robot and Fanuc FJ3 controller; the Lincoln CV-400 power source: Synergic 7 four-roll wire feeder: and LN-10 weld controller. The unit

from weld spatter and other airborne contaminants; a fluid/air module with self-sealing air and fluid ports and low pressure, high water flow rates for better transgun cooling; and a signal module with 19 rhodium-tipped contacts for longer life and stronger electrical connections. High-power contacts are easy to replace with a hex wrench. The fluid module's 1.7 Cv allows a 20% increase in water flow volume that helps reduce or prevent clogging. High acid pH problems associated with the available water supply are neutralized by a standard

ZICOR TM coating that protects the aluminum manifold from acid attack.

ATI Industrial Automation 101 Peachtree Center, 503D Hwy. 70 East, Garner, NC 27529

Turntables Ease Assembly Jobs has a complete metal surround flash and safety barrier and bifold safety doors with Powered and nonpowered turntables interlocks. An optional welding fume control hood and filtration system are can make repetitive jobs easier and re- available. The flexible automation capabilities of the System 10 make upgrading duce the risk of potential injury or acci- from various forms of arc welding processing easy. The small 66 x 90-ft footprint dent. The company's line of powered makes the unit forklift compatible and minimizes the amount of floor space needed. turntables comes in a variety of sizes and The workstation is assembled complete and shipped ready to install. styles: standard circular platforms, adjustable speed control, low and high pro- The Lincoln Electric Co. 100 file platforms, and weight capacities 22801 Saint Clair Ave., Cleveland, OH 44117-1199 from 2,000-10,000 lb. Its nonpowered, freestanding turntables can be manually pushed to put parts within easy reach of

22. I DECEMBER 2000 Brazing Technique Repairs Aircraft Engines compensates for the natural bevel inher- ent in plasma cutting. The plasma bevel The PreSintered Preform (PSP 'M) is head rotates the torch so that the same a combination of superalloy and braze side of the torch is used to cut on all sides powders that can refurbish the cold of the plate. A new tactile sensor system section compressors and superalloy hot maintains torch height from the workpiece and is not influenced by electrode wear. An improved collision protection system provides better protection for the torch in all lateral directions as well as on the vertical axis. The magnetic torch an employee, thus reducing fatigue and mount detaches the torch holder before potential accidents due to lifting, bend- the torch can be damaged; the mount can ing or twisting. Nonpowered turntables also be removed manually from its have a weight capacity of 2,000-10,000 bracket, making torch inspection and lb; standard square platform dimensions nozzle or electrode change easier. The range from 2 x 2-ft to 8 x 8-ft; circular plasma bevel system operates on ESAB's platforms are optional. Avenger series gantry.

Advance Lifts, Inc. 102 section components of aircraft engines. ESAB Welding & Cutting Products 105 701 Kirk Rd., St. Charles, IL 60174 PSP restores distorted and worn airfoil 411 S. Ebenezer Rd., Florence, SC 29501-0545 contours to its original shape; it can be Air-powered Arc Welding Reel used to repair airfoil throat reduction Laser Head Opens for Easy Handles High Amps and dimensional restoration of high- Maintenance pressure turbine nozzle guide vanes. The Series AWCR reel is a heavy- The product eliminates shrink The S-Series family of CW diode- duty arc welding reel designed to handle depressions, minimizes post-braze pumped solid-state laser systems has ex- cable current of up to 400 A. The reel grinding, and removes the need for panded on the Stiletto laser system. The rebraze cycles. has a rotary electrical device that can be instantly used with any unwound cable length. The AWCR chain and sprocket Morgan Advanced Ceramics 104 drive is powered by a compressed air 582 Monastery Dr., Latrobe, PA 15650

Bevel Head Produces Better Edge Quality

A new programmable plasma contour bevel cutting head enables better plasma beveling on gantry shape-cutting ma- new unit has multiple triggering options and field-replaceable components. The unit delivers up to 50-W CW, or can be AO Q-switched from 1-50 kHz, deliver- ing up to 35 W. Several models are available, including a TEM °° unit.

Cutting Edge Optronics, Inc. 106 20 Point West Boulevard, St. Charles, MO 63301 motor and includes a standard auxiliary rewind. The reel is designed for use with Water Saver Monitors up to single conductor electrode cable or Eight Weld Guns grounding lead. Provision is made for connection to the welding machine. The IntelliFlowTM III Water Saver features remote control bypass, line restart, Hannay Reels 103 and shutdown. The IntelliFlow monitors 553 State Route 143, Westerlo, NY 12193-0159 chines. The new torch station, working supply and return lines to detect leaks as with the CNC controller, automatically small as -+3% of the monitored flow rate

WELDING JOURNAL I 23 while compensating for normal pressure ference between supply and return flow fluctuations and the robot's dynamic mo- rates only. The water saver automatically tion. The entire water circuit, not just the shuts off the water flow within 0.4-0.7 s weld gun tips, is monitored via a built-in for gun tip removal. When finished, the microprocessing sensor method. Hose system can be reset. Automatic setup and configuration, mineralized waters and monitoring is one-touch, with continu- pressure drops will not cause a line shut- ous visual feedback on an easy-to-read f off because Intelliflow measures the dif- LCD screen. The system also has an op-

tional DeviceNet TM interface.

DE-STA-CO Industries 107 31791 Sherman Drive, Madison Heights, MI 49071

High-Temp, Inert Atmosphere Furnace Handles Heat Treating Jobs

No. 854 is a special high-temperature, 2200°F electrically heated, inert atmosphere floor furnace; the maximum operating temperature is provided by 53 kW from heavy-gauge, high-temperature Kanthal AF alloy wire and rod overbend design heaters. The furnace features 9- in. insulated walls and 2-in. thick block

Take the road to technology with Jetllne

Jetline's new optical seamtracker incorporates the ~very latest technology to provide you with the simplest solution to your seamtracking problems.

A new low price brings this product into everyone's price range. Laser tracking solves all those difficult tracking problems: insulation. A firebrick plate hearth is Tackwelds - No problem supported on firebrick piers. An electri- Tight joints - We can handle cally operated vertical lift door is pro- High speed - Virtually no limit vided, with remote foot pedal control. Special inert atmosphere construction Contact Jetline - let the company with the highest on the unit includes a continuously technology in hard automation bring their knowledge welded outer shell, high-temperature and technical expertise to solve your needs. door gasket, sealed heater terminal boxes and inert atmosphere inlet, outlet and flowmeter. Safety and control equipment include a digital indicating temper- ,jet.n,llngi eei g, ature controller, manual reset excess temperature controller with separate contactor, and a four-channel strip chart recorder.

The Grieve Corporation 108 1540 E. Dundee Rd., Suite 250, Palatine, IL 60074-8311 Circle No. 21 on Reader Info-Card

24 I DECEMBER 2000 Power Source and Robotic Interface Combined in current tasks (three robot motion jobs, One Package one external axis motion job, and two I/O instruction jobs). The XRC combines The Auto InvisionT"II is a robotic simple programming with dedicated arc GMAW/pulsed GMAW power source welding functions and advanced fea- that incorporates the Invision TM 456P tures, including multi-axis control capa- wire welding power source with the bilities. Customized application programming packages are available for arc b.. g welding, as well as dispensing, material cutting, jigless (dual robot), material of a personnel carrier vehicle and to as- handling, painting, spot welding, or gen- sist in the testing of prototype stability eral-purpose applications. The XRC of- and structural analysis. The tilt table can fers standard networks for Device Net, be tilted up to 45 deg in one direction Profibus-DP, and Interbus-S for connec- and up to 40 deg in a secondary direction with infrastructure. A built-in tion. The table allows a running person- PCMCI card reduces installation and nel carrier to be tilted in order to moni- system upgrade time. With Ethernet tor and starvation test a vehicle's fuel and TCP/IP capability, the XRC offers high- lubrication system. speed networking capability with a PC. Robotic Interface TMII into one package. Pentalift Equipment Corp. 111 The unit provides up to 600 A of weld- Motoman, Inc. 110 P.O. Box 1510, Buffalo, NY 14240 ing output (450 A at 100% duty cycle) 805 Liberty La., W. Carrollton, OH 45449 and has a 230/460-V or a 575-V, 60 Hz Walk-in Ovens Heat Heavy input. The Auto InvisionTMII provides Tilt Table Assists Testing Applications standard programs designed for commonly used materials and shielding gas A dual-direction tilt table has been A comprehensive line of 24 heavy- types. The "one box" solution eliminates designed to facilitate off-center testing duty walk-in ovens suitable for heavy external cabling and connectors between the power source and the robotic controls. A standard quick-change connec- tor make adaptation to robots easier, and an optional hi-flex cable is available for applications with complex robotic mo- tions that can put stress on standard cables. Electrode Grinder Miller Electric Mfg., Co. 109 1635 W. Spencer St., Appleton, W1 54912-1079

Robot Controller Handles Multiple Tasks

The XRC controller can control up to three robots (or 27 axes), allowing for independent job control for up to six con- HEAVY DUTY TUNGSTEN GRINDER FOR 3116" - . 040" ~LgETY: Enclosed diamond wheel grinding area QUM,ITY: 20 Ra finish improves tungsten life, starting & arc stability PRODUETIVITY: Longitudinal diamond grind your tungsten under 30 seconds YAI,I~ Diamond flat, grind & cut your tungsten economically

DIAMOND GROUND PRODUCTS (~ 2550 Azurite Circle, Newbury Park, California 91320 .~-. Phone (805) 498-3837 • FAX (805) 498-9347 Email: [email protected] • Website: www.diamondground.com

Circle No. 11 on Reader Info-Card

WELDING JOURNAL I 25 round bar. Utilizing neodymium magnet material, the NEO-250, NEO-500 and NEO-1000 are designed for use in steel, supply, machine and die shops where heavy steel objects must be moved rapidly and safely.

O.S. Walker 113 Rookdale St., Worcester, MA 01606 ment sensor features ranges to fit all weld load applications like heating heavy cast- machines and requires two shoulder ings prior to welding is available. The Lens Mounts Prevent Damage bolts for mounting. The meter provides ovens offer maximum temperatures to four programmable limits with relay con- 450°F (232°C), 650°F (343°C) and Lens Savers ® lens mounts have been tacts (AC or DC) that interface directly 750 ° F (398 ° C), and work area capacities developed for Trumpf L3030 and IA030 to your weld controller, PLC or quality of 96-360 ft 3. Both gas and electric lasers with 5.0- or 7.5-in. focal lengths. system. Relays can also control light heated versions are available, and stan- The Lens Savers ® are placed in front of posts to provide instant visual display of dard features include digital tempera- the focusing lens in CO 2 lasers to help weld quality status. A serial interface ture control, adjustable air ducts and alu- prevent damage to focusing lenses (RS232 or 485) allows data to be down- minized steel, interior, triple-hinged caused by the sparks, smoke and spatter loaded directly into a spreadsheet on a nonsag doors. unleashed during laser beam cutting or remote computer, providing permanent welding. The patented mounts and traceability for each weld. Precision Quincy Corp. 112 adapters enable use of the Lens Savers ® 1625 W. Lake Shore Drive, Woodstock, IL 60098 with high pressure. Sensotec, Inc. 115 2080 Ariingate La., Columbus, OH 43228 Lightweight Magnets International Crystal Laboratories 114 Lift Big Loads 11 Erie St., Garfield, NJ 07026 Single-Pass Deslagger Cuts Clean The NEO-500 weighs just 42 lb but System Monitors Nut can lift a 1100-1b steel plate or a 550-1b Weld Quality The single-pass carbide deslagging machine deslags one or two sides of oxy- The company offers a weld quality fuel-cut parts quickly and without using monitoring system consisting of an in- abrasives, leaving a clean surface. The dustrial-duty linear displacement trans- machine eliminates hand chiseling and ducer (LVDT)and the Model WM9100 grinding of slag from plasma or oxyfuel- weld meter. This system can detect miss- cut parts. By using a roll with floating ing or upside-down nuts or studs, mea- carbide inserts, standard widths of 39, sure weld "set-down," determine correct 55, and 78 in. are available. This machine part dimension before welding, and is capable of handling many cutting ta- monitor tool wear. The LVDT displace- bles and is equipped with motorized in- feed and out-feed tables. Parts can be fed directly from the cutting table with thicknesses ranging form 0.200 to 3 in., while the speed ranges from 12 to 240 in./min. There is a built-in auto-warpage COR MET compensation feature. The EM machine can deslag for such applications as agri- SPECIALTY CORED WIRE cultural, vessel, service centers, and any- AND COATED ELECTRODES where oxygen cut deslagging is required.

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Circle No. 8 on Reader Info-Card

26 I DECEMBER 2000 E NEED A OOD WOMEN! and Vice Presidents Only

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Visit our website http://www.aws.org A collaboration between manufacturers and educators in southwestern Pennsylvania provides free entry-level welder training

BY MARY RUTH JOHNSEN

n ordinary Saturday morning. You drive over to Eat Manufacturers Make Their Needs Known 'n Park and slide into a booth. The waitress flips over A a white crockery mug, pours you a cup of coffee, then The genesis for New Century Careers was a series of meet- hurries off to turn in your order. You take a sip, look down at ings in the mid-1990s between executives from manufacturing the place mat to see who the Charleroi Cougars will be playing companies in Pittsburgh and the Mon (Monongahela) Valley Friday night and see something that just might change your life and Barry Maciak and Silvio Baretta, partners in World Class -- an ad on the upper left-hand corner offering free welder and Industrial Networks, a consulting firm whose clients include machinist training. "Get the free training that gets you the job," Duquesne University and New Century Careers. Maciak serves it says. You decide to call the 800 number. as executive director of the Institute for Economic Transforma- Sound farfetched? Well, the free training is currently avail- tion, part of Duquesne's business school. Through the Institute, able to workers in southwestern Pennsylvania through a Pitts- the two men brought companies together to talk about their burgh-based nonprofit organization called New Century Ca- common issues, foremost of which was the work force. reers (NCC), the result of a collaboration between area Originally, most of the talk centered on the need to improve manufacturers, vocational schools, community colleges, the the skills of workers the companies already employed. '~round business school at Duquesne University, the University of Pitts- three years ago," Maciak said, "we started to see that conversa- burgh's Manufacturing Assistance Center, and with funding in tion change. A lot of the conversation focused on 'I can't find part from local foundations. The place mat ads are just one of good, quality, entry-level employees,' particularly in some of the the marketing tools being used to recruit students. most critical occupation areas like welding and machining." The training, textbooks and other materials are provided to "It used to be people could go into manufacturing with no the students at no cost on condition they make every effort to skill and get a good job," Baretta said. "That's not true today." take a job with one of the member companies. "This program is Getting new people in the door soon took priority over the all about getting a job," explained Paul Anselmo, NCC presi- need to train and advance incumbent workers. dent. "If you're not interested in getting a job, don't come into Although many of southwestern Pennsylvania's largest em- this program." ployers have left the area or reduced the size of their work force,

MARY RUTH JOHNSEN ([email protected]) is Features Editor of the Welding Journal

WELDING JOURNAL I 29 manufacturing still accounts for 15.9% of private-sector jobs in the 13-county area, according to figures from NCC. That translates into 162,633 jobs, making manufacturing the second-largest private sector employer in the area. And 44% of Pittsburgh's industrial manufacturing base is still related to metalworking, Maciak said. From these dialogues, a group of 17 manufacturers was established to address the emerging work force cri- sis. "One of the first things we asked them when we got to training was 'Who do you turn to to provide training in welding and machining?'" Maciak said. "Who's your best source for training locally?" The companies di- rected Maciak to the Steel Center Vocational-Technical School in Jefferson Hills, Pa., and Anselmo, then the school's adult education coordinator. The manufacturers identified entry-level machinists as their greatest need. Anselmo and others developed a curriculum for training machinists and in 1998 a pilot program called Manufacturing 2000 was set up with the goal of training 20 machinists and placing them in jobs. "We almost immediately geared that up," Anselmo recalled. "We realized that putting 20 machinists or 20 welders or anything else out in the street in one year isn't going to make any kind of an impact, so we immediately set out to increase that." Anselmo eventually left the public school system to become president of New Century Careers, which was in- corporated in April of this year. After machinists, the manufacturers identified welders as their next greatest need, so a pilot welder training program was established through area community colleges in 1999. Welder training became part of NCC with the spring/summer session. Each term, Anselmo said, the program has expanded. The current fall/winter session offers 10 classes in eight locations in four counties. The number of participating manufacturers has also grown from the initial 17 to more than 80. A student enrolled in the New Century Careers program at Westmoreland County Community College practices his welding skills. Finding the Students One element that distinguishes NCC from other programs is its use of a professional direct response marketing firm, Elliott Marketing Group. John and Jane Elliott liotts utilize direct mail; the list is now self-generating from peo- have worked with NCC since the initial machinist pilot project, ple who have responded in the past but for whatever reason did and are responsible for all recruitment and fulfillment activities. not enter the program. They advertise in a wide variety of media, All of NCC's recruiting efforts include a toll-free telephone from newspapers to billboards to bus shelters to inserts that can number. Within 24 hours after receiving a call, an information be placed in church bulletins, as well as the restaurant place packet is sent via first-class mail to the caller. "The package in- mats. The program has also benefited from news stories from cludes a complete description of the program," John Elliott ex- local newspapers and television stations. plained. "The call to action is to reserve a place in a seminar or The Penny Saver, a free, weekly shopping guide, produces the to actually sign up to test for the program." If they desire, single best results, according to Jane Elliott, followed by the prospective students can also sign up for the information semi- Green Sheet, another free publication distributed through local nars when they make their initial call. For the fall sessions, NCC grocery stores. Other community newspapers, shoppers and fly- personnel held 32 seminars explaining the program. ers are also effective, she said. The restaurant place mats, church Follow-up is vital. "If we send an information package and they bulletins and some of the other methods produce a small, but don't sign up for a seminar, we follow up," John Elliott said. "If they steady, trickle of leads. don't show up at the seminar, they receive a call. If they come to the New Century Careers had been relatively unsuccessful in at- seminar but don't sign up, they receive a call." He likens the re- tracting African-Americans to the program until recently. While cruiting effort to a funnel. For instance, for this fall's classes be- respondents are never asked questions regarding race or ethnic tween 2500 and 3000 responses were needed to fill the 200 avail- background, the Elliotts do make use of demographic informa- able spots, John Elliott said. About 10% of the people who respond tion. Leads from predominantly African-American neighbor- apply. Of those, about half take the screening test and enter the pro- hoods are passed on to Ken Nesbit, an NCC employee respon- gram. It costs approximately $750 to actually acquire a student, he sible for outreach in the African-American community. Nesbit explained. "For every dollar we spend generating a lead, we spend speaks to community organizations and works one-on-one with one to two dollars to follow up on that lead." prospective students. "One of Ken's key roles is to explain this Over the past eighteen months to two years, about 6000 re- isn't another program to train African-Americans for jobs that sponses have been received through a variety of means. The El- don't exist," John Elliott said.

30 J DECEMBER 2000 Through Nesbit's efforts and working with established media such as the New Pittsburgh Courier, probably the oldest African- American newspaper in the United States, more African-Amer- icans are entering the program.

The Welder Training Program Still in its infancy, New Century Career's welder training program is constantly being tweaked to make improvements, Anselmo said. Welder training consists of 400 hours over a 15 or 16 week period; machinist training is 525 hours. Class hours differ at each site, but most are in late afternoon and evening. At least once each term, the students are taken on field trips to visit manufacturers and see what their working life might be like. Stu- dents taking classes at the community college sites earn college credits. Prior to entering the program, students take a screening test that evaluates their verbal, mathematical, mechanical reasoning and problem solving skills. They must also present two letters of recommendation. New Century Careers is not involved with re- medial education, although Anselmo works with other agencies that can provide that type of help. Students typically are 24 to 30 years old. While some are displaced or otherwise unem- ployed workers, many are currently employed. For instance, seven members of the pilot machinist training class either made or delivered pizzas. The welding course covers welding safety, fundamentals such as the types of joints, blueprint reading, oxyfuel cutting and the shielded metal arc, gas metal arc and gas tungsten arc welding processes. Students learn to weld in the fiat, horizontal, vertical and overhead positions. Henry Cabrera, one of the instructors at Westmoreland County Community College (WCCC), said they aim for the students to spend about 90% of their time in the welding lab and Fig. 1 --All five members of the inaugural NCC welding class at 10% covering theory. Students demonstrate their competency Westmoreland Community College have now graduated. Shown in one area before advancing to the next level. standing from left to right are Nick Danser, Eric Calgagirone, John At the end of the program, students take certification tests C. Cortese, Jr., and Rick Kurdilla. Kneeling are Steve Jordan and according to the requirements ofAWS DI.1, Structural Welding instructor Henry V. Cabrera (in red). Code -- Steel. While passing the tests is not a requirement for graduation, certification is a strong selling point to prospective employers, Anselmo said. "We recognize that most manufacturers now are looking for some real industry standards, not just the educational curriculum," he said. college credit was a plus for him. Rick Kurdilla, a displaced steelworker who had worked as a welder many years ago, said he viewed the program as an opportunity to catch up on any Starting the Program at Westmoreland County changes in technology that had occurred since his welding days. Community College He also welcomed the opportunity to earn college credits. While the students praised the welding lab at the school, The inaugural class at WCCC started with the spring/sum- which is housed in a new facility, and instructor Cabrera, most mer session and consisted of five students -- Fig. 1. (Typically, expressed some concerns regarding being the guinea pigs for the NCC classes include 15-20 students.) All five students first con- program at Westmoreland. Some textbooks and materials had tacted NCC after seeing an ad in a community newspaper or been late in arriving and they felt they'd had too many instruc- shopper, although student John Cortese first learned of the pro- tors. "We've had four different teachers," Jordan said. "I think gram through his mother-in-law who works at the Community it should be narrowed down at least to two." Anselmo countered College of Allegheny County, another NCC site. that since it is an accelerated course, more than one instructor The students entered the program for a variety of reasons. is usually needed to teach it; however, he acknowledged some Although he'd never welded before, Cortese had observed the changes may need to be made. welders at factories he'd worked in and became interested. "I "I was in a guinea pig class myself, and it had some straight- have the feeling I can find a long career in welding," he said. ening out to do," Cabrera said. "These guys, in fact, will be bet- "I'm not interested in job-to-job. I'm looking for a career." Steve ter prepared to be in the field because of the adversity they've Jordan had taken welding classes in high school and had in- overcome. Right now they have a legitimate beef and complaint tended to enter the regular welding program at WCCC after because of some of the things that haven't worked out, but out graduation. However, he changed his mind and took a job. Jor- in the field they're going to run into problems like that, too, and dan viewed the NCC program as a way to get back into welding. they're going to be better prepared to handle it and be able to Nick Danser said he joined the program because of its offer of adapt, improvise and overcome." At the time this article was free training and promises regarding job placement. Eric Cal- being written, all five class members had graduated and were in- gagirone's goal also was for a good job with benefits. Earning terviewing for jobs.

WELDING JOURNAL I 31 job fair and students are not allowed to leave the program or be Job Placement placed in a job prior to the job fair. The companies can attend any or all of the job fairs, although many attend only the ones at Another of the distinguishing features of the New Century the training sites closest to their plants. Careers program is the level of accountability for each party. New Century Careers agrees to recruit, train and help place the students. The member companies agree to serve as advisors to What's Next for New Century Careers the program, open their facilities for field trips and to pay $1250 to NCC for each student they hire that passes a three-month Through surveys of the manufacturers in the region, Maciak probationary period. "I don't think we'd be doing this if the said, they know 1500 to 2000 new welders a year are needed just manufacturers wouldn't be contributing to it," Maciak said. to sustain the business economy as it is, let alone allow compa- "And not just in paying for the graduate, but in their time and nies to take on additional work. "We have the capacity to grad- energy and helping us to design and direct the program." The uate and place 200 to 300 students annually right now," he said. $1250 mostly covers recruiting and placement costs. Actual "We have to build that capacity to handle a couple of thousand training cost runs between $5000 and $7500 per student, Ma- annually, and in business you have to do that very carefully." ciak said. For NCC to produce large numbers of graduates, Maciak In turn, the students sign an agreement at the beginning of said, "The model we're using now can't remain the same, even their training in which they promise to attend at least 90% of all though it's successful. We have to change the way we do things classes, to show up at the job fair held at the end of each course if we really want to hit the scale that's going to help support the and to give NCC the opportunity to place them with one of the economy in the region." member companies, and that if they don't do so they will reim- In the meantime, plans call to gradually add more classes and burse NCC the same amount the member company would have training sites for the welding and machinist programs. New Cen- paid, $1250. tury Careers is also considering adding classes to train front-line Toward the end of each class, NCC personnel work with the supervisors and electronics assembly workers. It has also ob- students to hone their job search and interviewing skills and to tained a more than $1 million grant from the U.S. Department help them prepare r6sum6s. of Labor to provide advanced training to manufacturing work- Since so many companies were in need of entry-level em- ers. The money will be used to launch the Advanced Manufac- ployees, it was decided early on the fairest method to introduce turing Education program. • companies and graduates was through a job fair, Anselmo said. The companies get no information about the students until the

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Circle No. 25 on Reader Info-Card

32 I DECEMBER 2000 A Wise Method for Assessing Arc Welding Performance and Quality

Straightforward strategy antiquates trial-and- error methods

BY DENNIS D. HARWIG

raditionally, welding engineers, technicians T and operators are not taught a systematic strategy to develop procedures that produce consistent weld quality under the full range of production variations. When facing a new welding application, a common approach is to arbitrarily select a process (usually one already in use on The development of a comprehensive database of optimum weldingparameters for other applications) and values for certain welding specific applications has the potential for saving industry millions of dollars. parameters such as voltage, current and travel speed. Incremental adjustments are then made until a satisfactory weld is achieved. While the re- suiting procedure may be workable, it may not be robust enough processes for specific applications, this straightforward method to accommodate small changes in welding conditions or varia- provides a data set that relates functional welding parameters to tions in production factors, such as part mismatch, root opening productivity and weld quality. This data set provides a founda- variations, part cleanliness and torch offset, which may cause tion for selecting welding parameters and permits benchmark- the quality of welds to deteriorate quickly. When this occurs, ing of welding processes. In addition, because tests are per- there is often no clear direction toward the solution of the prob- formed under carefully controlled conditions, the data can be lem. stored for future use on similar applications and compared to The trial-and-error approach for developing arc welding pro- alternative processes. A database, which already contains de- cedures can be replaced with a systematic experimental strategy tails of nearly 100 applications, is currently being built by EWI. known as '~RCWlSE." Developed by Edison Welding Institute It is important to emphasize the ARCWISE experimental (EWI) and in use since 1996 (Refs. 1, 2) to assess arc welding method is best suited to evaluate and compare processes for a

DENNIS D. HARWIG is Manager, Arc Welding& Automation, Edison WeldingInstitute, Columbus, Ohio. (614) 688-5000.

WELDING JOURNAL I 35 plication, taking into consideration weld quality requirements. It also shows productivity capability compared to the level that will balance work flow in production. A major reason for the effectiveness of the method is that all test welds involve a constant ratio of deposition rate to weld travel speed. In this manner, the deposit area is kept constant while variations in tip-to-work distance, arc length, shielding gas and other factors are evaluated. ,.,7 In typical welding-related reference publications, it is common to find the following types of operational characteristics for consumable electrode processes: voltage vs. current, wire feed speed vs. current and deposition rate vs. current. Fig. 1 -- Bead shape photomacrographs for a GMA Wprocess (average deposit area Graphs showing these data often include the ef- = O. 0362 in.2). fects of electrode diameter, shielding gas, electrode extension and polarity. However, they ig- nore the effects of weld size and joint design, ~ ~,'~r)~ ~ contact tip-to-work distance and arc length. Therefore, these graphs are not "application rep- --! resentative," making it difficult for an engineer to select actual weld parameters. In contrast, the cr ARCWISE data set yields a set of graphs that can be used to define an operational window and se-

z ~ lect the best welding parameters. ~c The definition of an application is a set of fixed design factors such as base materials, joint type, 10 ~m position, weld size, bead shape and mechanical

Tmvll Speed properties requirements. The operational windows developed with this method are for a specific process-consumable combination that was evalu- Fig. 2 -- Bead shape photomacrographs for a FCA W process (average deposit area = 0.0342 in.2). ated on an application.

Applying the Method specific application. In contrast, statistical methods yield algo- rithms relating many factors and may be preferred when the re- The best way to illustrate ARCWISE is through example. lationships between process and production factors need to be Below are details from one application used in an ongoing pro- fully optimized. The statistical approach requires a high level of gram to develop an extensive database for user reference. expertise and is sometimes applied without a thorough understanding of the welding process, producing results that do not The Application reliably represent welding process behavior. The author be- lieves this systematic method identifies key relationships be- The gas metal arc welding (GMAW) and flux cored arc weld- tween process parameters and provides a solid foundation for ing (FCAW) processes were compared for welding T-joints on optimizing the relationship between process, design and pro- mild steel in the flat position. The base material was ~-in. SA36 duction factors. In other words, a systematic experimental hot-rolled bar sandblasted to remove scale. A ¼-in. fillet weld method is an ideal first step in optimizing the welding process was specified. for an application. The GMAW process was used with 0.045-in.-diameter This method is part of a broader program at EW! to develop ER70S-6 electrode and 80% argon-20% CO 2 shielding gas at a procedures and data that optimize parameter selection for arc contact tip-to-work distance (CTWD) of ¾ in. The FCAW welding applications. process was used with 0.078-in. E70T-1 electrodes and CO 2 at a CTWD of 1 in. All welds were made using a constant voltage Importance and Value of the Technique (CV) power supply rated at 600 A. From a relatively small group of 15-24 test welds, this Components of the Method method yields an integrated set of parameter relationships, corresponding weld bead shapes and graphical representations that The five elements of the method are as follows: describe operational and productivity capabilities of the weld- 1) Weld size and acceptance criteria ing process and filler metals being tested. Done properly, it ex- 2) Constant deposit area test matrix amines the full operating range of the process for a specific ap- 3) Constant arc length testing 4) Bead shape measurements 1. Note that filler metal deposit efficiency for FCA W is based on 5) Welding productivity windows-- voltage-current, voltage- wire outside diameter. wire feed speed and current-wire feed speed graphs.

36 [ DECEMBER 2000 Step I m Acceptance Criteria .-¢-- B uriid Arc Acceptance criteria for the application is the -.w-- l/S inch ~'c first thing that must be established. For this appli- 114 inch /~'¢ FCAW-ETTI- 1 .'0 ,-Mz~li a cation, it was as follows: 0.25 • No porosity greater than ~2 in. • No cracks. • No convexity greater than ~2 in. 0.2 • Depth-to-width ratio less than 2. / Step 2 m Constant Deposit Area Test 0.15 Matrix ---4 j ji~ .. •~- / 0.! The deposit area of a fillet is the triangular area j :/ __--4 based on leg size plus reinforcement. For welds this size (¼ in.), a reinforcement factor of 20% was selected to assure leg size with some convexity. Con- 0.05 stant deposit area tests are based on the volume balance between the wire feed speed (WFS), wire area (Aw), and filler metal deposit efficiencyO) (fd); and to the deposit area (DA), reinforcement fac- 10 20 30 40 tor (r) and travel speed (TS) where the WFS/TS Trawl Speed (ipm) ratio must be maintained constant as follows: GM AW-ERTI$ -If Cltndll~l.llllllli DAx TS x r = WFS x A w x fd 0.25

WFS/TS = (DA x r) / (Aw × fd) / For our examples: 0.2 /

WFSfFS0.045 = (0.03125 in.2 x 1.2)/

(0.00159 in.2 x 0.95) = 24.82 i O.l~i / ti I WFS/TS0.078 = (0.03125 in.2 x 1.2) / 0.I ,/ (0.00477 in.2 x 0.80) = 9.81 ¸"¸,¸% i

With the WFS/TS ratios established, a range of O .06 travel speeds is selected. Processes such as GMAW and FCAW in the automatic mode are typically tested from travel speeds starting at 10 in./min, e This speed represents a travel speed that can also 10 20 30 40 be applied semiautomatically. Travel speeds are in- Trawl Speed (ipm) creased in 5- or 10-in./min increments to build the constant deposit area test matrix. The goal is to bracket the entire productive range of the process Fig. 3 -- Forty-five-degree penetration vs. travel speed for two process combina- in 15-24 tests. The weld size determines the travel tions. speed test increments, Le., smaller welds would be evaluated with larger travel speed increments. The maximum speed may vary from 30 in./min for large fillet welds to more than 100 in./min for sheet welding applica- process. At each travel speed, three tests were performed to tions. evaluate each arc length. Arc length was set visually for the buried arc condition. A tungsten pointer was positioned in front of the electrode extension to set the ~- and V44-in. arc lengths. Note the set arc length was the observed distance between the Step 3 ~ Constant Arc Length Testing electrode tip and the surface of the workpiece. (The true arc Arc length test conditions are then determined for the ap- length depends on the weld pool size and shape, and arc pres- plication. Constant deposit area tests are performed at two or sure.) At high travel speeds and currents, the arc cavity was sub- three arc lengths to define the useful range for the process. Arc merged into the workpiece. Short circuiting often occurred lengths selected vary from the buried condition (apparent arc using the buried arc length at the lower wire feed speeds. length of zero) to arc lengths up to ¼ in. Contact tip-to-work distance, travel angle and work angle are Buried, ~-in. and Z-in. arc lengths were used to bracket the held constant for each set of tests. During each test, the voltage range of arc lengths that could be used with these processes. Test was adjusted to produce the desired arc length. Weld pool sta- travel speeds started at 10 in./min and were increased in 5- bility was observed and gross spatter or unstable weld pool be- in./min increments up to the maximum attainable speed for each havior was noted. After welding, the weld surface was inspected

WELDING JOURNAL I g7 shape image analysis was performed to measure I ---,4----. 0 u~ie d Ale leg length, penetration, undercut, deposit area -----8---- 1/'8 inch Arc and nugget area, etc. The measurements are then compared to the acceptance criteria for the ap- FCAW-ET7O-! Cembinatb: ~ 1/4 in©h Af© plication. 0.12 Figures 1 and 2 show the range of weld cross- 0.11 sections from this test series. Several observa- tions can be made from this analysis. 0.1 In general, penetration, nugget area and base metal dilution increased as the product- A 0.00 ivity increased for these ¼-in. fillet .~ 0.08 welds. The weld cross sections from each test set were arranged to illustrate how weld bead shape

38 I DECEMBER 2000 be possible with careful control of arc length. In contrast, the maximum produc- Process ClwactwisUcs Productivity VVmdows tivity for the GMAW process (Fig. 6) was * euded .~w • I/8" ko 25 in./min and 17 lb/h. In both cases, VoIhge N Qme~ VO~QO g~WFS .1/4" .-~ higher travel speeds are probably possible by further optimizing travel angle and 20il~m ~e~l ,,~-'~'1 work position for downhill welding. In -I I -~- t / I ~L• I -'.®'.-"*" general, the preferred arc length for this application was ~-in. At lower productivity levels of travel speeds from 10-20 in./min, the '/,-in. arc length also gave desirable bead shapes. Bead-shape analysis can also be performed and related to welding parameters C~(A,wun) for leg length, convexity, sidewall penetration, toe radius, etc., depending on the Ctsra~ nWke Feed Speed Ilmt ht )o~ion R~t~ application. The purpose of this example was to show by using the systematic ARC- t WISE method, significant knowledge can &- cl i; ,, ~L be developed for the welding process and g® I : application. I !

Conclusion i- The ARCWISE method provides a structured approach to characterizing welding process applications• The method Fig. 5 -- Parametric graphs for ¼-in. fillet welds using a FCA W process. develops relationships between welding parameters, productivity and weld quality. Welding procedures can be quickly developed for both semiautomatic and mecha- I ~ hrkdA~ [ nized welding applications by selecting the • ItgA[ weld bead shape or desired productivity ~hge v$ O.~re~ Volt~e vs Y~=S and graphing the preferred arc length, I ,.& ,,i,- ~*- voltage, wire feed speed and travel speed. The knowledge created by this method also supports the use of knowledge-based design of experiments to optimize the relationship between production factors, such as root opening and offset, and the process application. In the future, it is hoped a comprehensive database will be created, thereby minimizing redundant procedure development. The use of opti- Current vs W re Feed Speed ~t I~ vs- Derti~ ~ate mized welding procedures and the knowl- '~ " ~1 edge developed by this method could minimize redundant procedure development, ~tI, T which will save industry millions of dollars. !:: i!i!iiiii!i Acknowledgments

Charlie Ribardo (former applications --i 4#+-" I engineer), Matt Robinson and Mai Itti- '1 I wattana (graduate fellows) are acknowl- SF4~ I 49~JP Na~lew IJ~ ~WO C~.,O Deg~e~a~V~ W~I edged for their help in preparing test data. -, . . . , Fritz Saenger, director of marketing, is acknowledged for his help in preparing this Fig. 6 -- Parametric graphs for ¼-in. fillet welds using a GMA W process. article. 4,

References

1. Harwig, D. D., et aL 1997. The ARCWISE technique for increasing. SME Technical Paper RP96-291 SME Manufacturing 96, ing productivity in arc welding. ICAWT 97, Columbus, Ohio. Chicago, Ill. 2. Harwig, D. D. 1996. Weld parameter development for robot weld-

WELDING JOURNAL I 39 It's the i season for giving. 4 \ For those of you who have, thank you.

For those of who ha~ q J please consider a slightl: different resolution this

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1RAININGWELDEBS IN MEXICO For U.S. educators working in Mexico, an understanding of the differences between the two cultures can greatly improve the chance for success BY ANGLE HILL PRICE

any companies are turning to expect cultural differences. Anticipating neither culture is to be ranked better or Mexico as a site for their man- and adjusting to these differences will worse, just different. M ufacturing facilities because of result in the success of these endeavors, the low labor costs and increasing pro- just as much as denial and ignorance will ductivity. In an article in the June 1999 guarantee certain failure. This is cer- Evaluate Cultural Welding Journal titled Welding Forges tainly true regarding welding. Differences into the Future, industry leaders indi- Before trainers and educators from cated part of the future of welding is cen- the United States are sent to work with The first step to ensure success in tered in Mexico, as well as other Latin Mexican welders, they should undergo training welders in Mexico is to under- American countries. To move success- training themselves. This training should stand and appreciate their culture. To do fully in that direction, managers, educa- prepare the educator for the cultural dif- this well, we must step back and look at tors and engineers must understand and ferences that will be encountered and our own culture, then identify the differ- must be accommodated in order to suc- ences. Avoid the temptation to label ANGLE HILL PRICE (PRICE@ENT. ceed. To understand and appreciate these differences as right or wrong. TAMU.EDU) is an Assistant Professor of other cultures, we first must identify the While there is always a hazard in gener- Engineering Technology at Texas A&M American culture so we can make com- alization, the statements below are in- University, College Station, Tex. She parisons. An excellent reference is The tended to serve as guidance and as an gained insight for this article while training Challenge of Living and Working in Mex- initiation point. We must learn to em- workers at Grant Prideco S.A. de C.V. in ico by Dr. Marc I. Erlich. Educators pathize with our Mexican coworkers and Veracruz, Mexico. must keep an open mind and remember to appreciate their background and the

WELDING JOURNAL I 41 because of a constrained distribution in- Table I m Identifying Differences in Cultures Facilitates Training frastructure. American System Mexican System Mexican management tends toward micromanagement techniques. A presi- Commitments are to be honored. Commitments are good intentions. Schedules and deadlines are taken seriously. Schedules and deadlines should not be taken dent or high-level manager may spend a too seriously. great deal of time on what might be con- Information should be available to all. Information is power and may be withheld. sidered lower-level management deci- If it's broken, replace it. If it's broken, repair it. sions in the United States. The percep- Change is improvement. Stability is important. Choose the best qualified person for the job. The person is more important tion of power -- who has it and how than the performance. much -- is very important in Mexican Macromanagement. Micromanagement. companies and in the culture. Look toward future. Look at present. "Live to work:' "Work to live." Preparation cultural differences that influence their The Mexican culture is oriented to behavior. In his book, Dr. Erlich de- the family and life outside of work. An American educator of welders scribes cultural tendencies of interest to Work supports the life, never dictating who goes to Mexico and utilizes Ameri- management. These are broad state- to it. Family is very important to Mexi- can training methods and techniques full ments that apply to general groups. With cans and will not be sacrificed in favor of of American cultural biases will fail. exceptions, they essentially were true of work. Mexicans appreciate the present Those methods will result in quality and welders and welder/operators. These and worry about the future mahana or productivity decreasing and an increase differences are summarized in Table 1. tomorrow. They tend to believe success in worker turnover. A refusal to consider American attitudes include the belief in work relies on politics, luck and train- cultural differences leads to resentment success relies on hard work. Americans ing. It is more who you know than what on both sides. Preparation will soften ad- believe individual effort will be re- you know, much more so than in the justment difficulties and facilitate a warded; the amount of reward is ex- United States. Commitments and smooth transition. pected to be in proportion to the amount promises are made with good inten- Before traveling to Mexico, spend of work done. Time is taken seriously, it tions, and usually in good faith, but lit- some time reading about the country's governs our lives. We rush to meet dead- tle or no penalty is expected if there is history and culture. Familiarize yourself lines, race to and from work. Work is our no follow-through. Time does not gov- with the political structure and the work priority and life is what happens on the ern work life; if something is not fin- structure, including the unions. Prepare side. We work later, longer and harder in ished today, it can be completed tomor- for the differences in work philosophy a never-ceasing effort to get ahead. We row. A person is selected for a position that may impact your training efforts. make promises fully intending to keep based more on who they are rather than The Internet facilitates the gathering of them and we expect others to do the their skills. Information implies power information regarding these topics. same, for a broken promise is a serious and control; managers share little infor- Learn as much of the language as matter. Money, at least in comparison to mation in the fear they will undermine possible in advance. You will find the other countries, is readily available in their own authority. Stability in all facets Mexican people greatly appreciate any corporate America, so, in our disposable of life is very important. attempt you make to speak Spanish. As society, we spend money replacing items Historically, Mexican companies and they are extremely polite, they will not rather than repairing them. Change is an people have had little money, so when ridicule your accent or attempts to speak ever-present part of our lives; the "status something is broken, it is repaired again the language. quo" can always be improved, hence our and again, though the total cost of repair policies of continuous improvement. We may far outweigh the one-time replace- believe in seeking the best person for the ment cost. Incremental costs rather than Educational Techniques job and giving that person all the infor- total are more obvious. Another con- mation we can. We tend to use macro- tributor to the repair vs. replacement As you initially work with people who management and look toward the issue is the availability of commercial are employed as welders in Mexico, you future, sometimes completely disregard- goods. Access to imported products in will find, in many cases, they have had lit- ing the present. particular has been extremely limited tle formal training for their occupations. Often welders have been educated Keys to Successful Training in Mexico through informal apprenticeships or cursory training programs, with little exposure to the technical background of welding. Expect a wide difference in the Provide basic information. education and skill levels of people clas- sified as welders and be prepared to ac- Accommodate varying educational levels. commodate them. One hindrance is a Remember the lack of documentation in Spanish. lack of documentation in Spanish. The American welder has access to a great Repeat training at intervals. deal of written information the Mexican welder does not. The American Welding Offer help constantly and respectfully. Society has made great strides in addressing this issue with the publication in Avoid being critical. Spanish of Volume 2 of the Welding Work at speaking Spanish. Handbook, Eighth Edition, as well as Arc WeldingSafety. Beware when writing Respect cultural differences. welding procedures for translation. A

42 [ DECEMBER 2000 fluently bilingual person should review rather overwhelming optimism, a com- chining the smaller diameter tubes on company documentation translations. A mitment to trying. When the welders hand. Rather than this being regarded as number of computer translation pro- and supervisors at a manufacturing fa- a creative quick fix, it was viewed more grams are available, but many fail when cility initially were asked to make as a permanent solution. No one took used on technical papers. changes, they almost invariably agreed, the responsibility to follow up by order- When working with Mexican whether or not such a thing was possible ing the correct replacement parts and welders, offer help constantly, yet re- -- perhaps equipment, parts or person- the tool room operator was not in- spectfully. Do not wait until a problem is nel were unavailable. Americans are ac- formed these parts were critical and noticed by quality assurance; instead, be customed to discussing difficulties and should be kept in stock. With education observant and anticipate errors. Avoid obstacles up front in order to formulate and training in work and quality issues, being critical. No one enjoys being told a solution rather than address each issue the welders learned to take more re- what they are doing is wrong; this is par- as it arises. In Mexico, don't expect to ef- sponsibility for all the aspects of their ticularly true of the Mexican worker. fect alterations immediately, but have work. Criticism is apt to be met with silence patience and understand it takes time. One last thing to consider is reitera- and passive resistance. Positive rein- Mexican workers are expected to do tive training. Repeat training at frequent forcement is the best way to obtain the their jobs and no one else's -- initiative intervals, repeat elements and essential welder's best. You will also face passive is not always encouraged with a micro- facts, and review the basics. Again, never resistance if the welders are asked to try management philosophy. This could be assume that because a person is em- something new or to make changes with- construed as an encroachment on an- ployed as a welder, he or she has had any out explanation. Make them a part of the other person's power and is frowned real prior training. Don't assume the change process; educate them as to the upon. For example, to improve weld employees will ask for help or clarifica- reasons for doing something differently. quality, welders at one facility not only tion when needed. Offer assistance; There is little faith that change will result had to be trained to inspect their parts don't be critical, but instead provide a in any reward for the employee because but also made to understand that it was supportive environment. Respect the of their views regarding success and how acceptable to do so. differences in work philosophies and it is achieved. Make them know their ef- In a poor economy, there is little sur- cultures and find a means to work within forts are appreciated and find some way prise that parts or machines are repaired these constraints. Using these tech- to reward them, such as with certificates many times without consideration of re- niques, American educators seeking to or peer recognition, if monetary rewards placement. If something is no longer in establish themselves in Mexico can be are not options. stock, a substitution is found. For exam- truly successful and productive. • You may be told something can be ple, at the same facility, when the tool done and then find it does not happen. room ran out of the correct diameter This is not intentional dishonesty but contact tubes, welders made do by ma-

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1; i i\

A veteran instructor identifies the character traits and learning styles that lead a student to a career in welding

BY WAYNE WESTERN

ver the years, as I've dealt on welders in an effort to determine what What Makes Welders The a personal basis with literally the average welder is like. Following are Way They Are? O thousands of welders, I've no- the highlights of the profile of a welder I ticed some common behaviors among have developed. Our schools became something of an them. I've spent 20 years training • Did not like school. issue to me as I began looking for the welders at a technical school in Utah, • Has not attended much college. root causes for some of these behaviors, and I've also owned several small weld- • Is at least mildly antisocial. because I believe well-meaning but mis- ing shops and worked for a number of • Is a strong hands-on learner. guided educators begin directing us to- welding companies during that same • Competitive. ward welding careers when we are time period. I currently teach full time • Not a great team player. young children. Does it surprise you but also work as a welding consultant for • Twenty to thirty years old. that when you were a child with dreams one of the larger welding companies in • Has some issues with authority. of being a scientist, a doctor, or an as- Utah. Before anyone becomes defensive, tronaut, your teachers were, in fact, im- While I have tracked some of my for- there are, of course, exceptions and perceptibly steering you toward a life of mer students for nearly ten years, four these are not all negative tendencies. melting metal? Does it shock you to years ago I began a more concentrated Still, these questions beg to be asked: think that may be happening to your study following the careers of 300 "Why are welders like this?" and "Who children right now? will find this information useful?" The At this point, I have a mental image WAYNE WESTERN (westernw@ intent of this article is to help welders, of my fourth grade teacher, Mrs. Cone, owatc.tec.ut.us) is a welding instructor at their employers, those training prospec- trying to reach out past the grave to Ogden-Weber Applied Technology Cen- tive welders and anyone with a child in whack me with a ruler. I am sure she ter, Ogden, Utah. our nation's education system. would say she wanted me to succeed and

WELDING JOURNAL I 45 on learners. By contrast, earning a teach- FIGURE 1: AVERAGE GROUP OF STUDENTS ing degree requires very little eye/hand coordination, yet demands a high degree I V'musl/A~:litoryLearner ~ Tactile Lamer of visual/auditory learning. This sets the Curriculum bas~l on icctu~ n~g, and ~. Cumriculmn based on Imnds-on experiemc~ stage for a natural conflict. Can teachers teach math, reading and science using hands-on methods that our future welders can better understand? Yes, but it's harder and difficult for the teacher to relate to, so, instead, it's far more likely the student will be labeled "learning disabled." It's my personal opinion that most learning dis- i I I I abled students are not disabled at all but are victims of "teaching-disabled" in- Group most likelyto possess good welding skills structors. Let's face it, if my son gets an A+ in math and a D- in metal shop and your son gets a D- in math and an A+ in Group most likelyto get good grades in school Group likely Ito be labeledmost as metal shop, which child will more likely learningdisabled be labeled "learning disabled"? It sure won't be the kid with the A+ in math. As these tactile learners progress through the grades, their options begin Fig. 1 -- The types of learners in an average group of students. to narrow. Because so few teachers can teach any other way than visual/auditory, our future welders' chances of not be a burden on society by never pass- group of people, we would find a small doing well in advanced math or science ing fourth grade, but if her motives and group, perhaps 20%, who will succeed become less and less and so are their the motives of most of the teachers that no matter what method is used or how chances of going to college or on to the endured me as a student were pure, then bad the instruction is. My middle daugh- "professional" occupations. what went wrong? Why wasn't I a more ter, Ann, is like that. She is on the high You may think I'm being rather harsh successful student? Over the last few honor roll and will certainly have multi- in my assessment of teaching as a whole, years as I've developed this welder's pro- ple college scholarships whether she has but at our local high school's parent/ file, I've become a student of teaching good teachers or not. The rest of us lean teacher conference last year, I listened methods and philosophies, and I believe toward either learning with our eyes and in on a number of teachers as they coun- many of the problems result from how ears or learning with our hands. This seled with parents. Over and over again, different individuals learn. may seem like an oversimplification; in I heard teachers blaming their students fact, studies commonly outline many dif- for "not applying themselves enough" or ferent types of learners, but because the "not working hard enough." I wanted to Beginning the Learning vast majority of successful welders are hear just one teacher say, "Your kid's Process tactile learners and the vast majority of okay, but as a teacher, I lack the talent teachers are visual/auditory teachers, I and creativity to help him succeed." Of Let's look at how we all began the have focused on these two. Figure 1 il- course, it didn't happen. learning process. What happens when lustrates the visual/auditory learners and you hand something to a baby? It puts tactile learners in an average group of the object right in its mouth. It doesn't students. The illustrations are approxi- Good Students Don't Always matter if it's candy or the cat's tail, a baby mations and are not intended to repre- Equal Good Employees puts everything right into its mouth. sent an exact numerical value. That's how we all began to learn, by Perhaps the worst thing is the ten- using as many of our senses as we could dency for teachers and employers to as- to examine anything that was different Visual/Auditory vs. Tactile sume good students equal good employ- or new to us. As we got older, and after Learners ees. This is not true for welding. In fact, being told thousands of times to not put as I've tracked dozens of high school se- stuff in our mouths, we learned to satisfy It would be tempting to say the learn- niors entering the welding field, those our curiosity by looking at and handling ing style for any of the trades -- carpen- with poor attendance and below average an object. try, machinist, etc. -- would be the same grades actually have a slightly better That is the basis for tactile learning. as for welders, and, to some degree, it is. chance of being a successful welder than As we got older, society and our educa- But welding is unique in the intense level the "~' student. School is school and tional institutions began enforcing the of eye/hand coordination required. To work is work and one should not be used artificial and unnatural method of learn- be able to put on a helmet, block out the to judge the other. ing exclusively by visual and auditory rest of the world and concentrate on cre- Interestingly enough, once the methods. Read, listen to me talk, but ating uniform ripples in molten metal welders-to-be have left school and be- keep your hands to yourself! where any variation or loss of concen- come employed, they all do about as well Half the population is more or less tration is evident goes beyond the on the job. The best 5% are more in- successful at learning this way; the other eye/hand demands of other trades. clined to move into lead or supervisory half is more or less a failure at learning This intense eye/hand coordination positions, the worst 5% are more likely this way. If we were to chart an average encourages welders to be strong hands- to work as welder helpers, the rest will be

46[ DECEMBER 2000 equally successful at maintaining a job FIGURE 2: AVERAGEWELDING EMPLOYEE regardless of their performance in school. I Visual/AuditoryLearner ~ TactileLearner Whether it's called aptitude testing, career guidance, or counseling, the end result is to direct students to an occupation that best suits their aptitude and tal- ents. For many institutions, standard aptitude tests include math, reading comprehension and, sometimes, eye/hand coordination. I have found after 20 years of teaching welding that these standardized tests are poor indica- Group able to tors of how successful a person will be as learn both a welder. audiovisually and If you think back to the items I listed tactically in the welder's profile, it should become clear why certain behaviors are so com- IGroup most likely to not stay long in welding [ [ Profile of most long-term welders mon. It's only natural that an occupation I I as intensely dependent on eye/hand coordination as welding would attract the tactile learner. It's also logical that since Fig. 2 -- Profile of the average welding employee. most classes aren't taught in that way, these individuals will not enjoy school, and it is at school where many of our social interactions occur and our social As an employer, it's tempting to try to der learned "on the job" with no real for- skills are developed. Now we add to the hire from that middle 20% who can learn mal training. mix the inclination many high schools either way, and who are also better team The typical welder enters the field at have of "dumping" students who aren't players and prone to be better at a num- a young age, will work for several differ- doing well academically into the wood ber of different tasks. It is not hard to tai- ent companies and will pursue welding shop or welding shop or auto mechanics lor a company's hiring practices to ac- as a career for less than 10 years. As I've because they don't know where else to complish this. If a company testing for a collected data, I've come to realize what put them. It's sad, but with the average new hire includes some fairly compre- a valuable commodity older (30+) high school's fixation on sending every- hensive written testing in math, blue- welders are. They have spent years re- one to college, the "blue collar" trades print reading, reading comprehension, fining their skills and have stability and are considered somehow less important. as well as a difficult welding test, most of maturity not always found in younger the successful applicants will be from the welders. In much the same way experi- Becoming More Effective middle 20%. enced teachers are moved into adminis- However, depending on the com- trative positions, taking their skills from As educators or employers, what pany, this may not be such a good thing. the classroom, so, too, experienced does this mean to us? It means lots of The middle 20% are also more likely to welders often move into supervisory or reading, homework and lecture time will use welding as a stepping stone to an- supporting positions. not be very effective for the average other career and to leave welding com- In both an official capacity and on my welding student. It means what's hap- pletely within a few years. own, I have reviewed the welding pro- pening in the classroom needs to have an Using a very difficult weld test and grams at many high schools, vocational almost immediate connection to what is eliminating any other criteria will shift schools and colleges. These schools offer happening in the shop. It means a poor our graph significantly to the right. many different approaches to teaching traditional student may well have a very These people will be good welders and welding and to structuring the curricu- successful, high-paid career as a welder. more likely to stay in welding, but don't lum. It is important to recognize what What happens when the welder expect them to be great team players or the actual objective is. Is it to introduce leaves high school and goes to work? take orders real well. You will find the a person to welding, to teach welding as Once welders have been out of school a people being considered are now more a support to a related degree or to train few years and get over what it was like, likely to resemble the average welders' a job-ready welder? If the objective is to some will return and a few will earn col- profile discussed earlier. Figure 2 corre- train job-ready welders, then several lege degrees. Often this marks their exit lates the types of learners with their like- things are critical. First, training equip- from welding as a career. lihood of remaining welders. ment must be equal to local industry. What conclusion can we draw? The After conducting hundreds of inter- Second, industry expectations and qual- tendencies and abilities commonly pre- views with welders and being involved ity standards need to be enforced in the sent in a top-notch welder may, in fact, with hundreds more, I have found if we training. The AWS S.E.N.S.E. program not be looked at as very positive in an- look at a cross section of where those can be a valuable asset in establishing other situation. I find many students writ- currently working as welders came from, those standards. Lastly, students must ten off, labeled as failures when it should about 25% had some basic welding in get the maximum number of hours actu- not have happened. Also, the importance high school. This is rarely enough to ally welding. Teaching welding theory is of the teacher's attitude cannot be over- make them job ready. About 5% gained necessary and important, but job-ready stated. Studies have shown hands-on some welding training or experience in welding skills are learned in the shop, learners are very good at reading body the military, and 40% attended some not the classroom. And that works just language. If the teacher has already de- form of trade, vocational or other post- fine for our hands-on learners. • cided they are a failure, they will know it. secondary welder training. The remain-

WELDING JOURNAL I 47 m m I I

When the traditional education system can't produce what's needed, industry must rely on it own resources to train welders

BY DAVID LANDON

~A briskly growing Iowa economy I lk is expected to produce new jobs at the rate of about 18,000 a year through 2005, state labor officials said. And about twice that number, 36,000 jobs, will open up annually in Iowa because workers retire or quit, the officials said. But here's the problem: Almost everyone in Iowa who wants a job already has a job. Iowa's unemployment rate has remained below 3% for more than year and a halL" This was the opening paragraph to a news story that ran in The Des Moines Register in 1999. This is great news for those who are looking for work, but it's a difficult challenge for a global equipment manufacturer based in Pella, Iowa, whose annual growth over the last seven years has been between 10 and 15%. For a company that has built its reputation on innovation and a strong work ethic, a challenge has never been something to Fig. 1 -- A low student-to-instructor ratio ensures effective training when the time frame shy away from. for instruction is limited. Industry Needs Welders meer also manufactures a full line of hay schools, to train and supply them with Founded in 1948 by Gary Vermeer, a harvesting equipment. skilled welders. Unfortunately, these local farmer who invented a wagon hoist Over the past seven years, Vermeer sources of training were unable to meet to make unloading shell corn easier, Ver- has experienced a period of tremendous the demand for skilled welders or were meer Manufacturing Co. has grown to growth. In 1992, the company employed not able to satisfactorily train those in become an international manufacturer 1200 people. Because the equipment their programs to meet the necessary re- of industrial construction and agricul- consists of steel plate and shape con- quirements. tural equipment. The company employs struction, welding is vitally important. Because of these obstacles, the com- more than 2700 people with 1.4 million Almost one quarter of the hourly pro- pany decided to initiate its own in-house sq ft of manufacturing space under roof. duction employees at Vermeer are welder training program. The purpose Today, the company manufactures ap- welders. of the program was to provide company- proximately 115 different models of in- specific skills in gas metal arc welding dustrial construction equipment with full Training Comes In-House (GMAW) to new employees in a timely lines of utility and track-mounted fashion to facilitate the need for entry- trenchers, horizontal directional drilling Traditionally, industry relies upon the level welders. This training program was equipment, brush chipping, stump grind- education system, whether it is high not designed to take novice or unskilled ing and tub grinding equipment. Ver- schools, community colleges or trade welders and train them to become crafts-

DAVID LANDON is a Welding Engineer, Vermeer Manufacturing Co., Pella, Iowa.

48 J DECEMBER 2000 men in 80 hours. It was designed to take novice or unskilled welders and provide them with the basics in practical hands- on welding as well as blueprint reading. These basics are enough to allow the successful graduate to provide the company with value-added work on the first day of production.

Classroom and Hands-On Split the Time

The training program offers instruction in the GMAW process only. Al- though the capability is present to in- struct in other welding processes, more than 95% of all welding at Vermeer is GMAW. To provide this training in a timely fashion, a schedule of 80 contact hours was chosen. Of those 80 hours, 40 are in the classroom and 40 are actual welding time. The key to providing effective training in a concentrated time frame is a proper student to instructor ratio -- Fig. 1. The company chose a ratio of six students to one instructor. Although, in a classroom setting, this ratio can be much higher, for practical hands-on welding, a maximum ratio of 6 to 1 is critical. Anything greater than this will not provide the one-on-one instruction necessary to learn the skills in a timely fashion. The curriculum outline of the classroom training is broken down into four modules: • Safety • Welding symbols and blueprint reading • Welding fundamentals Fig. 2 -- Hands-on welding comprises a large portion of the training • Weld quality standards. program. The first hour of training is in welding and shop safety. This training covers job-specific personal protection equip- courses are taught as two separate pro- the people responsible for producing and ment as well as typical welding hazards. grammed learning sessions. These planning welding. The blueprint reading The new employee receives general ori- courses provide a simple yet complete course contains valuable information on entation and safety training prior to com- method for students to learn and under- mathematics, the International System ing to welder training. In the general ori- stand the principles of welding symbols of Units (SI), blueprint reading for entation, the new employee receives and blueprint reading. Each course uti- welders, setup tools and setup applica- training in hazardous materials, emer- lizes a self-paced student workbook sup- tions. The blueprint reading course is gency action plans and general personal plemented by instruction using video- supplemented with actual production protection equipment (safety glasses and tape. Each page of the workbook is de- prints used at Vermeer Manufacturing. steel-toed boots). The safety module signed to teach a small amount of infor- The welding fundamentals module provided in the welder training program mation, which is reinforced through an comprises approximately five hours in includes arc radiation, electric shock, air action/problem, and self check. the classroom. This portion of the train- contamination, fire and explosion, safe Each page builds for the next as the ing is designed to supplement the prac- handling of compressed gases and other student learns in an efficient and reward- tical hands-on welding portion of the related hazards. ing manner. The symbols for the course course. Topics of discussion are differ- The welding symbols and blueprint are based on American National Stan- ent welding electrodes and why they are reading module comprises approxi- dards Institute/American Welding Soci- used, different shielding gases and why mately 30 hours in the classroom. This ety A2.4, standard Symbols for Welding they are used, and basic wire feed speed material was developed by the Hobart Brazing and Nondestructive Examination. and voltage settings for short circuit, Institute of Welding Technology. The This system of communication provides spray and pulsed arc transfer. The com- welding symbols and blueprint reading the vital link between the designer and pany has found that even for the entry-

WELDING JOURNAL 149 level welder, it is important to have not Going Back to High School only an ability to perform the welding Since its inception in late but also a basic understanding of the 1993, more than 800 In September of 1999, Vermeer principles behind it. began a new endeavor in the area of weld The final module for classroom train- trainees have gone training. The company teamed up with ing consists of approximately four hours through the program. one of the local high schools to provide of instruction on the company's weld a production welding class for high quality standards. This training intro- The success completion school seniors. duces the student to the common weld rate is 83%. In the spring of 1999, Pella Christian discontinuities, the causes of the discon- High School requested help to enhance tinuities, acceptance criteria and the tour and shape of an acceptable fillet the welding portion of its industrial arts proper use of fillet weld gauges for mea- weld. classes. I went to the high school to eval- suring weld size. The core of this train- In the training for circular fillet welds, uate the program, and I was amazed at ing utilizes a weld comparison replica de- the student must learn how to properly the quality of instruction in the area of veloped by Caterpillar, Inc., which is a weld around tubing and round bar. Com- woodworking. But when it came to weld- three-dimensional representation of petency must be demonstrated in welding, all I saw was a small table and a cou- Vermeer's written standard for weld ing a horizontal fillet weld around a 1- ple of old buzz boxes. The thought of quality. Its purpose is to clarify what is in. tube, 2-in. tube or bar and 4-in. tube Vermeer providing training to a class of acceptable and provide a common ref- or bar, while maintaining proper weld high school students occurred to me. The erence for all those involved in judging bead contour and shape. Particular at- company has a world-class training pro- weld appearance. Welders, welding intention is given to weld tie-ins. gram two miles down the road, so I spectors and production supervisors are In the training for edge welds, the stu- thought who better to train for industrial all trained in this module. dent is exposed to lighter gauge steels. welding than industry. For lap welds, the student learns the Hands-On Welding proper technique to successfully make Student Curriculum Curriculum the weld without excessive undercut or "cut edge" on the top plate. In the train- I developed a modified curriculum of The hands-on welding portion of the ing for the three-corner intersection, the the company's standard welder training training nominally consists of 40 hours student learns the proper technique to course. The high school welder-training -- Fig. 2. Vermeer has specified 12 com- successfully tie-in three welds that inter- program consists of one semester of 90- petencies that are required to satisfacto- sect from three different planes. For the minute sessions. As with the industrial rily complete the training. Welders that cascade weld, the student learns the welder training program, the high school enter the training with previous skills in proper placement of each pass for mul- program has both classroom and hands- welding frequently demonstrate the re- tiple-pass fillet welds. on lab time. The high school program quired competencies in less time than the All of the performance qualification gives the student more than 90 hours of specified 40 hours, while those who enter testing required for competency in the instruction in an actual manufacturing the training with little or no previous training program meets the require- setting. skills in welding may require up to 80 ments of the welder performance quali- During the semester, seven high hours of hands-on training to demon- fication testing of ANSI/AWS D14.3, school students arrived at Vermeer and strate the required competencies. In ei- Specification for Welding Earthmoving just like in an actual production environ- ther case, the minimum required time in and Construction Equipment. ment, the students punch a time clock this portion of training is 40 hours. If the when they arrive and when they leave. requirements are completed early, the Each day they spend 30 minutes in the trainee is given light production work Evaluating the Results classroom learning how to read and un- while still under the direction and super- derstand industrial blueprints and weld- vision of the welding instructor. This training program has been very ing fundamentals. The last hour of the The 12 competencies required for successful. Each student evaluates the day, the students are issued the required successful completion are straight fillet program and the instructors at the com- personal protective equipment and weld welds, circular fillet welds, edge welds, pletion of the course. A common re- various projects. In the shop, the stu- lap welds, three-corner intersections, sponse to the evaluations is the out- dents are under the direct supervision of cascade weld, welder performance qual- standing knowledge of the instructors the instructor. Each student must com- ification groove test for limited thickness and the amount of material learned in a plete the same requirements the com- in the flat position, welder performance short time. The scores for the evaluations pany expects from its production qualification groove test for unlimited are consistently above average. In addi- welders. In addition, the students are thickness in the flat position, welder per- tion to a student evaluation, the plant given a welder qualification test for 1G formance qualification fillet weld test welding supervisors are periodically limited thickness. vertical position, welder performance asked to evaluate the students they have After successful completion of the qualification fillet weld test overhead po- received from the training program. The one-semester course, the students are el- sition, proper setup and safe usage of students are evaluated based upon the igible to participate in a school-to-work oxyfuel cutting torch, and carbon air arc competencies demonstrated in the train- program, which allows the students to do gouging. ing courses. These evaluations have been actual production welding, earn high In the training for the straight fillet average to above average. school credit and get paid. welds, the student must learn how to Since its inception in late 1993, more Through the efforts of the welder properly size a fillet weld. The student than 800 trainees have gone through the training program and the company's must demonstrate competence in 3A6-, program. The success completion rate is welding department, Vermeer continues ~6-,3~-, and 'A-in. fillet welds. In addition, 83%, proving it to be very successful over to meet or exceed customer expectations the student is trained in the proper con- the years. for quality and workmanship.~

50 J DECEMBER 2000 Datasheet 247a

Practical information for welders and others involved in welding and its allied processes. Flash Welding Process

Flash welding is a process that joins parts of similar cross section. The weld is performed across the entire joint area without filler metal. It is a resistance welding process where- by the faying surfaces are brought into contact, heating is generated and pressure applied. The flashing action begins as the parts are moved together. A rapid upsetting completes the weld. The joining process begins with the clamping of the two parts into dies, which also act as current-carrying electrodes. A resistance welding transformer is connected to the dies. As (A) one part slowly approaches the stationary part, voltage is applied. Resistance heating occurs when the faying surfaces are brought into contact. High amperage causes melting and vaporization of the metal at the points of contact, and miniature arcs form. This action is called "flashing" as part temperature and metal loss increase. The increasing contact between the faying surfaces, the growing molten state of the metal and the flashing action all reach a critical stage at which a rapid "upset" force is applied. When the molten surfaces are in full contact, the weld is completed and the current terminated. The metal expelled from the interface at the upset stage is called flash. Normally, the two parts should have the same cross section. When welding extruded or rolled shapes with different thicknesses within the cross section, the temperature distribution may vary during flashing. This situation can be sometimes counteracted through the proper design of the dies. With heavy sections, the beveling of one part end helps to start the flashing action. Like all processes, flash welding has advantages and limitations. The advantages include the welding of shapes other than circular parts, such as H shapes, angles and rectangles. Parts of similar cross section can be welded with their axes aligned or at an angle to each other, within limits. The ejection of the molten metal at the interface during upset acts to remove impurities from the joint. Generally, preparation of the faying surfaces is not critical with this process. Limitations of the process include the molten particles ejected at upset create a fire hazard and pose possible injury to the operator, as well as damage to shaft and bearings. The single-phase power demand produces an unbalanced condition with three-phase primary power lines. A secondary operation to remove flash and upset material is usually needed. Pieces with a small cross section are difficult to align. (O)

Basic steps of the flash welding process. A -- The parts are positioned and clamped; B -- apply voltage and begin movement of part; C -- flashing action; D -- upset force applied and current terminated.

Excerpted from Welding Handbook, Vol. 2, Eighth Edition.

WELDING JOURNAL I s~ Datasheet 247b Flash Welding Process Applications and Equipment

Both ferrous and nonferrous metals can be flash welded. Typically, carbon and low-alloy steels, stainless steel, aluminum, copper and nickel alloys all can be flash welded. Titanium can be joined with this process, but it is advisable to use an inert shielding gas at the joint to minimize the possibility of embrittlement. Dissimilar metals with similar upset characteris- DIES--~ tics can be flash welded. Careful control of welding variables is needed, but aluminum to copper and nickel alloys to carbon steel have been successfully joined. The automotive industry manufactures wheel rims from flash welded rings formed from flat cold-rolled F,XEO I I MOVABLE CROSSSECTION AFTER WELDING stock. Motor and generator frames used in the electri- PLATEN~ PLATEN cal industry are flash welded, as well as cylindrical transformer cases and circular flanges. The aerospace industry makes use of flash welding in the fabrication of landing gear struts, hollow propeller blades, control TRANSFORMER assemblies, rocket casings and jet engine rings. Oil (A) AXIALLYALIGNED WELD drilling pipe has fittings attached by flash welding and railroads have joined high-carbon steel rail with the process. Flash welding equipment is primarily automatic or semiautomatic in operation, although there are also manual machines. The major components of flash welding equipment are a machine bed with platen ways attached, two clamping assemblies, a motion CROSSSECTION AFTER WELDING controller to move the platen, a welding transformer with adjustable taps and a controller to initiate flashing current. With manual operation, the operator controls the TRANSFORMER speed of the platen from the time flashing is initiated (B) MITERWELD to the completion of upset. With semiautomatic operation, the operator initiates flashing manually and then completes the job automatically. Automatic operation performs the welding cycle without the need of adjustment by an operator. The platen motion may be initiated mechanically by a cam driven by an electric motor or through hydraulic or pneumatic means with the larger machines. Machine sequencing, current control and platen positioning during flashing and upsetting are all FIXED J~ MOVABLE controlled by electrical means. Silicon-controlled rec- PLATEN PLATEN CROSSSECTION AFTER WELDING tifier (SCR) contactors are commonly used on machines that draw up to 1200 A from power lines. Preheat and postheat cycles are typically controlled by electronic timers. TRANSFORMER The major variables with the process are dimen- (C) RING WELD sional, electrical, force and time. Good design should be concerned with heat balance in the part ends to ensure nearly equal compressive strength at the termination of the flashing time. Metal loss during flashing and upset must be designed into the overall length of Common types of flash welds. the part. This is especially critical if the parts are at an angle, such as with a miter joint. Flashing should start at the center or in the central area of the parts being joined, and the ends should be designed to allow the flash material to escape easily.

52 J DECEMBER 2000 2001-2002 AWS CONGRESSIONAL FELLOW PROGRAM

I. PREFACE A. Technology is affecting society to an ever-increasing extent;

B. Public policy issues affecting a broad constituency are increasingly based on technological factors;

C. Informed decisions regarding public policy issues require the input of the engineering profession, among others;

D. The engineering professional constitutes one of the nation's most valuable resources, and

E. This resource should be applied in the public interest to matters having a technological content.

II. POLICY A. AWS declares that it is the continuing policy of the American Welding Society to 1. be sensitive to the public's interests; 2. provide government at all levels with advice on engineering matters and policies affecting the public interest; and 3. maintain a climate of understanding and credibility that will foster continuing dialogue with the government.

B. As one measure for furthering its policy, The Board of Directors establishes a Congressional Fellow Program to assist legislators and officials of the Congress in public policy deliberations. Each year, AWS will select a member, in a manner herein described, to serve as Congressional Fellow to assist legislators and other federal officials.

C. It is preferential that AWS and the Fellow's employer share the compensation and the expenses of the Fellow so that all parties have a financial interest in the program. However, a Fellow may serve with full employer support, provided that she or he is selected in accordance with this policy and she or he adheres to all AWS policies and guidelines of the program. AWS'sshare shall not exceed the amount annually budgeted. A Fellow may also participate with no employer support but recognizing the limited stipend.

D. Although the Congressional Fellow is sponsored by AWS, the Fellow's primary objective is to provide assistance to Congress while representing the welding engineering profession in objective fashion without bias or favor toward AWS or her or his employer.

In addition, AWS will help in furnishing whatever technical assistance a Congressional Fellow will request of the Society.

E. It is desirable that the Congressional Fellow be familiar with AWS operations and organizational structure in order to obtain assistance promptly and efficiently.

E Congressional Fellows must comply with the AWS policy on Conflict of Interest and any appropriate rules of ethics of the host federal office. III. PROCEDURE A. Solicitation of applicants and Selection of Congressional Fellows

. AWS will solicit applicants through appropriate means, including letters to companies, announcements in the WeMingJournal,and appeals to the AWS leadership to identify candidates.

. The Candidate Review Committee shall a. Reviewapplications; b. Interview highly marked applicants; c. Identify the best qualified among these for possible selection as a Congressional Fellow; d. Forward list of recommendations for the AWS Congressional Fellows and necessary support documents to the Government Affairs Liaison Committee for final selection and approval.

. Individuals chosen to be Congressional Fellow(s) will be assisted by the AWS Washington Government Affairs Office in his or her placement with the staff of a Representative, Senator or a congressional committee.

4. The selection of the Fellow will be announced by the President of AWS.

B. Requirements

The requirements for the Congressional Fellow Program are as follows:

1. A Congressional Fellow's term shall be twelve months, beginning in September.

. Government Affairs Liaison Committee shall select the Fellow(s) using objective selection criteria, including a candidate's application, to determine a candidate's ability to communicate both orally and in written form, and such other attributes as the committee deems necessary for a candidate who will represent the welding profession.

. Sex, creed, race, ethnic background and political affiliation are expressly excluded as selection criteria for Congressional Fellows.

. Fellows shall hold at least the AWS grade of Member prior to submitting an application for Congressional Fellow.

5. Fellows shall be citizens of the United States of America.

Deadline for Receiving Applications is February 1, 2001. For a complete application package, contact: Richard French Deputy Executive Director 1-800-443-WELD, ext. 218 American Welding Socieiy 550 N.W. LeJeune Rd. Miami, Florida 33126 Visit our website http://www.aws.org A MANTECH Center of Excellence Na er Operatedby ~~ Friction Welding Increases Productivity for New Marine Corps Vehicle he Navy Joining Center (NJC) is specially modified to allow it to applying a number of new tech- weld appurtenances up to 1.625 T nologies to improve productivity in. in diameter. Modifications in- and reduce the manufacturing costs for volved adding a spring-loaded the Marine Corps' new Advanced Am- collet assembly to hold the ap- phibious Assault Vehicle (AAAV). The purtenances, and flywheels to in- development of friction stir welding and crease energy output. The design distortion control procedures were de- of the appurtenance was adapted scribed in the March 2000 issue of the to accommodate friction weld- Welding Journal. Another project at the ing. An optimum preweld clean- NJC is developing improved methods ing method was developed to to weld appurtenances to the high- maximize joint strength. Mock- strength aluminum armor structure of up parts were produced and suc- this vehicle. This project is being con- cessfully tested. Test data indi- ducted at Edison Welding Institute cates friction welded appurte- (EWI) and involves the AAAV Team, nances have between 25 and 30% which includes the Marine Corps and greater strength than the current Examph, oJ the al)l)urtenances that serve as at- General Dynamics Land Systems GMAW method and welds can tachment point sfor armor panels, electronic (GDLS.) be produced in about half the components, seats and other equipment on the Appurtenances are threaded alu- time using a mechanized gantry- Marine Corps" new Advanced Amphibious As- minum bosses that serve as attachment positioning system. sault Vehicle (AAA V). points for armor panels, electronic After refining the process, components, seats and other equip- several appurtenances were re- ment. The bosses range in size from cently friction welded on a pro- 0.875 to 1.625-in. in diameter. There are totype vehicle AAAV structure at the equipment to provide sufficient current approximately 1000 appurtenances that GDLS facility in Lima, OH. Six appur- and to control the weld upset. must be welded to 2519-T87 plates both tenances were friction welded to the These improved methods for attach- inside and outside the vehicle. The pre- roof of the vehicle. Tests on this vehi- ing appurtenances support the goals for sent method is to manually gas metal cle will permit a direct comparison of reduced acquisition and life cycle costs arc weld (GMAW) each appurtenance the performance of friction welded and of the AAAV. The alternate welding in place, which is costly and time con- gas metal arc welded appurtenances. processes and procedures developed suming. Savings in the production Final project tasks will produce ballis- during this project will improve the per- schedule and in costs could result from tic test panels, develop production pro- formance, reduce distortion and reduce the development of mechanized or au- cess controls and transition the technol- the fabrication cost of the AAAV. tomated appurtenance welding proce- ogy to GDLS. Technology transfer will For more information, contact Tim dures. The goal is to cut total welding include operator training and develop- Trapp, NJC, at (614) 688-5231 or time in half, while maintaining or im- ment of production equipment specifi- tim [email protected]. proving weld strength. cations. Initially, the NJC evaluated three al- The NJC is also developing the ternative welding processes for appur- drawn-arc stud welding (SW) process tenances: friction welding (FW), resis- for large diameter aluminum appurte- tance projection welding (RPW), and nances using a Silicon TM power source drawn-arc stud welding (SW). This and weld head. Arc stud welding equip- study demonstrated friction welding ment is more portable and requires and arc stud welding have productivity lower reaction loads during welding advantages for this application com- than friction welding. The weld head is pared to manual GMAW. more compact than FW or GMAW Friction welding of appurtenances equipment, which permits welding in The Navy Joining Center 1250 Arthur E. Adams Dr. has been successfully developed and areas with limited access. Initial feasi- ~~ Columbus, OH 43221 demonstrated on a production proto- bility tests on 0.5-in. diameter appurte- Phone: (614) 688-5010 type AAAV structure. The procedure nances showed weld strengths that are Operated by FAX: (614) 688-5001 uses a modified, direct-drive Ram equivalent to the GMAW process. Arc ~i e-mail:[email protected] Stud TM friction welding machine with a stud welding of large diameter alu- www: http://www.ewLorg hydraulic fluid motor. This machine was minum appurtenances requires special Contact: Harvey Castner

WELDING JOURNAL I 55 c Lvents

• 5th Robotic Are Welding Conference and Exposition. Febru- Conferences and Exhibitions ary 2-6, 2001, Grosvenor Resort, Orlando, Fla. Sponsored by the American Welding Society. Contact: AWS Conference EuroBLECH 2000: 16th International Sheet Metal Working Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 Technology Exposition. December 5-9, Hannover, Germany. ext. 223, FAX: (305) 443-1552. Contact: Mack-Brooks Exhibitions Ltd., Forum Place, Hatfield Herts ALl0 0RN, U.K., +44 (0)1707 275641, FAX: +44 NACE Northern Area Western Conference. February 26-28, 2001, Hilton Hotel, Anchorage, Alaska. Sponsored by NACE (0)1707 275544. International, the Corrosion Society. Contact: Dan Powell, Co- • ICAWT 2000, the International Conference on Advances in chairman, (403) 235-6400, e-mail: [email protected]. Welding Technology. December 7-8, Grosvenor Resort, Or- International Laser Safety Conference. March 5-8, 2001, Cata- lando, Fla. Sponsored by the American Welding Society. Con- maran Resort Hotel, San Diego, Calif. Sponsored by the Laser tact: AWS Conference Dept., 550 NW LeJeune Rd., Miami, FL Institute of America. Contact: LIA, 13501 Ingenuity Dr., Ste. 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552. 128, Orlando, FL 32826. Second EPRI Corrosion and Degradation Conference. Decem- NACE International -- Corrosion 2001, Conference and Exhi- ber 11-14, Wyndham's Casa Marina Resort & Beach House, Key West, Fla. Cosponsored by EPRI and NACE. Contact: bition. March 11-16, 2001, George R. Brown Convention Cen- Brent Lancaster, CCM Conference Manager, EPRI, 1300 WT. ter, Houston, Tex. Sponsored by NACE International, the Cor- rosion Society. Contact: NACE Membership Services, (281) Harris Blvd., Charlotte, NC 28262, (704) 547-6017, FAX: (704) 228-6223, FAX: (281) 228-6329, www.nace.org. 547-6168. WESTEC 2001: Advanced Productivity Exposition. March Orlando 2001 Advanced Productivity Exposition. January 16-18, 2001, Orange County Convention Center, Orlando, Fla. 26-29, 2001, Los Angeles Convention Center, Los Angeles, Contact Laura Heidrich, (313) 271-1500 ext. 1853 or e-maih heidlau @sme.org. Note: A diamond (#) denotes an A WS-sponsored event.

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Circle No. 31 on Reader Info-Card

56 J DECEMBER 2000 f Calif. Sponsored by the Society of Manufacturing Engineers. Powerful Solutions For Welding And Cutting Automation Contact: SME Customer Service, One SME Dr., Dearborn, MI 48121, (800) 733-4763, (313) 271-1500, FAX: (313) 271-2861. Precision Cutting Max International. May 6-10, 2001, IX Center, Cleveland, Ohio. Cohosted by the American Welding Society and The Pre- Automation cision Metalforming Association, this collocated event is com- prised of The AWS International Welding and Fabricating Ex- position and Annual Conference and METALFORM ExpoSium. Contact: AWS Convention and Expositions Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 256 or (305) 443-9353 ext. 256, FAX: (305) 442-7451.

Tenth International JOM Jubilee Conference on the Joining of Materials, Jom-10. May 11-14, 2001, Helsingor-Denmark. Cosponsored by the Institute for the Joining of Materials and AWS. Contact: Institute for the Joining of Materials, Klintoh0j V~enge 21, DK-3460 Birker0d, Denmark, 45 45 82 80 85, FAX 45 45 94 08 55 or e-mail: [email protected].

Twin Cities 2001 Advanced Productivity Exposition. May 15-17, Bug-O Systems has been showing manufacturen 2001, Minneapolis Convention Center, Minneapolis, Minn. how to automate their welding applications for mort Sponsored by the Society of Manufacturing Engineers (SME), than 50 years. We would be happy to discuss an' applications you have in mind. America Machine Tool Distributors' Association (AMTDA) If you have any questions or applications you'd lik~ and The Association for Manufacturing Technology (AMT). to discuss, call 1-800-245-3186 ext. 55. Contact: SME Customer Service, (800) 733-4763 or (313) 271- 1500 ext. 1600 or visit the SME Web site at www.sme.org. International Robots and Vision Show. June 5-7, 2001, Rose- O mont Convention Center, Chicago. Sponsored by the Robotic Bug-O Systems Industries Association (RIA) and Automated Imaging Associ- 3001 West Carson Street Pittsburgh, PA USA15204-1899 Phone: 1-412-331-1776 Fax: 1-412-331-0383 ation (AIA). Contact: RIA/AIA, 900 Victors Way, P.O. Box http://www.bugo.com o< C' 3724, Ann Arbor, MI 48106, (734) 994-6088, www. robotics.org or www.automated-imaging.org. Circle No. 5 on Reader Info-Card

International Conference on Advances in Materials and Pro- cessing Technologies. September 18-21, 2001, Legan6s, Madrid, Spain. Contact: AMPT '01 Congress Secretariat, Fun- daci6n Universidad Carlos III, Congrega, Avda. de la Universi- dad, 30, 28911 Legan6s, Madrid, Spain, 34 91 624 91 42, FAX: 34 91 624 91 47, e-mail: [email protected].

Machine Tool Exposition. September 24-26, 2001, Las Vegas Convention Center, Las Vegas, Nev. Contact: William Yeates, Show Manager, (702) 566-7300, FAX: (702) 566-7300. Educational Opportunities

ASME Section IX: Welding and Brazing Qualifications Course. January 31-February 2, 2001, New Orleans, La. Conducted by the American Society of Mechanical Engineers. Contact: Shari Romar, Senior Education Specialist, ASME International, Three Park Ave., New York, NY 10016, (212) 591-7902, FAX: (212) 591-7143, e-mail: [email protected]. manent marks'onmetal, wood, plastic, glass, cardboard, etc. They write on any surface: rough or smooth, wet or oily; even marks underwater. CWI/CWE Training. January 29-February 9, 2001, Edison The plastic case prevents the paint from drying out so it always writes Welding Institute, Columbus, Ohio. Contact: Rich Green, (614) easily and smoothly. The case also allows you to use the entire stick 688-5126, e-mail [email protected], or Candice Mahanay, without needing a separate holder. (614) 688-5180, e-mail [email protected]. To register, EWI Registration Hotline (614) 688-5252. For information, The markers are available in two sizes: Standard and ]umbo and four www.ewi.org. fast-d~.ing, lead-freecolors: white, yellow, red and black.

• ASME Section IX Seminar. January 4-5, 2001, Paper Valley Hotel and Conference Center, Appleton, Wis. Sponsored by the AWS Fox Valley Section. Contact: (920) 845-5992.

• DI.I: 2000 Structural Welding Code -- Steel. A five-day seminar. Sponsored by AWS. For more information and complete -- cont#uted on page 59 Circle No. 20 on Reader Info-Card

WELDING IOURNAL I 57 Educational Opportunities

AWS Schedule -- CWI/CWE Prep Courses and Exams

Exam application must be submitted six weeks before exam date. For exam information and application, contact the AWS Certification Dept., (800) 443-9353 ext. 273. For exam prep course information, contact the AWS Education Dept., (800) 443-9353 ext. 229. Dates are subject to change.

Cities Exam Prep CWI/CWE Cities Exam Prep CNVI/CWE Courses Exams Courses Exams

Los Angeles, Calif. Jan. 22-26, 2001 Jan. 27, 2001 Anchorage, Alaska EXAM ONLY March 24, 2001 (API 1104 clinic also offered) Atlanta, Ga. Feb. 26-March 2, 2001 March 3, 2001 Miami, Fla. Dec. 4-8 Dec. 9 (API 1104 clinic also offered) Miami, Fla. EXAM ONLY Jan. 18, 2001 Birmingham, Ala. EXAM ONLY May 26, 2001 Buffalo, N.Y. EXAM ONLY Feb. 17, 2001 Miami, Fla. EXAM ONLY March 15, 2001 Charlotte, N.C. Feb. 12-16, 2001 Feb. 17, 2001 Minneapolis, Minn. March 5-9, 2001 March 10, 2001 Chica~o, IlL April 30-May 4, 2001 May 5, 2001 Mobile, Ala. EXAM ONLY Feb. 17, 2001 Cleveland, Ohio Dec. 4-8 Dec. 9 Newark, N.J. EXAM ONLY Jan. 27, 2001 Columbus, Ohio EXAM ONLY March 3, 2001 Newark, N.J. March 12-16, 2001 March 17, 2001 Dallas, Tex. Jan. 29-Feb. 2, 2001 Feb. 3, 2001 Oklahoma City, Okla. Feb. 5-9, 2001 Feb. 10, 2001 (API 1104 clinic also offered) Perrysburg, Ohio EXAM ONLY March 24, 2001 Denver, Colo. Feb. 26-March 2, 2001 March 3, 2001 Portland, Maine April 2-6, 2001 April 7, 2001 Phoenix, Ariz. March 19-23, 2001 March 24, 2001 Fresno, Calif. EXAM ONLY Jan. 13, 2001 Gulfport, Miss. Feb. 19-23, 2001 Feb. 24, 2001 Salt Lake City, Utah Jan. 29-Feb. 2, 2001 Feb. 3, 2001 Houston, Tex. March 5-9, 2001 March 10, 2001 San Francisco, Ca. May 14-18, 2001 May 19, 2001 (API 1104 clinic/ Shreveport, La. Jan. 22-26, 2001 Jan. 27, 2001 SCWl also offered) Springfield, Mo. March 19-23, 2001 March 24, 2001 Knoxville, Tenn. March 12-16, 2001 March 17, 2001 Tampa, Fla. Jan. 29-Feb. 2, 2001 Feb. 3, 2001 (API 1104 clinic also offered) (API 1104 clinic also offered) Tulsa, Okla. EXAM ONLY March 10, 2001 Las Vegas, Nev. EXAM ONLY Jan. 13, 2001 Las Vegas, Nev. April 23-27, 2001 April 28, 2001

1Dedicated to the pipe fabrication industry I Setting

all AROUND the world

200u AUTOMATIONLTI~E 1321 Hocquart Street, St- Bruno, QC Canada J3V 6B5 Tel.: (450) 461-1221 Fax: (450) 461-0808 www.tecnar-automation.com

= ~ii!iiiiii!:i~! ¸I:

Circle No. 32 on Reader Info-Card 58l DECEMBER 2000 -- continued from page 57 schedule, contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

Plasma 2000 Training Courses. Conducted by Centricut. For class times and locations, contact: Centricut, LLC, Two Tech- nology Dr., West Lebanon, NH 03784, (800) 752-7623 or (603) 298-7849, FAX: (800) 317-0438 or (603) 298-5938.

Welding Skills Training Courses. Courses include weldability of ferrous and nonferrous metals, arc welding inspection and quality control, preparation for recertification of CWI and other courses. For complete schedule, contact: Hobart Institute of Welding Technology, 400 Trade Square E., Troy, OH 45373, (800) 332-9448, (937) 332-5000, FAX: (937) 332-5200.

Structural Welding: Design and Specification Seminars. Con- ducted by the Steel Structures Technology Center (SSTC). For 2000 schedule and locations, contact: SSTC, (248) 344-2910, FAX: (248) 344-2911.

Machine Safeguarding Seminars. Conducted by Rockford Sys- tems, Inc. For schedule and more information, contact: Rock- Cypress CB-1P Plasma Circle Burner ford Systems, EO. Box 5525, Rockford, IL 61125, (800) 922- 7533, (815) 874-7891, FAX: (815) 874-6144. Cypress Welding has been saving manufacturers time and money by making equipment that burns ASME International m Section IX Welding Guide. Course accurate holes for more than 25 years. #ZCD996. Introduction and review of Section IX welding in- -D! formation including welding documentation forms, review of Ar- ./~1~ CYPRESS WELDING EQUIPMENT, INC, ticles I and IV, sample WPS and review; sample PQR and review; P.O. BOX 690168 ° HOUSTON, TEXAS 77269 testing and examination requirements for performance qualifi- PHONE: 1-281-469-0746 ° FAX: 1-281-469-9354 cation; and other issues relating to Section IX. For information, www.cyypressweld.com ( E www.asme.org/pro_dev. Circle No. 9 on Reader Info-Card

MIX YOUR OWN SHIELD GASES Upgrade your MIG or TIG wel

Circle No. 33 on Reader Info-Card Circle No. 10 on Reader Info-Card WELDING JOURNAL J 59 by providing a sufficient amount of oxy- atmosphere is suitable to start the braz- gen, in the form of moisture, to react with ing operation. It will also show any BY R. L. PEASLEE the carbon to form CO, which is a gas. changes in the dew point as different There are a number of methods used parts are put into the furnace and door to increase the oxygen (dew point) in the openings are adjusted for the parts. Q: Our new continuous brazing furnace furnace. One of the most common meth- Since your furnace is already built, a has just been installed, and we are ex- ods is to bubble some of the atmosphere simple way of checking the dew point in periencing problems with it. The furnace through a water bath to pick up oxygen the hot zone is to feed in a stainless steel is six ft long, plus the cooling zone, and and mix it back into the furnace. Other tubing, approximately '/4 in. I.D., along it is equipped with a muffle for stainless methods consist of adding a controlled side of the belt until it reaches the cen- steel parts. We are using bottled nitro- amount of CO 2 gas, or air, into the at- ter of the hot zone. This can then be at- gen and hydrogen and flowing 800 ft3/h mosphere line going into the hot zone of tached to the dew-point recorder. It will of nitrogen and 120 ft3/h of hydrogen. the furnace. A small quantity of the air be necessary to use a small vacuum pump We do not have a dew-point instrument, will combine with hydrogen in the fur- to suck the atmosphere out of the fur- nor do we have a water bubbler to change nace to increase the dew point of the at- nace, through the pipe and into the dew- the dew-point atmosphere. Most of the mosphere. Similarly, some of the oxygen point instrument. To obtain an accurate time the copper does not melt but in- in the CO 2 will combine with the hydro- dew-point reading, you will not want to stead sits on the part, as a fillet or blob, gen at the brazing temperature to form use plastic- or rubber-type tubing, or, if as it has been applied. When the copper the higher dew point. you must, use just enough tubing to make does melt, it does not fill the bottom of Since you do not have the facilities to a connection. Thin-wall rubber and plas- the joint, and the bottom of the part that handle any one of these methods to in- tic tubing are porous. When the dew sets on the belt is discolored. Can you crease the oxygen content in the furnace, point and oxygen on the outside of the shed some light on this problem? an alternate method is to reduce the tubing are higher than on the inside, the amount of atmosphere flowing into the oxygen and moisture will actually diffuse A: Since your nitrogen and hydrogen furnace and allow the oxygen brought in through the wall of the tubing, causing cylinders are undoubtedly filled from a with the parts and at the door opening erroneous readings on the dew-point in- cryogenic source, the dew point is going to build up the dew point to a level that struments. to be very low. In a low-dew-point atmo- will burn off the carbon. This will allow The hydrogen of 2-5%, with nitrogen, sphere, the copper paste breaks down the copper to agglomerate and flow into is suitable atmosphere for brazing of the because the copper reacts as a catalyst the joint. carbon steel parts with copper. As you and breaks down the binders into oxy- To obtain satisfactory control of your vary the amount of nitrogen to control gen, hydrogen and carbon. The carbon brazing operation, it is important you the influx of oxygen, the nitrogen/hydro- coats all of the particles of copper, thus have a dew-point instrument to measure gen ratio should be maintained. In your not allowing them to agglomerate after the dew point of the atmosphere in the furnace, I suspect you could get by with melting. Therefore, when the parts come hot zone of the furnace. Most dew-point around 150 ft3/h of nitrogen in order to out of the furnace, the copper is in the instruments can be a continuous opera- allow enough oxygen to enter the fur- same form and location as when it was tion and can be connected to a multiple- nace to raise your dew point enough to applied. To allow the copper, when point temperature recorder or to a sep- eliminate your carbon problem. melted, to join with other melted copper arate recorder to show the variation in In reference to the parts being discol- particles and flow into the joint, it is nec- dew point when starting up the furnace. ored on the bottom next to the belt, essary to remove the carbon. This is done This will give you an indication when the check if the belt speed is running so fast the furnace does not have an opportunity to heat both the belt and the part to the brazing temperature. Slowing down the belt speed should allow the belt to come up to the brazing temperature, thus Torch Cleaner Turning Table Enclosed Robot (Indexer) Robotic Overload allowing the bottom of the part to clean Welding Cells Protection Sensors up and braze satisfactorily. While I do not know of many furnaces using the atmosphere-flow rate to control the dew point, it is a very suitable method. A benefit of this method is the reduction of the atmosphere cost.t With over 20 years experience with welding products, IPR-RAS designs and manufactures state-of-the-art torch cleaners, turning R. L. PEASLEE is Vice President, Wall tables, enclosed welding cells, overload protection sensors, & more. Colmonoy Corp., Madison Heights, Mich. This

For more info or a free brochure call us today. /nteH,q~r Pe,,~a/s fz ~ts article is based on a column prepared for the In Michigan: 734-433-0283 or in Connecticut: 203-222-0298 A WS Detroit Brazing and Soldering Division's newsletter. Reader questions may be sent to Mr. Peaslee c/o Welding Journal, 550 N. W. LeJeune Rd., Miami, FL 33126. Circle No. 19 on Reader Info-Card 60 I DECEMBER 2000 Powerful Solutions For Welding And Cutting Automation Precision Welding Automation

Bug-O Systems has been showing manufacturers N illions of times each day, Wolverine meets how to automate their welding applications for more the needs of its customers by producing the highest than 50 years• We would be happy to discuss any quality, most innovative tubular and fabricated applications you have in mind. products in the world. Our heat transfer products are If you have any questions or applications you'd like considered enabling technologies in many of the to discuss, call 1-800-245-3186 ext. 55• industries where our customers do business. Therefore, we are very sensitive to the needs of our customers and the markets that we serve and will only pursue those opportunities and businesses that 0 support both. Bug-O Systems 3001 West Carson Street Pittsburgh, PA USA15204-1899 Accordingly, we are delighted to announce Phone: 1-412-331-1776 Fax: 1-412-331-0383 that Wolverine , SILVALOY ~, http://www.bugo.com, <>< CE has completed its acquisition of ..... ~..,.~ ..... Engelhard's joining products [~,~'~'~,., Circle No. 6 on Reader Info-Card is outstanding news for our "~, ~~./." "~4b" company--a wm-wln• • for .,,;.~0,~,o~ ....~":~-~6-" ,¢~ - ~i...-" ,~,,.'.• everyone. In fact, we will fill/'~r "~'~i'i~a~ar.:," "~ operate the business as /////.~ ~">,i'#~;- Wolverine Joining ////', ..... ,'" Technologies, which ///. Bridge the gap with underscores our commitment to being a technology leader and uniquely positions us to better serve our DIVERS ACADEMY customers around the globe.

Wolverine Joining Technologies manufactures all forms of silver and phosphorous brazing alloys and solder, as well as the supplementary fluxes. These products are industry-leading brand names such as: Silvaloy'", Silvabrite, Silvabrite 100", Plymetal, Black Flux and Ultra Flux~L

TO YOUR FUTURE IN... WOLVERINE TUBE, INC. A WORLD-CLASSQUALITY I'A RTNt R COMMERCIAL DIVING To learn more about these • SURFACE SUPPLIED AIR/MIXED GAS • UNDERWATER WELDING AND BURNING • REMOTELY OPERATED VEHICLES great products call us today! (ROVs) • NDT ULTRASONICS • FINANCIAL AID FOR QUALIFIED STUDENTS • APPROVED FOR VETERANS TRAINING WolverineJoining Technologies Wolverine Tube, Inc• 235 Kilvert Street 1525 Perimeter Parkway - Suite 210 Warwick, RI 02886 Huntsville, AL 35806 CALL TODAY (800)-238-DIVE 800-225-2130 800-633-3972 DIVERS ACADEMY OF THE EASTERN SEABOARD,INC www.silvaloy.com www.wlv.com 0Qt~Training Since 1977 2500 BROADWAY,CAMDEN, NJ 08104

Circle No. 36 on Reader Info-Card WELDING JOURNAL I 61 nent to construction and repair opera- Literature tions in many other fields including au- For more information, circle number on tomotive restoration, antique auto parts, Reader Information Card. auto racing, aviation repairs, bicycle Gas Detecting and Monitoring Products Catalog Published

This 76-page, full-color catalog and reference guide features the company's full line of portable and fixed gas monitors and systems. Also featured are single- and multi-,,as~• portable monitors, confined

building, motorcycle repairs, agricultural equipment, sheet metal and general industrial maintenance. Much of the video cluded are a large selection of sorbents, footage was adapted from actual World booms, pads, mats, kits and more. The War II training films. Detailed opera- company offers free technical support tions include aluminum welding, preci- and fast shipping. If a client requires a sion frame alignment, tube straighten- product not listed in the catalog, the ing, replacement and welding, safety pro- company will make every effort to get it cedures, fabric covering, undercoating for them. and finish painting. Subjects of the his- toric original footage include the J3 Cub, Lab Safety and Supply Inc. 121 the P-38 Lightning and the Hellcat P.O. Box 1368, Janesville, WI 53547-1368 fighter. The videos are a marriage of the space kits, fixed monitoring systems, and old with the new, and culminate with repair and rental information. Contained Videos Highlight Sheet Metal some up-to-date tooling. Today's in the catalog are detailed specifications, and Tube Fabrication footage covers subjects such as modern calibration equipment, applicable acces- sheet metal tooling for free-forming sories and pricing information. A series of videos combines film sheet metal parts. Demonstrations in- footage of the craftsmanship that played clude stretching, shrinking, hammer/ Industrial Scientific Corp. 120 a major role in keeping World War II buck forming and planishing with man- 1001 Oakdale Rd., Oakdale, PA 15071-1500 fighter planes in the air with an introduc- ual tools. Also shown are a series of spe- tion to some of today's most diverse cially designed air and electric motor- Spill Control and Cleanup Catalog sheet metal tooling. Though the videos driven machines for shipping and plan- Helps Keep Workplaces Clean feature aircraft industry building, repair ishing larger sheet steel parts. and welding operations -- the sheet This catalog presents 272 pages of metal and tube fabrication techniques TM Technologies spill control and cleanup products. In- demonstrated would be directly perti- 17167 Salmon Mine Rd., Nevada City, CA 95959

Aluminum Brochure Provides PROTECT YOUR INVESTMENT Unique Welding Solutions This 10-page, full-color aluminum welding brochure details the challenges and solutions to welding the lightweight but durable metal. Included are customer testimonials and specifications for the

• CABLE PROTECTORJ, speciallydesigned for the welding Industry, strong enough to withstand the heat and wear of tlg and mig SCHAFF welding and plasma cutting applications • Custom made in leather to your exact specs INTERNATIONAL • Velcro closures for easy Installation 451 Oakwood Road • Robot covers, welding skirts also available Lake Zurich, Illinois 60047 Call or fax for price list and information (847) 4384560 • Fax (847) 438-4615 Circle No. 28 on Reader Info-Card

62 I DECEMBER 2000 company's most appropriate welding and are covered in this 12-page buyers' guide. wheels; and pipeline files, cones and plasma arc cutting products used in light, The brochure presents the company's plugs. Complete size and specification medium and heavy duty, automated and full line of abrasive and wire brush hand information is shown in easy-to-read ta- high-tech aluminum welding applications. tools specifically for pipeline weld prepa- bles along with pictures of the products ration, cleaning and finishing tasks. The and the recommended types of power Miller Electric Mfg. Co. 122 product categories include stringer bead, tools that are applicable. 1635 W. Spencer St., P.O. Box 1079, Appleton, WI 54912 knot and encapsulated wire wheels; crimped, knot and encapsulated cup PFERD Inc. 124 Hydrogen Generator Brochure brushes; mini-grinder wheels and cups; 30 Jytek Dr., Leominster, MA 01453 Ideal for Gas Chromatography scratch, dauber and welder's tooth brushes; pipeliner grinding and cut-off This brochure describes the generators produced by this specialty gas manufacturer. These generators produce hydrogen at delivery pressures up to 200 lb/in. 2 (newer techniques require higher

gas pressure). The generators use deion- ized water to produce ultra-pure hydrogen, without using caustic electrolyte solutions.The Proton Exchange Mem- brane Technology used in the generators reduces impurities, and a specially designed palladium purifier removes water from the produced hydrogen without using dessicant cartridges. The brochure illustrates this technology and includes specifications, ordering information and information on optional accessories.

Matheson Tri-Gas 123 166 Keystone Dr., Montgomeryville, PA 18936

Catalog Covers Hand Tools for Pipe Welding Tasks

More than 130 individual products

Circle No. 24 on Reader Info-Card

WELDING JOURNAL I 63 intersection points. The method of point relation between chemical composition counting to estimate volume percent of and percent ferrite is imperfect -- sig- a given phase is defined in the ASTM E nificant elements such as nitrogen were 562 standard. Manual point counting is not part of the Schaeffler Diagram, and BY DAMIAN J. KOTECKI laborious, but the job can be automated there are inaccuracies in any such dia- by using an image analyzing microscope, gram. For example, the Schaeffler Dia- Q: I understand a little ferrite in a following the method of ASTM E 1245. gram is clearly incorrect in its treatment nominally austenitie stainless steel weld A major drawback to point counting is of manganese in the Nickel Equivalent. is helpful in preventing hot cracking. that it is a destructive test -- the weld Determination of ferrite by metallo- But why are there two measures -- per- metal actually sampled usually can't be graphic means turned out to be equally cent ferrite and Ferrite Number? What the weldment put into service. A second non reproducible. In the late 1960s and is the difference? Does it matter which major drawback is that point counting early 1970s, round robins of ferrite de- I specify? results are very sensitive to the quality termination by metallographic means of the etching of the sample and to in- were run in the Welding Research Coun- A:You are quite correct, a little ferrite terpretation of points falling on bound- cil, Subcommittee on Welding Stainless in a nominally austenitic stainless steel aries between phases. Steel, and in the International Institute weld metal, such as 308L or 316L, is very In 1949, Anton "Tony" Schaeffler of Welding, Commission II. These round helpful in preventing hot cracking. So, published the well-known Schaeffler Di- robins showed, for example, that several of course, the various organizations in- agram that linked chemical composition laboratories might measure anywhere volved in provision of a welding filler to percent ferrite determined by metal- from 3 to 8% ferrite on a single sample metal have a vested interest in how the lographic methods (Metal Progress, of weld metal. So it was difficult for sev- ferrite requirements for a filler metal are 56(11): 680-680B). While the Schaeffier eral organizations to agree that a speci- specified. This has an important bearing Diagram was originally conceived as a fication like 5 to 10% ferrite was actu- on whether or not a given lot of filler predicting tool to provide guidance in ally met. When they didn't agree, delays metal is accepted for use. filler metal design and selection, people in construction resulted while the dis- By the time of World War II, the de- started to apply it for specification, e.g., agreeing parties attempted to resolve sirability of ferrite in nominally the filler metal shall provide 5 to 10% their differences. austenitic stainless steel welds as a means ferrite when its composition is plotted Besides etching appearance, ferrite of preventing hot cracking was recog- on the Schaeffler Diagram. While sim- has another property that allows it to be nized. The ferrite was originally detected ple in concept, this led to numerous differentiated from austenite -- ferrite by metallographic examination. The problems. A major problem is there are is ferro-magnetic, while austenite is not. weld metal examined had to be cut into usually several organizations concerned To a first approximation, the magnetic a specimen suitable for polishing, etched with the safety of a weldment that goes properties of a ferrite/austenite mixture carefully to differentiate between ferrite into, for example, a power plant. No one of weld metal are proportional to the fer- and austenite and then some means of organization entirely trusts the other, so rite content. (There is also a composi- determining the volume fraction of fer- chemical analysis might be provided by tional effect -- in general, ferrite higher rite had to be applied. Usually, this in- the filler metal manufacturer, checked in alloy content has a somewhat weaker volved point counting, in which a grid of by the fabricator and rechecked by the magnetic response than lower alloy fer- orthogonal intersecting lines would be master contractor. Not surprisingly, rite, but this effect is not important in in- overlaid on a photograph of the mi- when three organizations independently terpreting the measurements.) A mag- crostructure. Then, the percent ferrite perform chemical analysis on anything, netic scale for ferrite determination was would be obtained as the number of grid they don't all arrive at the same conclu- developed by the Welding Research intersection points falling on ferrite as a sion. Therefore, they don't get the same Council, and was published as the AWS percentage of the total number of grid predicted percent ferrite. Also, the cor- A4.2 standard in 1974. The A4.2 standard has been updated several times since 1974, and the latest edition was published ling Positioners in 1997. The magnetic method has become an international standard, ISO Productivity by over 125 % 8249, which was first published in 1985, and was updated in 2000. While the words )ration welding positioners from 200 to 1250 in AWS A4.2 are not identical to the ty. Compare our price, quality and features. words in ISO 8249, the standards are technically identical, as are the test results obtained by following the two stan- Call or Fax for free dards. The magnetic scale describes its brochures and price sheet. measurements in terms of Ferrite Num- M,,i, ,,,, ,, bers (FN), which were originally believed to numerically approximate percent fer- We also sell used welding positioners of all sizes. rite. However, it is quite clear today that, at least at higher Ferrite Numbers, the 1235 Lincoln Road ° Allegan, Michigan 49010 FN overstates the volume percent ferrite. Toll Free 800-710-9990 • PH: 616-673-6572 ° FAX: 616-673-1644 From the point of view of whether or not Circle No.2 on Reader Info-Card

64 I DECEMBER 2000 a specification requirement is met, the ment due to phase transformations at DAMIAN J. KOTECKI is Technical Director exact amount by which the FN overstates high temperature. And for duplex fer- for Stainless and High-Alloy Product ritic-austenitic stainless steel weld met- Development for The Lincoln Electric Co., the percent ferrite is unimportant. Of pri- Cleveland, Ohio. He is a member of the A WS mary importance is that the various par- als such as 2209, a specification range of A5D Subcommittee on Stainless Steel Filler ties in the supply and consumption chain 30 to 70 FN has been found to correlate Metals; AWS D1 Structural Welding for weld metal can reproduce the ferrite well with good corrosion resistance and Committee, Subcommittee on Stainless Steel measurement results, so there is no dis- good mechanical properties. Welding; and a member and past chair of the agreement about whether or not the spec- The Welding Research Council, the Welding Research Council Subcommittee on ification was met. And, of course, links International Institute of Welding and Welding Stainless Steels and Nickel Base the ASME Code strongly recommend Alloys. Questions may be sent to Mr. KotecM must be established between the speci- c/o Welding Journal, 550 N. W LeJeune Rd., fied ferrite range and acceptable weld specification of ferrite in stainless steel Miami, FL 33126. properties. After more than 25 years of weld metals by Ferrite Number, not by experience with Ferrite Numbers, the percent ferrite.4 links between FN and properties are well established. Round robin studies of FN determi- Vibratory Stress Relief nation by the Welding Research Council, and by the International Institute of Reduces Restdual Stresses Welding, for samples in the 5 to 10 FN range, demonstrated the reproducibility Due to Welding among a number of measuring laborato- "Formula 62 method utilizes high ampli- ries is better than _+ 1 FN. So, the repro- tude vibrations to reduce peak residual ducibility of FN measurements is consid- stresses close to yield stress levels near the erably better than that of percent ferrite weld center line. Vibrations remove high tensile determinations. In addition, FN measure- residual stresses due to welding in ferrous and non-ferrous metals. ment is non destructive. That is, the actual weldment can be evaluated, not only Send for a prefabrication weld sample. M free brochure. Predicting diagrams for welds, relat- STRESS RILIEF EnGInEERInG COmPAnY ing Ferrite Number to chemical compo- 1725 MonroviaAve., A-1 • Costa Mesa, CA 92627 sition, have been developed experimen- (949) 642-7820 • FAX (949) 642-0430 tally. The DeLong Diagram (Welding Journal 52(7): 281-s to 297-s) of 1973 was Circle No. 30 on Reader Info-Card updated by the Welding Research Coun- cil in 1988 (Welding Journal 67(12): 289- s to 298-s), and again in 1992 (Welding Journal 71(5): 171-s to 178-s). Today, the WRC-1992 Diagram is the official method of the ASME Code, for predicting FN when FN cannot be measured. But FN measurement is preferred to pre- Most Reliable Heat in the World TM diction from a Diagram. oulevard • Boaz, Alabama 35957 • phone 256-593-7770 So, to summarize, Ferrite Number measurement is more reproducible than ferrite percent measurement. Ferrite ,ntrolled Atmosphere Number is more conveniently measured than ferrite percent. And, because the uction Brazing System Ferrite Number measurement is a non- • All inclusive self contained installation destructive test, it is suitable for in-process quality assurance, while ferrite per- • Various size induction power supplies available cent is generally not. Specification of a Ferrite Number minimum, or of a FN • 50 to 60 parts per hour range when necessary, is far preferable to specifying a percent ferrite minimum • Atmosphere purity levels obtainable or range. For most weldments in nomi- to

WELDING JOURNAL I 65 viously with Textron Automotive Co. where he managed and developed electronic business programs and strategy. He holds a B.S. from Oakland Univer- sity and a master's degree from Central Michigan University with concentrations LORS Machinery in management information systems and Names Chairman economics. Jane Isley joined the company as Edward J. Onny [AWS], cofounder customer service manager. She will of LORS Machinery, Union, N.J., has Tifft manage all customer activities for the been named chairman of the board. A company's automation and industrial machine designer with more than 700 re- was the general manager of Tucker product lines. Prior to joining the com- sistance welder designs, he will continue Technology. He has more than 20 years pany, Isley was with ABT Building Prod- to guide LORS' design engineering staff of experience in the aerospace industry ucts Corp. She holds a B.A. degree from in addition to his corporate duties. Onny and holds a B.S. in Industrial Technol- DePauw University. began his welding career as a machine ogy from Northeastern State University. designer with the Larkin Welder Com- ASM Honors Member pany in New York. He left Larkin to form HI TecMetal Group the ONNY Pattern Works and, in 1960 Richard E. Feigel [AWS] vice presi- he became a cofounder and director of Announces Appointments dent of engineering at The Hartford LORS Machinery, Inc., where he headed Steam Boiler Inspection and Insurance the design engineering department. HI TecMetal Group (HTG), Cleve- Co., was honored by the American Soci- land, Ohio, announced the following ap- Onny is a Life Member of the American ety of Mechanical Engineers Interna- Welding Society. pointments: tional (ASME International) with the Kim Catron was named vice presi- Melvin R. Green Codes and Standards dent of operations. He has more than 25 LA-CO Industries Medal at the 2000 International Me- years of experience in materials manage- Appoints President chanical Engineering Congress and Ex- ment, human resources and general ac- position in Orlando, Fla. He was recog- count management. Catron will work La-Co Industries, Inc./Markal Co. ap- nized for visionary achievements in the with various Strategic Business Units to pointed John F. Hardin president and field of international standardization improve performance and assist with the chief operating officer. Before joining and advancing ASME's leadership role newly acquired companies and future ac- the company, Hardin spent ten years in the pressure equipment sector. quisitions. with Laporte plc, London, England. Feigel has been employed by The Mark Emerson [AWS] was appointed Hartford Steam Boiler Inspection and HTG Aerobraze as operations manager. Insurance Co. since 1977. He is currently Emerson received his B.S. degree in met- responsible for corporate quality initia- allurgical engineering from Purdue Uni- tives supporting the company's insurance versity. He is a member of the American and engineering consulting businesses. Welding Society, American Society for In previous positions, he was responsi- Materials, Society of Manufacturing En- ble for international inspection services gineers and is a voting member of the business, including ASME code inspec- Heat Treating Task Group for National tions. An early proponent of research Aerospace and Defense Contractors Ac- and application of risk-informed meth- creditation Program. ods, Feigel sponsored the company's support of the ASME Center for Re- Hardin DE-STA-CO Appoints Managers search and Technology Development's projects that resulted in the development DE-STA-CO Industries, Madison While there, he served as a divisional of widely used guidelines for risk-based Heights, Mich., a Dover Resources Com- managing director in the company's inspection. pany, announced the following appoint- Electronics Division. Hardin holds a B.S. A member of ASME since 1978, ments: in chemical engineering from the Uni- Feigei played a pivotal role in the devel- Tom Stimac was named product man- versity of Illinois and an M.B.A. from the opment of ASME codes and standards ager for the company's Industrial Prod- University of Chicago. Hardin replaces and has been instrumental in the effort uct Group. Stimac will manage all as- Dan Kleiman, who was promoted to to internationalize them. He was elected pects of product development and chairman and chief executive officer of to the ASME International Board of launch, competitive and market analy- the company. Governors and assumed that responsi- sis, pricing, promotion, sales and techni- bility in July 2000. cal support. After receiving his B.A. in philoso- Wall Colmonoy Names Dennis Gustafson was appointed In- phy at Purdue University in 1968, Feigel General Manager ternet and e-commerce business man- went on to earn his master's and doctor- ager. He will be responsible for develop- Bruce H. Tifft was named general ate degrees at Pennsylvania State Uni- ing, implementing and managing a mar- versity, University Park, in 1970 and manager of the Wall Colmonoy, Madi- keting plan for all U.S. Business units, 1984, respectively. son Heights, Mich., Oklahoma City Fa- evolving it into an Internet and electronic cility. Prior to joining the company, Tifft commerce presence. Gustafson was pre-

66 I DECEMBER 2000 / N E W S

By Susan Campbell # 2001-2002 National Leadership Nominees Annoulz(:ed

Richard L. Arn Ernest D. Levert Thomas M. Mustaleski James L: Greer

he 2001-2002 Nominating Committee has an- trict 11 director, Scott C. Chapple; District 14 director, nounced those candidates who will stand for Hil.J. Bax; District 17 director, Oren P. Reich; and Dis- election to AWS national offices for the trict 20 director, Jesse A. Grantham. 2001-2002 term, which begins in June 2001. The District 9 Nominating Committee elected John Bruskotter to fulfill the remaining term of District 9 Di- TNominated are the following: rector O.J.Templet commencing immediately through May 31, 2002 • For President: Richard L.Arn. The District 19 Nominating Committee elected Phil • ForVice President (three to be elected): Ernest Zammit to fulfill the remaining term of the late District D. Levert,Thomas M. Mustaleski and James E. Greer. 19 Director Don Delk, commencing immediately • For Director-at-Large (two to be elected): Damian through May 31, 2003. J. Kotecki and Richard Kellum. The National Nominating Committee was chaired by Past President Shirley Bollinger. Serving with Bollinger were M. D. Bell, R. E. Blaisdell, D. E Bovie, L. C. Nominated for President Heckendorn, J. L. Hunter, R. C. Lanier, V.Y. Matthews, R. Richard L. Arn C. Pierce, G. H. Putnam, P.Torchio III and R. K.Wiswesser. John J. McLaughlin served as secretary of the commit- Richard L. Arn, who is completing his third term tee. as an AWS vice president, is president of Teletherm The Nominating Committees for Districts 2, 5, 8, Technologies Inc. in East Liverpool, Ohio. Prior to as- 11, 14, 17 and 20 have selected the following candidates suming his current position, he held the position of for election or reelection as District Directors for three- division manager of the Fabricated Products Division year terms beginning June 1, 2001.The nominees are of Glunt Industries, Warren, Ohio. He also served the District 2 director, Al E Fleury; District 5 director, Wayne company as corporate manager of welding technology J. Engeron;District 8 director, Wallace E. Honey; Dis- concurrently with his division manager position.

WELDING JOURNAL [ 67 turing engineer for Lockheed Mar- several offices, including chairman tin Missiles and Fire Control in Dal- (1991-1992). He served on the Ex- las,Tex. Levert works in the Manu- ecutive Board of the San Diego Sec- facturing Engineering Department tion and was chairman of the AWS Prior to joining Glunt Industries on the International Space Station Student Chapter at The Ohio State as manager of welding technology, Thermal Control Units Program, Pa- University. Arn worked as a welder and weld- triot Advance Capability (PAC-3) Levert has received many ing technician for General American Army Tactical Missile System (ARMY awards for his work including the Transportation Corp., welder and TACMS), Line-of-Sight Missile Pro- Hypertherm Plasma Cutting Award welding foreman for the William B. gram (LOSAT), Joint Strike Fighter (April 2000), the Lockheed Martin Pollock Co., welding engineer for Program (JSF-F22),Advance Missile Vought Systems President Perfor- Pittsburgh Bridge and Iron Co., Programs and supports the X-33 Pro- mance Award Finalist for Employee welding engineer for Youngstown ject and Multiple Launch Rocket Sys- of the Year (1999), Lockheed Martin Welding and Engineering Co., man- tem. Previously, Levert worked for Vought Systems Special Recognition ager of fabricated products for Jefco General Dynamics, Convair Division, Award (1998), McDonnell-Douglas Industries and operations manager in San Diego as a welding engineer Certificate of Appreciation for Out- for Machine Dynamics and Engi- supporting the Atlas Space Vehicle standing Welding Engineering Sup- neering Co. Program, Tomahawk Cruise Missile port (1996) and the AWS District Arn, who began his career as a Program and Ground Launched Meritorious Award (1994). skilled craftsman, is proficient at Cruise Missile Program. Levert has most arc welding processes and has more than 30 years in welding sup- passed certification tests in accor- porting the aerospace and defense Nominated for Vice President dance with AWS,ASME,AAR,API and industries. He has presented several Thomas M. Mustaleski military specifications. He still en- papers on welding of aerospace ap- joys spending time on the shop floor plication with emphasis on the elec- Thomas M. Mustaleski, who is teaching up-and-coming craftsmen tron beam welding process. He is a currently serving his first term as the art and science of welding. registered professional engineer in vice president, has been with the Having been an active member the state of Texas and received his Oak Ridge Y-12 Plant of BWXT-Y12 of the Mahoning Valley Section for B.S. in welding engineering fromThe LLC (formerly Lockheed Martin En- 26 years, Arn still serves his local Ohio State University. ergy Systems, Inc.), Oak Ridge, section as a member of the Execu- Levert is currently serving on Tenn., since 1974. He is currently a tive Committee.As a third term vice the AWS Board of Directors, Execu- research staff member in the Devel- president of the Society, he serves tive Committee, Professional Devel- opment Division. Mustaleski's work on the National Board of Directors, opment Council, Government Affairs is in the areas of welding metallurgy Executive Committee, Compensa- Liaison Committee, National Educa- and process and procedure develop- tion Committee, Role and Missions tion Scholarship Committee, Gov- ment. He has been active in the tech- Committee, Government Affairs Li- erning Board Authorized National nology transfer programs at the Oak aison Committee, Honorary-Merito- Body, Prayer Breakfast Committee, Ridge Centers for Manufacturing rious Awards Committee and is B1 Committee on Method of Inspec- Technology. From 1980 to 1985, he chairman of the Standards Council. tion and C7B Committee on Electron served as group leader of the Join- Arn served on several Presidential Beam Welding and Cutting. He is ing Group. He had worked previ- Tasks Groups, both as a member and chairman of the Welding Industry ously as a senior welding engineer as chairman, and has been a member Networking (WIN) Committee and at the A. O. Smith Corp. (1969-1974) of Districts Council as District 10 di- a trustee with the Federation of Ma- and the Hamilton Standard Div. of rector. He has served as chairman of terials Societies (FMS). Levert repre- the United Aircraft Corp. as an elec- the Districts Council, Government sented the United States as a dele- tron beam welding applications en- Affairs Liaison Committee, Commu- gate for Commission IV, High-Energy gineer ( 1967-1969). nications Council and TFPS. He is Density Welding, at the 53rd Annual Mustaleski received his under- currently a member of the PEMCO, International Institute of Welding graduate degree in metallurgical en- Product Development, Certification (IIW) Assembly in Florence, Italy, and gineering at Rensselaer Polytechnic and Prayer Breakfast Committees. he served as the U.S. representative Institute in 1967. He has done sub- Arn studied business adminis- on the Select Committee forAircraft sequent graduate work in metallur- tration and metallurgical engineer- Engineering. gical engineering at the University ing at Youngstown State University Presently, Levert serves on the of Wisconsin-Milwaukee and the and welding technology at the Ho- Welding Advisory Boards of Texas University of Tennessee. bart School of Welding Technology. State Technical Community College, Mustaleski, who was designated Waco,Tex.; Mountain View Commu- a Distinguished Member of AWS in nity College, Dallas, Tex.; Tarrant 1989, is currently completing his sec- Nominated for Vice President County College, Fort Worth,Tex.; and ond term as director-at-large on the Ernest D. Levert Lakeview Centennial High School, Board of Directors for the American Garland,Tex. He also serves on the Welding Society. While on the board, Ernest D. Levert, an AWS Distin- Executive Board of the AWS North he has served on the Education,Tech- guished Member, is presently in his Texas Section. nical, Certification and Communica- second term as vice president. He is Levert joined the AWS North tions Councils and the Executive employed as a senior staff manufac- Texas Section in 1986 and has held Committee (1995-1996). He has

68 J DECEMBER 2000 been a member of a number of pres- tion of advanced joining processes idential task groups, including groups to industrial needs. addressing volunteer recognition, re- Mustaleski was the 1994 recipi- organization, the ANB, the Role & Mis- ent of the William Irrgang Memorial sions Committee and Technical De- Award from the American Welding partment review. Society. He has also received several Mustaleski has served as an of- Energy Systems and Department of ficer in two Sections of the Ameri- Energy awards for Quality Improve- canWelding Society. He relinquished ments and Technical Achievements. his post as first vice chairman of the DamiaH J. Kotecki Milwaukee Section when he left to accept employment in Oak Ridge, Nominated for Vice President Tenn.As a member of the Northeast James E. Greer Tennessee Section, he twice served as chairman (1982-1982 and James E. Greer has been em- Nominated for 1983-1984). He continues to serve ployed by Moraine Valley Commu- Director-at-Large the Section as education chairman nity College for 25 years and is cur- Damian J. Kotecki and foundation representative. He rently a professor and coordinator received the District Meritorious of the welding program. He is also Damian J. Kotecki received his Award in 1989, and he is on the president of Techno-Weld Welding Ph.D. degree in mechanical engineer- Welding Advisory Committee for Consultants. In his more than 20 ing from the University of Wisconsin- Oak Ridge High School. years as a consultant, Greer has had Madison. In 1989, he joinedThe Lin- Mustaleski is currently a mem- numerous experiences as a welding coln Electric Co., where he is now ber of the Technical Papers Commit- training specialist and master technical director for stainless and tee and its Poster Sessions and Peer welder. He has written and super- high-alloy product development. He Review Subcommittees, the Product vised the qualification of numerous has been active in the development Development Committee and the Welding Procedure Specifications to of welding filler metals, particularly Constitution and Bylaws Committee. various codes with many processes for stainless steels and hardfacing, He is also an advisory member of the on different types of material. Prior since 1974. C7 Committee on High Energy Beam to joining the college, Greer was Kotecki is a member of the Amer- Welding and Cutting and the C7B chief welding engineer for General ican Welding Society's (AWS) Na- Subcommittee on Electron Beam Railroad Co., Marseilles, Ill., and se- tional Board of Directors. He is past Welding and Cutting. From 1981 to nior welding specialist for Standard chair of the AWS Technical Activities 1995, he served as the chairman of Refrigeration Co., Melrose Park, Committee, the AWS Filler Metals the C7 Committee, of which he is a Ill.He is a hands-on welder qualified Committee, the WRC Subcommittee founding member, and served as the to AWS, API, ASME, MIL and DNV on Welding Stainless Steels and the first chairman of its C7B Subcom- specifications. WRC Subcommittee on Hardfacing mittee. During his term as chairman Greer holds an A.S. degree from and Wear and is currently an active of the Technical Activities Commit- Moraine Valley Community College, member of all four. In addition, he is tee (1989-1992), he was an ex offi- a B.S. from Northern Illinois Univer- the chair of the International Insti- cio member of the Safety and Health sity and an M.S. from Chicago State tute of Welding (IIW), Commission II, Committee, the Education Commit- University. as well as U.S. Delegate to that Com- tee and the Technical Papers Com- Currently, Greer is chairman of mission. He is a member of the AWS mittee, attending meetings of each the AWS Certification Committee, Technical Papers Committee, the IIW committee. On three occasions, he first vice chair of the A2 Committee Select Committee on Standardization, has served on the National Nominat- on Welding Terms and Definitions IIW Technical Committee and ISO ing Committee. He was also a partic- and a member of the Certification, TC44 and its Subcommittee 3. ipant at the AWS Concurro, Operations, Fabrication and Safety An AWS Fellow and registered Fastigium and Continuum and the Committee for the American Insti- professional engineer, Kotecki holds 1994 Henniker Conference. tute of Steel construction. He is also several patents for arc welding filler Mustaleski has also been a contrib- the AWS representative to the Steel metals and is the author of numerous utor to the Welding Handbook. Construction Roundtable. technical papers. Mustaleski is a member of the Greer remains active on the Sec- AWS presented Kotecki with the Industrial Advisory Board (IAB) of tion and District level. He is a mem- James E Lincoln Gold Medal in 1979 the Edison Welding Institute (EWI), ber of the Chicago Section where he and again in 1987; the William Irrgang and he chairs the Aerospace Indus- has served on the Board of Directors Award in 1987; the R. D. Thomas try Advisory Committee for EWI. He and was chairman for two terms Memorial Award in 1983; the R. D. is also a past chairman of the De- (1985-1986 and 1989-1990). Greer Thomas, Jr. International Lecture partment of Energy Interagency served as District 13 director from Award in 1994; the Prof. Dr. Rene Manufacturing Operations Groups 1990 to 1997. Wasserman Memorial Award in 1995 (IMOG) Joining Subgroup. He has Greer has been awarded the and 1997; the George E. Willis Award published more than 20 papers in AWS District Meritorious Award, the in 1995, and the A. E Davis Silver the field of joining research and de- Howard Atkins District Educator Medal in 1996. He was chosen for the velopment, emphasizing weldability Award and the District CWI of the IIWThomas Medal in 1999. of metals and alloys and the applica- Year Award. WELDING JOURNAL I 69 ~-~

Richard Kellum Alfred F. Fleury Wayne J, Engeron Wallace L: Honey John Brz~skotter Scott C Chapple

Nominated for 1978-1980, 1996), secretary (1964), forAnchor Research Corp. Honey re- Director-at-Large vice chairman (1967) and chairman ceived his bachelor's degree from Richard Kellum (1966). He has been active on many Samford University, Birmingham, committees including the Member- Ala., where he studied humanities Richard Kellum presently ship Committee, Program and Edu- and administrative services. Honey heads Willamette Welding Supply cational Lecture Committees (in served in the U.S. Army Reserves Co., a company he founded in 1984. 1963, he established the Section's from 1964 to 1970. Earlier he was employed in welding first Educational Lecture Series),Ad- In 1998, Honey was awarded the sales. He attended Oregon State Uni- vertising and Publicity Committees, District 8 Meritorious Certificate. He versity, where he studied chemistry Picnic Committee, Hospitality Com- served as chairman of the AWS and business. From 1968 to 1972, he mittee and the Executive Commit- Northeast Mississippi Section for served in the U.S. Navy, where he at- tee (1962, 1973-1984). Nationally, the 1999-2000 term. tended the Nuclear Power Program he has served on the National Nom- and served in the Office of Secure inating and National Membership Communications. Committees. Kellum joined AWS in 1979. In addition to being awarded Elected Director Over the years, he has held many of- AWS Life Member status in 1994, District 9 ficer posts in the Willamette Valley Fleury received the AWS District John Bruskotter Section. Kellum served as District 19 Meritorious Certificate in both 1997 director from 1994 to 2000. and 1985. John Bruskotter has been Kellum has served the Oregon elected to fulfill the remaining term Department of Education as a mem- Nominated for Director of District 9 Director O. J. Templet ber of the Reform Committee and District 5 for the term commencing immedi- the Committee on Applied Acade- Wayne J. Engeron ately through May 31, 2002. mics. He has also been an industry Bruskotter is currently a project advisor to the Oregon House of Rep- Wayne J. Engeron has been manager with Project Specialists Inc. resentatives. nominated to serve as District 5 di- From 1986 to 2000, he was employed rector. He has spent his entire work- with Houma Industries Inc., where ing career in the metal joining in- his positions included fabrication and Nominated for Director dustry.After 28 years as owner of quality control manager and vice District 2 welding supply distributorships, En- president of operations onshore, off- Alfred F. Fleury geron has been engaged in the op- shore fabrication and coatings and eration of Engineered Alloys/Sys- warehousing and maintenance. Alfred F. Fleury, an AWS Dis- tems & Supply in Tucker, Ga. Along Bruskotter joined the AWS New Orleans Section in 1993 and served tinguished member since 1989, with his sons, Engeron markets braz- began his welding career in 1953 ing, soldering and welding filler al- as treasurer (1997-1998), first vice with the Welding Products Division loys and systems. chairman (1997-1998) and chair- of M.T. Chemicals, Inc. In 1972, he Engeron earned an associate's man (1999-2000). While chairman, he also served as deputy District 9 joined Tempil ° Division of Big Three degree in industrial technology and Industries, Inc., which was later pur- is a Certified Welding Educator. director. chased by Air Liquide America, as Aside from AWS, Engeron is an general manager, and later served as active member of ASM, SME and senior business advisor. Fleury re- ASPE,ASHRAE. tired from Tempil ° in November of Nominated for Director 1997 and began his own consulting District 11 firm, A. Fleury and Associates, in Jan- Nominated for Director Scott C. Chapple uary of 1998. District 8 Fleury has been an active mem- Wallace E. Honey Scott Chapple has been a weld- ber of the New Jersey Section since ing engineer at Midway Products 1960.Among the many offices he has Wallace E. Honey has been Group, Monroe, Mich., since 1996. held are District director (1986- nominated to serve as District 8 di- Midway Products Group is a tier one 1992, 1998-2001), treasurer (1963, rector. He is a sales representative supplier of fabricated automotive

?0 I DECEMBER 2000 products for both foreign and do- .... mestic automakers. Chapple is a member of the AWS D8 Committee, D8C Subcommittee, Welding Handbook Committee, CIG, USA-TechnicalAdvisory Group and the Welding Engineering Advisory Coun- cil at Ferris State University, Big Rapids, Mich. Chapple is an AWS Certified Hila r), j~ Bax Oren P. Reich Pbil Zammit Jesse Grantham Welding Inspector and was the 1995-1996 chairman of the West Michigan Section of AWS. College.Among Reich's achievements in the National Association of Coating are the District Meritorious Certifi- Engineers and the Pacific Northwest cate in 1993, District EducatorAward Steel Fabrication Association. Nominated for Director in 1992 and being selected to serve District 14 as chairman of the State of Texas VICA Hilary J. Bax Welding Contest in 1985. Nominated for Director District 20 Hilary "Hil" J. Bax, an AWS Jesse Grantham member since 1979, is director of technical sales at Cee Kay Supply, St. Elected Director Jesse Grantham began his Louis, Mo. District 19 welding career in his grandfather's While serving on the board of Phil Zammit radiator repair shop and as a directors for the St. Louis Section, welder's helper in the offshore oil Bax has held several officers' posi- Phil Zammit has been elected and gas industry. He has been asso- tions including chairman, vice chair- to fulfill the remaining term of the ciated with fabrication, inspection man and secretary. His Section com- late District 19 Director Don Delk and testing laboratories since 1970. mittee chairs include program commencing immediately through Grantham is well-regarded as an ex- arrangement, awards and CWI activ- May 31,2003. pert on matters such as the current ities. Bax also serves as a Certified Zammit was born in Malta and practices and applications of weld- Welding Inspector test supervisor. began his working life in an intellec- ing science for management, metal- tual, rather than technical, career. After lurgy and processes used in manu- graduation, he worked for three years facturing and fabrication. He spe- as a customs officer. He then left Malta cializes in welding management and Nominated for Director for London, England, and worked in forensic engineering. District 17 the Dept. of Health and Social Secu- Grantham's formal education in- Oren P. Reich rity. Zammit, however, found he was cludes a B.S. in industrial engineer- unhappy with a position that relied ing and management from Okla- Oren P. Reich is an instructor solely on his intellect. He missed using homa State University in 1969; an in Industrial Maintenance Engineer- his hands. He soon traded in his suit M.B.A. from University of South- ing Technology at Texas State Tech- and tie for a pair of coveralls and work- western Louisiana with studies in nical College in Waco,Tex. He has an boots and plunged full time into weld- management, marketing and finance associate's degree in welding. Reich ing school. Eight months later, Zammit in 1982; an M.S. in welding engi- has been employed at Texas State was welding in a London shop using neering from The Ohio State Univer- Technical College since 1982. In mostly oxyacetylene and gas tungsten sity in 1988; and, in 1992, a Ph.D. in 1990, Reich founded Reich Services arc welding nonferrous metals. welding engineering from The Ohio Company, a consulting firm for sev- In 1978, Zammit moved to the State University. eral Texas companies in quality con- United States and accepted a position Grantham is an active member trol and quality assurance in the as a fitter/welder for R.A. Hanson Co. of a number of technical and profes- welding field. Reich also worked (RAHCO). During that time, he con- sion societies and has held offices with large Texas companies training tinued his welding education locally and nationally. He has re- their work forces on company sites through self-study and received his ceived many AWS honors and has from 1982-1995. CWI certification in 1985. In 1998, served as chairman of threeAWS Sec- Presently, Reich serves on the Ex- he accepted an opportunity to serve tions. Grantham is a registered pro- ecutive Board of the Central Texas as quality control inspector with Red fessional engineer in four states, and Section and is a judge for the Skills Iron Corp. (now Brooklyn Iron is currently a member of Colorado USA Secondary Welding Contest. He Works, Inc., and Brooklyn Industrial Professional Engineers and the Na- has held several AWS offices, includ- Coatings, Inc.), a steel fabrication tional Academy of Forensic Engi- ing chairman (1985-1987, 1987- shop. Zammit now serves as QA man- neers. His publications are primar- 1988, 1990-1991 and 1998-1999). ager for both Brooklyn Iron Works ily in the welding consumables, test- Reich is a supporter of the AWS Stu- and Brooklyn Industrial Coatings. ing and management fields. • dent Chapter at Texas State Technical Aside from AWS, Zammit is active

WELDING JOURNAL I ~l • Sustaining Company Member Dues Update AWS WELCOMES NEW SUPPORTING COMPANIES r ffective June 1, 2000, the following adjustments have been imple- ,~ mented for AWS Sustaining Company Members: New Supporting Companies

Dues: The annual dues are $750, domestic; $850, international; plus a Acropolis Steel Industries Ltd. $500 initiation fee. 7555 51st Street S.E. Benefits: The enhanced AWS Sustaining Company Member benefits Calgary, Alberta T2C 4At package includes one of the following primary offerings: 1) the complete Canada library of AWS publications ($5600 value), including 130+ specifications, with complimentary publication updates included; or 2) a discount Work for Wisconsin promotional package, including a 5% discount on ads in the Welding 231 West Wisconsin Avenue, Ste. 200 Journal and a $4-per-sq-ft discount on booth space at the AWS/PMA Show; Milwaukee,WI 53203 or 3) ten additional AWS Individual Memberships for company employees or customers. In addition,AWS Sustaining Company Members enjoy the following: New Educational Institutions

• Ten free Individual Memberships for company employees or customers. Central Piedmont Community College • Publicity of the company's name and product/service offerings in the P.O. Box 35009 Welding Journal and on the AWS Web site. Charlotte, NC 28235-5009

• Company recognition at the annual AWS/PMA Show. DALUS, S.A. DE C.V. Av. Lazaro Cardenas No. 2400 PTE. • Usage of the AWS Sustaining Company Member logo on company letter- Edificio Losoles, Desp. C-14 head and promotional material. Garza Garcia N.L. 66260 Mexico • AWS Sustaining Company engraved wall plaque. Humphreys County • Free hyperlink from the AWS Web site to the member company's site. Vocational Center 1327 Highway 70 West For information on becoming an AWS Sustaining Company Member, Waverly, TN 37185 contact the AWS Membership Dept. at (800) 443-9353 ext. 418, FAX (305) 443-5647 or write AWS, 550 N.W. LeJeune Rd., Miami, FL 33126. • Owens Community College P.O. Box 10000 Toledo, OH 43699

• Member Dues Adjustment • Sustaining Me~ Company he AWS Board of Directors, acting on the recommendations made by the Membership Committee, approved a dues adjustment to $75 for T the "Regular Member" classification effective June 1, 2000. Upon joining, and every third membership year, Regular Members dues will include an expanded publication choice of either the latest Welding Handbook, Welding Metallurgy,Jefferson "s Welding Encyclopedia, Solder- ing Handbook or the Design and Planning Manual for Cost-Effective Weld- ing upon request. In addition,AWS members receive a monthly subscription COtt Manufacturing, Inc. to the award-winning Welding Journal. AWS-certified personnel also receive (SMI), specializes in custom quarterly issues of Inspection Trends magazine. S metal fabrication. Specialties AWS members enjoy access to widely respected technical information include small and large weldments in the materials-joining industry at discounted rates. Members-only dis- of varying complexities, laser and counts apply to AWS technical publications, as well as top-notch certifica- plasma cutting, CNC punching, roll tions, conferences and other educational offerings. Members also benefit forming of lengths up to 32 ft and from networking opportunities at local Section meetings and at the complete machining capabilities. AWS/PMS Show.AWS members can choose between two value-added mem- SMI is currently pursuing ISO 9000 bership package offerings -- the Gold and the Platinum membership pack- certification. • ages -- for modest fees.And, in the near future,AWS members will enjoy members-only access to special information and services on the AWS Web site, www. aws. org. •

72 J DECEMBER 2000 SAFETY AN D H EALTH T O P I C S • Electric and Magnetic Fields Superintendent of Documents, U.S. Government Printing Fact Sheet No. 1 Office,Washington, DC 20402. Environmental Protection Agency (EPA). Questions and Introduction Answers about Electric and Magnetic Fields. National Insti- tute of Environmental Health Sciences (of Dept. of Health Electric and magnetic fields are often referred to as and Human Services) and Dept. of Energy. Miles Kahn, P.O. "electromagnetic fields," or EMEThere is concern that EMF Box 37133,Washington, DC 20013-7133. may affect your health. United States Congress, Office of TechnologyAssess- ment. Biological Effects of Power Frequency Electric & Mag- netic Fields -- Background Paper, Ota-BP-AE-63, May 1989. How is EMF Produced? Superintendent of Documents, U.S. Government Printing Office,Washington, DC 20402. Voltage is the difference in electric potential between American Conference of Governmental Industrial Hy- two points.This voltage creates an electric field between gienists (ACGIH).Threshold Limit Values for Chemical Sub- those points. Now, suppose an electric connection is made stances and Physical Agents and Biological Exposure In- between those two points, so there is an electric current. dices. ACGIH, Inc., 6500 Glenway Ave., Cincinnati, OH This current produces a magnetic field. Magnetic fields 45211. occur whenever there is current flow. National Electrical Manufacturers Association (NEMA). Q &A" Biological Effects of Electric and Magnetic Fields. NEMA, 2101 L St., NW,,Washington, DC 20037.0 What Does EMF do?

EMF produces forces that drive most of the devices The Safety and Health Fact Sheets, 2nd ed., cover all aspects that we use every day. For examp|e, EMF is involved in light- of safety and health applicable to welding and cutting. The Fact ing our homes and starting our cars. Sheets include 20 pages on subjects such as fumes and gases, radiation, noise and electrical hazards. Compiled in 1998. Price for AWS members is $27; nonmembers, $36. Copies of Safety Is EMF Harmful? and Health Fact Sheets can be ordered by calling AWS Publica- tion Sales at (800) 334-9353, or (305) 443-9353 ext. 280 outside the United States, Monday through Friday, 8 a.m. to 5 p.m. Many scientific tests have been and are still being con- Eastern Standard Time. ducted by governmental and private agencies to determine if EMF is harmful to our health. Most studies to date indicate there is no evidence of significant health problems from EME • Tenth International JOM How Do I Minimize Exposure? Jubilee Conference

• Do not place your body between the torch and work he Institute for the Joining of Materials CIOM) cables. Route cables on the same side of your body. has announced the Tenth International JOM Ju- T bilee Conference on the Joining of Materials, • Route the welding cables close together. Secure them JOM-IO, May 11-14, 2001, in Helsingor, Denmark. with tape when possible. The following are the main themes of JOM-lO: • Information technology, cases in its exploita- • Connect the work cable to the workpiece as close tion as well as prediction of its value for future and to the weld as possible. present welding fabrication. • Robotization and automation in welding and • Keep the welding power source and cables as far associated processes. away from your body as possible. • Brazing, soldering and associated processes in nonmelt joining. • Never coil the torch or work cable around your body. JOM welcomes the active support of AWS to the JOM-10 through speakers and participants. AWS cosponsored previous JOM conferences 7 through 9. Information Sources For further information on JOM-IO, contact the Insti- tute for the Joining of Materials, Klintehoj Vaenge 21, DK- Occupational Safety and Health Administration 3460 Birkerod, Denmark; e-mail to jom_aws@post 10.tele.dk; (OSHA). Code of Federal Regulations,Title 29 Labor, Chap- telephone 45 45 82 80 95; or FAX 45 45 94 08 55. • ter XVII, Parts 1900 to 1910, Order No. 869-019-00111-5.

WELDING JOURNAL I 73 • AWS Foundation • AWS Publications Elects Trustee • Earthmoving & Construction Equipment Welding he American Welding Society in a New AWS Specification (AWS) Foundation announced the election of D. Fred Bovie The American Welding Society (AWS) has completed an updated ver- T as Trustee Emeritus.A distinguished sion of Specification for Welding Earthmoving and Construction Equip- Alumnus from The Ohio State Uni- ment (D14.3/D14.3M:20OO).ANSI-approved, this guide provides the standards needed to produce the structural welds used in the manufacture of crawlers, tractors, loaders, power shovels, backhoes and other self-propelled machinery. Specification for Welding Earthmoving and Construction Equipment places a heavy emphasis on workmanship and welder qualification. In addition, the specification also provides illustrations of prequalified welded joints for a variety of welding procedures. Presented in the U.S. Customary and metric units, Specification for Welding Earthmoving and Construction Equipment is 97 pages and includes 41 figures, 11 tables and four annexes. Specification for Welding

Earthmoving and Construction Equipment is available to AWS members D I:ved Bot,ie for $54; $72 for nonmembers.

Ordering Information versity, Bovie has served the Society Copies of AWS publications can be ordered by calling AWS Publication for more than 30 years. He will bring Sales at (800) 334-9353, (305)334-9353 outside the United States, Monday his years of experience in the weld- through Friday, 8 a.m. to 5 p.m. EST, or through the AWS Web site at ing industry, including work as pres- www.aws.org. Additional information on AWS's programs and publications ident and CEO of the ESAB Group, can also be found on the Web site. • to the philanthropic efforts of the AWS Foundation. In addition to his commitment TECHNICAL COMMITTEE • Technical Topics to AWS and the welding industry as a whole, Bovie is also a founding di- MEETINGS 0 Errata forANSI/AWS B2.1-1-205-96, rector of the Agricultural and In- Carbon Steel Primarily Pipe Appli- dustrial Museum of York. cations, SMAW Welding Procedure The AWS Foundation was All AWS technical committee founded in 1989 and is dedicated meetings are open to the public. Specification. to supporting research and educa- Persons wishing to attend a meet- Page 3, in the "Electrical Characteris- tion in welding and related tech- ing should contact the staff secre- nologies. The Foundation awards tary of the committee as listed tics Table," change "1.2.2.3." to read "1.2.3.4."0 more than $250,000 in undergrad- below at AWS, 550 N. W LeJeune Rd., uate scholarships and graduate fel- Miami, FL 33126; telephone (305) lowships each year. 443-9353. For further information on the AWS Foundation scholarship, December 7, G2E Subcommittee on fellowship and student loan pro- Stainless Steel Alloys. Las Vegas, Nev. • AWS MEMBERSHIP grams, visit the AWS Foundation Standards preparation meeting. Staff on the Web at www. aws.org/ contact:T. R. Potter. Member As of foundation/. • Grades November 1, 2000

December 8, G2C Subcommittee on • Student Chapters, Nickel Alloys. Las Vegas, Nev. Stan- Sustaining Companies ...... 312 Send Us Your News dards preparation meeting. Staff contact:T. R. Potter. Student Chapters are encour- Individual Members ...... 45,333 aged to send reports of their meetings, activities and events, along with December 8, G2 Committee on Join- Student Members ...... 4,823 photographs, for publication in the ing Metals andAlloys. Las Vegas, Nev. Welding Journal's Student Activities General meeting. Staff contact:T. R. department. Potter. • Send your meeting/event re- Total ...... 50,468 ports to Susan Campbell,Asst. Editor, Welding Journal, 550 N.W LeJeune Rd., Miami, FL 33126. Reports can also be faxed to (305) 443-4704 or e-mailed to camp- beU@aws, org. •

741 DECEMBER2000 I N E W S

District 1 Director GeoJfr{:l, Pltt- nam, left, presenting Maine Sec- tion Chairman Russ Norris with the District Director's Award. AWS Presidenl Bill Myers, fitr left in sport coal, and Maine Section members listening to Russell Van Billiard at the dedicalion of the USS Alba- core submarine as an AWS Historical Welded Structure.

• BOSTON DISTRICT I OCTOBER 2 Activity: The Section was given Director: Geoffrey H. Putnam demonstrations on plasma arc cut- Phone: (802) 439-5916 ting, pulsed gas metal arc welding with synergic controls and oxyfuel • MAINE metal spray process using Ther- SEPTEMBER 12 malarc, Miller and Eutectic equip- Speaker: Geoff Putnam, District ment. The demonstrations were 1 director. given at the South Easton Regional Affiliation:The American Welding Vocational Technical High School Long Island SeclioH speaker Society. by instructors Steve Flowers and Hugh Callaghan during his pre- Activity:The Section held a meeting Derrick Knudsen and students sentation in October. to discuss Section and District activ- BillJarrid, Kris Creighton, Ryan ities.The District Director's Award Grover, Jennifer Ellis and An- sales manager. was presented to Chairman Russ drew Cerci. Affiliation :Victor Equipment, New Norris. York and New England. Topic: Oxyfuel Welding, cutting OCTOBER 3 and heating. Speaker: Bill Myers, president. DISTRICT 2 Affiliation:The American Welding Director: Alfred F. Fleury Society, Miami, Fla. Phone: (732) 868-0768 DISTRICT 3 Activity: President Myers presented a plaque dedicating the USS • NEW JERSEY Director: Claudia Bottenfield Albacore Research Submarine an SEPTEMBER 19 Phone: (717) 397-1312 AWS Historical Welded Structure. Speaker: Pat Dorris, director. Accepting the plaque was Prof. Affiliation: Welder Training and • LEHIGH V~ Gene Allmedinger, one of the Testing Institute. SEPTEMBER 5 submarines original designers. Topic:Welder training, certification Speaker: Bob Jones, regional sales Myers was presented with a book and inspection. manager. on the history of the submarine Affiliation: Praxair TAFA Corp. and received a tour. • LONG ISLAND Topic:Thermal spray coating OCTOBER 12 Speaker: Hugh Callaghan, district

WELDING JOURNAL I ~s Florida gt, st Coast Chairman Dar- Southwest Virginia Section ryl Jardine, right, presenting Mike Southwest ViJ~inia SectioH (,'hctirma~t L:d members and guest speaker Dortch with a speaker's gift. Butch Charlton, left, taking Wyatt, right, presenting guest speaker Wal- a break from their October ter Sperko with a speaker's gift. tour to pose for a photo.

Lehigh Vallej' Section Pttblicity Chairman Dave Marks, left, with From left are guest speaker Chris guest speaker Bob Wiswesser. P. Sacco, Joyce Sacco and York- Lehigh Valley Section Chairmalz Central Pennsylvania Section Rich Gallagher, right, presenting First Vice Chairman Mike Fink. a speaker's gift to Bob Jones. • SOUTH CAROLINA SEPTEMBER 21 Speaker: Jeff Martin, sales and technical representative. OCTOBER 3 Topic: Welding metallurgy of low Affiliation: The Lincoln Electric Speaker: Robert Wiswesser, pres- carbon steels. ident. Co. Topic: Surface tension transfer. Affiliation: Welder Training and OCTOBER 18 Testing Institute,Allentown, Pa. Speaker: Butch Charlton, QA Topic: Nondestructive examina- manager. • SOUTH FLORIDA tion. Affiliation: Roanoke Electric Steel. OCTOBER 19 Topic:The Section received a tour Speaker: Ernest Levert, senior of the company's facilities. • YORK-CENTRAL PENNSYLVANIA staff manufacturing engineer OCTOBER 3 and project manager and AWS Speaker: C. P. Sacco, retired pres- vice president. ident. DISTRICT 5 Affiliation: Lockheed Martin Affiliation: Herr & Sacco, Lan- Director: Boris A. Bernstein Missiles and Fire Control, Dal- disville, Pa. Phone: (787) 883-8383 las, Tex. Topic:Welding: It's not a job, it's an Topic: Welding the international space station. art. • FLORIDA WEST COAST Activity:The Section also held SEPTEMBER 13 Education Night. The event Speaker: Mike Dortch. took place at the McFadder Vo- DISTRICT 4 Affiliation: AlcoTec. cational-Technical School. Director: Roy C. Lanier Topic:Welding aluminum. Phone: (919) 321-4285 Activity: Darryl Jardine received the District/Section Meritorious Award. Industry Sponsor Recogni- • SOUTHWEST VIRGINIA tion Awards were given to South- DISTRICT 6 SEPTEMBER 20 eastern Mechanical Services and i Director: Gerald R. Crawmer Speaker: Walter J. Sperko, P.E. Ardaman and Associates. Affiliation: Sperko Engineering, Phone: (518) 385-0570 Greensboro, N.C.

76 I DECEMBER 2000 Pascagoula Section Chairman Levis Carter, right, presenting guest District 7 Director RobertJ. "l}lber, tik, Guest Speaker Lorne Weete,; &J?, ac- speaker George Jones with a left, with AWS Vice President Richard cepting a speaker's gift from Colum- speaker's gift. Arn, center, and Columbus Section bus Section Vice Chairman and Trea- Chairman Jim Worman. surer Tom Kuntzman. Topic: Advancements in Robotic Welding. DISTRICT 8 Director: Harrell E. Bennett Phone: (423) 478-3624

• MEMPHIS SEPTEMBER 1 1 Speaker: Harrell Bennett, District 8 director. Activity: Members met to discuss re- organizing the Memphis Section as the West Tennessee Section.A new Executive Committee and officers were selected.

• PASCAGOULA Greater Ituntsville Seclion members pose fi~r a photograph during the SEPTEMBER 14 Section's September meeting. Speaker: William Dowden, director of safety. Activity: The Section toured this Affiliation: Nordeen Smith. more than 1,000,000 ft 2 facility. DISTRICT 7 Topic: Safety in the workplace. Director: Robert J. Tabernik OCTOBER 14 Phone: (614) 488-7913 • COLUMBUS Speaker: George Jones, construc- SEPTEMBER 14 tion superintendent. • PITTSBURGH Speaker: Robert J. Tabernik,AWS Affiliation: Ingalls Shipbuilding. JuLY 21 District 7 director. Topic: Commercial shipbuilding. Speaker: Dave Daugherty, tech- Affiliation:The Lincoln Electric Co. Activities: The Pascagoula Section nical sales representative. Topic:Waveform ControlTechnology. has a Professional Welders Honor Affiliation: The Lincoln Electric Activity: Vice President Richard Program where two area welders Co. Arn attended the meeting and dis- (one from pipe and one from struc- Activity: Section members met to cussed his rise from welding tech- tural) are selected for excellence in plan the upcoming year's meet- nologist to vice president and in- their profession. At this meeting, ings and to approve an acceptable coming president of AWS. Section- Mr. Stringfellow, a welding in- budget. Vice Chairman/Treasurer Tom structor at Ingalls Shipbuilding, was Kuntzman discussed his recent visit honored as the best structural to AWS headquarters for the AWS Na- welder at Ingalls. Cleo Nichols was SEPTEMBER 21 tional Leadership Symposium. selected as Ingalls's best pipe Speakers: Spencer Burnside, fab- welder. Steve Brown received the ricating manager, and Adrian OCTOBER 14 District Director's Award for his Hilbeck, training manager. Speaker: Lorne Weeter, director of work in putting together the Affiliation: Pennsylvania Trans- sales. Pascagoula Section's annual golf former Tech., Inc., Cannonsburg, Pa. Affiliation: Motoman Inc., Troy, tournament. Ohio. WELDING JOURNAL I 77 Mobile Section Past Chairman Johnny Dedeaux, right, presenting guest speaker Simon Thornton with a speaker's plaque. New Orleans Section Chairperson Marie I:l,gate and First Vice Chairman John Pajak, right, present guest speaker Patrick Hoyt, left, with a speaker's award.

• NORTHEAST MISSISSIPPI SEPTEMBER 21 Activity: Robert Breland conducted a tour of the Bechetel Red Hills Project plant.

• GREATER HUNTSVILLE SEPTEMBER 28 Speaker: Harrell Bennett, District New Orleans Section Chairperson 8 director. Marie Lygate, left, and First Vice Affiliation:American Welding Soci- Cleveland Section Skills USA Repre- Chairman John Pajak present guest ety. sentative and Education Chairman speaker Nancy McAfee with a Actities:Joe Smith was awarded Dan Harrison, left, presenting Steve speaker's gift. the Section Educator Award and a Houston with a speaker's gift. Meritorious Certificate by District 8 Director Harrell Bennett. Ben- DISTRICT I 0 nett presented Jim Thomson • BATON ROUGE with the District Educator Award, SEPTEMBER 20 Director: Victor Y. Matthews the Dalton E. Hamilton Memorial Speaker: Tom Howard, chairman Phone: (216) 383-2638 CWIAward and the District CWI of of student affairs. the Year Award. Affiliation:AWS Baton Rouge Sec- • CLEVELAND tion and Air Liquide. SEPTEMBER 12 Topic: Careers in welding. Speaker: Steve Houston, trainer. DISTRICT 9 Activity: The Section held Career Affiliation: Hobart Brothers. Director: John Bruskotter Night with 59 high school students Topic:The welder training program Phone: (504) 367-0603 from five area schools attending. developed by Steve Houston for Ho- Vendors held demonstrations and bart Brothers. distributed information on careers Activity:The Section's new officers • NEW ORLEANS in welding to students and parents. were introduced at a clambake din- SEPTEMBER 19 The event was sponsored by the ner. Speaker: Patrick Hoyt, chief weld- Central High School, Baton Rouge ing engineer. Student Chapter. • NORTHWESTERN PENNSYLVANIA Affiliation: Litton Avondale Indus- SEPTEMBER 14 tries, Avondale, La. Activity: The Section held its annual Topic:Titanium welding. • MOBILE golf outing at the Culbertson Hills SEPTEMBER 21 Golf Course in Edinboro, Pa. Eighty OCTOBER 17 Speaker: Simon Thornton, vice golfers attended the four-man Speaker: Nancy McAfee, national president, operations. scramble and dinner. Bob Knep- account representative. Affiliation: Austal USA. per,Jack Lux,Jim Whitehill and Affiliation: 3M Co., Houston,Tex. Topic:Austal's plans for a new alu- Isreal Shabtai of General Electric Topic: Respiratory hazards for minum shipyard to be constructed won the scramble. welders. in Mobile.

78 J DECEMBER 2000 Three members of the winning foursome of the Northwestern Pennsylvania golf scramble, from left, Bob Knepper, Jack Lux and Jim Whitehill. Topic:The study of waterflow and temperature and its effects on resistance welding electrodes. Detroit Sectiott 2000 academic sct~olarshi[) tvimters, bacL~ row, left to r~q,t~t,Joel Diller, Andrew Dake, Bill England, Jeff Albrecht, Jerome Meldrum, Jared Medler, • FOX VALLEY front row, left to right, Wesley Doneth, Chris Soule, Chad Schondehnayer, Troy OCTOBER 7 Bittner, Chris Knaffle, Jeremy Purmala, Keven Fleming and Kyle Dockery. Activity:The Section held a Sport- ing Clay Shoot event at the J & H ris State Hunting Club and Game Farm.After University the clay rounds, a luncheon was and Washt- served in the clubhouse enau Com- munity OCTOBER 10 College. Speaker: Dennis Harwig, man- Wesley ager/principle engineer. Doneth of Affiliation: Edison Welding Insti- Ferris tute, Columbus, Ohio. State was Topic: An integrated approach to awarded arc welding optimization. the James W. Mitchell • NORTHWEST OHIO Scholar- OCTOBER 10 St. Lottis Sect~oH members pose dl lDeir A'eptember ])laltt tour st/ ship and Speaker: Rich Menzel, public re- the Hillsdale Fabricators facility, j~om left, Jim Black, speaker Jeremy lations. Larry Ingram, Christine, Glenn Kayser and Mike Kamp. Purmala, Affiliation: North Star BHP Steel also a stu- Co., Delta, Ohio. dent at Ferris State, was awarded Activity: The Section toured the the Robert L.Wilcox Scholarship. North Star BHP Steel plant and saw DISTRICT I I The Section awarded more than everything from the melting of raw $5300 in scholarships to the top materials to casting billet slabs to Director: Scott C. Chapple finalists in the 2000 Detroit Area the final coiled sheet steel product. Phone: (913) 241-7242 High School Welding Contest. Scholarship winners included Jeff Albrecht, Joel Diller, Andrew DISTRICT 1 2 • DETROIT Dake, Jerome Meldrum, Bill SEPTEMBER 14 Director: Michael D. Kersey England, Jared Medler, Chris Phone: (262) 650-9364 Speakers: James Ward, Aaron Soule, Chad Schondelmayer, Hauschildt, Richard Carlson Troy Bittner, Chris Knaffle, and Eric Urbas. Keven Fleming and Kyle Dock- • MILWAUKEE Affiliations: General Motors Corp, ery. SEPTEMBER 14 Ford Motor Co., General Motors Corp. Activity: One hundred and thirty and Ford Motor Co., respectively. members of the Section toured the Topic: Life (Work!) -- the transfor- • WESTERN MICHIGAN nearly completed Miller Park, mation to profitability. SEPTEMBER 25 which will be the new home for Activity: The Section awarded Speaker: Ron Leibovitz. the Milwaukee Brewers when it $30,500 in academic scholarships Affiliation: Unitrol Electronics, opens in April 2001. to 15 outstanding students at Fer- Inc., Northbrook, Ill.

WELDING JOURNAL I 79 Guest 3"pealeer Mike Anderson, center, accepting a speaker's award from Indiana Sec- tion Chairman Joe Daumeyer, left, and Vice Chairman Kevin Lynn. Lexingto,t Section member and Welding Inslructor Alan Mattox, left, congratulating scholarship winners, from right, Jason Woolery, Jacob Bradford, and Jonathan Jones.

Activity: The Section toured the Hillsdale Fabricators facility. DISTRICT 1 5 Director: J. D. Heikkinen • INDIANA Phone: (218) 741-9693 SEPTEMBER 18 Speaker: Mike Anderson, welding • NORTHWEST instructor. SEPTEMBER 20 Affiliation: New Castle Area Voca- Activity: The Section toured the tional School. Donaldson Company plant in Bald- Topic: Level 1 and Level 2 educa- win,Wis. Chuck Ash, plant manager tion and curriculum in Indiana. Lexington Section Chairman P)-ank of Donaldson, led the tour. McKinley, left, presenting Wayne Reece with a speaker's gift. • MISSISSIPPI VALLEY SEPTEMBER 21 Activity:The Section held its Annual DISTRICT 16 • LAKESHORE Fish Fry Social. OCTOBER 12 Director: C. F. Burg Speaker: Missy Sparrows, wildlife Phone: (515) 294-5428 biologist. • TRI RIVER SEPTEMBER 21 Affiliation: Dept. of Natural Re- • KANSAS CITY Speaker: John Durbin, Welding sources. SEPTEMBER 14 Topic: Wetlands conservation pro- Department and Section chairman. Speaker: Kevin Johnston, welding grams and a wildlife slide presen- Affiliation: Ivy Tech State College, specialist. Evansville, Ind. tation. Affiliation: Kansas City Power and Topic: Oxyacetylene cutting and Light Company. welding safety. DISTRICT 1 3 Topic:The Section toured the new Director: J. L. Hunter boiler units and construction. Members discussed the failure of (309) 888-8956 • LEXINGTON unit #5 and what caused it. SEPTEMBER 28 Speaker: Wayne Reece, district manager. • SIOUXLAND Affiliation: Miller Electric Mfg. Co. DISTRICT 14 SEPTEMBER 21 Topic:The project car for Miller 31- Speaker: Merle Meade, welding in- Director: Hil Bax Ford NASCAR welding. One hun- structor and Regional Educator of Phone: (314) 644-3500, ext. 105 dred and twenty people attended the Year. the meeting. Affiliation: Northeast Community • ST. LOUIS College, Norfolk, Neb. OCTOBER 2 SEPTEMBER 14 Topics: What is the American Weld- Activity: District scholarships were Speaker: Larry Ingram. ing Society? And ten things indus- awarded to Jonathan Jones,Jacob Affiliation: Hillsdale Fabricators. try can do to improve welder per- Bradford and Jason Woolery. Topic: Structural steel fabrication. sonnel retention and recruitment.

80 I DECEMBER 2000 Northwest Section Chairman Mike Hanson, right, presenting a speaker's plaque to Chuck Ash.

Guest speaker Kevin./obnston addressing the Kansas City Section at the Kansas City Power and Light Company in September.

Sabine Section Clmirmalt Care3, I~{,s- ley, left, presents a speaker's gift to Puget Sound &,ctioH Chairman A2,n Don Mills. Johnson, right, presenting Gordy Robertson with an AWS Outstand- San Di~o Section Chairman Mike Activity: The Section toured Kol- ing Contributions Award. Kitten presents a speaker's gift to berg-Pioneer in Yankton, S.D., cour- Bernard Mannion. tesy of Section Chairman Robert Olsen. DISTRICT 18 Affiliation: Intercon Enterprises Director: J. M. Appledorn Inc. DISTRICT 17 Phone: (281) 847-9444 Topic: Pipe GTAW and the proper Director: Oren P. Reich use of purging along with other Phone: (254) 867-2203 • SABINE GTAW pipe welding accessories by SEPTEMBER 19 Intercon. • EAST TEXAS Speaker: Don Mills, district man- Activity: Gordy Robertson was presented with the AWS Outstanding SEPTEMBER 14 ager. Contributions Award for his unfail- Speaker:Jim Mumaw, staff engineer, Affiliation: Specialized Mainte- ing support for more than 26 years. Robotics and Automation Group. nance, Inc. Affiliation: The Lincoln Electric Topic: Chemical cleaning of piping Co., Cleveland, Ohio. and equipment. Topic: Robotics application for DISTRICT 20 welding Director: Neil R. Kirsch DISTRICT 19 Phone: (970) 842-5695 • OZARK Director: Phil Zammit COLORADO SEPTEMBER 20 Phone: (509) 468-2310 ext. 120 SEPTEMBER 14 Speaker: Richard L. Holdren, P.E. Speaker: Dennis Bartley, steriliza- Topic: Future trends in welding • PUGET SOUND tion facility manager. technology OCTOBER 5 Speaker: A.J. Shenk. Affiliation: Cobe Labs Sterilization Services.

WELDING JOURNAL I 81 • Fox Valley Section to Hold ASME • Section 106 Reorganized and Renamed West Section IX Seminar Tennessee Section

n Thursday and Friday, January 4 and 5, 2001, theAWS Fox Valley ection 106, previously the Mem- Section will hold a seminar devoted to ASME Section IX.This inten- phis Section, has been reorga- o sive two-day seminar covers the requirements of ASME Boiler and s nized and is now the West Ten- Pressure Vessel Code Section IX.The objective of the seminar is to impart nessee Section. the knowledge and experience necessary to properly prepare welding pro- The West Tennessee Section will cedures and qualify the procedures and personnel. be headquartered in Jackson,Tenn., This comprehensive seminar features the following: at the Tennessee Technology Center. All AWS members are welcome and Day One vendors are invited to attend meet- • Writing adequate and understandable Welding Procedure Specifica- ings when the meeting schedule is tions. In addition to the ASME IX, focus will be placed on how to deal with announced. • construction code requirements and other restrictions. • Review of the common manual, semiautomatic and automatic welding processes. • How basic steel metallurgy is addressed by the Code. • How filler metals are addressed by the Code. • District Director Awards • Planning, preparing, conducting and documenting procedure qualification tests. Ihe District Director Awards • Notch toughness and supplementary essential variables. provides a means for District Directors to recognize indi- Day Two T viduals who have contributed their • An overview of changes to ASME IX. time and effort to the affairs of • Review of Performance Qualification variables for manual, semiau- their local Section and/or District. tomatic, machine and automatic processes. • Basic performance qualification requirements. District 17 Director Oren • Planning, conducting and documenting performance qualification tests. Reich, presented the following in • Continuity and Qualification renewals. his District with this award: Welding procedures and welder qualifications usually present com- • Paul Morgan, Tulsa plex challenges.Among the problem areas are failure to address all of the variables, unqualified procedures for the job and/or welders not being • Phil Walker, Ozark qualified for the procedure or the job.This seminar will address all of these problems and will provide you with solutions. In addition, the seminar • Richard Hoffman, Ozark meets the continuing education requirements for CWI nine-year renewals. Participants will be awarded a Certificate of Completion certified by the presenter and the Fox Valley Section's Education Chairman. The cost of the seminar is $425 for AWS members and $475 for nonmembers.TheASME IX Code Book can be purchased for an additional $225. Registration deadline is December 15.To register for the seminar or for further information, write AWS Seminar Coordinator, N5611 Veeser Lane, Luxemburg,WI 54217 or call (920) 845-5992.0

Affiliation:American Welding So- gies, Newbury Park, Calif. ciety. Topic: Orbital and automatic weld- Topic:AWS Testing for SCWI, CWI, ing lathes. CWE and CAWI. Activity: The Section toured the Activity: Forty men and women • HAWAII state-of-the-art sterilization facility. took the CWI test in Denver. SEPTEMBER 20 Speaker: Ray Jablonski, Section SEPTEMBER 25-29 chairman. Speaker: Rich Campbell, instructor. Affilia tio n: AWS. Activity:The Section held an AWS DISTRICT 21 Activity:The District Conference in seminar for CWI and CWE testing. Director: F. R. Schneider San Diego. • Twenty-three students attended the Phone: (619) 693-1657 seminar. • SAN DIEGO DISTRICT 22 SEPTEMBER 30 SEPTEMBER 13 Speaker: Galen Altman, SCWI and Speaker: Bernard Mannion. Director: Mark Bell test supervisor. Affiliation: Pro-Fusion Technolo- Phone: (209) 367-1398

82 J DECEMBER 2000 • 2000-2001 Member-Get-A-Member Campaign Listed below are the people participating in the 2000-2001 Member-Get-A-Member Campaign. For a list of rules and prizes, please see page 83 of this Welding Journal If you have any questions regarding your member proposer points, please call the Membership Department at (8(70) 443-9353 ext. 270.

Winner's Circle President's Club E Larzabal, Corpus Christi -- 2

(AWS Members sponsoring 20 or more (AWS members sponsoring 6-10 new M. Mott, Florida West Coast -- 2 new members since June 1, 1999) Individual Members between June 1, I. C. Pierre, New York -- 2 2000, and May 31, 2001.) G.Teague, Eastern Carolina -- 2

J. Compton, San Fernando Valley -- 68 R.Teuscher, Colorado -- 2

E. H. Ezell, Mobile -- 35 J. Compton, San Fernando Valley -- 9 M. Weeks, Sabine - 2

B.A. Mikeska, Houston -- 24 W. R. Beck, Rochester -- 8 G.Williams, Sangamon Valley -- 2 W. L. Shreve, Fox Valley -- 22 G.Taylor, Pascagoula -- 6 D. Wright, Kansas -- 2 J. Merzthal, Peru -- 21 R. Buse, Mobile -- 6 R. Wray, Nebraska -- 21 D. Hatfield -- 6 Student Sponsors President's Honor Roll (AWS members sponsoring 3 or more (AWS members sponsoring 1-5 new In- AWS Student Members are listed.) President's Guild dividual Members between June 1, (AWS Individual Members sponsoring 2000, and 21~ay 31, 2001. Only those G.WoomerJohnstown/Altoona -- 20

20 or more new Individual Members sponsoring 2 or more AWS Individual P. Baldwin, Peoria -- 16 between June 1, 2000, and May 31, Members are listed.) T. Strickland,Arizona -- 13 2001.) C.AIonzo, San Antonio-- 7

J.T. Blank, Northern Michigan -- 5 B. Patchett, Northern Michigan --7 J. Merzthal, Peru -- 21 H. E. Cable, Sr., Pittsburgh -- 4 D. Hatfield -- 6 E Soto, New Jersey -- 4 D. Nelson, Puget Sound -- 5 C.-L.Tsai, Columbus -- 4 R. Rux, Wyoming -- 5 President's Roundtable J. Rosado, Puerto Rico -- 3 M.Tait, Los Angeles -- 4 (AWS Individual Members sponsoring J. Craft, Louisville -- 2 J.T. Blank, Northern Michigan -- 3 11-19 new Individual Members be- D. S. Dodds, Pittsburgh -- 2 W. L. Galvary, Jr., Long Beach -- 3 tween June 1, 2000, and May 31, 2001.) E. Ezell, Mobile -- 2 R. Grays, Kern -- 3 J. Gump, Maryland -- 2 J. D. Sanders, Houston -- 3 A. O. Smith III, Tulsa -- 12 R. Hannan,JAK -- 2 J. H. Smith, Mobile -- 3 L.J. Smith, Houston -- 12 J. Koster, Western Michigan -- 2 W. R. Beck, Rochester -- 2 •

SECTION EVENTS • ISO/TC44 Meet in Paris CALENDAR

• NEW JERSEY DECEMBER 19 Activity: Manufacturers' Night.All major manufacturers will be in attendance.

JANUARY 16 Miller Electric. Topic:To be announced.

FEBRUARY20 Thermal Dynamics. Topic: Simple automation for plasma arc cutters.

• FOX VALLEY Members of lhe ISO/TC4.t WeMing and Allied Processes Committee met at the JANUARY 4 AND 5, 2001 Institut de Soudure in Paris, France, on September 14 and 15. Pictured in Activity:ASME Section IX Seminar. front of the lnstitut are, from left to right, International Standards Activities Location: Paper Valley Hotel and Committee (ISAC) Chairman Waiter Sperko, A WS Technical Activities Com- Conference Center, (920) 733- mittee (TAC) Chair Nancy Cole, 1SAC Secretary Andrew Davis, ISAC Vice Chair- 8000. For further information or man Damian Kotecki atzd ISO/TC44/SC5, Testing and Inspection of Welds to register, call (920) 845-5992. Chairman Henry Hahn.

WELDING JOURNAL 18s TAN AR NOTICES

B2.1-8-212:2000, Standard Welding Standards for Public Review ISO/DIS 14373, Welding -- Resis- tance Spot Welds -- Procedure for Procedure Specification (WPS) for AWS was approved as an accred- Spot Welding of Uncoated and Gas Tungsten Arc Welding of ited standards-preparing organiza- Coated Low Carbon and High Austenitic Stainless Steel (M-8/P- tion by the American National Stan- Strength Steels. 8/S-8, Group 1), % through 1~ Inch dards Institute (ANSI) in 1979. AWS Thick, ER3XX, As-Welded Condi- rules, as approved by ANSI, require tion, Primarily Pipe Applications. that all standards be open to public Approval date: October 9, 2000. review for comment during the ap- Revised Standard Approved proval process. This column also ad- by ANSI B2.1-8-214:2000, Standard Welding vises of ANSI approval of documents. Procedure Specification (WPS) ) for The following standards are submit- A5.13:2000, Specification for Sur- ted for public review. A copy may be Gas Tungsten Arc Welding Followed facing Electrodes for Shielded obtained by sending the amount by Shielded Metal Arc Welding of shown to AWS Technical Dept., 550 Metal Arc Welding. Approval date: Austenitic Stainless Steel (M-8/P- N.W. LeJeune Rd., Miami, FL 33126, September 7, 2000. 8/S-8, Group 1), % through 1½Inch or by calling (800) 334-9353. Thick, ER3XX, E3XX-XX, As-Welded B2.1-1-210:2000, Standard Welding Condition, Primarily Pipe Applica- A5.7-84, Specification for Copper Procedure Specification (WPS) for tions. Approval date: October 9, and Copper Alloy Bare Welding Gas Tungsten Arc Welding with 2000. Rods and Electrodes. Reaffirmed Consumable Inserts of Carbon standard. $4.50. [ANSI Public Re- Steel (M-I/P-I/S-1, Group 1 or 2), B2.1-8-215:2000, Standard Welding view expires December 19, 2000.] % through 1% Inch Thick, INMs-1 Procedure Specification (WPS) for and ER70S-2, As-Welded or PWHT Gas Tungsten Arc Welding with c5.2:200x, Recommended Prac- Condition, Primarily Pipe Applica- Consumable Insert of Austenitic tices for Plasma Arc Cutting and tions. Approval date: October 9, Stainless Steel (M-8/P-8/S-8, Group Gouging. Revised standard. $18.00. 2000. 1), % through 1'/-, Inch Thick, IN3XX [ANSI Public Review expires Janu- and ER3XX, As-Welded Condition, ary 16, 2001.] B2.1-1-211:2000, Standard Welding Primarily Pipe Applications. Ap- Procedure Specification (WPS) for proval date: October 9, 2000. Gas Tungsten Arc Welding with Consumable Inserts Followed by B2.1-8-216:2000, Standard Welding ISO Draft Standards for Shielded Metal Arc Welding of Car- Procedure Specification (WPS) for Public Review bon Steel (M-I/P-I/S-1, Group 1 or Gas Tungsten Arc Welding with 2), % through 1 '/2 Inch Thick, INNs- Consumable Insert Followed by Copies of the following Draft 1, ER70S-2, and E7018, As-Welded Shielded Metal Arc Welding of International Standards are or PWHT Condition, Primarily Pipe Austenitic Stainless Steel (M-8/P- available for review and com- Applications. Approval date: Octo- 8/S-8, Group 1), % through 1¼ Inch ment through your national ber 9, 2000. standards body, which in the Thick, IN3XX, ER3XXX, and E3XX- United States is ANSI, 11 West XX, As-Welded Condition, Primarily 42nd Street, New York, NY B2.1-8-024:2000, Standard Welding Pipe Applications. Approval date: 10036; telephone (212) 642- Procedure Specification (WPS) for October 9, 2000. • 4900. Any comments regarding Gas Tungsten Arc Welding of ISO documents should be sent to Austenitic Stainless Steel (M-8/P- your national standards body. 8/S-8, Group 1), %through 1~ Inch In the United States, if you Thick, As-Welded Condition. Ap- • Visit AWS on the Web wish to participate in the devel- proval date: October 9, 2000. opment of International Stan- The world of AWS is as just a click dards for welding, contact An- B2.1-8-025:2000, Standard Welding of the mouse away.While visiting the drew Davis at AWS, 550 N.W. American Welding Society's Web site, LeJeune Rd., Miami, FL, 33126; Procedure Specification (WPS) for you can renew your membership, buy telephone (305) 443-9353 ext. Gas Tungsten Arc Welding Followed 466, e-maih [email protected]. by Shielded Metal Arc Welding of books and standards, get scholarship Otherwise contact your national Austenitic Stainless Steel (M-8/P- applications and even look for a new standards body. 8/S-8, Group 1), % through 1'/2 Inch job.To see what's on the AWS Web site Thick, As-Welded Condition. Ap- for you, visit http:/www.aws.org. • proval Date: October 9, 2000. ISO/DIS 14345, Fatigue Testing of Welded Components.

86 J DECEMBER 2000 • Sustaining Member Companies

A. O. Smith Corp. Alexander Binzel Corp. Auburn Mfg., Inc. Browne Dreyfus Int'l, Ltd. Milwaukee,Wis. Frederick, Md. Mechanic Falls, Maine New York, N.Y.

ABA Industries, Inc. Algoma Steel Inc. Avondale Shipyards, Inc. Bug-O Systems Pinellas Park, Fla. Ontario, Canada New Orleans, La. Pittsburgh, Pa.

ABB Flexible Automation & All Star Bleachers Mfg., Inc. AZCO, Inc. Burco Welding & Cutting Welding Systems Division Lakeland, Fla. Appleton,Wis. Products, Inc. Fort Collins, Colo. Burlington, N.C. Alpine Steel, LLC BP Amoco ADB Industries Las Vegas, Nev. Middlesex, England CK Worldwide Inc. Burbank, Calif. Auburn, Wash. Aluminum Company of America Base Line Data, Inc. A.E.E. Destructive & Alcoa Center, Pa. Portland,Tex. CNH Global N.V. Non Destructive Testing Ltd. Racine,Wis. Kwai Tak Chung, Hong Kong Aluminum Company of America Bath Iron Works Davenport, Iowa Bath, Maine. CRC-Evans Automatic Welding ABBALSTOM Power-Brazil Houston,Tex. Taubate, Brazil Aluminum Company of America Beaird Industries Inc. Wenatchee,Wash. Shreveport, La. C-Spec AGA Gas Inc. Pleasant Hill, Calif. Cleveland, Ohio American Bureau of Shipping Bechtel Corp. Paramus, N.J. San Francisco, Calif. Carolina Steel Corp. AGA General Gases Greensboro, N.C. San Juan, Puerto Rico American Filler Metals Co. Belmont Technical College Houston,Tex. St. Clairsville, Ohio Caterpillar, Inc. AGA S.A. Peoria, Ill. Ecuador American Torch Tip Co. Bender Shipbuilding & Bradenton, Fla. Repair Co. Cee Kay Supply Inc. AGA S.A. Mobile,Ala. St. Louis, Mo. Peru AMET Inc. Rexburg, Idaho Benteler Automotive Cement Industries, Inc. AK Steel Corp. Galesburg, Mich. Ft. Myers, Fla. Middletown, Ohio Arc Machines, Inc. Pacoima, Calif. Bethlehem Steel Corp. Centerline,Windsor Ltd. Accudata, Inc. Bethlehem, Pa. Detroit, Mich. Clarklake, Mich. ARCONE,a Division of A.C.E. International Co., Inc. Bishop State Centricut, LLC Acute Technological Taunton, Mass. Community College West Lebanon, N.H. Services, Inc. Mobfle,Ala. Houston,Tex. Arcos Alloys Cerbaco Ltd. Mt. Carmel, Pa. Black & Decker Brooklyn N.Y. Air Liquide America Corp. Hunt Valley, Md. Walnut Creek, Calif. Arcsmith, Inc. Certanium Alloys & Pittsburgh, Pa. BMS, inc. Research Co. Air Products & Chemicals, Inc. Pearland,Tex. Cleveland, Ohio Memphis,Tenn. Arctec Alloys Ltd. Alberta, Canada BOC Gases Certified Welding Bureau Aker Gulf Marine Murray Hill, N.J. Chicago, Ill. Ingleside,Tex. Artisan Industries, Inc. Waltham, Mass. Bohler Thyssen Chart, Inc. Alabama Shipyard, Inc. Welding USA, Inc. Burnsville, Minn. Mobile,Ala. Arvin Industries Stafford,Tex. Columbus, Ind. Charles E. Daily Welding & Aladdin Welding Products, Inc. Bombardier Concarril Management Consultant Grand Rapids, Mich. Askaynak S.A. de C.V. Kirkland, Wash. Istanbul,Turkey Estado Hidalgo, Mexico Alcoa Chasma Nuclear Massena, N.Y. Atlantic Marine, Inc. Bortech Corp. Power Project Mobile,Ala. Keene, N.H. lslamabad, Pakistan Alcoa Rockdale,Tex. Atlantic Marine Holding Co. Boss Mfg. Co. Chicago Bridge & Iron Jacksonville, Fla. Kewanee, Ill. Houston,Tex. Alcoa Cressona Operation Cressona, Pa. Atlas Welding Accessories, Inc. Brown and Root, Inc. Chevron Research & Troy, Mich. Houston,Tex. Technology Co. Alcotec Wire Corp. Richmond, Calif. Traverse City, Mich. WELDING JOURNAL I 81 Cigweld Eagle Bending Machines, Inc. Exxon Upstream Div. Co. Victoria,Australia Stapleton,Ala. Houston,Tex.

College of the Canyons Eastman Chemical Co. FTV Proclad,V.A.E., LLC Valencia, Calif. Kingsport,Tenn. Abu Dhabi, U.A.E.

College of Eastern Utah Eastman Kodak Co. FANUC Robotics North America Price, Utah Rochester, N.Y. Auburn Hills, Mich.

Columbia Energy Group Edison Welding Institute Federal Aviation Administration Herndon,Va. Columbus, Ohio Oklahoma City, Okla.

Community College of Edison Welding Institute- Fibre-Metal Products Co. Southern Nevada Technical Div. Concordville, Pa. Henderson, Nev. Columbus, Ohio Filler Metals Inc. Concurrent Technologies Corp. E.G. HeUer's Son Inc. Pottstown, Pa. Johnstown, Pa. Tarzana, Calif. Fisher Tank Co. Conoco, Inc. E. H.Wachs Co. Chester, Pa. Houston,Tex. Wheeling, Ill. Florida Pneumatic Mfg. Co. Controls Corp. of America ELCO Enterprises, Inc. Jupiter, Fla. Virginia Beach,Va. Clarklake, Mich. Florida Power & Light Co. Cooperheat Inc. Electrodos Oerlikon Colombia Juno Beach, Fla. Piscataway, N.J. Bogota, Columbia Folsom State Prison- COR-MET Inc. Electron Beam Technologies, Inc. Dept. of Corrections Brighton, Mich. Kankakee, Ill. Represa, Calif.

DaimlerChrysler Corp. Electronics Research, Inc. Franklin Electric Co. Auburn Hills, Mich. Chandler, Ind. Bluffton, Ind.

Cranfield University, Emhart Fastening Teknologies- Fraunhoffer Institut for Welding Engineering a Black & Decker Company Laser Technology Research Center New Haven, Conn. Ann Arbor, Mich. Bedfordshire, United Kingdom Emirates Building Systems, LLC Friede Goldman Offshore DBI, Inc. Dubai, U.A.E. Pascagoula, Miss. Milford, Neb. Empresas Hopsa, S.A. Fuller and Co., Inc. Detroit Edison Co. Republic of Panama Houston,Tex. Detroit, Mich. Engineering & Materials Group G.E.Aircraft Engines Devasco Int'l Inc. Columbus, Ohio Evendale, Ohio Houston,Tex. Erlikon Metal Mfg. Co. S.A. G. M. Powertrain Dickson GMP Int'l Athens, Greece Flint, Mich. Belle Chase, La. ESAB Welding & Cutting Products GSE Construction Co., Inc. Dimet rics-Merric/Taliey Industries Hanover, Pa. Livermore, Calif. Davison, N.C. ESAB Group, Inc. GSI Lumonics Direct Wire & Cable Equipment-Automation Ontario, Canada Denver, Pa. Florence, S.C. Gateway Amsafe, Inc. Dixie Metal Products Inc. Essex Group, Inc.- Cleveland, Ohio Ft. Lauderdale, Fla. Division of Superior Essex Ft.Wayne, Ind. Gauld Equipment Co. Conaldson Co., Inc. Theodore,Ala. Bloomington, Minn. Estructuras de Acero, D-G, S.A. Republic of Panama General Dynamics Land Systems Doosan Mfg. Co. Ltd. Sterling Heights, Mont. Kyung, Korea Eutectic Corp. Charlotte, N.C. Genesis Systems Group DOVATECH Ltd. Davenport, Iowa Beecher, Ill. EXSA, S.A. Lima, Peru Gibson Tube Co. Dow Chemical Co. North Branch, NJ. Freeport,Tex. Exxon Research & Engineering Co. Global Engineering Documents Dresser Rand-Turbo Products Div. Florham Park, N.J. Irvine, Calif. Olean, N.Y.

88 I DECEMBER 2000 Goss Inc. ITF Engineered Valves John Deere Co. The Lincoln Electric Co. Glenshaw, Pa. Amory, Miss. Moline, Ill. Texas Sales Houston,Tex. Greystone Adult School ICESA/MODICON Johnson Controls, Inc. Vocational Welding P.I.A. Tlainepantla, Mexico Plymouth, Mich. Link-Belt Construction Represa, Calif. Equipment Idaho Testing & KAPL, Inc. Lexington, Ky. Grupo Zeta Inspection, Inc. Schenectady, N.Y. El Paso,Tex. Nampa, Ind. Lockheed Martin Kaplan Industries, Inc. Astronautics Group Gulf States Airgas Illinois Tools Works Maple Shade, N.J. Denver, Colo. Theodore,Ala. Piqua, Ohio Kawasaki Robotics, USA, Inc. Lockheed Martin Missiles & Gullco Int'l Inc. Inco Alloys Int'l Wixom, Mich. Fire Control Cleveland, Ohio Huntington,W.Va. Dallas,Tex. Kayo Products Co. Ltd. H20 2000 Corp. Indura S.A. Industria y Taiwan, P. R. of China Los Angeles Dept. of Water Clearwater, Fla. Comercio Los Angeles, Calif. Santiago, Chile Kedman Co. Hacienda la Puenta Unified Salt Lake City, Utah Lucas-Milhaupt Inc. Saugus, Calif. Industrial Gas Products & Cudahy, Wis. Supply Co. Kellogg Brown & Harbert's Products Inc./ Bristol,Tenn. Root, Inc. Machinery & Welder Corp. Allied Flux Reclaiming Ltd. Mobile,Ala. Menomonee Falls,Wis. Greencastle, Pa. Ingalls Shipbuilding Pascagoula, Miss. Kemper USA, Inc. Mack Products Harnischfeger Industries Atlanta, Ga. Cleveland, Ohio P&H Mining Equipment International Training Inst. Milwaukee, Wis. Alexandria,Va. Kennametal Inc. Madison Area Latrobe, Pa. Technical College Harris Calorific Div. Interstate Welding Madison,Wis. Gainesville, Fla. Sales Corp. Keystone Fastening Appleton,Wis. Technologies, Inc. Magnatech-The DSD Co. Harris/Welco Pittsburgh, Pa. East Granby, Conn. King Mountain, N.C. Inversiones Arco Metal, S.A. Aragua,Venezuela Kimura Denyoki, Inc. MajorTool and Machine, Inc. Henderson Mfg. Inc. Carson, Calif. Indianapolis, Ind. Manchester, Iowa Inweld Corp. Rod Factory Ambridge, Pa. K & K Welding Products Manitowoc Cranes, Inc. Herrick Corp. Lake Zurich, Ill. Manitowoc,Wis. Pleasanton, Calif. Ipsco Steel Alabama, Inc. Axis,Ala. Klingspor Abrasives, Inc. Marathon Oil Co. H & H Sales Co., Inc. Hickory, N.C. Houston,Tex. Huntertown, Ind. J & S Machine, Inc. Ellsworth,Wis. Kobelco Welding MarionTesting & Inspection H & M Pipe Beveling of America Inc. Collinsville, Conn. Machine Co., Inc. J.A.Jones Construction Co. Houston,Tex. Tulsa, Okla. Charlotte, N.C. Martinez Refining Co. Koike Aronson, Inc. Equilon Ent. Hornell Speedglas, Inc. J. P Nissen Co. Arcade, N.Y. Martlnez, Calif. Twinsburg, Ohio Glenside, Pa. Komatsu Mining Mathey Dearman Hougen Mfg. Inc. J.W~ Harris Co., Inc. Systems, Inc. Tulsa, Okla. Swartz Creek, Mich. Cincinnati, Ohio Peoria, Ill. Mauritzon, Inc. Houma Industries, Inc. J.Walter Inc. LA-CO Industries Inc. Chicago, Ill. Harvey, La. Hartford, Conn. Markal Co. Chicago, Ill. Matsuo Bridge Co. Ltd. Hyd-Mech Saws Jackson Products, Inc. Osaka,Japan Ontario, Canada Chesterfield, Mo. Lake Washington Technical College McDermott Int'l Inc. Hypertherm, Inc. James Morton, Inc. Kirkland, Wash. New Orleans, La. Hanover, N.H. Batavia, N.Y. Le Tourneau University McMahon Steel, Inc. ICM, Inc. Jancy Engineering Co. Longview, Tex. San Diego, Calif. Colwich, Kans. Davenport, Iowa Liburdi Pulsweld Corp. McNeilusTruck and Mfg. IGM Robotic Systems, Inc. Jeffboat Div.,A.C.M.S. Ontario, Canada Dodge Center, Minn. Menomonee Falls,Wis. Jeffersonville, Ind. The Lincoln Electric Co. Mechanical Contractos, S.A. IQC Training & Services Jetline Engineering Inc. Cleveland, Ohio Balboa, Republic of Panama Privated Ltd. lrvine, Calif. Chennai, India

WELDING JOURNAL I 89 Meritor Automotive Naylor Pipe Co. Penton Publishing, Roy Smith Co. Troy, Mich. Chicago, Ill. a Subsidiary of Pittway Corp. Detroit, Mich. Cleveland, Ohio Messer Welding Products Nederman Inc. Saf-T-Cart, Inc. Menomonee Falls,Wis. Westland, Mich. PFERD Inc. Clardsdale, Miss. Leominster, Mass. Metal Industries Co., Ltd. Nelson Stud Welding Inc. Salinas Valley State Prison Trinidad &Tobago Elyria, Ohio Phillips Petroleum Co. Soledad, Calif. West Indies Bartlesville, Okla. Newcor Bay City Salvino Steel & Iron Metal Industries Bay City Mich. Phoenix Int'l, Inc. Works, Inc. Development Center Milwaukee,Wis. Franconia, Pa. Kaohsuing, China New Orleans Pipe Trades Metairie, La. Pinney Machinery & Supply Sandvik Steel Metal Processing Systems, Inc. Florence, Ky. Scranton, Pa. Schaumburg, IlL Newport News Shipbuilding & Dry Dock Co. Plant Maintenance Service Sciaky Inc. Midstates Wire Newport News,Va. Memphis,Tenn. Chicago, Ill. Crawfordsville, Ind. The Nippert Co. Plymovent Corp. Selectrode Industries, Inc. Miller Electric Mfg. Co. Delaware, Ohio Edison, N.J. Huntington Station, N.Y. Appleton, is. Nooter Corp. Postle Industries Sellstrom Mfg. Co. Miller Electric Mfg. Co. St. Louis, Mo. Cleveland, Ohio Palatine, Ill. Equipment Technology Ctr. Appleton,Wis. Nordan SmithWelding Supplies Potomac Airgas Inc. Serra Soldadura, S.A. Pascagoula, Miss. Linthicum, Md. Barcelona, Spain Minnesota Department of Transportation- Norfolk Southern Corp. Pratt & Whitney Sewage & Water Board of Bridges and Structures Roanoke,Va. East Hartford, Conn. New Orleans St. Paul, Minn. New Orleans, La. Norris Cylinder Co. Praxair, Mitsubishi Materials Corp. Longview, Tex. Ankeny, Iowa Servo-Robot, Inc. Irvine, Calif. Quebec, Canada Norton Co. Praxair Inc. M K Products Inc. Niagara Falls, N.Y. Tarrytown, N.Y SGL Carbon Group Irvine Calif. Valencia, Calif. OCI Wyoming LP Praxair Inc. Mohave Generating Station Green River, Wyo. Hudson, Ohio Shanghai Grand Tower Laughlin, Nev. Steel Structure Co., Ltd. Oshkosh Truck Corp. Praxair S.A. Shanghai, P. R. of China Moltech Oshkosh,Wis. Peru Gainesville, Fla. Sheet Metal & Osram Sylvania Inc. Precision Components Corp. Air Conditioning Motoman, Inc. Towanda, Pa. York, Pa. Chantllly, Va. West Carrollton, Ohio OTC America Inc. Preston-Eastin, Inc. Siemens Westinghouse Municipal Testing Charlotte, N.C. Tulsa, Okla. Power Corp. Hicksville, N.Y. Orlando, Fla. Otis Elevator Co. Products Mexicanos Nacco Materials Bloomington, Ind. Flex-Arc Smith Equipment Handling GRP Lerma, Mexico Mfg. Co. LLC Berea, Ky. Ozarks Technical College Watertown, S.D. Springfield, Mo. Public Transport Corp. Nassau Research Corp. Melbourne,Australia Soldadura Movil, S.A. Aliquippa, Pa. PRL Industries Inc. Panama, Republic of Panama Cornwall, Pa. Quality Inspection National Certified Pipe Services, Inc. Springs Fabrication, Inc. Welding Bureau Pacific Technical Services Buffalo, N.Y. Colorado Springs, Colo. Rockville, Md. Torrance, Calif. Ransome Co. Stoody Co. National Energy Panasouic FactoryAutomation Houston,Tex. Bowling Green, Ky. Skills Center Franklin Park, Ill. La Romaine,Trinidad Revco Industries Inc., Stupp Brothers Bridge & Pandjiris Inc. Black Stallion Iron Co. National Standard Co. St. Louis, Mo. Paramount, Calif. St. Louis, Mo. Niles, Mich. Pangborn Corp. Robinson Industries, Inc. Superior Products, Inc. Naval Surface Hagerstown, Md. Zelienople, Pa. Cleveland, Ohio Warfare Center Carderock Div. Pennsylvania Power Roman Mfg., Inc. Syncro Vac, Inc. West Bethesda, Md. & Light Co. Grand Rapids, Mich. Elgin,Tex. Allentown, Pa.

90 [ DECEMBER 2000 Tatras, Inc., DBA Thermacut Tower Automotive United States Welding, Inc. Welding Engineering Claremont, N.H. Milwaukee, Wis. Denver, Colo. Supply Co. Prichard,Ala. Taylor-Wharton Tregaskiss Ltd. United Welding & Theodore,Ala. Ontario, Canada Supplies Co. Ltd. Welding Research Council Jeddah, Saudi Arabia New York, N.Y. Technalloy Co. Inc. Triangle Engineering Inc. Baltimore Div. West Hanover, Ma. Uniweld Products Inc. The Welding Rod Factory, Baltimore, Md. Ft. Lauderdale, Fla. a Subsidiary of Nassau Research Corp. TechniWeld Products Trinity Industries, Inc. U.S. Steel Corp.-Tech Center Aliquippa, Pa. Corp./RobinsonTech Longview, Tex. Monroeville, Pa. Ontario, Canada Weldco, Inc. Trinity Industries, inc. UT Automotive Mobile,Ala. Technostyle Ltd. Longview, Tex. Dearborn, Mich. Kaminia, Greece Weldsale Co. Div. Of Tri Tool Inc. UTP Brasileira de Soldas Ltda. J.A. Cunningham Tempil Inc. Rancho Cordova, Calif. Sao Pauio, Brazil Philadelphia, Pa. South Plainfield, N.J. Underwater Engineering Valley State Prison for Women Wellex Industries Ltd. Testwell Laboratories, Inc. Services, Inc. Chowchilla, Calif. New Plymouth, New Zealand Ossining, N.Y. Port St. Lucie, Fla. Vermeer Mfg. Co. Western Enterprises Texas Eastman Co. UNICOR Pella, Iowa Westlake, Ohio Longview, Tex. Littleton, Colo. Viking Steel Erectors, Inc. Westinghouse Government Thermadyne Industries Union Tank Car Co. Phoenix,Ariz. Services Group-Electro St. Louis, Mo. East Chicago, Ind. Mechanical Div. Webb Corp. Cheswick, Pa. Thrall Car mfg. Co. United Abrasives, Inc. Dallas,Tex. Cartersville, Ga. Willimantic, Conn. The Wheelabrator Corp. Weiler Corp. Shenandoah, Ga. Thrall Car Mfg. Co. United Airlines MOC Cresco, Pa. Chicago Heights, Ill. San Francisco, Calif. Williams Enterprises of Weld-Aid Products, Inc. Georgia, Inc. Thrall Car Mfg. Co. United States Air Force Detroit, Mich. Smyrna, Ga. Clinton, Ill. Cataloging & Standardization Center Weldcoa Wilson Industries, Inc. Thrall Car Mfg. Co. Battle Creek, Mich. Northlake, Ill. Pomona, Calif. Winder Georgia Facility Winder, Ga. United States Army Tank- Weld Mold Co. Worthington Industries Automotive & Armaments Brighton, Mich. Columbus, Ohio Thrall Europe Command York, United Kingdom Warren, Mich. Weld Wire Co., inc. X-Ergon King of Prussia, Pa. Irving,Tex. TienTai Electrode Co. Ltd. United States Department Taiwan, P. R. of China of Energy Welding Consultants Inc. Albuquerque, N. Mex. Columbus, Ohio

• Submit Your Technical OAnnounce Your Section's Activities Committee Reports

Stimulate attendance at your Section's meetings and Committee Chairmen -- We want to recognize training programs with free listings in the Section Meet- the efforts of your committee and inform our readers of ing Calendar column of Society News. its accomplishments. Send a brief profile of its activities Useful information includes your Section name; activ- and recent accomplishments, along with a member roster ity date, time and location; speaker's name, title, affiliation and contact numbers, and we will publish it in the Weld- and subject; and notices of golf outings, seminars, contests ing Journal's Society News section. and other special Section activities. If some of your meeting plans are sketchy, send the Send your submissions to name and phone number of a person to contact for more information. Susan Campbell,Associate Editor Send your new calendar to Susan Campbell,Associate American Welding Society Editor, Welding Journal Dept.,AWS, 550 N.W. LeJeune Rd., 550 N.W. LeJeune Rd. Miami, FL 33126; FAX: (305) 443-7404.0 Miami, FL 33126 Telephone, (305) 443-9353 ext. 244, FAX: (305) 443-7404 e-mail: campbell@ aws.orgO

WELDING JOURNAL I 9t EDUCATION GUIDE TO AWS SERVICES Director James R. Cunningham (219) 550 N.W. LeJeune Rd., Miami, FL 33126 Phone (800) 443-9353; Telex 51-9245; (888) WELDING Information on education products, projects and programs. CWI, SCWl and other semi- FAX (305) 443-7559; lnternet: www. aws. org nars designed for assistance in Certification. Phone extensions appear in parentheses. Responsible for the S.E.N.S.E. beginning welder program and dissemination of edu- AWS PRESIDENT Corporate Director of Administrative Services cation information on the Web. Jim Lankford (214) L.WilliamMyers CONFERENCES 482WolfRun Road Corporate Director of Marketing Technical Services Division Cuba, NY14727 Debrah C.Weir (279) Director Giselle 1. Rodriguez (278) Promotes Society programs and activities to AWS members, the welding commu- Responsible for national and local confer- nity and the general public. ences/exhibitions and seminars on industry ADMINISTRATION topics ranging from the basics to the leading edge of technology. Executive Director CONVENTION & EXPOSmONS Frank G. DeLaurier, CAE (210) Exhibiting Infurmation (221, 256)

Deputy Executive Directors Managing Director CERTIFICATION OPERATIONS Richard D. French (218) Tom L. Davis (231) Information and application materials on Jeffrey R. Hnfsey (264) certifying welders, welding inspectors and John J. McLaughlin (235) Organizes the week-long annual AWS In- educators. (273) ternational Welding and Fabricating Ex- position and Convention. Regulates Managing Director Assistant Executive Director Wendy S. Reeve (215) Dehbie A. Cadavid (222) space assignments, registration materials and other Expo activities. Awards & Fellows Director of Quality Management Systems Linda K. Williams (298) PUBLICATION SERVICES Managing Director Division Information (348) Wendy S. Reeve (215) Corporate Director of Finance/Comptroller Frank R.Tarafa (252) Managing Director Coordinates awards and AWS Felk)w nominees. JeffWeber (246) INFORMATION SERVICES TELEWELD Corporate Director WELDING JOURNAL Joe Cilli (258) Publisher FAX:(305) 443-5951 HUMAN RESOURCES JeffWeber (246) For information about AWS technical publi- Director Editor Luisa Hernandez (266) Andrew Cullison (249) cations, contact the Technical Services personnel listed below. National Sales Director INTERNATIONAL INSTITUTE Rob Saltzstein (243) TECHNICAL SERVICES OF WELDING WELDING HANDBOOK Department Information (340) Information (294) Welding Handbook Editor Managing Director Provides liaison activities involving other Annette O'Brien (303) Leonard P. Connor (299) Qualification, Inspection, Food professional societies and standards organizations, nationally and internationally. Publishes AWS's monthly magazine, the Processing Equipment Welding Journal, which provides infor- GOVERNMENT LIAISON SERVICES mation on the state of the welding in- Andrew R. Davis (466) International Standards dustry, its technology and Society activi- Program Manager, Welding in Marine Hugh K.Webster ties. Publishes the Welding Handbook Construction Webster, Chamberlain & Bean and books on general welding subjects. Stephen P. Hedrick (305) Safety and Health Washington, D.C. Manager, Symlx)lsand Definitions (202) 466-2976 FAX (202) 835-0243 MEMBER SERVICES

Identifies sources of funding for welding ed- Department Information (261) Engineers ucation and research & development. Moni- tors legislative and regulatory issues impor- Managing Director Hardy H. Campbell III (300) Structural tant to the industry. Cassie R. Burrell (253) Rakesh Gupta (301) Filler Metals Director WELDING EQUIPMENT Rhenda A. Mayo (260) Christopher B. Pollock (304) Braziog,Soldering MANUFA~RS COMMrlTEE Testing,Railroads, C~mputetization, Serves as a liaison between Section members Insmm'tentation Associate Executive Director and AWS headquarters. Informs members about Richard L.Alley (217) AWS benefits and other activities of interest. Tim Potter (309) Robotics,Joining of Metals and Alloys, Piping and Tubing, INDUSTRY ACTION COMMITrEE Friction Welding CERTIFICATION PROGRAMS/ Associate Executive Director BUSINESS DEVELOPMENT Melvin O. Kulp (314) Oxyfuel GasWelding & Charles R. Fassinger (297) Cutting,Arc Welding and Cutting, Machinery Director of Int'l Business Development and Equipment,Welding Iron Castings Walter Herrera (475) COMMUNICATIONS John L Ccayler(472) Metric Pmcticcs,Sheet Metal, For customized certification and educational Plasticsand Composites, Perstmnd Qualification Corporate Director, Communications programs to industry and government. Nannette M. Zapata (308)

92 J DECEMBER 2000 • Nominees for National Office PUBLICATION SALES (800) 334-9353 Only Sustaining Members, Members, Honorary Members, Life Members or Re- (305) 443-9353 tired Members who have been members for a period of at least three years shall be eligible for election as a Director or National Officer. Publication orders. It is the duty of the National Nominating Committee to nominate candidates for na- Seminar and conference tional office.The committee shall hold an open meeting, preferably at the Annual Meet- registrations. ing, at which members may appear to present and discuss the eligibility of all candidates. Ed E Mitchell (254)Thermal Spray, High- To be considered a candidate for positions of President,Vice President,Treasurer or Energy Beam Welding and Cutting, Re- Director-at-Large, the following qualifications and conditions apply: sistance Welding, Automotive, Aerospace President:To be eligible to hold the office of President, an individual must have served as a Vice President for at least one year. Senior Publications Coordinator Vice President:To be eligible to hold the office of Vice President, an individual must have served at least one year as a Director, other than Executive Director and Rosalinda O'Neill (451) Secretary. AWS publishes more than 160 volumes of Treasurer:To be eligible to hold the office of Treasurer, an individual must be a material, including standards that are used member of the Society, other than a Student Member, must be frequently available throughout the industry. to the National Office and should be of executive status in business or industry With regard to technical inquiries, oral opin- with experience in financial affairs. ions on AWS standards may be rendered. Director-at-Large:To be eligible for election as a Director-at-Large, an individual However, such opinions represent only the shall previously have held office as Chairman of a Section; as Chairman or Vice personal opinions of the particular individuals giving them.These individuals do not Chairman of a standing, technical or special committee of the Society; or as District speak on behalf of AWS, nor do these oral Director. opinions constitute official or unofficial opin- Interested parties are to send a letter stating which particular office they are ions or interpretations of AWS. In addition, oral seeking, including a statement of qualifications, their willingness and ability to serve opinions are informal and should not be used as a substitute for an official interpretation. if nominated and elected and 20 copies of their biographical sketch. This material should be sent to Robert J.Teuscher, Chairman, National Nominat- ing Committee,American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. It is the intent of the American Weld- The next meeting of the National Nominating Committee is currently sched- ing Society to build the Society to the uled for May 1,2001, in Cleveland, Ohio.The terms of office for candidates nomi- highest quality standards possible. We, nated at this meeting will commence June 1,2002. • welcome any suggestions you may hat~. Please contact any of the staff listed on the previous page or A WS President • Honorary-Meritorious Awards L. William Myers, Welding Engineer, Dresser-Rand, Olean Operations, p.o. Box The Honorary-MeritoriousAwards Committee has the duty to make recommendations 560, Paul Clark Dr, Olean, NY 14760. regarding nominees presented for Honorary Membership, National Meritorious Certificate, William Irrgang Memorial and the George E. Willis Awards. These awards are presented in conjunction with the AWS Exposition and Convention held each spring.The descriptions of these awards follnw, and the submission deadline for consideration is July 1 prior to the AWS FOUNDATION, INC, year of presentation. All candidate material should be sent to the attention of John J. McLaughlin, Secretary, Honorary-Meritorious Awards Committee, 550 N.W LeJeune Road, 550 N.W. LeJeune Rd. Miami, FL 33126. Miami, FL 33126 National Meritorious Certificate Award: International Meritorious Certifi- (305) 445-6628 This award is given in recognition of the cate Award: This award is given in (800) 443-9353, ext. 293 candidate's counsel, loyalty and devotion recognition of the candidate's signifi- Or e-mail: [email protected] to the affairs of the Society, assistance in cant contributions to the worldwide promoting cordial relations with industry welding industry.This award should re- Chairman, Board of Trustees and other organizations, and for the con- flect"Service to the International Weld- Ronald C. Pierce tribution of time and effort on behalf of ing Community" in the broadest terms. the Society. The awardee is not required to be a Executive Director member of the American Welding So- Frank G. DeLaurier, CAE William Irrgang Memorial Award: This ciety. Multiple awards can be given per award is administered by theAmericanWeld- year as the situation dictates. The ing Society and sponsored by The Lincoln award consists of a certificate to be Director of Development Electric Company to honor the late William presented at the award's luncheon or Robert B.Witherell Irrgang. It is awarded each year to the indi- at another time as appropriate in con- vidual who has done the most to enhance junction with the AWS President's the American Welding Society's goal of ad- travel itinerary, and, if appropriate, a vancing the science and technology of one-year membership to AWS. welding over the past five-year period. The AWS Foundation is a not- Honorary Membership Award: An for-profit corporation estab- George E. Willis Award: This award is Honorary Member shall be a person of fished to provide support for administered by the American Welding So- acknowledged eminence in the weld- educational and scientific ciety and sponsored byThe Lincoln Elec- ing profession, or who is accredited endeavors of the American tric Company to honor George E.Willis. It with exceptional accomplishments in Welding Society. Information is awarded each year to an individual for the development of the welding art, on gift-giving programs is promoting the advancement of welding upon whom the American Welding So- available upon request. internationally by fostering cooperative ciety sees fit to confer an honorary dis- participation in areas such as technology tinction. An Honorary Member shall transfer, standards rationalization and pro- have full rights of membership. • motion of industrial goodwill.

WELDING JOURNAL J 93 WELDING JOURNAL INDEX

VOLUME 79 m 2000

PUBLISHED BY THE AMERICAN WELDING SOCIETY, 550 N.W. LEJEUNE RD., MIAMI, FL 33126

Part 1 --WELDING JOURNAL

SUBJECT INDEX

Advancements Push Pipeline Welding Productivity, Tech- Penso, C. L. Tsai, D. G. Howden and W. O. Soboyejo, 45 nology -- S. A. Blackman and D. V. Dorling, 39 (Aug) (Aug) Airport Expansion, Welding Lends Architectural Flair to -- Companies Enter into the Judiciary System, From Naivet~ to 43 (Oct) Desperation: When Small -- J. A. Miller, 35 (Oct) Architectural Flair to Airport Expansion, Welding Lends -- Company Embraces Automatic Laser Gas Supply System -- 43 (Oct) F. Steele, 61 (Apr) Assessing Arc Welding Performance and Quality, A Wise Consolidates Cutting Operations to Cut Costs, Steel Center Method for -- D. D. Harwig, 35(Dec) -- 41 (May) Assessing Deterioration Conditions in Coke Drums -- J. A. Cost Effective, Repairing an Offshore Jacket Structure Proves Penso, C. L. Tsai, D. G. Howden and W. O. Soboyejo, 45 -- J. R. Still and V. Blackwood, 43 (May) (Aug) Cost of GMAW Gun Ownership, Calculating the Total -- H. Auto Industry Gears Up for Aluminum, The -- B. Irving, 63 Shah, 49 (Oct) (Nov). Contact-Tube Performance through Cryogenics, Improving Automotive Industry, Electron Beam Welding: A Useful Tool -- J. Villafuerte, 45 (Oct) for the -- D. Powers and G. Schubert, 35 (Feb) Critical for Offshore Oil Production Vessels, Hull Weld Alkaline Cleaning, Back to Basics: A Guide to -- G. Sanko, Quality--J. R. Still and J. B. Speck, 33 (Aug) 49 (Jul) Cutting Operations to Cut Costs, Steel Center Consolidates Back to Basics: A Guide to Alkaline Cleaning -- G. Sanko, -- 41 (May) 49 (Jul) Densities of Many Thermal Sprayed Coatings, HVIF Process Backscattered Electron Diffraction to Understand Weldabil- Improves -- B. Irving, 42 (Feb) ity, Using--J. N. Dupont, J. R. Michael and C. V. Robino, Desk to the Desktop, Moving Weld Management from the 43 (Mar) -- A. D. Brightmore and M. Bernasek, 43 (Jan) Basics: A Guide to Alkaline Cleaning, Back to -- G. Sanko, Desperation: When Small Companies Enter into the Judi- 49 (Jul) ciary System,From Naivet6 to- J. A. Miller, 35 (Oct) Boiler Tubing, Cladding Operation Doubles Life of-- T. He- Deterioration Conditions in Coke Drums, Assessing- J. A. ston, 45 (Jul) Penso, C. L. Tsai, D. G. Howden and W. O. Soboyejo, 45 Brazing Flux Breakthroughs, Manufacturers Capitalize on -- (Aug) S. A. Urban, 37 (Sep) Development of Titanium Weld Color Inspection Tools --J. Bridge Construction, Electroslag Welding Stands Poised for Talkington, D. Harwig, H. Castner and G. Mitchell, 35 a Comeback in -- M. R. Johnsen, 39 (Feb) (Mar) Caterpillar, Robotic Arc Welding Is Off and Running at -- B. Diffraction to Understand Weldability, Using Backscattered Iving, 55 (Apr) Electron --J. N. DuPont, J. R. Michael and C. V. Robino, Cell with Its Own Web Site, A Welding-- T. P. Quinn, J. D. 43 (Mar) Gilsinn and W. Rippey, 46 (Jan) Drawn Arc Stud Welding: Crossing Over from Steel to Alu- Chicago: There's a Whole Lot of Welding Going On -- M. minum -- S. Ramasamy, 35 (Jan) R. Johnsen and T. Heston, 48 (Apr) Electron Beam Welding: A Useful Tool for the Automotive Choose Brazing, Ten Reasons to -- W. D. Kay, 33 (Sep) Industry -- D. Powers and G. Schubert, 35 (Feb) Chrome Plating, Thermal Spray Coatings as an Alternative to Electroslag Welding Stands Poised for a Comeback in Bridge Hard -- B. D. Sartwell, 39 (Jul) Construction -- M. R. Johnsen, 39 (Feb) Cladding Operation Doubles Life of Boiler Tubing -- T. He- Entry-Level Welders, Program Answers Industry's Call for- ston, 45 (Jul) M. R. Johnsen, 29 (Dec) Coast Guard Always Ready, Weld Shop Keep U. S. -- 31 Equipment Industry, Survey Reflects Stability in Welding- (May) A. Cullison, 65 (Apr) Coatings as an Alternative to Hard Chrome Plating, Thermal Filler Metal for Welding Aluminum, How to Select the Best Spray -- B. D. Sartwell, 39 (Jul) --T. Anderson, 69 (Nov) Coke Drums, Assessing Deterioration Conditions in --J. A. Forcing Adjustments in Welding and Cladding, Petrochem-

94 J DECEMBER 2000 ical Requirements Are -- B. Irving, 53 (Aug) --J. Villafuerte, 45 (Oct) Flux Breakthroughs, Manufacturers Capitalize on Brazing-- Pipe Production and Reduce Cost, Two New Technologies S. A. Urban, 37 (Sep) May Increase -- T. McGaughy, 65 (Aug) Flux-Free Ultrasonic Soldering, A New Look at, H. R. Faridi, Pipe Welding, Methods of Weld Root Purging for -- R. J. H Devletian and H. P. Le, 41 (Sep) Sewell, 57 (Aug) GTA Welding Machines Improve Fabrication, Inverter-Based Pipeline Welding Productivity, Technology Advancements --M. Sammons, 35 (May) Push -- S. A. Blackman and D. V. Dorling, 39 (Aug) Future, Training for the -- D. Landon, 40 (Dec) Petrochemical Requirements Are Forcing Adjustments in Gas Supply System, Company Embraces Automatic Laser-- Welding and Cladding -- B. Irving, 53 (Aug) F. Steele, 61 (Apr) Powder Spraying, A New Approach to -- V. Bogachek, 45 Gears Up for Aluminum, The Auto Industry -- B. Irving, 63 (Feb) (Nov). Program Answers Industy's call for Entry-Level Welders -- GMAW Gun Ownership, Calculating the Total Cost of-- H. M. R. Johnsen, 29 (Dec) Shah, 49 (Oct) Protection: Preparing for an OSHA Inspection, Respiratory Great Master's Horse Returns Home after 500 Years, The -- -- C. E. Colton, 49 (Mar) 44 (Apr) Purging for Pipe Welding, Methods of Weld Root-- 57 (Aug) HVlF Process Improves Densities of Many Thermal Sprayed Repairing an Offshore Jacket Structure Proves Cost Effective Coatings -- B. Irving, 42 (Feb) --J. R. Still and V. Blackwood, 43 (May) Heavy Weldments, Metal Cored Welding Wire Comes Respiratory Protection: Preparing for an OSHA Inspection -- Through on -- D. Phillips, 52 (Mar) C. E. Colton, 49 (Mar) Horse Returns Home after 500 Years, The Great Master's -- Robotic Arc Welding Is Off and Running at Caterpillar -- B. 44 (Apr) Irving, 55 (Apr) Hull Weld Quality Critical for Offshore Oil Production Ves- Safety Programs, Too, Small Shops Need -- 39 (Mar) sels -- J. R. Still and J. B. Speck, 33 (Aug) Select the Best Filler Metal for Welding Aluminum, How to Inspection Tools, Development of Titanium Weld Color -- -- 69 (Nov) J. Talkington, D. Harwig, H. Castner and G. Mitchell, 35 Shop Keeps U. S. Coast Guard Always Ready, Weld -- 31 (Mar) (May) Inspects Pipe Welds, Portable Video Probe -- 73 (Nov) Small Shops Need Safety Programs, Too -- 39 (Mar) Inverter-Based GTA Welding Machines Improve Fabrication Sprayed Coatings, HVIF Process Improves Densities of Many --M. Sammons, 35 (May) Thermal- B. Irving, 42 (Feb) Japan's High-Speed Trains on Track, Advanced Welding Stability in Welding Equipment Industry, Survey Reflects -- Technology Keeps -- S. Yamada and K. Masubuchi, 48 A. Cullison, 65 (Apr) (Nov). Steel Center Consolidates Cutting Operations to Cut Costs Judiciary System, From Naivet6 to Desperation: When Small -- 41 (May) Companies Enter into the -- J. A. Miller, 35 (Oct) Steel to Aluminum, Drawn Arc Stud Welding: Crossing Over Laser Gas Supply System, Company Embraces Automatic -- from -- S. Ramasamy, 35 (Jan) F. Steele, 61 (Apr) Stud Welding: Crossing Over from Steel to Aluminum, Machines Improve Fabrication, Inverter-Based GTA Welding Drawn Arc -- S. Ramasamy, 35 (Jan) -- M. Sammons, 35 (May) Survey Reflects Stability in Welding Equipment Industry -- Management from the Desk to the Desktop, Moving Weld A. Cullison, 65 (Apt) -- A. D. Brightmore and M. Bernasek, 43 (Jan) Technologies May Increase Pipe Production and Reduce Master's Horse Returns Home after 500 Years, The Great -- Cost, Two New -- T. McGaughy, 65 (Aug) 44 (Apr) Technology Advancements Push Pipeline Welding Produc- Metal Cored Welding Wire Comes Through on Heavy Weld- tivity -- S. A. Blackman and D. V. Dorling, 33 (Aug) ments -- D. Phillips, 52 (Mar) Technology Stars at 2000 AWS Exposition, Welding -- A. Methods of Weld Root Purging for Pipe Welding -- R. Cullison and M. R. Johnsen, 33 (Jul) Sewell, 57 (Aug) Thermal Spray Coatings as an Alternative to Hard Chrome Mexico, Training Welders in -- A. Hill Price, 41 (Dec) Plating -- B. D. Sartwell, 39 (Jul) Moving Weld Management from the Desk to the Desktop -- Titanium Weld Color Inspection Tools, Development of-- A. D. Brightmore and M. Bernasek, 43 (Jan) J. Talkington, D. Harwig, H. Castner and G. Mitchell, 35 National Landmark, Preserving a -- T. Siewert, C. Mc- (Mar) Cowan, R. Bushey, B. Robinson, T. Christ and K. Hilde- Trains on Track, Advanced Welding Technology Keeps brand, 54 (Nov). Japan's High-Speed -- S. Yamada and K. Masubuchi, 48 Networking of Welding Applications: A Tutorial -- T. P. (Nov). Quinn, J. D. Gilsinn and W. Rippey, 49 (Jan) Tube-to-Tubsheet Joints, Improving the Reliability of -- H. New Approach to Powder Spraying, A -- V. Bogachek, 45 W. Ebert, 47 (Sep) (Feb) Two New Technologies May Increase Pipe Production and OSHA Inspection, Respiratory Protection: Preparing for an Reduce Cost -- T. McGaughy, 65 (Aug) -- C. E. Colton, 49 (Mar) Ultrasonic Soldering, A New Look at Flux-Free, H. R. Faridi, Offshore Jacket Structure Proves Cost Effective, Repairing an J. H Devletian and H. P. Le 41 (Sep) --J. R. Still and V. Blackwood, 43 (May) Using Backscattered Electron Diffraction to Understand Oil Production Vessels, Hull Weld Quality Critical for Off- Weldability -- J. N. Dupont, J. R. Michael and C. V. shore -- J. R. Still and J. B. Speck, 33 (Aug) Robino, 43 (Mar) Operation Doubles Life of Boiler Tubing, Cladding-- T. He- Video Probe Inspects Pipe Welds, Portable -- 73 (Nov) ston, 45 (Jul) Web Site, A Welding Cell with Its Own -- T. P. Quinn, J. D. Pathway to the Stars, Welding a -- M. R. Johnsen, 39 (Oct) Gilsinn and W. Rippey, 46 (Jan) Performance through Cryogenics, Improving Contact-Tube Weld Root Purging for Pipe Welding, Methods of -- R.

WELDING JOURNAL I 9S Sewell, 57 (Aug) Forcing Adjustments in -- B. Irving, 53 (Aug) Weld Shop Keeps U. S. Coast Guard Always Ready -- 31 Welding Going On, Chicago: There's a Whole Lot of- M. (May) R. Johnsen and T. Heston, 48 (Apr) Welder?, Who Will Become a -- W. Western, 45 (Dec) Welding Is Off and Running at Caterpillar, Robotic Arc -- B. Welders in Mexico, Training-- A. Hill Price, 41 (Dec) Irving, 55 (Apr) Welders, Program Answers Industry's Call for Entry-Level -- Welding Performance and Quality, A Wise Method for As- M. R. Johnsen, 29 (Dec) sessing Arc -- D. D. Harwig, 35 (Dec) Welding: A Useful Tool for the Automotive Industry, Electron Welding Stands Poised for a Comeback in Bridge Construc- Beam -- D. Powers and G. Schubert, 35 (Feb) tion, Electroslag -- M. R. Johnsen, 39 (Feb) Welding Aluminum, How to Select the Best Filler Metal for Welding Technology Stars at 2000 AWS Exposition -- A. -- T. Anderson, 69 (Nov) Cullison and M. R. Johnsen, 33 (Jul) Welding Aluminum, What You Should Know about -- 54 Welding Technology Keeps Japan's High-Speed Trains on (Jan) Track, Advanced -- S. Yamada and K. Masubuchi, 48 Welding Applications: A Tutorial, Networking of -- W. (Nov). Rippey, T. P. Quinn and J. D. Gilsinn, 49 (Jan) What You Should Know about Welding Aluminum -- 54 Welding Cell with Its Own Web Site, A -- T. P. Quinn, J. D. (Jan) Gilsinn and W. Rippey, 46 (Jan) Wire Comes Through on Heavy Weldments, Metal Cored Welding and Cladding, Petrochemical Requirements Are Welding -- D. Phillips, 52 (Mar)

AUTHORS FOR FEATURE ARTICLES

Anderson, T. -- How to Select the Best Filler Metal for Weld- ing Applications: A Tutorial, 49 (Jan) ing Aluminum, 69 (Nov) Harwig, D. D. -- Assessing Arc Welding Performance and Bernasek, M. and Brightmore, A. D. -- Moving Weld Man- Quality, A Wise Method for, 35 (Dec) agement from the Desk to the Desktop, 43 (Jan) Harwig, D., Castner, H., Mitchell, G. and Talkington, J. -- Blackman, S. A. and Dorling, D. V. -- Technology Ad- Development of Titanium Weld Color Inspection Tools, vancements Push Pipeline Welding Productivity, 39 (Aug) 35 (Mar) Blackwood, V. and Still, J. R. -- Repairing an Offshore Jacket Heston, T. -- Cladding Operation Doubles Life of Boiler Structure Proves Cost Effective, 43 (May) Tubing, 45 (Jul) Bogachek, V. -- A New Approach to Powder Spraying, 45 Heston, T. and Johnsen, M. R. -- Chicago: There's a Whole (Feb) Lot of Welding Going On, 48 (Apr) Brightmore, A. D. and Bernasek, M. -- Moving Weld Man- Hildebrand, K., Siewert, T., McCowan, C., Bushey, R., agement from the Desk to the Desktop, 43 (Jan) Robinson, B. and Christ, T. -- Preserving a National Land- Bushey, R., Robinson, B., Christ, T., Hildebrand, K., Siewert, mark, 54 (Nov) T. and McCowan, C. -- Preserving a National Landmark, Howden, D. G., Soboyejo, W. O., Penso, J. A. and Tsai, C. 54 (Nov) L. -- Assessing Deterioration Conditions in Coke Drums, Castner, H., Mitchell, G., Talkington, J. and Harwig, D. -- 45 (Aug) Development of Titanium Weld Color Inspection Tools, Irving, B. -- HVlF Process Improves Densities of Many Ther- 35 (Mar) mal Sprayed Coatings, 42 (Feb) Christ, T., Hildebrand, K., Siewert, T., McCowan, C., Bushey, Irving, B. -- Petrochemical Requirements Are Forcing Ad- R. and Robinson, B. -- Preserving a National Landmark, justments in Welding and Cladding, 53 (Aug) 54 (Nov) Irving, B. -- Robotic Arc Welding Is Off and Running at Colton, C. E. -- Respiratory Protection: Preparing for an Caterpillar, 55 (Apr) OSHA Inspection, 49 (Mar) Irving, B. -- The Auto Industry Gears Up for Aluminum, 63 Cullison, A. -- Survey Reflects Stability in Welding Equip- (Nov) ment Industry, 65 (Apr) Johnsen, M. R. -- Program Answers Industry's Call for Entry- Cullison, A. and Johnsen, M. R.--Welding Technology Stars Level Welders, 29 (Dec) at 2000 AWS Exposition, 33 (Jul) Johnsen, M. R. -- Welding a Pathway to the Stars, 39 (Oct) Devletian, J. H. Le, H. P. and Faridi, H. R., -- A New Look Johnsen, M. R. and Cullison, A.- Welding Technology Stars at Flux-Free Soldering, 41 (Sep) at 2000 AWS Exposition, 33 (Jul) Dorling, D. V. and Blackman, S. A. -- Technology Ad- Johnsen, M. R. and Heston, T. -- Chicago: There's a Whole vancements Push Pipeline Welding Productivity, 39 (Aug Lot of Welding Going On, 48 (Apr) DuPont, J. N., Michael, J. R. and Robino, C. V. -- Using Johnsen, M. R. -- Electroslag Welding Stands Poised for a Backscattered Electron Diffraction to Understand Weld- Comeback in Bridge Construction, 39 (Feb) ability, 43 (Mar) Kay, W. D. -- Ten Reasons to Choose Brazing, 33 (Sep) Ebert, H. W., -- Improving the Reliability of Tube to Tub- Landon, D. -- Training for the Future, 48 (Dec) sheet Joints, 47 (Sep) Le, H. P., Faridi, H. R., and Devletian, J. H. -- A New Look Faridi, H. R., Devletian, J. H. and Le, H. P. -- A New Look at Flux-Free Soldering, 41 (Sep) at Flux-Free Soldering, 41 (Sep) Masubuchi, K. and Yamada, S. -- Advanced Welding Tech- Flitter, L., Rippey, W. and Gilsinn, J. -- Networking of Weld- nology Keeps Japan's High-Speed Trains on Track, 48 ing Applications: A Tutorial, 49 (Jan) (Nov) Gilsinn, J. D., Rippey, W. and Quinn, T. P.--A Welding Cell McCowan, C., Bushey, R., Robinson, B., Christ, T., Hilde- with Its Own Web Site, 46 (Jan) brand, K., and Siewert, T. -- Preserving a National Land- Gilsinn, J., Flitter, L. and Rippey, W. -- Networking of Weld- mark, 54 (Nov)

96 I DECEMBER 2000 McGaughy, T. -- Two New Technologies May Increase Pipe Sartwell, B. D. -- Thermal Spray Coatings as an Alternative Production and Reduce Cost, 65 (Aug) to Hard Chrome Plating, 39 (Jul) Michael, J. R., Robino, C. V. and DuPont, J. N. -- Using Schubert, G. and Powers, D. -- Electron Beam Welding: A Backscattered Electron Diffraction to Understand Weld- Useful Tool for the Automotive Industry, 35 (Feb) ability, 43 (Mar) Sewell, R. -- Methods of Weld Root Purging for Pipe Weld- Miller, J. A., -- From Naivet~ to Desperation: When Small ing, 57 (Aug) Companies Enter into the Judiciary System, 35 (Oct) Shah, H. -- Calculating the Total Cost of GMAW Gun Own- Mitchell, G., Talkington, J., Harwig, D. and Castner, H. -- ership, 49 (Oct) Development of Titanium Weld Color Inspection Tools, Siewert, T., McCowan, C., Bushey, R., Robinson, B., Christ, 35 (Mar) T. and Hildebrand, K.- Preserving a National Landmark, Penso, J. A., Tsai, C. L., Howden, D. G. and Soboyejo, W. 54 (Nov) O.- Assessing Deterioration Conditions in Coke Drums, Soboyejo, W. O., Penso, J. A., Tsai, C. L. and Howden, D. 45 (Aug) G.- Assessing Deterioration Conditions in Coke Drums, Phillips, D. -- Metal Cored Welding Wire Comes Through 45 (Aug) on Heavy Weldments, 52 (Mar) Speck, J. B. and Still, J. R. -- Hull Weld Quality Critical for Powers, D. and Schubert, G. -- Electron Beam Welding: A Offshore Oil Production Vessels, 33 (Aug) Useful Tool for the Automotive Industry, 35 (Feb) Steele, F. -- Company Embraces Automatic Laser Gas Sup- Price, A. H. -- Training Welders in Mexico, 41 (Dec) ply System, 61 (Apr) Quinn, T. R, Gilsinn, J. D. and Rippey, W.- A Welding Cell Still, J. R. and Blackwood, V. -- Repairing an Offshore Jacket with Its Own Web Site, 46 (Jan) Structure Proves Cost Effective, 43 (May) Ramasamy, S. -- Drawn Arc Stud Welding: Crossing Over Still, J. R. and Speck, J. B. -- Hull Weld Quality Critical for from Steel to Aluminum, 35 (Jan) Offshore Oil Production Vessels, 33 (Aug) Robino, C. V., DuPont, J. N. and Michael, J. R. -- Using Talkington, J., Harwig, D., Castner, C and Mitchell, G. -- De- Backscattered Electron Diffraction to Understand Weld- velopment of Titanium Weld Color Inspection Tools, 35 ability, 43 (Mar) (Mar) Rippey, W., Quinn, T. P. and Gilsinn, J. D. -- A Welding Cell Tsai, C. L., Howden, D. G., Soboyejo, W. O. and Penso, J. with Its Own Web Site, 49 (Jan) A.- Assessing Deterioration Conditions in Coke Drums, Rippey, W., Gilsinn, J. and Flitter, L. -- Networking of Weld- 45 (Aug) ing Applications: A Tutorial, 54 (Jan) Urban, S.A. Manufacturers Capitalize on Brazing Flux Robinson, B., Christ, T., Hildebrand, K., Siewert, T., Mc- Breakthroughs, 37 (Sep) Cowan, C. and Bushey, R. -- Preserving a National Land- Villafuerte, J.- Improving Contact-Tube Performance mark, 54 (Nov) through Cryogenics, 45 (Oct) Sammons, M. -- Inverter-Based GTA Welding Machines Im- Western, W. -- Who Will Become a Welder?, 45 (Dec) prove Fabrication, 35 (May) Yamada, S. and Masubuchi, Koichi -- Advanced Welding Sanko, G. -- Back to Basics: A Guide to Alkaline Cleaning, Technology Keeps Japan's High-Speed Trains on Track, 48 49 (Jul) (Nov)

PART 2- RESEARCH SUPPLEMENT

SUBJECT INDEX

Aluminum Alloy AA5754, Cracking in Spot Welding -- J. Approximate Stress Intensity Factor and Notch Stress for Spot Senkara and H. Zhang, 194-s (Jul) Welds -- S. Zhang, 54-s (Feb) Aluminum Alloys, A Method for Studying Weld Fusion Basicity of a FCAW Consumable -- Part 1 : Solidified Slag Boundary Microstructure Evolution in -- A. Kostrivas and Composition of a FCAW Consumable as a Basicity Indi- J. C. Lippold, 1-s (Jan) cator, Reconsidering the -- E. Baun6, C. Bonnet and S. Aluminum Alloys Using the Front Weld Pool Image Signal, Liu, 57-s (Mar) Control of Weld Penetration in VPPAW of -- B. Zheng, Basicity of a FCAW Consumable-- Part 2: Verification of the H. J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec) Flux/Slag Analysis Methodology for Weld Metal Oxygen Aluminum During Diffusion Welding, Interfacial Reactions Control, Reconsidering the-- E. Baun6, C. Bonnet and S. of Titanium and -- J-G Luo and V. L. Acoff, 239-s (Sep) Liu, 66-s (Mar) Aluminum Resistance Spot Welding Processes Using Cou- Bead Volume for the Submerged Arc Process -- Part 1, Pre- pled Finite Element Procedures, Analysis of-- X. Sun and diction and Optimization of Weld -- V. Gunaraj and N. R Dong, 215-s (Aug) Murugan 268-s (Oct) Aluminum Welds -- Liquation Mechanism and Directional Bead Volume for the Submerged Arc Process -- Part 2, Pre- Soldification, Partially Melted Zone in -- C. Huang and diction and Optimization of Weld -- V. Gunaraj and N. S. Kou, 113-s (May) Murugan, 331-s (Nov) Analysis of Aluminum Resistance Spot Welding Processes Beam Welding of Magnesium AZ91 D Plates, Electron -- A. Using Coupled Finite Element Procedures -- X. Sun and Munitz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul) P. Dong, 215-s (Aug) Brazed Alumina Tensile Specimens, Microstructural and

WELDING JOURNAL I 97 Mechanical Characterization of Actively -- F. M. Hosk- ulations, Cracking Susceptibility of a New -- J. G. ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, Nawrocki, J. N. Dupont, C. V. Robino, and A. R. Marder, P. T. Vianco and C. A. Walker, 222-s (Aug) 355-s (Dec) Brazed Joints, A New Approach to Improving the Properties Ferritic-Austenitic Dissimilar Metal Welds -- Part 2: On- of-- B. Zorc and L. Kosec, 24-s (Jan) Cooling Transfromations, Nature and Evouliton of the Fu- Brazed Joints, Model Equation for Predicting the Tensile sion Boundary in -- T. W. Nelson, J. C. Lippold and M. J. Strenght of Resistance- -- K. Takeshita, 261 -s (Sep) Mills, 267-s (Oct) Characteristics of Resistance Spot Welding of Steels, Force Ferritic Steel -- Part 1 : Single-Pass Heat-Affected Zone Sim- -- H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul) ulations, Cracking Susceptibility of a News -- J. G. Characterization of C-Mn Steel Laser Beam Welded Joints Nawrock, J. N. Dupont, C. V. Robino, and A. R. Marder, with Powder Filler Metal, Structural -- S. Missori and A. 355-s (Dec) Sill, 31 7-s (Nov). Filler Metal, Structural Characterization of C-Mn Steel Laser Construction Diagram, A New Ferritic-Martensitic Stainless Beam Welded Joints with Powder-- S. Missori and A. Sill, Steel -- M. C. Balmforth and J. C. Lippold, 339-s (Dec) 317-s (Nov) Consumable as a Basicity Indicator, Reconsidering the Ba- Finite Element Analyses, Modeling of Projection Welding sicity of a FCAW Consumable -- Part 1: Solidified Slag Processes Using Coupled -- X. Sun, 244-s (Sep) Composition of a FCAW -- E. Baun6, C. Bonnet and S. Finite Element Analysis of Heat Flow in Single-Pass Arc Liu, 57-s (Mar) Welds- E. A. Bonifaz, 121-s (May) Convection in Simulated Weld Pools Containing a Surface- Finite Element Procedures, Analysis of Aluminum Resis- Active Agent, Visualization of Marangoni -- C. Limma- tance Spot Welding Processes Using Coupled -- X. Sun neevichitr and S. Kou, 324-s (Nov) and P. Dong, 215-s (Aug) Convection in Simulated Weld Pools, Visualization of Fluid Physical Properties on Weld Qualification for In-Ser- Marangoni -- C. Limmaneevichitr and S. Kou, 126-s vice Pipelines, The Influence of Working -- R. J. Belanger (May) and B. M. Patchett, 209-s (Aug) Convection on Weld Pool Shape, Experiments to Simulate Fluoride Additions in Welding Flux Hydrogen Control in Effect of Marangoni -- C. Limmaneevichitr and S. Kou, Steel Weld Metal by Means of- M. Matsushita and S. 231 -s (Aug) Liu, 295-s (Oct) Cracking in Spot Welding Aluminum Alloy AA5754 -- J. Flux/Slag Analysis Methodology for Weld Metal Oxygen Senkara and H. Zhang, 194-s (Jul) Control, Reconsidering the Basicity of a FCAW Consum- Cracking Susceptibility of a New Ferritic Steel -- Part 1: Sin- able -- Part 2 Verification of the -- E. Baun~, C. Bonnet gle-Pass Heat-Affected Zone Simulations, The Stress-Re- and S. Liu, 66-s (Mar) lief- J. G. Nawrocki, J. N. Dupont, C. V. Robino, and A. Force Characteristics of Resistance Spot Welding of Steels-- R. Marder, 355-s (Dec) H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul) Defect Formation in Friction Welded Aluminum, Spiral -- K. Friction Welded Aluminum, Spiral Defect Formation in -- K. Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s (Jul) (Jul) Diffusion Welding, Interfacial Reactions of Titanium and Fusion Boundary in Ferritic-Austenitic Dissimilar Metal Aluminum During--J-G Luo and V. L. Acoff, 239-s (Sep) Welds-- Part 2: On-Cooling Transformations, Nature and Dissimilar Metal Welds -- Part 2: On-Cooling Transfroma- Evolution, Nelson, T. W., Lippold, J. C. and Mills, M. J., tions, Nature and Evolution of the Fusion Boundary in 267-s (Oct) Ferritic-Austenitic -- T. W. Nelson, J. C. Lippold and M. Fusion Boundary Microstructure Evolution in Aluminum Al- J. Mills, 267-s (Oct) loys, A Method for Studying Weld -- A. Kostrivas and J. Electron Beam Welding of Magnesium AZ91 D Plates -- A. C. Lippold, 1-s (Jan) Muniz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul) GTAW Process Light Mechanism and Its Application in Sens- Evolution of Titanium Arc Weldment Macro and Mi- ing of the -- P. J. Li and Y. M Zhang, 252-s (Sep) crostructures -- Modeling and Real Time Mapping of Heat-Affected Zone Simulations, The Stress-Relief Cracking Phases -- Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, Susceptibility of a New Ferritic Steel -- Part 1 : Single-Pass 97-s (Apr) -- J. G. Nawrocki, J. N. Dupont, C. V. Robino, and A. R. FCAW Consumable -- Part 1: Solidified Slag Composition Marder, 355-s (Dec) of a FCAW Consumable as a Basicity Indicator, Recon- Heat Flow in Single-Pass Arc Welds, Finite Element Analy- sidering the Basicity of a -- E. Baun6, C. Bonnet and S. sis of- E. A. Bonifaz, 121-s (May) Liu, 57-s (Mar) High-Strength Aluminum Alloy, A Hot-Cracking Mitigation FCAW Consumable -- Part 2: Verification of the Flux/Slag Technique for Welding -- Y. P. Yang, P. Dong, J. Zhang Analysis Methodology for Weld Metal Oxygen Control, and X. Tian, 9-s (Jan) Reconsidering the Basicity of a -- E. Baun6, C. Bonnet Hot-Cracking Mitigation Technique for Welding High- and S. Liu, 66-s (Mar) Strength Aluminum Alloy, A -- Y. P. Yang, P. Dong, J. Fatigue Assessment of Spot Welds Based on Local Stress Pa- Zhang and X Tian, 9-s (Jan) rameters- D. Radaj, 51-s (Feb) HSLA-100 Welds Fabricated with New Ultra-Low-Carbon Ferrite Number Prediction in Stainless Steel Arc Welds Using Weld Comsumables, Microhardness Variations in, D. W. Artificial Neural Networks-- Part 1 : Neural Network De- Moon, R. W. Fonda and G. Spanos, 278-s (Oct) velopment, Improved --J. M. Vitek, Y. S. Iskander and E. Image-Based Penetration Monitoring of CO 2 Laser Beam M. Oblow, 33-s (Feb) Welding-- R. K. Holbert, R. W. Richardson, D. F. Farson Ferrite Number Prediction in Stainless Steel Arc Welds Using and C. E. Albright, 89-s (Apr) Artificial Neural Networks- Part 2: Neural Network Re- Image Signal, Control of Weld Penetration in VPPAW of, Alu- sults, Improved -- J. M. Vitek, Y. S. Iskander and E. M. minum Alloys Using the Front Weld Pool -- B. Zheng, H. Oblow, 41-s (Feb) J. Wang, Q. I. Wang and R. Kovacevic, 346-s (Dec) Ferritic Steel -- Part 1 : Single-Pass Heat-Affected Zone Sim- Improved Ferrite Number Prediction in Stainless Steel Arc

98 I DECEMBER 2000 Welds Using Artificial Neural Networks -- Part 1 : Neural Neural Networks -- Part 1: Neural Network Development, Network Development -- J. M. Vitek, Y. S. Iskander and Improved Ferrite Number Prediction in Stainless Steel Arc E. M. Oblow, 33-s (Feb) Welds Using Artificial --J. M. Vitek, Y. S. Iskander and E. Improved Ferrite Number Prediction in Stainless Steel Arc M. Oblow, 33-s (Feb) Welds Using Artificial Neural Networks -- Part 2: Neural Neural Network Results, Improved Ferrite Number Predic- Network Results -- J. M. Vitek, Y. S. Iskander and E. M. tion in Stainless Steel Arc Welds Using Artificial Neural Oblow, 41-s (Feb) Networks -- Part 2 -- J. M. Vitek, Y. S. Iskander and E. Influence of Working Fluid Physical Properties on Weld M. Oblow, 41-s (Feb) Qualification for In-Service Pipelines, The -- R. J. Be- New Approach to Improving the Properties of Brazed Joints, langer and B. M. Patchett, 209-s (Aug) A -- B. Zorc and L. Kosec, 24-s (Jan) Interaction of a Molten Droplet with a Liquid Weld Pool Sur- On-Cooling Transformations, Nature and Evolution of the face: A Computational and Experimental Approach, An Fusion Boundary in Ferritic-Austenitic Dissimilar Metal Investigation of the -- M. H. Davies, M. Wahab and M. Welds -- Part 2: Nelson, T. W., Lippold, J. C. and Mills, J. Painter, 18-s (Jan) M. J., 267-s (Oct) Investigation of the Interaction of a Molten Droplet with a Optimization of Weld Bead Volume for the Submerged Arc Liquid Weld Pool Surface: A Computational and Experi- Process -- Part 2, Prediction and -- V. Gunaraj and N. mental Approach, An -- M. H. Davies, M. Wahab and M. Murugan, 331-s (Nov) J. Painter, 18-s (Jan) Oxygen Control, Reconsidering the Basicity of a FCAW Laser Beam Welded Joints with Powder Filler Metal, Struc- Consumable-- Part 2: Verification of the Flux/Slag Analy- tural Characterization of C-Mn Steel -- S. Missori and A. sis Methodology for Weld Metal -- E. Baun6, C. Bonnet Sill, 317-s (Nov) and S. Liu, 66-s (Mar) Laser Beam Welding, Image-Based Penetration Monitoring Partially Melted Zone in Aluminum Welds -- Liquation of CO 2- R. K. Holbert, R. W. Richardson, D. F. Farson Mechanism and Directional Soldification -- C. Huang and C. E. Albright, 89-s (Apr) and S. Kou, 113-s (May) Laser Beam Welding, Magneto-Fluid Dynamic Control of Penetration Monitoring of CO 2 Laser Beam Welding, Image- Seam Quality in CO 2 --M. Kern, P. Berger and H. HL~gel, Based -- R. K. Holbert, R. W. Richardson, D. F. Farson 72-s (Mar) and C. E. Albright, 89-s (Apr) Light Mechanism and Its Application in Sensing of the Penetration in VPPAW of Aluminum Alloys Using the Front GTAW Process -- P. J. Li and Y. M Zhang, 252-s (Sep) Weld Pool Image Signal, Control of Weld -- B. Zheng, H. Liquation Mechanism and Directional Melted Zone in Alu- J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec) minum Welds -- C. Huang and S. Kou, 113-s (May) Pool Shape, Experiments to Simulate Effect of Marangoni Magnesium AZ91 D Plates, Electron Beam Welding of-- A. Convection on Weld -- C. Limmaneevichitr and S. Kou Munitz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul) 231-s (Aug) Magneto-Fluid Dynamic Control of Seam Quality in CO 2 Pools Containing a Surface-Active Agent, Visualization of Laser Beam Welding -- M. Kern, P. Berger and H. HL~gel, Marangoni Convection in Simulated Weld -- C. Limma- 72-s (Mar) neevichitr and S. Kou, 324-s (Nov) Marangoni Convection in Simulated Weld Pools, Visualiza- Predicting the Tensile Strength of Resistance-Brazed Joints, tion of -- C. Limmaneevichitr and S. Kou, 126-s (May) Model Equation for -- K. Takeshita, 261-s (Sep) Martensite Boundary on the WRC-1992 Diagram -- Part 2: Preheat, The Welding of Structural Steels without-- A.J. Kin- The Effect of Manganese -- A, D. J. Kotecki 346-s (Dec) sey, 79-s (Apr) Mechanical Characterization of Actively Brazed Alumina Projection Welding Processes Using Coupled Finite Element Tensile Specimens, Microstructural and -- F. M. Hosk- Analyses, Modeling of-- X. Sun, 244-s (Sep) ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, Properties of Brazed Joints, A New Approach to Improving P. T. Vianco and C. A. Walker, 222-s (Aug) the -- B. Zorc and L. Kosec, 24-s (Jan) Mechanical Properties of Titanium Welds, Oxygen Equip- Properties on Weld Qualification for In-Service Pipelines, ment Effects on the -- D. D. Harwig, C. Fountain, W. It- The Influence of Working Fluid Physical -- R. J. Belanger tiwattana and H. Castner, 305-s (Nov) and B. M. Patchett, 209-s (Aug) Method for Studying Weld Fusion Boundary Microstructure Qualification for In-Service Pipelines, The Influence of Evolution in Aluminum Alloys, A--A. Kostrivas andJ. C. Working Fluid Physical Properties on Weld -- R. J. Be- Lippold, 1-s (Jan langer and B. M. Patchett, 209-s (Aug) Microstructural and Mechanical Characterization of Ac- Real Time Mapping of Phases, Evolution of Titanium Arc tively Brazed Alumina Tensile Specimens -- F. M. Hosk- Weldment Macro and Microstructures -- Modeling ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, and-- Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, 97-s P. T. Vianco and C. A. Walker, 222-s (Aug) (Apr) Microstructure Evolution in Aluminum Alloys, A Method for Reconsidering the Basicity of a FCAW Consumable -- Part Studying Weld Fusion Boundary -- A. Kostrivas and J. C. 1: Solidified Slag Composition of a FCAW Consumable Lippold, 1-s (Jan) As a Basicity Indicator -- E. Baun~, C. Bonnet and S. Liu, Microstructures -- Modeling and Real Time Mapping of 57-s (Mar) Phases, Evolution of Titanium Arc Weldment Macro and Reconsidering the Basicity of a FCAW Consumable -- Part -- Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, 97-s (Apt) 2: Verification of the Flux/Slag Analysis Methodology for Mitigation Technique for Welding High-Strength Aluminum Weld Metal Oxygen Control -- E. Baun6, C. Bonnet and Alloy, A Hot-Cracking-- Y. P. Yang, P. Dong, J. Zhang and S. Liu, 66-s (Mar) X. Tian, 9-s (Jan) Seam Quality in CO 2 Laser Beam Welding, Magneto-Fluid Molten Droplet with a Liquid Weld Pool Surface: A Com- Dynamic Control of-- M. Kern, P. Berger and H. HL~gel, putational and Experimental Approach, An Investigation 72-s (Mar) of the Interaction of a -- M. H. Davies, M. Wahab and Sensing of the GTAW Process, Analysis of an Arc Light M. J. Painter, 18-s (Jan) Mechanism and Its Application in -- P. J. Li and Y. M

WELDING JOURNAL I 99 Zhang, 252-s (Sep) tion of Weld Bead Volume for the -- V. Gunaraj and N. Simulate Effects of Marangoni Convection on Weld Pool Murugan 268-s (Oct) Shape, Experiments to -- C. Limmaneevichitr and S. Kou Submerged Arc Process -- Part 2, Prediction and Optimiza- 231-s (Aug) tion of Weld Bead Volume for the -- V. Gunaraj and N. Single-Pass Arc Welds, Finite Element Analysis of Heat Flow Murugan, 331-s (Nov) in -- E. A. Bonifaz, 121-s (May) Surface-Active Agent, Visualization of Marangoni Convec- Slag Composition of a FCAW Consumable as a Basicity In- tion in Simulated Weld Pools Containing a -- C. Limma- dicator, Reconsidering the Basicity of a FCAW Consum- neevichitr and S. Kou, 324-s (Nov) able -- Part 1 : Solidified -- E. Baun6, C. Bonnet and S. Tensile Specimens, Microstructural and Mechanical Char- Liu, 57-s (Mar) acterization of Actively Brazed Alumina -- F. M. Hosk- Spiral Defect Formation in Friction Welded Aluminum -- K. ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s P. T. Vianco and C. A. Walker, 222-s (Aug) (Jul) Tensile Strength of Resistance-Brazed Joints, Model Equa- Spot Welds, Approximate Stress Intensity Factor and Notch tion for Predicting the -- K. Takeshita, 261 -s (Sep) Stress for -- S. Zhang, 54-s (Feb) Titanium and Aluminum During Diffusion Welding, Interfa- Spot Welds Based on Local Stress Parameters, Fatigue As- cial Reactions of-- J-G Luo and V. L. Acoff, 239-s (Sep) sessment of- D. Radaj, 51-s (Feb) Titanium Arc Weldment Macro and Microstructures -- Spot Welding Aluminum Alloy AA5754, Cracking in -- J. Modeling and Real Time Mapping of Phases, Evolution of Senkara and H. Zhang, 194-s (Jul) -- Z. Yang, J. W. Elmer, J. Wong, and T. DebRoy, 97-s Spot Welding of Steels, Force Characteristics of Resistance (Apr) -- H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul) Titanium Welds, Oxygen Equivalent Effects on the Mechan- Spot Welding Processes Using Coupled Finite Element Pro- ical Properties -- D. D. Harwig, C. Fountain, W. Ittiwat- cedures, Analysis of Aluminum Resistance -- X. Sun and tana, and H. Castner, 305-s (Nov) P. Dong, 215-s (Aug) Ultra-Low-Carbon Weld Comsumables, Microhardness Stainless Steel Arc Welds Using Artificial Neural Networks Variations in HSLA-100 Welds Fabricated with New -- -- Part 1 : Neural Network Development, Improved Fer- D. W. Moon, R. W. Fonda and G. Spanos, 278-s (Oct) rite Prediction in -- J. M. Vitek, Y. S. Iskander and E. M. Visualization of Marangoni Convection in Simulated Weld Oblow, 33-s (Feb) Pools -- C. Limmaneevichitr and S. Kou, 126-s (May) Stainless Steel Arc Welds Using Artificial Neural Networks VPPAW of Aluminum Alloys Using the Front Weld Pool --Part 2: Neural Network Results, Improved Ferrite Num- Image Signal, Control of Weld Penetration in- B. Zheng, ber Prediction in -- J. M. Vitek, Y. S. Iskander and E. M. H. J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec) Oblow, 41-s (Feb) Weld Metal by Means of Fluoride Additions in Welding Flux Stainless Steel Constitution Diagram, A New Ferritic- Hydrogen Control in Steel -- M. Matsushita and S. Liu, Martensitic -- M. C. Balmforth and J. C. Lippold, 339-s 295-s (Oct) (Dec) Weld Pool Surface: A Computational and Experimental Ap- Stress Intensity Factor and Notch Stress for Spot Welds, Ap- proach, An Investigation of the Interaction of a Molten proximate -- S. Zhang, 54-s (Feb) Droplet with a Liquid -- M. H. Davies, M. Wahab and Stress Parameters, Fatigue Assessment of Spot Welds Based M. J. Painter, 18-s (Jan) on Local -- D. Radaj, 51-s (Feb) Welding of Structural Steels without Preheat, The -- A.J. Structural Steels without Preheat, The Welding of- A. J. Kinsey, 79-s (Apr) Kinsey, 79-s (Apt) WRC-1992 Diagram -- Part 2: The Effect of Manganese, A Submerged Arc Process -- Part 1, Prediction and Optimiza- Martensite Boundary on the -- D. J. Kotecki 346-s (Dec)

AUTHORS FOR RESEARCH SUPPLEMENTS

Acoff, V. L. and Luo, J-G. -- Interfacial Reactions of Tita- 57-s (Mar) nium and Aluminum During Diffusion Welding, 239-s Baun~, E., Bonnet, C. and Liu, S. -- Reconsidering the Ba- (Sep) sicity of a FCAW Consumable -- Part 2: Verification of Albright, C. E., Holbert, R. K., Richardson, R. W. and Farson, the Flux/Slag Analysis Methodology for Weld Metal Oxy- D. F. -- Image-Based Penetration Monitoring of CO 2 gen Control, 66-s (Mar) Laser Beam Welding, 89-s (Apr) Belanger, R. J., Patchett, B. M., -- The Influence of Working Ahmadi, G., Aidun, D. K. and Domey, J. J. -- Effect on High Fluid Physical Properties on Weld Qualification for In- Gravity on Weld Fusion Zone Shape, 145-s (Jun) Service Pipelines, 209-s (Aug) Aidun, D. K., Domey, J. J. and Ahmadi, G. -- Effect of High Bendzsak, G. J., Uenishi, K., Zhai, Y. and North, T. H. -- Gravity on Weld Fusion Zone Shape, 145-s (Jun) Spiral Defect Formation in Friction Welded Aluminum, Balmforth, M. C. and Lippold, J. C. -- Construction Dia- 184-s (Jul) gram, A New Ferritic-Martensitic Stailess Steel, 339-s Berger, P. Hi,igel, H. and Kern, M. -- Magneto-Fluid Dy- (Dec) namic Control of Seam Quality in CO 2 Laser Beam Weld- Baun(~, E., Bonnet, C. and Liu, S. -- Reconsidering the Ba- ing, 72-s (Mar) sicity of a FCAW Consumable -- Part 1: Solidified Slag Bonifaz, E. A. -- Finite Element Analysis of Heat Flow in Sin- Composition of a Consumable as a Basicity Indicator, gle-Pass Arc Welds, 121 -s (May)

100 J DECEMBER 2000 Bonnet, C, Liu, S. and Baun6, E. -- Reconsidering the Ba- C.E. Image-Based Penetration Monitoring of CO 2 sicity of a FCAW Consumable -- Part 1: Solidified Slag Laser Beam Welding, 89-s (Apr) Composition of a ECAW Consumable as a Basicity Indi- Hosking, F. M., Cadden, C. H., Yang, N. Y. C., Glass, S. J., cator, 57-s (Mar) Stephens, J. J., Vianco, P. T., and Walker, C. A. -- Mi- Bonnet, C, Liu, S. and Baun6, E. -- Reconsidering the Ba- crostructural and Mechanical Characterization of Ac- sicity of a FCAW Consumable -- Part 2: Verification of tively Brazed Alumina Tensile Specimens, 222-s (Aug) the Flux/Slag Analysis Methodology for Weld Metal Oxy- Hou, W., Hu, S. J., Zhang, H. and Tang, H. Force Char- gen Control, 66-s (Mar) acteristics of Resistance Spot Welding of Steels, 175-s Cadden, C. H., Yang, N. Y. C., Glass, S. J., Stephens, J. J., (Jul) Vianco, P. T., Walker, C. A., Hosking, F. M. -- Mi- Hu, S. J., Zhang, H., Tang, H. and Hou, W. -- Force Char- crostructural and Mechanical Characterization of Ac- acteristics of Resistance Spot Welding of Steels, 175-s tively Brazed Alumina Tensile Specimens, 222-s (Aug) (Jul) Castner, H.,Harwig, D. D., Fountain, C. and Ittiwattana, W. Huang, C. and Kou, S. -- Partially Melted Zone in Aluminum Oxygen Equivalent Effects on the Mechanical Proper- Welds -- Liquation Mechanism and Directional Solidifi- ties of Titanium Welds, 305-s (Nov) cation, 113-s (May) Chen, S. B., Lou, Y. J., Wu, L. and Zhao, D. B. -- Intelligent HL)gel, H., Kern, M. and Berger, P. -- Magneto-Fluid Dy- Methodology for Sensing, Modeling and Control of namic Control of Seam Quality in CO 2 Laser Beam Weld- Pulsed GTAW: Part 1 -- Bead-on-Plate Welding, 151-s ing, 72-s (Mar) (Jun) Iskander, Y. S., Oblow, E. M. and Vitek, J. M. -- Improved Chen, S. B., Zhao, D. B., Wu, L. and Lou, Y. J. -- Intelligent Ferrite Number Prediction in Stainless Steel Arc Welds Methodology for Sensing, Modeling and Control of Using Artificial Neural Networks Part 1 : Neural Net- Pulsed GTAW: Part 2 -- Butt Joint Welding, 164-s (Jun) work Development, 33-s (Feb) Cotler, C., Shaham, H., Kohn, G. and Munitz, A.- Electron Iskander, Y. S., Oblow, E. M. and Vitek, J. M. -- Improved Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul) Ferrite Number Prediction in Stainless Steel Arc Welds Davies, M. H., Wahab, M. and Painter, M.J. An Investi- Using Artificial Neural Networks -- Part 2: Neural Net- gation of the Interaction of a Molten Droplet with a Liq- work Results, 41-s (Feb) uid Weld Pool Surface: A Computational and Experi- Ittiwattana, W., Castner, H.,Harwig, D. D. and Fountain, C. mental Approach, 18-s (Jan) -- Oxygen Equivalent Effects on the Mechanical Proper- DebRoy, T., Yang, Z., Elmer, J. W. and Wong, J. Evolution ties of Titanium Welds, 305-s (Nov) of Titanium Arc Weldment Macro and Microstructures Kinsey, A. J. -- The Welding of Structural Steels without Pre- Modeling and Real Time Mapping of Phases, 97-s (Apr) heat, 79-s (Apr) Dong, E, Sun, X., Analysis of Aluminum Resistance Spot Kern, M., Berger, P. and HQgel, H.- Magneto-Fluid Dy- Welding Processes Using Coupled Finite Element Proce- namic Control of Seam Quality in CO 2 Laser Beam Weld- dures, 215-s (Aug) ing, 72-s (Mar) Dong, P., Zhang, J., Tian, X. and Yang, Y.P. A Hot-Crack- Kohn, G., Munitz, A., Cotler, C. and Shaham, H. -- Electron ing Mitigation Technique for Welding High-Strength Alu- Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul) minum Alloys, 9-s (Jan) Kosec, L. and Zorc, B. A New Approach to Improving the Dupont, J. N., Robino, C. V., Marder, A. R., and Nawrocki, Properties of Brazed Joints, 24-s (Jan) J. G. -- The Stress-Relief Cracking Susceptibility of a New Kostrivas, A. and Lippold, J. C. -- A Method for Studying Ferritic Steel Part 1: Single-Pass Heat-Affected Zone Weld Fusion Boundary Microstructure Evolution in Alu- Simulations, 355-s (Dec) minum Alloys, 1-s (Jan) Elmer, J. W., Wong, J., DebRoy, T. and Yang, Z. -- Evolution Kotecki, D. J.,-- A Martensite Boundary on the WRC-1992 of Titanium Arc Weldment Macro and Microstructures -- Diagram Part 2: The Effect of Manganese, 346-s (Dec) Modeling and Real Time Mapping of Phases, 97-s (Apr) Kou, S. and Huang, C. -- Partially Melted Zone in Aluminum Farson, D. F., Albright, C. E., Holbert, R. K. and Richardson, Welds -- Liquation Mechanism and Directional Solidifi- R. W. -- Image-Based Penetration Monitoring of CO 2 cation, ] 13-s (May) Laser Beam Welding, 89-s (Apr) Kou, S., and Limmaneevichitr, C. -- Experiments to Simu- Fonda, R. W., Spanos, G. and Moon, T.W. Microhard- late Effect of Marangoni Convection on Weld Pool Shape, ness Variations in HSLA-100 Welds Fabricated with New 231-s (Aug) Ultra-Low-Carbon Weld Consumables, 278-s (Oct) Kou, S. and Limmaneevichitr, C. -- Visualization of Fountain, C., Ittiwattana, W., Castner, H. and Harwig, D. D. Marangoni Convection in Simulated Weld Pools, 126-s -- Oxygen Equivalent Effects on the Mechanical Proper- (May) ties of Titanium Welds, 305-s (Nov) Kou, S. and Limmaneevichitr, C. -- Visualization of Glass, S. J., Stephens, J. J., Vianco, P. T., Walker, C. A., Hosk- Marangoni Convection in Simulated Weld Pools Con- ing, E. M., Cadden and C. H., and Yang, N. Y. C. -- Mi- taining a Surface-Active Agent, 324-s (Nov) crostructural and Mechanical Characterization of Ac- Kovacevic, R., Zheng, B, Wang, H. J., and Wang, Q. I., -- tively Brazed Alumina Tensile Specimens, 222-s (Aug) Control of Weld Penetration in VPPAW of Aluminum Al- Gunaraj V., and Murugan, N. -- Prediction and Optimiza- loys Using the Front Weld Pool Image Signal, 363-s (Dec) tion of Weld Bead Volume for the Submerged Arc Process Li, P. J. and Zhang, M. Y., -- Analysis of an Arc Light Mech- -- Part 1,286-s (Oct) anism and Its Application in Sensing of the GTAW Gunaraj, V. and Murugan, N. -- Prediction and Optimiza- Process, 252-s (Sep) tion of Weld Bead W)lume for the Submerged Arc Process Li, L. and Messier, Jr., R. W. -- Stress Relaxation Study of -- Part 2, 331 -s (Nov) HAZ Reheat Cracking in Type 347 Stainless Steel, 137-s Harwig, D. D., Fountain, C., Ittiwattana, W., and Castner, H. (lun) -- Oxygen Equivalent Effects on the Mechanical Proper- Limmaneevichitr, C. and Kou, S. -- Experiments to Simulate ties of Titanium Welds, 305-s (Nov) Effect of Marangoni Convection on Weld Pool Shape, Holbert, R. K., Richardson, R. W., Farson, D. F. and AIbright, 231-s (Aug)

WELDING JOURNAL I I (I I Limmaneevichitr, C. and Kou, S.--Visualization of Marangoni Dissimilar Metal Welds -- Part 2: On-Cooling Transfor- Convection in Simulated Weld Pools, 126-s (May) mations, 267-s (Oct) Limmaneevichitr, C. and Kou, S.- Visualization of North, T. H., Bendzsak, G. J., Uenishi, K. and Zhai, Y. -- Spi- Marangoni Convection in Simulated Weld Pools Con- ral Defect Formation in Friction Welded Aluminum, 184-s taining a Surface-Active Agent, 324-s (Nov) 0ul) Lippold, J. C. and Balmforth, M. C. -- A New Ferritic- Oblow, E. M., Vitek, J. M. and Iskander, Y. S. -- Improved Martensitic Stainless Steel Construction Diagram 339-s Ferrite Number Prediction in Stainless Steel Arc Welds (Dec) Using Artificial Neural Networks -- Part 1: Neural Net- Lippold, J. C. and Kostrivas, A. -- A Method for Studying work Development, 33-s (Feb) Weld Fusion Boundary Microstructure Evolution in Alu- Oblow, E. M., Vitek, J. M. and Iskander, Y. S. -- Improved minum Alloys, 1-s (Jan) Ferrite Number Prediction in Stainless Steel Arc Welds Lippold, J. C. and Mills, M. J. and Nelson, T. W. -- Nature Using Artificial Neural Networks -- Part 2: Neural Net- and Evolution of the Fusion Boundary in Ferritic- work Results, 41-s (Feb) Austenitic Dissimilar Metal Welds -- Part 2: On-Cooling Painter, M. J., Davies, M. H. and Wahab, M. -- An Investi- Transformations, 267-s (Oct) gation of the Interaction of a Molten Droplet with a Liq- Liu, S., Baun~, E. and Bonnet, C. -- Reconsidering the Ba- uid Weld Pool Surface: A Computational and Experi- sicity of a FCAW Consumable -- Part 1: Solidified Slag mental Approach, 18-s (Jan) Composition of a FCAW Consumable as a Basicity Indi- Patchett, B. M., Belanger, R. J. -- The Influence of Working cator, 57-s (Mar) Fluid Physical Properties on Weld Qualification for In- Liu, S., Baun~, E. and Bonnet, C. -- Reconsidering the Ba- Service Pipelines, 209-s (Aug) sicity of a FCAW Consumable -- Part 2: Verification of Radaj, D. -- Fatigue Assessment of Spot Welds Based on the Flux/Slag Analysis Methodology for Weld Metal Oxy- Local Stress Parameters, 51-s (Feb) gen Control, 66-s (Mar) Richardson, R. W., Farson, D. F., Albright, C. E. and Holbert, Liu, S. and Matsushita, M. -- Hydrogen Control in Steel R. K. -- Image-Based Penetration Monitoring of CO 2 Weld Metal by Means of Fluoride Additions in Welding Laser Beam Welding, 89-s (Apr) Flux, 295-s (Oct) Robino, C. V., Marder, A. R.,Nawrocki, J. G., and Dupont, J. Lou, Y. J., Wu, L., Zhao, D. B. and Chen, S. B. -- Intelligent N. -- The Stress-Relief Cracking Susceptibility of a New Methodology for Sensing, Modeling and Control of Pulsed Ferritic Steel -- Part 1: Single-Pass Heat-Affected Zone GTAW: Part 1 -- Bead-on-Plate Welding, 151-s (Jun) Simulations, 355-s (Dec) Lou, Y. J., Chen, S. B., Zhao, D. B. and Chen, S. B. -- Intel- Senkara, J. and Zhang, H. -- Cracking in Spot Welding Alu- ligent Methodology for Sensing, Modeling and Control of minum Alloy AA5754, 194-s (Jul) Pulsed GTAW: Part 2 -- Butt Joint Welding, 164-s (Jun) Shaham, H., Kohn, G., Munitz, A. and Cotler, C. -- Electron Luo, J-G. and Acoff, V. L. -- Interfacial Reactions of Titanium Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul) and Aluminum During Diffusion Welding, 239-s (Sep) Sill, A. and Missori, S. -- Structural Characterization of C- Marder, A. R., Nawrocki, J. G., Dupont, J. N., and Robino, Mn Steel Laser Beam Welded Joints with Powder Filler C. V., -- The Stress-Relief Cracking Susceptibility of a Metal, 317-s (Nov) New Ferritic Steel -- Part 1: Single-Pass Heat-Affected Spanos, G. and Moon, T. W. and Fonda, R. W. -- Micro- Zone Simulations, 355-s (Dec) hardness Variations in HSLA-100 Welds Fabricated with Matsushita, M and Liu, S., -- Hydrogen Control in Steel New Ultra-Low-Carbon Weld Consumables, 278-s (Oct) Weld Metal by Means of Fluoride Additions in Welding Stephens, J. J., Vianco, P. T., Walker, C. A., Hosking, F. M., Flux, 295-s (Oct) Cadden, C. H., Yang, N. Y. C., and Glass, S. J. -- Mi- Messier, Jr., R. W. and Li, L. -- Stress Relaxation Study of HAZ crostructural and Mechanical Characterization of Ac- Reheat Cracking in Type 347 Stainless Steel, 137-s (Jun) tively Brazed Alumina Tensile Specimens, 222-s (Aug) Mills, M. J. and Nelson, T. W. and Lippold, J. C. -- Nature Sun, X. -- Modeling of Projection Welding Processes Using and Evolution of the Fusion Boundary in Ferritic- Coupled Finite Element Analyses, 244 (Sep) Austenitic Dissimilar Metal Welds -- Part 2: On-Cooling Sun, X., and Dong, P. -- Analysis of Aluminum Resistance Transformations, 267-s (Oct) Spot Welding Processes Using Coupled Finite Element Missori, S. and Sill, A. -- Structural Characterization of C- Procedures, 209-s (Aug) Mn Steel Laser Beam Welded Joints with Powder Filler Takeshita, K. -- Model Equation for Predicting the Tensile Metal, 317-s (Nov) Strength of Resistance-Brazed Joints, 261-s (Sep) Moon, T. W., Fonda, R. W., and Spanos, G., -- Microhard- Tang, H., Hou, W., Hu, S. J. and Zhang, H. -- Force Char- ness Variations in HSLA-100 Welds Fabricated with New acteristics of Resistance Spot Welding of Steels, 175-s Ultra-Low-Carbon Weld Consumables, 278-s (Oct) (Jul) Munitz, A., Cotler, C., Shaham, H. and Kohn, G. -- Electron Tian, X., Yang, Y. if, Dong, P. and Zhang, J. -- A Hot-Crack- Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul) ing Mitigation Technique for Welding High-Strength Alu- Murugan, N. and Gunaraj V. -- Prediction and Optimiza- minum Alloy, 9-s (Jan) tion of Weld Bead Volume for the Submerged Arc Process Uenishi, K., Zhai, Y., North, T. H. and Bendzsak, G. J. -- Spi- -- Part 1,286-s (Oct) ral Defect Formation in Friction Welded Aluminum, t 84-s Murugan, N. and Gunaraj, V. -- Prediction and Optimiza- 0ul) tion of Weld Bead Volume for the Submerged Arc Process Vianco, P. T., Walker, C. A., Hosking, F. M., Cadden, C. H., -- Part 2,331-s (Nov) Yang, N. Y. C., Glass, S. J., and Stephens, J. J. -- Mi- Nawrocki, J. G., Dupont, J. N., Robino, C. V., and Marder, crostructural and Mechanical Characterization of Ac- A. R. -- The Stress-Relief Cracking Susceptibility of a New tively Brazed Alumina Tensile Specimens, 222-s (Aug) Ferritic Steel -- Part 1: Single-pass Heat-Affected Zone Vitek, J. M., Iskander, Y. S. and Oblow, E. M. -- Improved Simulations, 355-s (Dec) Ferrite Number Prediction in Stainless Steel Arc Welds Nelson, T. W., Lippold, J. C. and Mills, M. J. -- Nature and Using Artificial Neural Networks -- Part 1 : Neural Net- Evolution of the Fusion Boundary in Ferritic-Austenitic work Development, 33-s (Feb)

102. I DECEMBER 2000 Vitek, J. M., Iskander, Y. S. and Oblow, E. M. -- Improved ing Mitigation Technique for Welding High-Strength Alu- Ferrite Number Prediction in Stainless Steel Arc Welds minum Alloy, 9-s (Jan) Using Artificial Neural Networks -- Part 2: Neural Net- Yang, Z., Elmer, J. W., Wong, J. and DebRoy, T. -- Evolution work Results, 41-s (Feb) of Titanium Arc Weldment Macro and Microstructures -- Wahab, M., Painter, M. J. and Davies, M. H. -- An Investi- Modeling and Real Time Mapping of Phases, 97-s (Apr) gation of the Interaction of a Molten Droplet with a Liq- Zhai, Y., North, T. H., Bendzsak, G. J. and Uenishi, K. -- Spi- uid Weld Pool Surface: A Computational and Experi- ral Defect Formation in Friction Welded Aluminum, 184-s mental Approach, 18-s (Jan) (Jul) Walker, C. A., Hosking, F. M., Cadden, C. H., Yang, N. Y. C., Zhang, H. and Senkara, J. -- Cracking in Spot Welding Alu- Glass, S. J., Stephens, J. J., and Vianco, P. T. -- Mi- minum Alloy AA5754, 194-s (Jul) crostructural and Mechanical Characterization of Ac- Zhang, H., Tang, H., Hou, W. and Hu, S. J. -- Force Charac- tively Brazed Alumina Tensile Specimens, 222-s (Aug) teristics of Resistance Spot Welding of Steels, 175-s (Jul) Wang, H. J., Wang, Q. I., Kovacevic, R., and Zheng, B -- Zhang, J., Tian, X., Yang, Y. P. and Dong, P. -- A Hot-Crack- Control of Weld Penetration in VPPAW of Aluminum Al- ing Mitigation Technique for Welding High-Strength Alu- loys Using the Front Weld Pool Image Signal, 363-s (Dec) minum Alloy, 9-s (Jan) Wang, Q. I., Kovacevic, R., Zheng, B, and Wang, H. J., -- Zhang, M. Y. and Li, P. J. -- Analysis of an Arc Light Mech- Control of Weld Penetration in VPPAW of Aluminum Al- anism and Its Application in Sensing of the GTAW loys Using the Front Weld Pool Image Signal, 363-s (Dec) Process, 252-s (Sep) Wong, J., DebRoy, T., Yang, Z. and Elmer, J. W. -- Evolution Zhang, S. -- Approximate Stress Intensity Factor and Notch of Titanium Arc Weldment Macro and Microstructures -- Stress for Spot Welds, 54-s (Feb) Modeling and Real Time Mapping of Phases, 97-s (Apr) Zhao, D. B., Wu, L., Lou, Y. J. and Chen, S. B. -- Intelligent Wu, L., Zhao, D. B., Chen, S. B. and Lou, Y. J. -- Intelligent Methodology for Sensing, Modeling and Control of Methodology for Sensing, Modeling and Control of Pulsed Pulsed GTAW: Part 1 -- Bead-on-Plate Welding, 151-s GTAW: Part 1 -- Bead-on-Plate Welding, 151-s (Jun) (Jun) Wu, L., Lou, Y. J., Chen, S. B. and Zhao, D. B. -- Intelligent Zhao, D. B., Wu, L., Lou, Y. J. and Chen, S. B. -- Intelligent Methodology for Sensing, Modeling and Control of Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 2 -- Butt Joint Welding, 164-s (Jun) Pulsed GTAW: Part 2 -- Butt Joint Welding, 164-s (Jun) Yang, N. Y. C., Glass, S. J., Stephens, J. J., Vianco, P. T., Zheng, B., Wang, H. J., Wang, Q. I., and Kovacevic, R. -- Walker, C. A., Hosking, F. M. and Cadden, C. H. -- Mi- Control of Weld Penetration in VPPAW of Aluminum Al- crostructural and Mechanical Characterization of Ac- loys Using the Front Weld Pool Image Signal, 363-s (Dec) tively Brazed Alumina Tensile Specimens, 222-s (Aug) Zorc, B. and Kosec, L. -- A New Approach to Improving the Yang, Y. P., Dong, P., Zhang, J. and Tian, X. -- A Hot-Crack- Properties of Brazed Joints, 24-s (Jan) 6[T IH THE SWIM If you know a child with muscular dystrophy who can benefit from a special getaway, tell him or her about MDA summer camps. They're fun and free!

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WELDING JOURNAL I 103 CALL FOR PAPERS

Eleventh International Conference on Computer Technology in Welding

September 19 and 20, 2001 m Columbus, Ohio

This is the eleventh in a series of computer conferences designed to provide the welding industry with the latest information regarding the use of computers for welding. This conference, jointly sponsored by the American Welding Society, The Welding Institute and the National Institute of Standards and Technology, will be held September 19 and 20, 2001, in Columbus, Ohio. Authors from around the world are strongly encouraged to submit an abstract, as attendance from an international audience will be encouraged.

Authors should submit the Author Form (on reverse side), together with an abstract of no more than 500 words to American Welding Society, Conference Department, 550 NW LeJeune Road, Miami, FL 33126, by January 31, 2001. The abstract should be sufficiently descriptive to give a clear idea of the content of the proposed paper. Authors will be notified of acceptance by March 5, 2001. Completed manuscripts will be required from selected speakers by May 1, 2001.

Authors are not limited to any specific topics, except that papers should be appropriate for the conference subject. Contributions are encouraged in the following areas:

• Modeling of Welds and Welding Processes • Off-Line Planning~Weld Simulation~Visualization • Computerized Data Acquisition and Sensing Systems • Real-Time Welding Information and Control Systems • Weld Process Automation • Network and Web-Based Implementations • Case Histories~Experiences with Commercial Software (by users) • Welding Documentation (e.g., WPS, PQR) • Databases, Database Applications and Knowledge Bases •Standards

To ensure your paper's consideration for the conference, your abstract must be postmarked no later than January 31, 2001 Author Application Form

Eleventh International Conference on Computer Technology in Welding September 19-20, 2001 m Columbus, Ohio

Date Mailed

Author's Name: Please check how you are addressed: Mr. Ms. Dr. Other Title or Position: Organization: Mailing Address: City: State: Zip Code: Country Telephone: Fax:

For joint authorship, give names. (if more than two coauthors, please use separate sheet.

Name: Name: Organization: Organization: Address: Address:

PROPOSED TITLE (10 words or less):

ABSTRACT: • Typed, double-spaced, 250-500 words, attached to this form. • Be sure to give information to provide a clear idea of content of the proposed paper. • If completed manuscript is available now, in addition to abstract, attach copy to this form. • Application form and abstract must be postmarked no later than January 31, 2001. MANUSCRIPT DEADLINE: • All manuscripts must be submitted no later than May 1, 2001. • Guidelines for submission of manuscripts will be provided to authors selected for the program.

PRESENTATION AND PUBLICATION OF PAPERS: Has material in this paper been previously published or presented at any meeting? Yes No When? Where?

Return to AWS postmarked no later than January 31, 2001, to the following address: Conferences American Welding Society 550 N.W. LeJeune Road Miami, Florida 33126 Phone: 800/443-9353, Ext. 223, or 305/443-9353, Ext. 223 Fax: 305/443-1552 AWS FELLOWSHIPS AND WRC GRANTS-IN-AID

To: Professors Engaged in Joining Research

Subject: Request for Proposals for AWS Fellowships and for WRC Grants-in-Aid for the 2001-02 Academic Year

The American Welding Society (AWS) and the Welding Research Council (WRC) seek to foster university research in joining and to recognize outstanding faculty and student talent. Each of these two organizations has its own programs to channel funding into graduate research programs at universities. In recent years, AWS and WRC have coordinated their award programs and have made their respective selections based on responses to a joint Request for Proposals. We are again requesting your proposals for consideration by AWS and WRC.

Please note that AWS and WRC have separate selection committees, criteria and objectives as described below. However, if you wish, you need only provide a single proposal for consideration by the two organizations in their respective evaluation activities. Of course, only one award, a Fellowship to the Student (from AWS) or a Grant (from WRC) will be made for any one program of research at a university.

With both organizations, it is expected that the winning researchers will take advantage of the opportunity to work with industry committees interested in the research topics and report work in progress.

Please note, there are important changes in the schedule which you must follow in order to enable the awards to be made in a timely fashion. Proposals must be received at American Welding Society by February 5, 2001. New AWS Fellowships will be announced at the AWS Annual Meeting, May 6-10, 2001. WRC will notify applicants for its Grants by mail by June 1,2001.

THE AWARDS

The Fellowships or Grants are to be in amounts of up to $25,000 per year, renewable for up to three years of research. However, progress reports and requests for renewal must be submitted for the second and third years. Renewal by AWS or WRC will be contingent on demonstration of reasonable progress in the research or in graduate studies. WRC expects awardees to interact with any of its committees working in related areas of research.

The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D Degree under a sponsoring professor at a North American University. The qualifications of the Graduate Student are the key elements to be considered in the award. The academic credentials, plans and research history (if any) of the student should be provided. The student must prepare the proposal for the AWS Fellowship. However, the proposal must be under the auspices of a professor and accompanied by one or more letters of recommendation from the sponsoring professor or others acquainted with the student's technical capabilities. Topics for the AWS Fellowship may span the full range of the joining industry. Should the student selected by AWS be unable to accept the Fellowship or continue with the research at any time during the period of the award, the award will be forfeited and no (further) funding provided by AWS. The bulk of AWS funding should be for student support. AWS reserves the right not to make awards in the event that its Committee finds all candidates unsatisfactory.

The WRC Grant is to the university and professor for support of research in the defined area. The student need not be identified for consideration by WRC. Thus, if WRC makes the award for a proposal in which the student has been identified a change may be made at any time without loss of the Grant from WRC. It is hoped that the WRC funds will seed broader programs and any such plans to obtain follow-on or supplementary support should be mentioned in the Proposal. Proposals may be for innovative research in new areas or for research of interest to current WRC Committees. Subjects of interest to WRC Committees include underwater welding, linepipe welding, evaluating susceptibility to hydrogen cracking, corrosion resisting alloys such as duplex or other high alloy steels, high-strength welding consumables, hardfacing, automation or other timely subjects.

All proposals received will be considered for an award by WRC. Only those proposals containing suitable supporting information about the student and identified as having been prepared by the student will be considered by AWS. Please clearly specify in your cover letter if you intend AWS consideration. SELECTION

The AWS and WRC selection committees operate separately, AWS may award up to six Fellowships. WRC will award as many Grants as funding permits. The number will depend on the size of the requests and the number of renewals from last year's group. Topics selected by WRC's group in recent years have been:

(a) Underwater Welding Consumables Research (b) Joining of Particulate Reinforced Metal Matrix Composites (c) Residual Stresses in Weldments (d) Fundamental Studies on Metallurgical Causes for Reheat Cracking (e) Analysis of Transient Liquid Phase (TLP) Diffusion Bonding (f) Hydrogen Effects on Cracking of Duplex Steel Welds (g) Brazing Alloys for Ceramic Substrates (h) On-Line Underwater Welding Control and Inspection by Ultrasonics (i) Weld Pool Geometry (j) Microstructure and Property Development of HSLA 100 and 130 Steel (k) Crack Growth in Weldments (I) Causes of Hot Cracking (m) Corrosion Behavior of Welds

DETAILS

The Proposal should include:

1. Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.) 2. Matching Funding or Other Support for Intended Research 3. Duration of Project 4. Statement of Problem and Objectives 5. Current Status of Relevant Research 6. Technical Plan of Action 7. Qualifications of Researchers 8. Pertinent Literature References and Related Publications 9. Special Equipment Required and Availability 10. Statement of Critical Issues Which Will Influence Success or Failure of Research

In addition, for the AWS Fellowship:

. Student's Academic History, Resume and Transcript 2. Recommendation(s) Indicating Qualifications for Research 3. Brief Section or Commentary on Importance of Research to the Welding Community and to AWS, Including Technical Merit, National Need, Long Term Benefits, etc. . Statement Regarding Probability of Success

The technical portion of the Proposal should be about ten typewritten pages. Four copies should be sent by February 5, 2001, to:

Richard D. French Deputy Executive Director American Welding Society 550 N. W. LeJeune Rd. Miami, FL 33126

Yours sincerely,

Frank G. DeLaurier Martin Prager Executive Director Executive Director American Welding Society Welding Research Council ;las ::

~ HORIZON Arcsmith, manufacturer of welding PERSONNEL and cutting equipment, is seeking a 4Dlllme O~lceR IR gel @tltPI sales trainer to support our sales Weld Eng. Mgr., Automotive/spotweld $84K team. Excellent benefits, 50% travel Mfg. Eng., roboVweld/laser/stamping $65K U.S. and Canada. Background in Application Eng., robots/spotweld $62K welding instruction preferred. Send Weld Eng., robotic/GMAW/manual $70K resume to Arcsmith, 2601 Lockheed Robotic Weld Technician, MIG $55K tlant].'cMarine, Inc. Mfg. Eng., stamp/assemble/weld $55K Ave., Watertown, SD 57201. E-mail antic Dry Dock Corp. Companies pay all costs. Send resumein [email protected] confidence to Joe Micksch, ASM Life Member What Floats 683 Fox Meadow Road Princeton, KY 42445 Fabrication Sales Your Boat? Emaih joe<~micksch.com Looking for a great career and a great www.jobsonthehorizon.com American Welding & Engineering, LLC, has o0mpany?AdamJcMarine IncdAdanticDry Phone 270-365-9165 or Fax 270-365-2248 an opportunity availablein its sales and mar- Dock Coqx is one of the nation's premier keting department. American Welding & En- international shipbuilders, renown for our gineering is a well-establishedproducer of excellence in craftsmanship and superior quality. We are seeking motivated leaders ATTENTION! contract fabrications and burned plate. The ro join our team of skilledcraflzmen in the right individualfor this position will be highly following positions: Welding Equipment Sales Personnel energetic, well organized and have a WELmNG SUmERVmORS We pay you for finding us good used seasoned knowledge of the fabrication and F/ux Corn We/d/rig exp~ence mqu/red welding systems, seamers, positioners, burned plate industry. Co//ege degree preferred manipulators, turning rolls, etc. We We offer a full complement of benefits Providing Top Industry Benefltm will buy your customers' trade-ins. and competitive salary package. Interested Compem/ve Pay individualsshould submit their resume, with HeolthlOentalll.~ Coverage 401K . Pm~t Shm'tng • Paid VacmJon WELD PLUS, INC. 1-800-288-9414 salary requirements, to For further mto~ send/bx your resem to: 8500 Heckscher Dr., Jacksonville, American Welding & Engineering, LLC FL 32226, Fax: 904-251-1579. Equal PO Box 588 Opportunity Employer. 6001 S. Pennsylvania Ave. V/s/t Our Web s/te at AS A NATIONWIDEWELDING ENGINEERING SPECIALIST Cudahy, Wl 53110 www.atlantlcmarine, corn Numerousclient companies hove engaged me to recruitweld- Attn: Personnel Department ing prosat variouslevels of experience.If your expertiseis or email [email protected] Welding Engineering,Coil, Moil, Fox resumeto BILLELIAS DeptWE, PO Box 396, EastBrunswick, NJ 08816. I Phone732-390-4600 Fox 732-390-9769 ELIAS ASSOCIATES ,, Nelding Engineei "Annually a NationalAward Winning Searchfirm Atlas Foundry, located in the Pacific Northwest, has an immediate opening for a Welding Engineer to assist shop personnel in managing welding ESAB Welding & Cutting Producls is looking for qualified Territory Sales and fabrication functions as well as Managers. The job requires a 4-year college degree, or equivalent education/expe- weld filler material control rience; proven sales skills in the welding industry; excellent team/people skills; operations. This person ensures that customer empathy, dedication to task; willing to travel as required. ESAB offers a the Welding Dept. complies with all very competitive salary and benefits package. codes, standards and customer requirements. In addition, you will • v ESAB ESAe Welding & support Sales in resolving Cutting Products welding/metallurgical issues and quotations. Qualified candidate will Human Resources Department be PC literate and familiar with ESAB Welding & Cutting Products Microsoft Word, Excel, Access and P.O. Box 407 have CAD skills. EOE. Send resume Burlington, MA 01 803 to TOLL FREE FAX: (800) 894-9751 Atlas Foundry Machine Company EMAIL: [email protected] 3021 So. Wilkeson To guarantee immediate receipt, complete an online application at Tacoma, WA 98409 http://recruiter1 .webhire.com/esab Fax: 253-471-7037 or Equal Opportunity Employer Emaih [email protected]

108 [ DECEMBER 2000 EMPLOYMENT OPPORTUNITIES

Senior Welding Engineer, 40 hrs/wk, 8 am/5 pm, $56,5!)2.45/yr. Develop WPSs and WELDING JOBS.com PQRs to AWS code for manual and autonlated welding procedures; destructive and nondestructive testing in evaluation of welded samples; write and interpret failure Leading job site for all Welding Jobs. analysis reports; write and program weld schedules for automated welding equip- Top 10 lislmg on major search engines. ment; and welding and induction brazing of stainless steel and aluminum. Requires 250 total visitors/day and growing. MS in materials engineering and 2 years' experience as senior welding engineer, En- Site has Mailing Lists, gineering specialist, research associate or graduate research assistant; experience AD Stats, Job Links. must include developing WPSs and PQRs to AWS code for manual and automated Companies/Recruiters Place ADS welding procedures; dc'structive and nondestructive testing in evaluation of welded http ://www.WeldingJobs.com samples; write and interpret failure analysis reports; write and program weld s(hed- uies for automated welding equipment; and welding and induction brazing of stain- WELDING ENGINEERS less steel and aluminum. Applicants should direct resumes to David Hill, Director of Human Resources, Eaton Aeroquip, 300 South East Avenue, Jackson, Michigan CAREER OPPORTUNITIES 49203, Ph. 517-789-2975. EOE. PRI is a Recruitment ( (~or(linatorfor 350 Sear~ h Firms Nationwide. High demand for Junior through Advan(ed Ievels in variety of industries. Top ¢(~ml)anies, $40-80K. EQUIPMENT FOR SALE Fee PI). ( ontact Jerry or Mark.

Professional Recruiters, Inc. mmmmmmm 1----- P.O. Box 24227 .-7, USED I Omaha, NE 68124 I ~~PLATENS I 800-999-8237 or Fax: 402-397-7357 | Re-Ground Tops | staff~jobteam.com or FOB: Shipping Point ° Call for Details I www.jobteam.com ! Weldsale Company (215) 739-7474 ," | www.weldsale.com !P .~" ,,dlllllW ,Jr ,i" ~i, ..i- ~im- Aim," ~i- ,I, .~i EQUIPMENT RENTAL WELDING i Ca//usfirst! ODS AND WIRI 800-523-2791 WANTED PA: 610-825-1250 All types and sizes FAX: 610-825-1553 EXCESS ~ding Alloys, i NEW & RECONDITIONED WELDING POSITIONERS, 800-523-1266 MANIPULATORS, SEAMERS, ax 610-265-78@ TURNTABLES, CIRCULAR WELDERS, TURNING ROLLS RED-D-ARC JUST IN! Aronson 14' X 14' Welderentals Manipulator/Var. Speed Car. Aronson, www.red-d-arc.com Pandjiris, Ransome Positioners, Manipulators, Turning Rolls. Jetline, All Types of Welding and Positioning USED I Pandjiris Seamers to 16 ft. Jetline and Equipment for Rental and Lease Cyclomatic Controls, Cold Wire Feeders, Seam Trackers. Lincoln, Miller 1-800-245-3660 Sub-Arcs, Heads, Feeders, Oscillators. Service Centers Across North America lime 1-800-323-9555 I -- www.antenen.com Web Site: www.weldplus.com e-mail: [email protected] WELD PLUS, INC. WANTED TO BUY Cincinnati, Ohio Jack Schroeder 1-800-288-9414 Fax: I-513-467-3585 We buy surplus WELDING ROD & WIRE Surplus Welding Alloys 2632 TEE DRIVE BATON ROUGE, LOUISIANA 70814

ro bots4weld ing. com All typcsoQuantitics large & small 888-228-9119 (Guess what we sell :) 225-272-9119/FAX 225-273-4814

WELDING JOURNAL [109 • Welding Supply Co., Inc. Allied Welding & Assoc/ates, Inc. Auto Gas tight - Sermng huh~stO' Since 1920- Michael J. Jidne¢ ROBERT PETRONE ASME Metallurgical & Welding Consultant Technical Sales AWS Certified Welding Inspector ants Fenelon Building 3269 Bakersmill CT. o Dacula. GA 30019 680 Route 46 West at Hazer St Main 973-478-5000 PH: 770.614.4985 ,,FAX: 678482.5979 P O Box 1707 Fax 973-478-8548 Clifton, NJ 07015 Dgect973-478-5001 x621 Cellular: 770.401.6434 • E-Mail: [email protected]

I <~;.R.K.WELDING= INSPECTIONSERVICES I F Anvcr Classens

KENNETH KARWOWSKI B.S., M Ed. 1610 CHIPPE~/A DRIVE ltshuller KANSASVILLE, W153139 /WELDING CONSULTANT A. E. Cla.~e~ & Assooates (262) 534-3006 2217 Flagstid~D~ive FAX (262) 534-5844 307 Avenue Road Matthews, MC 28104 WELDIRGCERTIFICATIONS Kingston, Ontario K7M lC8 Phone: 7044824)535 CERTIFIEDWELDING INSPECTIONS / (613) ~46-6832 (613) 546-7395

Expe W...... g ~* ...... Weld Prepare De,,elopnlent:Rcview ASME M&nufaclurlng Syslems ~ .~'~ • ~ /1~ ::=' Welding Procedure Development ANSi Fabrk, ad0n ~ 7472 Melody Drive Audils & Troubloshooling : '~ ! Pr~y. MN 55432 An I Pfol~s/onwl l~eld~ngE~g/ne#fln #Con, v~I//nff ,Service~ Investment a ySlS Li~ensedln US and C~n~d~ Welder Qualifications AWS Company, Inc. Referrals an any aspecl w~l~J/ll~l/w~.tl~m II NBIC ()C/R-Stamp Proarams API of welding BRUCE R. DANIELSON, CMfgE II BRIANCHURCH WElding Consulting, LI,C WELD4NG/MANUFACTURING AWS Certified Welding Inspector SPECIAUST ~, ~.- pRESIDI:NT 29 Joseph Circle Phone: (860) 345-2259 Pt~ne~phx AWS-Ce~:I ~ Imp 278 B~oorSt. East, Suite 2304, Toronto, Ontario M4W 3M4 {6121786-8145 SME~led M~g En~eer Tel.: (416) 96~-7725 Fax:(4161 964-8425 E-Mail: sgeintellaCtioncorn l[ Higgan!J'__n'06441_CT ...... E-Marl: hchurch02(¢}~snet net

ASME AWS NYS-DOT TUV API MIL-248 CARVALE ASSOCIATES Metollurltical Con~llon~ Certified Weld Inspection & Consultants Mat~ioh Ensineen • QA/QC Services cwI Weldk'q~t Eegi~eri~ • Deputy & Special Inspection n Welder & procedure Qualification CHARLES IL CIVELLO • Nondestructive Evaluation, Mechanical Testing Consultant • Welding & Metallurgical Engineering Consultation MANUFACTURING & WELDING CARVALE Daniel G. Luna M. C. Welding Consultant $~ni0r Weldina Insoector 73 HENEL AVENUE 2800 WEST GOLF BLVD. V~ Ul jl~: CowoJe-Asso¢iotes.¢om E-mail: DGXL@woddneLatt net CLOISTER SQUARE AP'~ 2 LEISUREVILLE APE 220 1555 Artesia BNd., #12 (310) 748-5004 AMHERST. NY 14226 POMPANO BEACH, FL 33O64 Manhattan Beach, CA 90266-7108 Fax (3101 376-6337 (716) 636-5964 (954,) 7B2-1349

Inspection ~ ~,~ AWS Certified Testing L~I~ Chicago Bddge & Iron Company ~/~tt ~ CONSULTANT 8900 Fairbanks N Houston Road (77064) p.o Box 41146 TECHNOLOGY RESEARCH CHARLES E. STRICKLER Houston,Texas 77241-1146 11B W. Dolaware St Thomas J. Landon Decatur, MI 49045 Manager of Sales & Markebng Mfg. Managemer~ Welding & Q A. Technologies 713 896 2973 1810 Park Valley Dr. Profitability Studies Cer~ed Fax: 713 466 4259 Columbus, IN 47203 Automation Ph: (6161 423-7470 Weld Phone/Fax 812-376-0202 Wed-Braze Engr. Fax: (616) 423-6115 Inspects" E.Mail:tlandon@C hicagoBridge Corn

II John Travaglini q Corrpro Staff Engineer ~R • Meta~rgical, Welding & InspectionEngineenng Earthtec Testing and Engineering, P.C. Comp=nles • ProjectSpecs. & WPB Deve~t & RevL~w 133 North 1330 West • Orem, Ut 84057 Incorpor•led • CWI & Welding Technology Training "-- I]II]Ig'// Office: (8011 225~5711 ° Fax: (8011 225-3383 "A Commitment tO Excellence" Toll Free: 1-888-822-5711 • Cell: (80I) 361~2604 Douglas E. Williams, P.E. J] e-mail: skip@r ockandryeranch@webtv, neE Skip Peterson, Tennessee Avenue & Beach Thorofarc MetallurgicalEngineering for Engineers Ill V. C. Jr. Ocean City, N 108226 GeotechnicM Studies Concrete Testing Phone: (609) 399 2417 21 Ocean Ave Phone: 5101235-9353111 ichmond, CA 94801 Fax: 5101232-9546 i Geology Fill Control Fax: (609)399-5233 Corrosion Ensineedn 8 L!J~ ...... @...... Nond~t~ctive Testing/Inspection Masonry Inspection E-maih (~:rcjt@ao]CDm Cathodic Protection Failure Analysis AWB / ICBO / ACI

~L porJ~'-~ ~=oR~ CWJ~:) (937) 754-1750 REGISTERED PROFESSIONAL EDUARDO~ED~ OJEDA JR. ~Lol[r~g lrJc. ExpertQualityWimess Contrul *Consulting * la~oection *WPSs* I=~truetion & PQRs ¢J...~oRk.-~ (937) 754-1754 (FAX) WELDING ENGINEER Welder Qufificafion Peter Bumpu$ Qualified Welder AWS Senior Certified Welding Inspector Fischer Engineering Compare/ AWS, ASME, & API ! 1@4. Marine Construct(onWeld(ng Consultant welding e~ sem~ces 1215 S. Hermosa St. AWS Certified Weld Inspector Baeeing, Ca. 92220 984 Main St. Phone: 781 294 I t88 AWS Certified Weld Educator Phone (909) 8493127 Hanson, Me. 02341 Fox: 781 294 1188 GLENN N. FISCHER 8220 EXPANSION WAY Over 30 ~llrs Experience Pager (909) 755-4125 Emag: eelt~gl~iocnet PRESIDENT DAYTON, OHiO 45424

110 J DECEMBER 2000 Specialis~ in Wel0ing Engineeong/Macageenent & QuaMy Conlml HAROLD P. ELLISON AWS MEMBER

Harold DewsnapCEng FWeldl Cer#/'~d European We/~ng Eng/neer Mechanized and Manual Welding Setup - Training - Procedures - Parameter Dev.

149 Brier Circle Tel: (561) 7474516 Jupiter, FL 33458 Fax: (561) 625-8744 75 Kepalr Chere, Crawcrook, Ryton, Tyr~ & Weal;. UK, NE40 4UR Tol/Fa=: +44(0) 191 413 g~14. E-Malh [email protected]

IDEAL WELDING SOLUTIONS INSFECTION & CONSULTANT SERVICES American Welding Society A.P.I. 1104 Code - Magnatech orbital pipe & tube welding equipment sales and leasing. - Contract weldmg services for precision micro-plasma & GTA applications. Jimmy Hmtfidd - Weld procedure development/AWS CWl 82 Poplar Drive (208)521-6277 Ernail- [email protected] Hattiesburg, MS 39402 hick¢, iolx Ilel 209-|23-$141 601-264-7470 C.W.I.#00041221 Fl1:20(~-825-4851 Maaeeea CA 95337

www.metallur g P..al.com J. M. ROLNICK (440) 461.9399 INTERLOCK,INC. jhmchaney@metalMr gical.com I/ METALLURGICAL CONSULTANTS, INC, ~.,~Idll ALEX CAPLOON, M.S. AWS C'Wl J. M. Rolnick, Consultant CONSULTING WEt DING ENGINEER J, H, (JIM) McHANEY, RE Covered Electrode Deign & Devek)pment SENIOR CONSULTANT

• ~me Ko eox lou 7701 PARNELL • HOUSTON, TEXAS 77021 F .... RO. BOX 88046 • HOUSTON, TEXAS 77288-0046 PHONE: (713) 526"6351 • FAX: (713) 526-2964 2112 Acacia Pad( Dr. #121 Lyndhurst, OH 44124

KAMMER ASSOCIATES AS'S ca,.¢~ m.um~ ~lt,e~w • A~PS~ :raY.8 F-auam- Mlrketlng and Tecllnlcll Cmlsultlntl Ales Ceffl/~d IFdder • ASNTSNT-TC- M ~ E PT/MT/Yr

JESSE A GRANTHAM, Ph.D., P.E PAUL A. KAMMER Pre~dent PRESIDENT Kevin L. Langdon 7100 N. B~md~ly 1C 303-451-6759 O~wm, CO S~g21-2917 ti00-g87-g~89 252 Sho.dlneOdve Phons: 252-633-9~'5 lYa62 Fife Rd. • VanWert, Ohio 45891 P, O. Box 211113,80221-0813 F~ 303-280-4747 NOw Dam, NO 28.~2 Fax: 252-633"3721 Mg~ mtp:#*ww.wjm0.~

Mike Cooper South~East Region Bert Montee Crunk Technical [email protected] General Manager RSO/CWI Services, Inc. ~/753-2375 Office: 903/753-2375 800/256-5442 800/256-5442 WILLIAM J. CRUNK, JR. Longview Fax: 903/753-6533 Longview Inspection Mobile:903/238-5416Res:903/236-4854 Welding Consultant, AWS-CWl Fanail: [email protected] Advanced TechnologyGroup. Inc 405 N. Eastman Rd. Inspection EO. Box 8204 Longview Inspection ASME, AWS Codes 1301 Live Oak Circle Longview, Texas 75601 Welding Procedures Knoxville, TN 37932 405 N. Eastman Rd. Fax: 903/753-6533 EO. Box 8204 A ~ek~ oa~ Welder Cottlticatlens Phone (865) 966-4235 Materials Engineering and Testing N~ctj~ Tesllnz CemFamy www.lii-nde.com Inspections, Auditing Mobile (865) 607-2504 A Rockwood Company Longview, Texas 75601

Odell McWane. P.E, Phone (559) 230-144; President oll~:v,'atw~, materialsit¢.~), ~\ PRO-Inspection Production (~/~'~/ - / and Racing Technolog,es McWANE AND ASSOCIATES Welding KEVIN A. DISNEY ENGINEERING SERVICES :~ Systems, Inc. MATERIALS JOINING AND PROCESSING Metals Ceramics plastics Composites CW[ - #85010831, AI - #8861 Welding Brazing Soldet~tg CMI - #80267, RCI - #5176 Get answers to your materials p¢ocessing and joining qucsti~ls 2517 Gay Lane, Lan~ng, MmhPgan48912-4405 Phone (517)372-9813 and cnginocring suppod at ~-,vw.materialsltc,com 1852 W. 11th St., #327 (209) 836-9574 ]-racy, CA 95376 Fax: (209) 833-0707 Wllllmm E. Mumford P.O. Box 5516 San Jose, CA 95150-55I(~ http:llhome,pacbell.rmVV,adpro Email: kadp~pacrbell.net

AWS-QC- 1 - APt 653 CERTIFIED B6dges-Buildings Plant Layoul-Fixlures PURITY SYSTEMS, INC. Welding-Barges DravAngs-Es6rnating Shipbuilding Railroad Cam-Jigs Professional Welding Consultant HIGH PURITY PIPING CONSULTANTS REX FRONDUTI, PE., CmigE Welder Certification • Matoiab Testing CHUCK CARNI~ DWISlONM/~iEWCWI Induswial lmpection • Destrucnve & Non Destructive Testing National Pager:.(408) 388-4264 Rex FronduII & As~clales Steel Fabricating Consultants

303 S. Aiq)orl Road 1933 O'TooleAve., SuiteA104 Longmont, CO 80503 San Jose, CA 95131 2981 Sandtuwn Road Tel 334-285-7781 36941 Patton P~ Dade City [:l. 33523 Tel: (303) 401-7049 Tel: (408) 435-9119 Millbrook, AL 36054-4 ! 45 Fax 334-285-0980 speeddalel @mm.com Fax: (303) 401-7051 Fax: (408) 435-1155

WELDING JOURNAL I III Tube-to-Tubesheet Welding Specialist I.C15.0.A .WS . 4 RobertKeilbach, P.E. Materials and Welding Engineering

Richard Fremgen 926 Coronado Dr. 134-28 601h Avenue lleat Exchanger Gulf Breeze, FL 3256 I Welding Flushing, N.Y. 11355 "reeh.olo¢#, hie. Phone: (850) 934-6380 KO. F.~, 15~ 9 Ptm ~kg'Y-5"2:9-~,O?5" (718) 358-8568 Fax: {530} 323-8582 c~ 95ow e~r w~-~,e~)-ez. [email protected] Email: fremgenjteh@ya~omo

350 BRIARLANE (717) 2e4 o635 Fellow. Amm¢~ Welding Society PE, PA 0vf~udlISiCalF.agia¢~ing) SCIENTIFIC TESTING CHAMBER~BURGPA~7201 Fellow, Ammlou Society for Metals PIE, CA ( (?.~xe~~ Eesi~ng) Member. ASME SCIX L ABORA] ORIES. iN(:

ROBERT L. PROCTOR SAMUEL D. REYNOLDS, JR. (;erald Hunt Y*('e Presklent WELDINGCONSULTANT Engineering Semices Materials and Welding P/lONE: (225) 358-0648 2703 WELLER/fVE 24Hour:(225) 382-686~ Baton Rouge, I.ouis~ana F.~" AWSCODE ASMECODE 1003 Neely Sue~ (225) 358-0636 P~ OCE~URE~ & CE~TIFICA TION MiLITArY (407) 365-7579 Oviedo. FL 32765 E-MAIL: inqulry(<~sc'tentifictestmg corn CW1#9505008 I, API 510,653,& E~UIPMENT ~ECIFIC A TION ~ JUSTIFIC A rlON NAVSEA ww~v.scient!fictestmg.com 570

solo TM Fax or Phone CONSE]LLERS EN SOUDAGE El" ASSURNNC E QUALITI~ 81~439-1916 WELDla'qG AND QUAU~Y ASSURANCE CONSULTING AAI~ AISI, ASME,ASTM, AWS,CSA, ISO STANLEY WEISS, Sc.D., P.E. Augestia MARISCA,B.ASc., T.P. Spitzmesser Inc. Welding Consultants 400 de Rigaud, Suite 1014 MONTREAL Quebec WEISS AND eURCK. LTO CONSULTING ENGINEERS CANADA, HZL 4S9 633 WEST WISCONSIN AVENUE 16629 SPansln Phone/Fax: (514)982-9023 SUITE 1410 (414) 27e~x)O8 Ray E. Spitzmesser Plainfidd, IL 60544 e-mail: [email protected] MILWAUKEE, WISCONSIN 53203 FAX (414) 27e-~0~

ASME Section IX E. Roger Stevens ASME Construction Codes Consultant NDT • QAJ~;C Sy,len:s ^ws ASME Atn A^R ^ASHTO AI~- STEVENSENGINEERING, LLC STEVENS WELDING CONSULTING, L.L.C. Welding Consultant Welding Procedure/Performance Qual#ication ~,• ~ WELDING Welding and Hardsurfacing Materials/Metallurgy Instructional Classes in Welding Metallurgy Technical Support for Auditing and Inspection 77~ ~ SFir~ R~td,• Bow~ C,een.KY 42104

IL Charl~ Stevens, P.E. 13~r7 Wlmllql Trill lane 314-966-1B23 Des Pere~, MO 63131 Telephone: 515-752-7385 1205 Highview Drive E-mail: [email protected] Marshalltown, Iowa 50158 AWS-SCWI~.'Wf.tNDt E.mail: welOc0nsultant@mindst~ngc~ WeldingConsultation Doesn't Cost... e. "It Pays"" " TipMate SYSTEMS Mr. Vincent Repper '~? ProfessionalWelding Consultant VINTON QUBBINS RANDY DAVIS Ftorida State Cert. #330709 Welding Cor~ultonl Welding Coualtaat AWS Certified Welding Inspector (561) g42d649 / (321) 956-8741 Specializing in Submerged Arc p.o. Box 246 Tele/FAX Mobile: 329-5676 Belpre, OH 45714 (741~)423-5765 C.TE / (:.~I 424 WEST 32nd STI~ET PHONE Wdding Cerl lest 3660 E lndusmal Way KEARNEy NE 68847 308 234 5391 e-mail: tipmate@¢ityaeLnet Quality Control • Welding fi'aining Rivieea 8each, FL 33404

Brazing phone/fox (610) 278-9325 On-site training sermnars(1-3 days)/ problem-solving E'rAILS ,,~ gr.o,.oThe Inaustff t~der In ~ .~tes & Industrial GR$ WELDING TECHNOLOGIES -25-yrs in furnace/torch/induction/resistance brazing-- Er~inoering Services ond Equipment W. Daniel Kay Tonygajor Automated Welding Systems Specialists President OWl,CWE 1604 East Fourteen Mile Road MonufocIurer Reprosentotives Kay & Associates Teclmicg$uppon MadisonHeights, M148071.0483 DR. JOSEPH V. NEDOREZOV 4 Lawton Drive Fax: (860) 217-1717 810-777-7995 Fax 810-777-2878 Simsbury. CT 06070 E-mail: dankay @ct2.nai.net Pager 248-401-0798 www.weldingnet.com 1365 Hocseshce Dr. Phone: (860) 651-5595 Web Page: nw3.nai.net/.-dankay Cell 810-484-0062 1-888-383-WELD (9353) B~ue Bell, PA 19422

JOHN G. ACOSTA "AWS CERTIFIED WELDING EI~it NEER WELDING INSPECTOR ~~ WELDPRO • CERTIFIEDCT Welding Safety Specialist VOC TECH INSIRUCTOR : Randy F. Thibodeau WeldSmart Edward A. Green W WELDTECH Specializing in Resistance Welding Specialist WelderTraining, "WELDING INSPECTION Certification and Safety o WELDINGIN~RUCTIO~I & TECHNK~UES HOME: F~O-689.39~5 • WELDINGPROCEDURE DEVELOPMENT WORK: 060~1-0341 289 North Fourth St. Tel. (207) 827-2468 5291 Craig Avenue Phone or Fax: • WELDERQUALIFICATION EMAE: JGAWELO@a~l.~m (330) 847-9398 • WELDINGMETALLURGY & TECHN0~0GY 49 SCHOOLHOUSERD Old Town, ME 04468 Fax (207) 827-1326 Warren, Ohio 44483 • PROCES*%ANALYSIS & SET-UP USEON CT 06351

I 12 J DECEMBER 2000 TRAINING

PIPE WELDING VIDEOS TRAINING 2000/01 Acquire difficult pipe welding skills CWI PREPARATORY and techniques through easy-to-follow Course Guarantee - Pass or Repeat instruction. Six different videos are FREE! available at $39.95 each: SMAW 2G, Dec 11-15 Jan 22-26 5G and 6G. Techniques are Test follows on Saturday @ same demonstrated, including walking the facility cup, tungsten extension, welding 1/4" gap, etc. Call today for more info. Visa "ADVANCED" VISUAL and M.C. accepted. INSPECTION 40 hours toward re-certification of CWl Quality School of Pipe Welding Dec 4-8 600 Great SW Pkwy SENIOR CWI PREP Muscular Dystrophy Association Atlanta, GA 30336 Also 40 hours toward re-certification of 1-800-572-1717- www.mdausa.org phone 404-629-9909 CWl Jan 15-19 People Help MDA... fax 404-629-1229 Because MDA HelpsPeople pipewelding.com **Office now open in Houston, TX** Accredited AWS test facility. For more information and our 2ool class schedule, ca// REAL EDUCATIONAL SERVICES, INC. at 1 - 800 - 489 - 2890

Abicor Binzel ...... 21 All Fab Corp ...... 64 Lincoln Electric ...... 11 American Torch Tip ...... 4 AWS ...... 6,27,28,40 Mack Products ...... 63 Metorex ...... 32 Bug-O Systems ...... 57,61 National Standard ...... 13 Cor-Met ...... 26,43 Cypress Welding ...... 59 Panametrics ...... 1

Diamond Ground ...... 25 Schaff International ...... 62 DCT ...... 59 Select Arc ...... IBC Divers Academy ...... 61 Stress Relief ...... 65

Edison Welding Institute ...... 2 T.J. Clark ...... 56 Enerpro ...... 18 Tecnar ...... 58 ESAB Welding & Cutting ...... 17,OBC Thermco ...... 59 Tocco ...... 65 F&M Mafco ...... 3 Weld Hugger ...... 20 G.A.L Gage ...... 8 Weldcraft Products ...... IFC Generico ...... 15 Wolverine Tube ...... 61

Hobart Institute ...... 19 IFC = Inside Front Cover IPR ...... 60 IBC = Inside Back Cover OBC = Outside Back Cover J.P. Nissen ...... 57 Jetline Engineering ...... 24

Koike Aronson ...... 20

WELDING JOURNAL I I 13 AWS Peer Review Panel

All papers published in the Welding Journal's Welding Research Supplement undergo Peer Review before publication for: 1) originality of the contribution; 2) technical value to the welding community; 3) prior publication of the material being reviewed; 4) proper credit to others working in the same area; and 5) justification of the conclusions, based on the work performed. The following individuals serve on the AWS Peer Review Panel and are experts in specific technical areas. All are volunteers in the program.

D. Abson E Hall Principal Reviewers D. K. Aidun D.L. Hallum Y. Adonyi P.W. Fuerschbach D.W. Meyer G. A. Andreano I.D. Harris C. E. Albright W. E Gale J.O. Milewski D. G. Atteridge D.A. Hartman J. A. Brooks J.M. Gerken K.W. Mitchiner R. E. Avery R.T. Hemzacek H. R. Castner D.D. Harwig P.E. Murray S. S. Babu M.J. Higgins M. J. Cieslak D. Hauser T.M. Mustaleski D. J. Ball T. Hikido M. J. Cola G.K. Hicken D.L. Olson W. L. Ballis J.E. Hinkel C. E. Cross J.E. Indacochea B.M. Patchett R Banerjee J. E Hinrichs C. B. Dallam J.L. Jellison T.P. Quinn T. S. Bannos T. R Hirthe B. Damkroger M.Q. Johnson A. Rabinkin R. E. Beal R Hochanadel V. R. Dav~ R.R. Kapoor B. Radhakrishnan E R. Beckman D.G. Howden S. A. David T.J. Kelly W.G. Reuter S. S. Bhargava R Howe T. DebRoy G.A. Knorovsky R.W. Richardson B. Bjorneklett C. Hsu J. H. Devletian D.J. Kotecki J. E Saenger O. Blodgett J.P. Hurley R. D. Dixon R. Kovacevic M.L. Santella R. J. Bowers D.L. Isenhour P. Dong E V. Lawrence, Jr. S.D. Sheppard J. E. M. Braid J.R. Jachna J. N. DuPont W. Lin H.B. Smartt K. L. Brown J. Jaeger T. W. Eagar J.C. Lippold B.R. Somers S. B. Brown B.A. Jones G. R. Edwards S. Liu C.L. Tsai J. Bundy J.E. Jones J. W. Elmer H.W. Ludewig G.D. Uttrachi S. N. Burchett W. Kanne D. E Farson R.P. Martukanitz D.R. White M. L. Callabresi B. Kapadia Z. Feng R. Menon T. Zacharia D. A. Canonico A. Kar S. R. Fiore S.J. Merrick Y. Zhou K. W. Carlson D.D. Kautz L. H. Flasche R.W. Messier, Jr. N. M. Carlson H.W. Kerr C. L. Chan D.S. Kim Y. J. Chao J. E King J. Mazumder M. Prager J.J. Vagi C. C. Chen S. Kolli V. E. Merchant D.D. Rager T.L. VanderWert J. C. Chennat P.J. Konkol M. T. Merlo K. E Rao I. Varol B. A. Chin S. Kou W. C. Mohr W. Ridgway R T. Vianco G. E. Cook J.J. Kozelski A. J. Moorhead A. Ritter K.K. Wang R. E. Cook H.G. Kraus T. Morrissett M.N. Ruoff D.K. Watney R. A. Daemen K.W. Kramer L. W. Mott D.J. Rybicki M.M. Weir S. Daniewicz J.J. Kwiatkowski C. G. Mukira E. E Rybicki C.E. Wirsing J. C. Danko E Lake K. Mundra K. Sampath C.E. Witherell J. DeLoach J.D. Landes O. Myhr J.M. Sawhill, Jr. W.E. Wood G. den Ouden J.W. Lee K. Nagarathnam A.P. Seidler J. Xie X. Deng A. Lesnewich R Nagy L.R. Shockley Y.P. Yang P. J. Ditzel G.K. Lewis S. Nasla L.E. Shoemaker H. Zhang R. J. Dybas M.V. Li T. W. Nelson M. Sierdzinski J. Zhang H. W. Ebert T.J. Lienert J. L. Novak T.A. Siewert S. Zhang G. M. Evans M.J. Lucas A. Ortega S.D. Smith Y.M. Zhang R. G. Fairbanks R.O. Lund M. Parekh T.M. Sparschu D. A. Fink K.A. Lyttle R. A. Patterson W.J. Sperko D. W. Fitting B. Madigan R. L. Peaslee D.E. Spindler W. R. Frick M.C. Maguire D. D. Peter J.E. Stallmeyer E. Friedman A.K. Majumdar E. Pfender R.J. Steele Y. P. Gao M. Manohar M. Piltch E L. Sturgill J. A. Gianetto A. E Manz L. E. Pope D.W. Trees E E. Gibbs K. Masubuchi N. Potluri A.J. Turner

114 J DECEMBER 2000 WELDING RESEARCH

SUPPLEMENTTO THE WELDING JOURNAL, DECEMBER2000 Sponsored by the American Welding Society and the Welding Research Council

A New Ferritic-Martensitic Stainless Steel Constitution Diagram

New equivalency relationships improve the accuracy for predicting weld metal microstructure

BY M. C. BALMFORTH AND J. C. LIPPOLD

ABSTRACT. A new constitution diagram decade has focused considerable atten- As the compositional influence on that more accurately predicts the mi- tion on the weldability of these alloys. weld microstructure is understood, crostructure of ferritic and martensitic The mechanical properties of the weld greater confidence in utilizing ferritic stainless steel weld deposits has been de- zone are very sensitive to microstructure, and martensitic stainless steels will be veloped. This diagram represents an im- and poor microstructure control can limit possible. Development of a diagram that proved version of the diagram presented their application. These microstructural allows more accurate prediction of the by the authors in the January 1998 weld- effects, including the presence of ferrite compositional influence on weld mi- ing Journal Research Supplement. Button in martensitic welds and martensite in crostructure will facilitate both alloy de- melting and quantitative metallography ferritic welds, were summarized in a pre- velopment and selection for welded ap- techniques were used to produce addi- vious paper by the authors (Ref. 1 ). plications and the choice of filler metals. tional microstructures, which supplied Historically, constitution diagrams In an earlier paper (Ref. 1), a prelimi- information about specific alloying ele- using chromium and nickel equivalents nary ferritic-martensitic stainless steel ment effects and provided microstruc- for the elements present in the alloy have constitution was proposed. This diagram tures near the phase boundaries, includ- served as road maps for determining weld was based on an initial database pro- ing the boundary for austenite formation. deposit microstructure (or constitution). duced by quantitative metallography and Using the entire database and linear re- Most of the diagrams currently available, a large number of samples produced gression analysis techniques, new equiv- such as the WRC-1992 diagram, do not using a button melting technique. The alency formulae were developed and represent the constitution region for fer- preliminary diagram provided a rough compared with existing formulae. Using ritic and martensitic stainless steels. estimate of weld metal microstructure, the new equivalency formulae and iso- Those that include the ferrite plus marten- but further experimentation and evalua- ferrite contour maps, a new ferritic- site region, such as the Schaeffler dia- tion were needed. The results reported martensitic stainless steel constitution di- gram, do not accurately predict mi- here include a larger number of compo- agram was developed. Based on arc crostructure. The objective of the work sitions that were produced by button welds made using commercial marten- reported here was to develop a constitu- melting in an effort to improve the accu- sitic and ferritic stainless steels, this dia- tion diagram over a composition range racy of the preliminary diagram. gram has proven to be extremely accu- that predicts weld deposit microstructures rate in predicting weld metal for ferritic and martensitic stainless steels Experimental Approach microstructure within the composition with a higher degree of accuracy. and Procedures limits of the diagram. The previous paper (Ref. 1) provides Introduction the details of the experimental procedures used to develop this diagram. The The increasing popularity of ferritic KEY WORDS following sections are a summary of the and martensitic stainless steels in engi- procedures used. neering applications over the past Constitution Diagram Stainless Steel Production of Alloy Buttons M. C. BALMFORTH is with Dept. of Materials Ferritic-Martensitic Science and Engineering, Massachusetts Insti- M icrostructure Materials for this study included con- tute of Technology, and was formerly with the Weld Metal ventional, commercially available ferritic Welding and Joining Metallurgy Group, The WRC-1992 and martensitic stainless steels, along Ohio State University. J. C. LIPPOLD is with Equivalency Formulas with other ferritic materials and grades of Weldin~ and Joining Metallurgy Group, The stainless steels. Some experimental com- Ohio State University, Columbus, Ohio. positions were also used. All of the chem-

WELDING RESEARCH SUPPLEMENT J 339-s 4.5

4 /~e 4 5 3.5 -t~. 6, • 8e 39 3 .u , #°* ~s3 4l eM • 39 ~t6~7 /°~o~ 2.5 eM eM M *99 .V :e / 3 *M 2 Me e97 e97 ~M 1.5 2 M~ 1 * eF F eF M .e 1~ *~z eF eF 1 'M • ~ ~/ "~'T--" ..... " 1 0.5 M

0 0 5 10 15 20 25 0 5 10 15 20 25 Cr + Me + 1.5Si + 0.5Nb Cr + Me + 1.5Si + 0.5Nb

Fig. I -- Button melt vol-% data plotted using the Schaeffler Fig. 2 -- Button melt w)l-% data plotted using the DeLong equiv- equivalents. alents.

9 6 8 e8 + 5 7 1"4 • 4,(D~see6~7,1~ 69 ,:5 6 + 4 + z eM o z 5 ea M 16 44 4"9~ 97 + M e39 e~ e + 3 ~ . u o . ,t*~ ~ / 4 ~M 12~1~e • E8 • 98 • • F • e~ 3 + '~F ~'FF • ~_ 2 .~. "~'~ .~ 2 e~¥ 16 e81 e~9 e~ M eeFF 1 tF 1 .o:

0 0 0 5 10 15 20 25 30 0 5 10 15 20 25 Cr + 6Si + 8Ti +4Me + 2AI Cr + Me + 0.7Nb

Fig. 3 Button melt vol-% data plotted using the Kaltenhauser Fig,. 4 -- Button melt vol-% data plotted using the WRC-1992 equivalents. equivalents.

ical compositions for the materials used nique is a highly efficient and reliable Characterization Techniques were provided by the producers and are method for simulation of weld metal and listed in Table 1. These base materials developing constitution diagrams. Button melt specimens were sec- were combined in different dilutions in The alloys were melted and allowed tioned in half using an abrasive wafering order to produce a range of microstruc- to cool under a high-purity argon-shield- saw and ground and polished through tures. Other materials were used, in ad- ing atmosphere. Initially, dilutions of 25, colloidal silica. Three different etching dition to the ferritic and martensitic stain- 50 and 75% of each base metal were pre- techniques were employed to reveal the less steels, in order to create pared. Button melts of the undiluted base two-phase microstructures of these al- combinations containing various metals were also made. Later, intermedi- loys. Most of the alloys responded well to amounts of alloying elements and mi- ate dilutions, such as 12.5%, were made an electrolytic etch using 10% oxalic crostructures bordering the duplex ferrite in order to fill in appropriate areas on the acid in distilled water at 6 V for times up plus martensite constitution region. diagram. The compositions of the indi- to 2 min. Some of the martensitic alloys Combinations of the base metals that vidual buttons were estimated by dilu- were more easily characterized when im- would transect the duplex ferrite plus tion calculations based on the chemical mersed in Vilella's reagent (5 mL HCI, 1 martensite constitution region were se- compositions of the base materials. For g picric acid, 100 mL ethanol) for 3-4 s, lected and mixed in different dilutions example, if 1 g of Alloy A was combined and, in some of the two-phase alloys, using a button melting technique. The with 3 g of Alloy B, the carbon content martensite was much more visible, as a button melts, which were used to simu- could be estimated by the following dark phase within light-colored ferrite, late weld metal for microstructural data, equation: when swabbed for 1 2 s using Fry's were made by melting four grams of ma- reagent (5 g CuCI 2, 40 mL HCI, 30 mL terial, (e.g., 3 g of one type of stainless water, 25 mL ethanol). Cbutton steel with 1 g of another) in a water- 4 A colloidal suspension of Fe304 parti- cooled copper crucible using the GTAW where Cbutton = the carbon content of the cles, known as ferro-fluid (Ref. 2), was process. It was confirmed in the earlier button, CA = the carbon content of alloy used to determine whether austenite ex- paper (Ref. 1) the button melting tech- A and C B = the carbon content of alloy B. isted in specimens near the triplex austen-

340-S J DECEMBER 2000 Table I -- Chemical Compositionsof the Materials Used in This Study

Composition, wt-% Alloy C Mn Si Cr Ni P S AI Mo Cu Nb Ti N Ferrite Stainless Steels 409 0.018 0.28 0.49 11.54 0.14 0.023 0.001 .... 0.18 -- 444 0.02 0.36 0.23 17.85 0.37 0.031 0.001 -- 1.92 0.33 0.33 0.019 430-A 0.046 0.45 0.38 16.48 0.27 0.026 0.003 0.005 0.09 0.08 -- 0.003 0.046 430-B 0.036 0.47 0.31 16.1 0.11 ------0.02 0.08 -- 0.035 430-C 0.04 0.44 0.42 16.6 0.21 0.024 0.001 0.003 0.17 0.08 0.017 -- 0.035 439-A 0.02 0.3 0.4 17.89 0.2 ------0.04 0.07 0.48 0.41 439-B 0.012 0.27 0.28 17.32 0.32 0.031 0.001 0.064 0.039 0.074 0.01 0.33 0.012 409Ni 0.01 0.64 0.36 10.99 0.8 0.023 0.001 0.049 0.027 0.074 0.01 0.19 0.008 405 0.019 0.46 0.76 13.21 0.17 0.019 -- 0.23 O. 13 0.05 0.007 0.002 0.002 Martensitic Stainless Steels 403-A 0.11 0.37 0.35 12.38 0.28 0.015 0.004 0.003 0.069 0.099 0.008 0.002 0.028 403-B 0.089 0.65 0.33 12.15 0.32 0.019 0.002 0.003 0.036 0.08 0.003 0.002 0.029 410 0.106 0.38 0.37 12.52 0.23 0.022 0.025 -- {).02 -- 0.053 410Cb 0.122 0.24 0.29 12.0 0.17 0.023 0.007 -- 0.03 0.09 0.174 0.002 0.008 410K 0.1 0.6 0.5 16.7 2.1 0.01 0.01 -- 1.0 -- -- HT9 0.22 0.52 0.38 11.3 0.5 0.019 0.006 -- 0.85 ------0.27 CC8 0.024 0.46 0.48 8.13 0.22 0.012 0.004 -- 0.31 0.04 -- -- 0.018 13Cr 0.031 0.389 0.155 12.88 3.96 0.012 0.002 -- 1.01 ------0.02 Other Materials Fe 0.02 0.32 0.01 -- -- 0.01 0.013 ------A36 0.088 0.627 0.236 -- -- 0.005 0.025 ...... 304L 0.023 1.79 0.58 18.12 8.09 0.023 0.006 -- -- 0.069 312 0.05 1.75 0.51 30.4 8.36 0.021 0.002 -- 0.01 0.04 ------2205 0.014 1.46 0.48 22.16 5.64 0.028 0.001 -- 3.04 0.18 21-6-9 0.067 8.31 0.29 20.16 7.03 0.017 0.003 0.018 0.22 0.072 0.001 0.002 0.197

ite-ferrite-martensite constitution region. ments included in the regression. Ele- Results and Discussion Because the particles are ferromagnetic, ments chosen for inclusion in the regres- they adhere to ferrite and martensite, giv- sion were based on previous equivalency Development of the New Diagram ing a blue or brown color, while leaving formulae, experience and whether or not austenite unaffected and white when ob- sufficient data existed for the element. After the preliminary diagram was pro- served with an optical microscope. Various combinations of elements were posed, more button melt samples were To determine the volume fraction of chosen, which produced a variety of made in an attempt to fill in gaps where ferrite or martensite in the microstructures equivalency relationships. more microstructural data was needed. of the specimens, quantitative analysis The various coefficients produced The data from these microstructures was was performed using the point-counting were evaluated using statistical methods, then added to the existing database. All of method according to ASTM E562. such as the standard deviation, T-value, the data from this work, including dilu- P-value, R-squared value, and by exam- tions and phase ratios, are listed in the Data Analysis ining the correlation matrix of the coeffi- primary author's thesis (Ref. 3). The ex- cients. Once the initial regressions were panded data set was plotted, using exist- To determine which elements and completed, ridge regression was used to ing equivalency formulae, as shown in their coefficients should be used in the improve the predictions for the coeffi- Figs. 1 through 4. Only the equivalency new equivalency relationships for the cients. Ridge regression uses a ridge pa- relationships from the Schaeffler (Ref. 4), prediction of volume-percent ferrite in rameter (theta) to modify the least DeLong (Ref. 5), Kaltenhauser (Ref. 6) and ferritic and martensitic stainless steel squares regression procedure to help WRC-1992 (Ref. 7) diagrams were used in welds, two linear regression techniques avoid problems caused by highly these plots; the microstructure boundary were used. Multiple linear regression, collinear independent variables. As theta lines from the original diagrams were not which analyzes relationships between increases, biases in the coefficients in- used. The boundary lines separating the one dependent variable and one or more crease, but the coefficients may be more martensite and ferrite regions from the independent variables, was used to deter- precise. The goal is to find a small value two-phase region in the Figs. 1-4 were de- mine the initial equations. Volume- of theta beyond which the estimates termined optimally. It is apparent bound- percent ferrite was defined as the depen- change slowly. ary lines for determining 100% ferrite or dent variable, while the elements affect- Chromium and nickel equivalent for- martensite formation are possible using ing ferrite content, such as nickel, mulae developed during the regression any of these equivalency relationships. chromium, nitrogen, etc., were defined as analysis were then used to plot the vol- If guaranteeing either a fully ferritic or the independent variables. This process ume-percent ferrite data. By plotting the fully martensitic microstructure is all that produces linear equations of the form: various relationships and determining is required, any of the diagrams in Figs. 1 vol-% ferrite = C 0 + C I(E I )+C2(E2)+...+Ci(E i) best-fit lines for the data, an iso-ferrite through 4 would be sufficient. However, (1) contour map was produced. The lines the addition of iso-ferrite lines to the dia- were drawn without curvature and were gram requires further analysis because where C o is a constant, the C i terms are allowed to be nonparallel and non-equi- the data is not distributed in a smooth coefficients and the E i terms are the ele- spaced. transition from 0 to 100% within the two-

WELDING RESEARCH SUPPLEMENT J 341-s 6 2.5

5 ¸ / le 2 '.e,t 3, I ".~.~. 4~ / ~ ~.'~" ". ~ / M • °~707 7 1.5 ! OM . M .I . ~ ,~.~:;*.~#~ / /~. -,,~ .~,~ / o/" OM • I "~,b26~ 0 73 ~97 o97 iF 3- .M M ~ o9~ .... f .-~ .,,~.~, IF .M ~'....~ ...... 1- OM ~ 187 2 "/ :,;~.:, ~/'., ..%% ., • 112 ~99 , ~F~FF 0.5 ~ u 1 ~M 0 0 0 5 10 15 20 25 30 5 10 15 20 25 30 0 Cr + 8Si + 4Ti + 2Mo + 85AI Cr+ 4Si + 4Ti + 2Mo + 69A1+ 2Mn

Fig. 5 -- Button melt vol-% data plotted using experimen- Fig. 6 -- Button melt vol-% data plotted using experimental equivalents developed by linear regression analysis in- tal equivalents developed by linear regression analysis cluding the 0% and 100% data. using only the two-phase data. phase region. 2205 were combined with the ferritic Because austenite is not ferromagnetic, Using linear regression analysis, few and martensitic stainless steels, as well the iron particles in the ferro-fluid do not experimental equivalency relationships as with pure iron and A36 structural attach to it, and it appears white when ob- were determined, and the data was plot- steel, to create button melt samples with served under an optical microscope, ted, with these values for the axes, in Figs. a range of nitrogen, manganese, alu- while ferrite and martensite are colored 5 and 6. The equivalency relationships in minum and nickel contents. It was hy- blue or brown. The ferro-fluid technique Fig. 5 were determined using the com- pothesized that by producing a wider was thus determined to be an efficient plete data set, including the 0 and 100 range of compositions, a more applica- and reliable method for determining vol-% ferrite data, while the equivalency ble coefficient could be determined for whether austenite was present in the mi- relationships in Fig. 6 were determined the element in question. crostructure. using only the data from the two-phase microstructural region. It was felt that it Austenite Formation Equivalency Relationships was better to use only the two-phase data for the development of the constitution Another objective in the development With the addition of the new button diagram. This is because the 0 and 100 of the diagram was to identify the bound- melt data to the database, statistical pre- vol-% data could be assigned to an entire ary for austenite formation on the upper dictions were improved significantly. region, not a specific point on the dia- right side of the diagram. To do this, mi- Compositional ranges for the data were gram, thus making this data less useful for crostructures containing austenite were as follows: 7-20 Cr, 0.1-8 Ni, 0.01-0.6 the linear regression analysis. The equiv- required. These were produced by mix- Si, 0.01-0.22 C, 0.3-1.8 Mn, 0-0.23 AI, alency relationships in Fig. 6 are similar ing various alloys, such as austenitic Type 0-0.33 Ti, 0-0.48 Nb, 0-3 Mo and to the Kaltenhauser factors, if the 304L and duplex Type 312, mainly with 0-0.2 N. A total of 125 button melt sam- Kaltenhauser nickel relationship ( 40[C + ferritic stainless steels. Some austenite ples were included in the database used N] + 2Mn + 4Ni ) is divided by four, and was also present in mixtures of 2205 with for regression analysis. Multiple linear with the exception of the overly large co- both ferritic and martensitic alloys. In regression analysis was used to evaluate efficient for aluminum. collecting the microstructural data, a the alloying element effects on weld At this point, the data analysis led to note was made if a microstructure was metal volume-percent ferrite. One of the the conclusion that a diagram could be found to contain austenite, and this data predictive equations, developed using developed using new equivalency rela- was not used in the regression analysis. the same elements Kaltenhauser in- tionships developed with linear regres- This data was later applied to the com- cluded in his ferrite factor, is given in the sion analysis. Also, by using the new pleted diagram in order to determine a following: equivalency relationships, iso-ferrite lines boundary above which austenite can be could be added within the two-phase re- expected to form in the weld metal. vol-% ferrite =-109 + 14.3(Cr + 2 [Si + Mo] + gion to provide a means of predicting These microstructures presented a 9[AI + 1]])-21.7(Ni + 20C + 10N + 0.3 Mn) weld metal constitution accurately within challenge in determining whether austen- (2) the ferrite plus martensite region. ite was present or whether the austenite The chromium and nickel equivalency had transformed to martensite on cooling. relationships are the terms in parenthe- Specific Alloying Element Effects Some of the microstructures appeared ses. Various combinations of elements very similar when etched using standard were chosen, based on previous equiva- To resolve concerns over terms such procedures. Alloys possessing a duplex lency formulae, experience and whether as the coefficient for aluminum in Fig. 6, ferritic/martensitic microstructure some- or not sufficient data existed for the ele- several buttons were made with specific times appear very similar to alloys with a ment, producing a variety of equivalency alloying elements in mind. Alloys such duplex ferritic/austenitic microstructure. relationships. From these regressions, co- as the nitrogen-strengthened austenitic To determine whether austenite was pre- efficients were determined for several of stainless steel Nitronic 40 (21Cr-6Ni- sent in these alloys, ferro-fluid color met- the elements in the chromium and nickel 9Mn-0.2 N) and the duplex stainless steel allographic techniques were used (Ref. 2). equivalency formulae.

342-s J DECEMBER 2000 The coefficient of 2 for molybdenum was consistent throughout the regres- ///////~ .F sions on various combinations of ele- MARTINSIT~ ments. Aluminum and titanium also had coefficients consistently in the 8 to 10 z range. In most of the trials, carbon was o 4 stronger as an austenite stabilizer than -I- nitrogen. The C:N ratio of around 1:5 (Jin 3 found in the development of the WRC- tv~ 1988 diagram (Ref. 8) seemed to apply 4- here also. Coefficients of around 20 for ~2 carbon and 12 for nitrogen were common. Coefficients determined for /~~/~~~FERRITE chromium and nickel were statistically j///////, significant, with relatively small stan- I , i i dard deviations. Chromium and carbon always showed the strongest effect on 10 12 14 16 18 20 22 volume-percent ferrite. Cr + 2Mo + IO(AI +Ti) Coefficients for manganese and silicon were not as consistent and left a de- Fig. 7 -- New territic-martensitic stainless steel constitution diagram, which contains a bound- gree of uncertainty. Each of these had ary for austenite formation. Iso-ferrite lines are in vol-% ferrite. small coefficients, and thus effects, on the volume-percent ferrite. Also, each was present in both the chromium and 6 nickel equivalency relationships when included in various combinations with other elements. A very surprising finding 5 was that niobium ended up with a negative coefficient, suggesting it acted as an Z 4 ~' //,.4 austenite stabilizer, with values ranging ~/ M+F i i from 2 to 8. A coefficient for copper was 4. also investigated, but insufficient data o. 3 and uncertain results precluded its inclu- 4. sion in the equivalency relationships. ~_2 Because of these uncertainties and in- consistencies with other equivalency for- ///z/84,~" / / F ERRITE mulae, further evaluation was needed for some of the coefficients. Using the combinations of elements that made the most sense from the previous analysis, the cor- 8 10 12 14 16 18 20 22 relation matrix of coefficients was examined. It was determined that some of the Cr + 2Mo + 10(AI + Ti) estimates of coefficients could have errors that were inflated from correlation with other element effect estimates. For Fig. 8 GTA weld vol-% ferrite data plotted on the new diagram. example, niobium was strongly corre- lated to the titanium effect estimate. This means the coefficient for niobium was masked by the effect of titanium. This is for silicon and manganese were still un- point. By plotting the various relation- a possible explanation why niobium certain. Also, the coefficients for nickel ships and determining best-fit lines for the seemed to have a negative coefficient. and possibly molybdenum could be re- data, iso-ferrite contour maps were pro- Nickel and molybdenum also showed duced slightly. Reducing the nickel coef- duced. If only the equations developed possible inflation of the standard devia- ficient would have the effect of increas- using linear regression analysis were tion error due to correlation with other ef- ing the coefficients for carbon and used, they would produce a diagram with fect estimates. nitrogen and other austenite stabilizers in equispaced and parallel lines. The con- To evaluate these compositional ef- the nickel equivalent relationships. tour maps had lines that were not parallel fects further, ridge regression was em- or equispaced and that were based on ac- ployed. This technique, which improves Plotting the Data tual data, thus potentially increasing the the coefficient estimates by helping to predictive accuracy. The iso-ferrite con- avoid problems caused by highly Using the above information, several tour maps were then used to determine collinear independent variables, was potential equivalency relationships were the best equivalency relationships. used to look for coefficients for niobium, determined, and the chromium and On the basis of these evaluations, the silicon and manganese, and to determine nickel equivalent values were calculated best nickel and chromium equivalent if there was inflation of errors for nickel for the button melt samples. The equations were the following: and molybdenum. This analysis showed chromium and nickel equivalent values a coefficient for niobium could not be de- were then plotted with the volume- Creq = Cr + 2Mo + 10IAI + Ti] (3) termined with this data set. Coefficients percent ferrite as the data label for each

WELDING RESEARCH SUPPLEMENT J 343-s within this range, the heat input did not | ; -' ".. o- greatly affect the volume-percent ferrite, and hence the predictive capability of the MARTENSITE I:. ,":,.f., M + F ' ."";'. , A + M + F ,,° -'1I new diagram. The weld data was then plotted on the 6 z new diagram, as shown in Fig. 8. It can be seen the weld metal volume-percent fer- 4- rite is predicted with a reasonable degree I )-- of accuracy by the new diagram. Further I , III '// G ,/ verification should be conducted using + 3 welds in alloys not used for production of Z Ill,/~';rill / 2 button melt samples, but all of the available alloys were used in this study. It is felt, however, the microstructures of most , gl 'l d l conventional ferritic and martensitic stainless steel welds can be predicted ac- 8 10 12 14 16 18 20 22 24 26 28 30 curately with the new diagram. Cr + 2Mo + 10(AI + Ti) Practical Imolications

Fig. 9 -- New ferritic-martensitic stainless steel constitution diagram with slightly extended axes. The new ferritic-martensitic stainless steel constitution diagram provides a significant improvement over existing meth- and and nitrogen were chosen, and it was felt ods for predicting weld metal volume it would be best to have the diagram as percent ferrite in these alloys. The data- Nieq = Ni + 35C + 20N (4) much in agreement with the WRC equiv- base used in its development was more alents as possible. extensive than that used by Lefevre (Ref. Although only the two-phase volume- The shape of the martensite plus ferrite 9) or Lippold (Ref. 10), and the alloys percent ferrite data was used in the linear region is similar to the Schaeffler diagram were from the microstructure region of regression analysis, the data for 0 and (Ref. 4). The martensite boundary has a interest, unlike the Schaeffler diagram 100 vol-% ferrite were included in plot- steeper slope than the ferrite boundary (Ref. 4), which was developed using ting the diagram. This allowed boundary line. This trend also carries over from the austenitic alloys. lines to be determined accurately, along Lefevre diagram (Ref. 9) and Lippold's fer- Because most constitution diagrams with iso-ferrite lines within the two- ritic stainless steel constitution diagram have been developed based on measured phase region. All of the iso-ferrite lines (Ref. 10). The iso-ferrite lines gradually chemical compositions, there was a ques- were approximated as straight lines. change from steeper to lower slope as vol- tion whether using composition values ume-percent ferrite increases. based on dilution calculations would be Austenite Boundary For higher alloyed stainless steels accurate. As a check, the actual chemical where austenite formation is a possibil- compositions of several of the button melt Some of the button melt samples were ity, an austenite boundary line has been samples were measured. A simple investi- mixed in dilutions that would form included. gation, using the measured nitrogen val- austenite in the microstructure. These ues in place of the nitrogen values esti- data points were plotted using the new Evaluation of the New Diagram mated by dilution calculations for the equivalency relationships, and a bound- nickel equivalent values, was performed. ary where austenite begins to form was Verification with Actual Welds It was determined the slight differences added to the diagram. Most of the data for between measured values and estimated austenite formation fell outside the re- To check the accuracy of the new fer- values were negligible in determining the gion of volume-percent data and was ritic-martensitic stainless steel constitu- volume-percent ferrite predicted by the di- thus not useful for inclusion in the new tion diagram, autogenous GTA welds agram. When using the new diagram, the diagram. However, enough data existed were made in all of the base metals used final microstructure of a dissimilar weld or to add a boundary to the upper right cor- in this study, and volume-percent ferrite weld with filler metal can be predicted by ner of the diagram. was determined for each. An autogenous estimating the dilution and using the square-groove weld was also made be- chemical composition of the base materi- New Diagram tween Types 410Cb and 409Ni, giving a als to calculate the final weld metal com- 50% dilution weld. This procedure position with dilution calculations. The ferritic-martensitic stainless steel helped verify the point counting tech- Table 2 provides a comparison of constitution diagram developed in this nique for determining volume-percent weld metal constitution (volume-percent study is presented in Fig. 7. The iso-fer- ferrite in these alloys, as several of the ferrite) between the Schaeffler diagram rite lines are in volume-percent ferrite. button melt samples and actual welds and the new diagram, and that deter- The equivalents were developed based were found to contain the same fraction mined metallographically for autoge- on linear regression analysis and previ- of ferrite in the microstructure by point nous welds in Type 409 and Type 410 ous experience and intuition. Notice the counting. In the plate materials, heat in- and a dissimilar combination between nickel equivalent is identical to the puts of 20 and 40 kJ/in, were used. This, A36 and Type 430. It is evident the new WRC-1988 nickel equivalent (Ref. 8). combined with the low heat inputs used diagram predicts weld metal microstruc- Because the ridge regression technique for the sheet materials, ensured that the ture much more accurately than the suggested lowering the coefficient for range of conventional arc welding heat Schaeffler diagram in the ferrite plus nickel, the larger coefficients for carbon inputs was represented. It was found that, martensite region.

344-s J DECEMBER 2000 Table 2 -- Predicted vs. Actual Volume Percent Ferrite Table 3 -- Compositional Range of Confidence for the New Diagram Alloy Phrase Vol-% Vol-% Vol-% Field Ferrite Ferrite Ferrite(New Element Compositional (Schaeffler) (Schaeffler) (Actual) Diagram) Range (wt-%) 410 M+F 30 8 8 Cr 11-30 409 M + F 90 99 96 Ni 0.1-3.0 635 430 + M+F 20 0 0 Si 0.3-1.0 37% A36 C 0.07-0.2 Mn 0.3-1.8 Mo 0-2.0 It is felt the boundary lines for 100% and those previously listed in the Equiv- AI 0-0.3 ferrite and martensite on the new dia- alency Relationships section are due to Ti 0-0.5 gram are highly accurate, while the iso- the wide range of experimental data. The N 0-0.25 ferrite lines are more qualitatively accu- previously listed ranges were from the rate. Also, the austenite formation specific compositions of the experimen- boundary is considered qualitative. The tal button melts, which included other Menon at Stoody Company. We are ap- diagram can be used with a high level of types of stainless alloys and some non- preciative of the Edison Welding Institute confidence to determine whether or not stainless alloys. The compositional for allowing the use of the button melting a second phase will form when welding ranges listed in Table 3 are based more equipment. We are also indebted to Pro- the ferritic and martensitic stainless on commercially available ferritic and fessor Theodore T. Allen at The Ohio steels, and provides an accurate estimate martensitic stainless steels. State University for his help with statisti- of the actual volume-percent of the sec- cal analysis and interpretation. ond phase. Figure 9 shows the new dia- Conclusions gram with slightly extended axes. This References was done to allow the diagram to be used 1) A new ferritic-martensitic stainless when welding alloys, such as the 25Cr steel constitution diagram is proposed 1. Balmforth, M. C., and Lippold, J. C. ferritics, whose base metal compositions that uses compositional factors devel- 1998. A preliminary ferritic-martensiticstain- fall outside the initial boundaries. Pre- oped using linear regression analysis. less steel constitution diagram. Welding Jour- diction of weld metal volume-percent This new diagram includes iso-ferrite nal 77(1 ): 1-s to 7-s. ferrite or martensite above Nieq = 6 lines within the martensite plus ferrite re- 2.1989. ASM Handbook, Volume 9, Met- should be considered qualitative. gion. A boundary for austenite formation allography and Microstructures, John Newby, is also proposed. Ed. ASM International, Materials Park, Ohio. Limitations 2) The diagram provides improved 3. Balmforth, M. C. 1998. Developmentof predictive accuracy over currently avail- a ferritic-martensitic stainless steel constitu- The new diagram should only be ap- able methods for predicting ferritic and tion diagram. Master's thesis. Columbus, plied to alloys welded with conventional martensitic stainless steel weld metal mi- Ohio, The Ohio State University. arc welding processes. High-energy- crostructure. The boundary lines for 4. Schaeffler, A. L. 1949. Constitution dia- density (HED) processes, such as laser 100% ferrite and martensite on the new gram for stainless steel weld metal. Metal beam welding (LBW) or electron beam diagram are highly accurate, while the Progress 56(11 ): 680-680B. welding (EBW), produce high solidifica- iso-ferrite lines and austenite formation 5. DeLong, W. T., Ostrom, G. A., and Szu- tion and cooling rates. Under these con- boundary are qualitatively predictive. machowski, E. R. 1956. Measurementand cal- ditions, both the solidification and phase 3) The new diagram should be applied culation of ferrite in stainlesssteel weld metal. transformation behavior may be altered only to alloys welded with conventional Welding Journal 35(11 ): 521 -s to 528-s. relative to arc welds. This may result in arc welding processes. The use of high- 6. Kaltenhauser,R. H. 1971. Improvingthe different proportions of ferrite and energy-density processes, such as laser engineering properties of ferritic stainless martensite and could promote the reten- and electron beam welding, may result in steels. Metals Engineering Quarterly 11 (2): tion of austenite in some alloys. different proportions of ferrite and 41-47. Extrapolation of the lines on the dia- martensite and could promote the reten- 7. Kotecki, D. J., and Siewert, T. A. 1992. gram outside the boundary regions tion of austenite. WRC-1992 constitution diagram for stainless shown in Fig. 9 is not recommended. The steel weld metals: a modification of the WRC- microstructure database used in the de- Acknowledgments 1988 diagram. WeldingJournal71 (5): 171 -s to velopment of the diagram is represented 178-s. by the axes of the diagram; therefore, er- The authors acknowledge the Ameri- 8. Siewert, T. A., McCowan, C. N., and rors may be introduced by predicting mi- can Welding Society, which provided Olson, D. L. 1988. Ferrite number prediction crostructures outside the boundaries of principal funding for this project through to 100 FN in stainlesssteel weld metal, weld- the diagram. Prediction below Nie~ = 0.5 an AWS graduate research fellowship. ing Journal 67(12): 289-s to 298-s. is also not recommended. Microstruc- We are grateful to Damian Kotecki of The 9. Lefevre, J., Tricot, R., and Castro, R. tures of alloys containing very low car- Lincoln Electric Co., who provided assis- 1973. Noveaux aciers inoxyables a 12% de bon contents may not be accurately pre- tance and expert advice during the pro- chrome. Revue de Metallurgie 70(4): 259. dicted by the new diagram. The diagram ject. Thanks also to Paul Lovejoy, for- 10. Lippold, J. C. 1991. A review of the is very accurate within the compositional merly with Allegheny Ludlum, for welding metallurgy and weldability of ferritic limits of conventional ferritic and providing materials and advice, and oth- stainless steels. EWl Research Brief B9101, martensitic stainless steels. A composi- ers who provided materials, including Columbus, Ohio. tional range of confidence is listed in Mauro Losz at Armco Research, Terry Table 3. The differences between the DeBold at Carpenter Technologies, compositional values listed in Table 3 Bryan O'Neal at Air Liquide and Ravi

WELDING RESEARCH SUPPLEMENT I 345-s A Martensite Boundary on the WRC-1 992 Diagram Part 2: The Effect of Manganese

Manganese is found to be more powerful than nickel in stabilizing austenite with respect to transformation to martensite

BY D. J. KOTECKI

ABSTRACT. The upper boundary for Accordingly, a study was undertaken to work to consider higher Mn levels than martensite appearance in stainless steel allow placement of a martensite bound- 1%, and to examine how higher Mn lev- weld metals on the Schaeffler Diagram is ary on the WRC-1992 Diagram. The first els in the weld metal affect the position shown to be overly conservative, it also part of this study concentrated on com- of the upper martensite boundary on the does not predict a manganese effect be- positions containing nominally 1% Mn, WRC-1992 Diagram. yond its coefficient in the nickel equiva- and showed the upper martensite bound- lent. A modification to the WRC-1992 ary on the Schaeffler Diagram does not Experimental Materials Diagram is proposed, which takes varia- agree well with the experimental results tion of manganese into account. The (Ref. 5). Using results of magnetic mea- Numerous chromium-nickel stainless martensite boundary is based upon mag- surements and 2T longitudinal face bend steel single-pass deposits were produced netic measurements and 2T longitudinal tests, an upper martensite boundary, for by submerged arc welding on carbon face bend tests of numerous submerged 1% Mn compositions, was proposed for steel plate. All of the wires employed in arc weld claddings. Separate boundaries the WRC-1992 Diagram. Part 2 of this study were ~g2-in. (2.4-mm) are offered for 1%, 4% and 10% Mn. However, it must be recognized there diameter tubular metal cored wires. Two are a number of stainless steel weld filler series of wires were specially fabricated, Introduction metal compositions of appreciably more one to obtain single-pass deposit com- than 1% Mn content. Such compositions positions on ASTM A36 steel of about 4% The Schaeffler Diagram (Ref. 1), now include AWS Type 307 (typically around Mn, and the second to obtain single-pass fifty years old, is well outdated for ferrite 4% Mn), the European 18 8 Mn (typically deposit compositions of about 10% Mn. prediction in stainless steel welds. It was around 6% Mn) and the AWS Type 219 The wire compositions were all designed supplanted in large part by the DeLong (typically around 10% Mn). These filler to produce deposits of about 0.1% C, Diagram (Ref. 2), which has in turn been metals are often used as cladding or 0.5% Si and 0.02% N, with no significant supplanted by the WRC-1992 Diagram buffer layers, or for dissimilar metal join- Mo or Nb content. The compositional (Ref. 3). The newer diagrams make pre- ing. Manganese has been shown to have variables, then, were Mn, Cr and Ni. dictions in terms of Ferrite Number (FN) a negligible effect on solidification of Table 1 lists the nominal wire composi- instead of ferrite percent (FP). FN is more stainless steel weld metals as regards for- tions, based upon calculation from the reproducible than FP, and it is obtained mation of ferrite or austenite at high tem- fill formulation. Since dilution from the nondestructively, by magnetic means. perature (Ref. 6). But manganese has a A36 steel is not taken into account in Since 1995, the WRC-1992 Diagram has very important effect of stabilizing these calculated wire compositions, and been the recommended method of ferrite austenite as regards transformation to since some loss of manganese during prediction in the ASME Code (Ref. 4). martensite at low temperatures (Ref. 7). welding was expected, the nominal wire However, the WRC-1992 Diagram did So it is of interest to extend the earlier compositions are appreciably higher in not take martensite formation into ac- Mn than the 4% and 10% targets for the count. Because the Schaeffler Diagram weld deposits, it is the deposit composi- does make martensite predictions, it tion that is important. tends still to be referenced in stainless Only unalloyed high basicity fluxes steel weld cladding and dissimilar metal KEY WORDS were used in this part of the study. They joining situations. are standard commercial products. Since the WRC-1992 Diagram is rec- Stainless Steel ommended for ferrite prediction, it is Manganese Experimental Welds and Evaluation rather awkward to still rely on the Schaef- Weld Cladding tier Diagram for martensite prediction. Martensite Each wire was used to make deposits WRC-1992 Diagram under several welding conditions, pri- Bend Test marily varying wire feed speed (current), D. J. KOTECKI is with The Lincoln Electric Co., with corresponding change in travel Cleveland, Ohio. speed to obtain more-or-less consistent

346-s J DECEMBER 2000 Table 1 -- Calculated Wire Compositions

Calculated Wire Composition (wt-%)

Wire C Mn S Si Cr Ni Mo Nb N Number Wires Producing Diluted Deposits of about 4% Manganese

1761 0.119 7.65 0.007 0.006 0.06 5.61 11.32 0.00 0.00 0.0004 1762 0.031 8.57 0.015 0.010 0.33 27.39 6.29 0.16 0.00 0.027 1775 0.122 8.57 0.015 0.012 0.30 21.89 10.48 0.16 0.00 0.027 1776 0.109 6.65 0.008 0.008 0.46 7.28 19.63 0.00 0.00 0.0004 1777 0.103 6.64 0.010 0.005 0.58 24.54 2.93 0.00 0.00 0.0004 1786 0.102 7.18 0.008 0.006 0.49 27.55 2.70 0.00 0.00 0.0004 1787 0.111 7.19 0.008 0.009 0.42 7.19 20.71 0.00 0.00 0.0004 1791 0.112 7.72 0.007 0.009 0.41 6.53 22.06 0.00 0.00 0.0004 1792 0.102 7.18 0.008 0.006 0.46 28.76 2.70 0.00 0.00 0.0004 Wires Producing Diluted Deposits of about 10% Manganese 1793 0.111 19.28 0.008 0.009 0.41 6.56 9.00 0.00 0.00 0.001 1794 0.110 19.28 0.008 0.008 0.49 14.81 3.65 0.00 0.00 0.001 1795 0.111 19.28 0.007 0.008 0.46 14.90 4.55 0.00 0.00 0.001 weld deposit weight per unit length, but varying dilution so a number of different compositions could be obtained with a 32 f single wire. In the early part of the study, ~- ~Jpp_erMartpnsltl /t /t .... / L~ Z -~-o%- s°~ '28 weld deposits were stringer beads. Later Boundary~ccordlng / ~uste te I | I I ~ i ~,/ i S in the study, 1-in. (25-mm) oscillation ,/. ' . i _i [ .... !.. / | [ x g" / ~j10% was employed to produce a wider de- '< I I I ~ r ,-~,,~.,,~,,- E I I/" [/" S t __ ~-~ [e : ~ i Bo..,4ry [ I Y-~- Jl ~L_ posit that was more easily chemically an- + alyzed by spectrographic methods. In all g 2o cases, the base metal was ASTM A36 car- J bon steel of approximately 0.15% C, '~ in. (12.7 mm) thick and 3 in. (75 ram) + I ---/, -" ...... 8o~ wide. The weld deposits were about 14 ~ 12 in. (355 mm) long, so that bending in the |1 "~v,,. "T~.I)'>C. / /~" iD.~ I,..r-~I longitudinal direction did not include the ; ! l. I arc start or crater area. Except for intro- w ducing oscillation, the approach is the \ Maitenslte | / I ~/x/ ~1 / I • 4 same as during the first part of the study, ~F ~ - ' I. ; as reported in Ref. 5. Two methods were used to evaluate ! r • i • the presence of martensite in the as- 0 4 8 12 t6 20 24 28 32 36 40 welded condition. The first was a mag- Cr Equiv. = %Cr + %Mo + 1.5(%Si) + 0.5(%Nb) netic measurement of "FN" in the as- deposited condition after lightly grinding Fig. 1 -- Martensite-free 4% Mn compositions on the Schaeffler Diagram. Many 4% Mn com- the weld centerline smooth. "FN" is used positions, indicated by solid circles, are below the 1% Mn martensite-free boundary. in quotation marks here to indicate that, while the instrument is calibrated according to AWS A4.2 for FN measurements, that which is being measured can twice the thickness of the base metal (a metallographic examinations, and none be ferrite and/or martensite, since both test commonly referred to as a "2T" bend are reported herein. microstructures are ferromagnetic. The test). This test requires at least 20% ten- After the "FN" measurement and measured "FN" was compared with the sile elongation in the weld metal to pass bend test, the sample was bent back flat. FN calculated from the WRC-1992 Dia- the test without cracking. A given weld Then the region of the apex of the bend gram, extrapolating the iso-ferrite lines in then either passes the test, or it cracks. was prepared for chemical analysis. the diagram if necessary. Then the pres- Cracking is taken to be evidence of Chips were machined for C, S and N by ence of martensite is indicated by the martensite, which is brittle, in the as- fusion analysis. The remainder of the measured "FN" exceeding the calculated deposited condition. analysis was performed by optical emis- FN by more than 1.0. Conversely, the ab- Metallographic examination had sion spectrophotometry and/or X-ray flu- sence of martensite is indicated by the been used in the first part of this study to orescence, with a limited number of wet measured "FN" being nearly equal to, or verify martensite was indeed present in analyses done also as checks on the less than, the calculated FN. certain samples. Given the excellent cor- spectrographic methods. From the The second method used to evaluate relation of metallographic determina- chemical analysis data, chromium and the presence of martensite was to per- tions with magnetic measurements and nickel equivalents according to both the form a longitudinal face bend test bend test results, it was not considered Schaeffler and the WRC-1992 Diagrams around a mandrel whose radius was necessary to perform more than a few were calculated. These were then plot-

WELDING RESEARCH SUPPLEMENT I 347-s Table 2 -- Experimental Results

Deposits Composition, % Measure WRC Schaeffler Test C Mn P S Si Cr Ni Mo Cu Nb N "FN" FN % Ferrite Weld Number

1761-1 0.107 4.80 0.018 0.013 0.34 9.58 10.25 0.10 0.16 N.D '(al 0.022 0.0 0.0 0.0 1761-2 0.106 4.10 0.017 0.015 0.29 8.93 9.31 0.08 0.15 N.D. 0.021 0.0 0.0 0.0 1761-3 0.117 4.05 0.017 0.014 0.25 6.49 9.14 0.10 0.14 N.D. 0.021 0.0 0.0 0.0 1761-4 0.111 3.85 0,017 0.015 0.27 7.87 8.80 0.08 0.15 N.D. 0.021 0.8 0.0 0.0 1761-5 0.117 4.15 0.017 0.015 0.26 7.78 9.20 0.08 0.14 N.D. 0.020 0.4 0.0 0.0 1761-6 0.115 4.00 0.017 0.015 0.25 7.50 8.35 0.08 0.14 N.D. 0.020 2.7 0.0 0.0 1761-7 0.101 3.99 0.016 0.016 0.38 8.80 8.73 0.12 0.16 N.D. 0.021 0.1 0.0 0.0 1761-8 0.110 4.36 0.015 0,015 0.40 8.86 9.19 0.12 0.15 N.D. 0.020 0.0 0.0 0.0 1761-9 0.112 4.39 0.019 0.018 0.49 8.72 8.83 0.13 0.16 N.D. 0,020 0.0 0.0 0.0 1762-1 0.065 4.85 0.023 0.007 0.48 15.45 4.52 0,13 0.18 N.D. 0.044 25.5 6.2 3.9 0.036 14.7 11.3 7.4 1762-2 0.064 4.85 0.022 0.010 0.46 16.05 4.23 0.13 0.17 N.D. 0.032 8.1 8.9 6.0 1762-3 0.071 4.55 0.020 0.011 0.44 15.45 3.97 0.12 0.16 N.D. 0.031 11.0 9.0 6.1 1762-4 0.073 4.40 0.019 0.014 0.38 15.38 3.79 0.12 0.16 N.D. 0.030 14.4 4.9 2.3 1762-5 0.075 4.15 0.018 0.011 0.33 14.51 3.64 0.10 0.15 N.D. 0.027 11.4 3.6 2.1 1762-6 0.072 4.20 0.017 0.014 0.56 14.16 3.76 0.13 0.17 N.D. 0.025 54.3 0.0 0.0 1762-7 0.079 4.06 0.020 0.015 0.69 12.56 3.51 0.13 0.17 N.D. 0.023 3.1 0.0 0.0 1775-1 0.102 4.25 0.017 0.019 0.47 11,12 5.77 0.14 0.17 N.D. 0.023 36.3 0.0 0.0 1775-2 0.101 3.90 0.017 0.018 0.47 10.86 5.34 0.12 0.17 N.D. 0.024 19.0 0.0 0.0 1775-3 0.098 3.75 0.018 0.014 0.54 11.61 5.67 0.13 0.17 N.D. 0.024 7.4 0.0 0.0 1775-4 0.108 4.22 0.017 0.016 0.50 10.589 5.53 0.13 0.16 N.D. 0,027 0.0 0.0 0.0 1775-5 0,103 4.84 0.019 0.014 0.67 12.98 6.64 0.15 0.18 N.D. 0.024 9.0 0.0 0.0 1775-6 0.105 3.95 0.019 0.016 0.59 10.75 5.40 0.13 0.17 N.D. 0.024 4.2 0.0 0.0 1775-7 0.099 4.07 0.021 0.014 0.61 11.16 5.63 0.13 0.17 N.D. 0.026 0.0 0.0 0.0 1775-8 0.103 4.45 0.025 0.020 0.85 12.18 5.93 0.15 0.17 N.D. 0.010 23.2 0.0 0.0 1776-1 0.080 3.76 0.021 0.014 0.81 4.90 12.57 0.02 0.05 N.D. 0.011 74.1 0.0 0.0 1776-2 0.092 3.30 0.017 0,015 0.61 4.34 10.26 0.01 0.06 N.D. 0.011 0.5 0.0 0.0 1776-3 0.084 3.72 0.020 0.011 0.70 5.08 I3.35 0.01 0.03 N.D. 0.012 57.5 0.0 0.0 1776-4 0.086 3.36 0.034 0.023 0.43 4.22 11.06 0.03 0.09 N.D. 0.013 23.6 0.0 0.0 1776-5 0.082 3.62 0.018 0.023 0.72 5.04 11.77 0.02 0.04 N.D. 0.020 77.2 10.7 11.7 1777-1 0.098 3.55 0.018 0.013 0.83 14.46 1.73 0.02 0.04 N.D. 0.018 79.4 0.3 0.0 1777-2 0.106 3.11 0.019 0.016 0.82 11.88 1.53 0.02 0.06 N.D. 0.020 76.7 5.2 6.7 1777-3 0.107 3.33 0.027 0,016 0.54 13.77 1.73 0.03 0.06 N.D. 0.025 49.5 12.2 13.1 1777-4 0.112 3.56 0.018 0.022 0.78 15.71 2.07 0.03 0.04 N,D. 0.024 52.7 12.5 15.0 1777-5 0.106 3.32 0.019 0.022 0.89 15.54 2.08 0.03 0.05 N.D. 0.026 44.8 6.6 8.2 1777-6 0.123 4.04 0.020 0.020 0.91 14.99 2.15 0.02 0.05 N.D. 0.019 75.3 0.0 0.0 1786-I 0.125 4.15 0.015 0.011 0.76 10.89 2.26 0.02 0.04 N.D. 0.016 80.6 0.0 0.0 1786-2 0.144 3.94 0.018 0.016 0.69 8.77 1.60 0.02 0.06 N.D. 0.019 76.2 0.0 0.0 1786-3 0.125 3.86 0.017 0.010 0.79 9.76 1.78 0.02 0.05 N.D. 0.012 2.5 0.0 0.0 1787-I 0.089 4.24 0.012 0,017 0.61 5.27 13.33 0.02 0.04 N.D. 0.011 74.2 0.0 0.0 1 787-2 0.113 3.15 0.0014 0.019 0.48 3.40 8.98 0.01 0.05 N.D. 1787-3 0,106 3.41 0.015 0.017 0.57 3.86 10.11 0.01 0.05 N.D. 0.011 77.8 0.0 0.0 1787-4 0.099 3.42 0.014 0.018 0.57 3.96 11.06 0.02 0.05 N.D. 0.011 56.2 0.0 0.0 1791-1 0.082 4.00 0,012 0.014 0.58 4.54 13.48 0.01 0.03 N.D. 0.015 26.1 0.0 0.0 1791-126 0.073 5.40 0.014 0.009 0.73 5.61 17.62 0.01 0.03 N.D. 0.012 0.0 0.0 0.0 1791-128 0.074 4.88 0.015 0.011 0.80 5.18 16.40 0.01 0.03 N.D. 0.012 0.0 0.0 0.0 1791-2 0.101 3.19 0.011 0.017 0.35 2.97 9.60 0.01 0.07 N.D. 0.014 84.0 0.0 0.0 1791-3 0.085 4.58 0.013 0.012 0.63 5.01 15.62 0.01 0.03 N.D. 0.016 0.0 0.0 0.0 1791-4 0.079 4.30 0.013 0.011 0.60 4.60 14.91 0.01 0.03 N.D. 0.015 0.0 0.0 0.0 1792-1 0.115 3.36 0.012 0.011 0.65 15.98 1.57 0.01 0.04 N.D. 0.019 68.9 17.3 16.6 1792-2 0,121 2.79 0,014 0.016 0.41 11.51 1.23 0.01 0.04 N.D. 0.018 81.2 0.0 0.0 0.022 67.9 76.4 33.3 1792-3 0.111 3.99 0.011 0.010 0.67 19.15 2.08 0.01 0.03 N.D. 0.022 66.8 >100 44.9 1792-4 0.I 09 4.49 0.012 0.011 0.70 20.30 1.94 0.01 0.03 N.D. 0.025 78.7 >100 48.1 1792-5 0.102 4.28 0.012 0.012 0.68 20.26 2.01 0.01 0.03 N.D. 0.018 0.0 0.0 0.0 1793-1 0.112 11.66 0,012 0.010 0.80 4.95 6.61 0.02 0.03 N.D. 0.012 17.2 0.0 0.0 1793-2 0.110 9.22 0.010 0.014 0.42 3.51 4.76 0.01 0.05 N.D. 1793-3 0.101 11.33 0.011 0.010 0.71 4.75 6.35 0.01 0.04 N.D. 0.021 0.0 0.0 0.0 1793-4 0.109 9.31 0.011 0.013 0.54 3.70 4.97 0.01 0.04 N.D. 0.010 11.6 0.0 0.0 0,012 4.0 0.0 0.0 1793-5 0,110 9.49 0.011 0.014 0.47 3.63 5.14 0.01 0.05 N.D. 0.012 0.1 0.0 0.0 1793-6 0.103 10.47 0.015 0.010 0.71 4.23 5.68 0.01 0.07 N.D. 1793-7 0.103 9.78 0.018 0.011 0.76 3.81 5.14 0.01 0.08 N.D. 0.012 4.3 0.0 0.0 1794-1 0.102 11.72 0.015 0.008 0.97 11.25 2.73 0.01 0.05 N.D. 0.025 4.1 0.0 0.0 1794-2 0.099 11.68 0.018 0.008 0.99 10.50 2.70 0,01 0.06 N.D. 0.021 + 5.7 0.0 0.0 1794-3 0.108 9.21 0.013 0.011 0.77 8.91 2.06 0.01 0.08 N.D. 0.017 12.6 0.0 0.0 1794-4 0.105 8.60 0.019 0.012 0.81 7.47 1.90 0.01 0.08 N.D. 0.016 25.9 0.0 0.0 1794-5 0.111 9.81 0.015 0.013 0.66 8.34 2.15 0.01 0.09 N.D. 0.017 21.6 0,0 0.0 1795-1 0.108 11.04 0,012 0.009 0.80 9.91 3.06 0.01 0.04 0.00 0.020 0.8 0.0 0.0 1795-1R 0.104 11.25 0.013 0.009 0.79 10.77 3.36 0.01 0.03 0.00 0.020 0.7 0.0 0.0 1795-2 0.109 10.36 0.013 0.010 0.63 9.27 2.94 0.01 0.04 0.00 0.018 4.5 0.0 0.0 1795-3 0.111 9.90 0.013 0.016 0.60 8.88 2.77 0.01 0.04 0.00 0.016 9.3 0.0 0.0 1795-4 0.115 9.92 0.013 0.013 0.55 8.58 2.69 0.01 0.04 0.00 0.016 10.2 0.0 0.0 1795-5 0.116 9.38 0.012 0.015 0.49 8.09 2.48 0.01 0.04 0.00 0.015 14.0 0.0 0.0

(a) N.D. = Not Determined. (b) Some bending before crack.

348-s I DECEMBER 2000 Table 2 -- Continued

WRC- 1992 Schaeffler Bend Measured Creq Nieq Crc~I Ni~ Wire Travel Volts Amps Electrical Welding "FN" after Feed, Speed, DCEP Extension Technique bend in./min in.lmin in. ok 2.5 9.68 14.48 10.19 15.86 2OO 20 34 N.D. stringer ok 21.1 9.01 13.48 9.45 14.54 24O 24 34 N.D. stringer ok 21.0 8.59 13.69 8.97 14.68 280 28 34 IN.D. stringer ok 32.8 7.95 13.14 8.36 14.06 28O 28 38 N.D. stringer ok 35.9 7.86 13.73 8.25 14.79 3OO 28 40 N.D. stringer crack 44.9 7.58 12.81 7.96 13.80 320 30 40 N.D. stringer ok 26.8 8.92 12.73 9.49 13.76 24O 8 30 N.D. oscillation ok 25.7 8.97 13.48 9.58 14.67 28O 9 30 49O oscillation ok 22.8 8.85 13.19 9.58 14.39 32O 10 30 515 oscillation ok 33.2 15.58 7.72 16.30 8.90 9O 12 34 N.D. stringer ok 42.6 16.18 7.23 16.87 8.58 120 15 34 N.D. stringer ok 63.8 15.57 7.14 16.23 8.38 150 18 34 N.D. stringer ok 63.2 15.48 7.01 16.05 8.18 180 21 34 N.D. stringer c~ck 80.0 14.61 6.90 15.11 7.97 210 24 34 N.D. stringer crack 82.2 14.29 6.86 15.12 8.02 180 6 30 370 oscillation crack 82.7 12.69 6.81 13.73 7.91 220 7 30 415 oscillation c~ck (b) 46.0 11.26 9.84 11.96 10.96 240 8 30 N.D. oscillation crack 76.7 10.98 9.38 11.69 10.32 280 9 30 N.D. oscillation c~ck Ib) 83.0 11.74 9.62 12.54 10.49 200 8 30 N.D. oscillation crack 70.3 11.02 9.83 11.77 10.88 180 7 30 375 oscillation ok 16.3 13.13 10.82 14.13 12.15 160 6 30 355 oscillation crack (b~ 53.7 10.87 9.60 11.75 10.52 170 6.5 30 360 oscillation crack {b~ 54.6 11.28 9.62 12.19 10.64 165 6 30 345 oscillation ok 33.4 12.33 10.10 13.60 11.25 160 5 30 350 oscillation crack {b~ 64.8 4.92 15.58 6.14 16.85 150 4 30 360 oscillation crack 82.5 4.35 13.71 5.27 14.77 200 6.5 30 415 oscillation ok 34.3 5.10 16.51 6.15 17.72 120 4 30 310 oscillation crack Ibl 81.7 4.25 14.33 4.90 15.32 130 5 30 340 oscillation crack (b) 43.8 5.06 14.91 6.15 16.04 130 4 30 340 oscillation crack 84.2 14.48 5.57 15.73 6.45 150 4 30 360 oscillation crack 81.0 11.90 5.61 13.13 6.27 200 6.5 30 410 oscillation crack 80.5 13.80 5.89 14.61 6.60 120 4 30 300 oscillation crack 72.0 15.73 6.50 16.90 7.21 100 4 30 340 oscillation crack 69.4 15.57 6.28 16.90 6.91 80 4 3O 22O oscillation crack 72.1 15.02 6.99 16.38 7.86 120 4 30 280 oscillation crack 77.0 10.91 7.02 12.05 8.08 100 4 30 270 oscillation crack 81.2 8.79 6.97 9.83 7.89 200 8 3O 34O oscillation crack 80.8 9.78 6.54 10.96 7.46 80 4 30 175 17., oscillation ok 26.9 5.29 16.69 6.21 18.12 100 4 30 270 1 oscillation crack 84.2 3.41 13.17 4.13 13.95 200 8 30 435 1 oscillation crack 86.8 3.88 14.05 4.73 14.99 150 6 30 375 1 oscillation c~ck 77.6 3.98 14.76 4.84 15.74 125 5 30 345 1 oscillation c~ck (b~ 65.9 4.55 16.66 5.43 17.94 100 4 30 295 1 oscillation ok 0.0 5.62 20.43 6.71 22.51 100 4 26 N.D. 1 oscillation ok 0.4 5.19 19.24 6.38 21.06 100 4 28 265 1 oscillation c~ck 86.1 2.98 13.44 3.50 14.23 200 8 30 465 1 oscillation ok 0.3 5.02 18.92 5.97 20.46 100 4 30 250 1~ oscillation ok 11.5 4.61 17.99 5.50 19.43 100 4 30 265 1~ oscillation c~ck 76.9 15.99 5.98 16.96 6.70 100 4 3O 285 I oscillation crack 81.7 11.52 5.83 12.13 6.25 200 8 30 445 1 oscillation crack ~N 69.7 19.17 6.41 20.16 7.40 100 3O 240 17-, oscillation crack d~l 66.6 20.30 6.20 21.35 7.45 100 30 210 2 oscillation crack ~b~ 77.6 20.27 6.09 21.29 7.21 100 30 245 1¼ oscillation ok 11.1 4.97 10.90 6.17 15.80 100 30 265 oscillation crack (h) 65.8 3.52 8.86 4.15 12.67 200 30 425 oscillation ok 12.8 4.76 10.31 5.82 15.05 125 30 315 oscillation crack Ibl 55.2 3.71 9.00 4.52 12.90 150 30 365 oscillation crack Ib) 56.7 3.64 9.24 4.35 13.18 175 30 390 oscillation ok 31.5 4.24 9.55 5.30 14.01 150 28 355 oscillation crack ~h~ 50.2 3.82 9.00 4.95 13.12 175 28 390 oscillation c~ck ~b) 34.5 11.26 6.82 12.72 11.65 100 28 265 oscillation c~ck Ib; 50.2 10.51 6.60 12.00 11.51 125 28 315 oscillation crack 50.9 8.91 6.20 10.07 9.90 150 28 330 oscillation crack 45.4 7.47 5.91 8.69 9.35 175 28 360 oscillation crack 61.7 8.35 6.39 9.34 10.38 200 28 395 oscillation ok 30.0 9.92 7.25 11.13 11.82 100 28 295 oscillation ok 23.6 10.78 7.41 11.98 12.10 100 28 295 oscillation crack Ibl 38.6 9.28 7.12 10.22 11.39 125 28 345 oscillation ok 50.9 8.89 6.98 9.78 11.05 150 28 370 oscillation c~ck ~b) 53.6 8.59 7.05 9.41 11.10 175 28 400 oscillation crack Ib) 64.4 8.10 6.85 8.83 10.65 200 28 445 oscillation

WELDING RESEARCH SUPPLEMENT I 349-s bending, which indicates considerable transformation of austenite to martensite 18 during bending, which is to be expected. It is the presence or absence of marten- 16 site before bending that is of interest. 14 More than 50 compositions were examined at the nominal level of 4% Mn, and 12 18 were examined at the nominal level of 10% Mn. 10 Mn Compositions 8 4%

6 Figure 1 plots the magnetically determined martensite-free 4% Mn compositions, from Table 2, on the Schaeffler Di- agram. No lower left boundary for martensite-free compositions is offered for 4% Mn compositions because it is not 0 2 . 4 6 8 10 12 14 16 18 20 22 24 26 28 30 the intent to propose a correction to the Schaeffler Diagram. Despite the fact the CrEquiv. = %Cr + %Mo + 0.7(%Nb) Schaeffler Diagram includes manganese in the nickel equivalent, it can be qualitatively seen that, for 4% Mn, the mag- Fig. 2 -- Martensite-free 4% Mn compositions on the WRC-1992 Diagram. Many 4 % Mn com- netically determined limit of martensite- positions, indicated by solid circles, are below and left of the 1% Mn martensite-free boundary. free compositions has shifted leftward A 4% Mn martensite-free boundary, based on magnetic measurements, is indicated. and somewhat counterclockwise relative to the 1% Mn boundary observed in Part 1 of this study. Figure 2 plots the same composition data on the WRC-1992 Diagram. A I i I I : / boundary line for 4% Mn compositions --I .4/- is indicated in this figure. Without man- A..,e.,,. 'Z ' I--'.X, i." ganese in the nickel equivalent, the leftward and counterclockwise shift of the

• " " " magnetically determined martensite boundary from 1 to 4% Mn is more pro- nounced in this diagram than in the Schaeffler Diagram. Figure 3 plots the bend test results on the Schaeffler Diagram. As was noted in ~ 12 !_ .a: , ~~ [~L ! "~ the first part of this study where 1% Mn compositions were considered, there is a 8 lO% transition region of mixed pass-fail results. Above and to the right of this mixed zone, all compositions, except three very high in ferrite, pass the 2T bend test. The 0 failure of the high ferrite compositions to 4O pass the bend test can be attributed to excessive ferrite, not to martensite. In a Sl + ( study of duplex ferritic-austenitic stainless steel weld metals, it was found (Ref. Fig. 3 -- Bend~break results at 4% Mn on the 5chaeffler Diagram. Compositions that passed the 8) that ferrite above 60 FN resulted in re- 2T bend test are shown as solid circles. Compositions that cracked during bending are shown as duced ductility in the weld metal, so this open squares. is not unexpected. Below and to the left of this mixed bend test zone, all compositions fail the 2T bend test. Again, the ted on the diagrams in two ways. First, Experimental Results magnetically determined martensite only compositions whose measured boundary lies within the zone of mixed "FN" was less than the calculated FN Table 2 lists all the experimental weld bend test results. plus 1 were plotted on each diagram to compositions in this phase of the study, Figure 4 plots these same bend test re- find the lower left boundary of such along with the welding conditions em- sults on the WRC-1992 Diagram. Com- compositions. Then, all the results were ployed in making each weld, calculated positions in the upper right portion of the plotted on each diagram, with a different nickel and chromium equivalents, 2T diagram all bent, except for the three symbol for those that passed the bend longitudinal face bend test results, and high ferrite compositions, as noted test than for those that cracked, in order measured "FN" before and after bending. above. These three compositions are cal- to find a boundary dividing the two types In many cases, the measured "FN" after culated, by extrapolating the iso-ferrite of bend test behavior. bending is much higher than before lines of the WRC-1992 Diagram, to have

350-s J DECEMBER 2000 more than 75 FN each. Compositions in the lower left portion of the diagram all broke. And there is a transition zone, in- 18 dicated by a pair of heavy parallel lines, 16 of mixed behavior in bending. The magnetically determined martensite bound- 14 ary is within this transition zone. This zone of mixed bending behavior is 12 shifted leftward and rotated counter- 10 clockwise from the similar zone for 1% Mn compositions, as determined in the 8 first part of this study. 6 10% Mn Compositions 4

Figure 5 plots the magnetically deter- 2 mined martensite-free compositions of nominally 10% Mn on the Schaeffler Di- 0 agram. Further leftward shift of marten- 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 site-free compositions can be seen as Cr Equiv. = %Cr + %Mo + 0.7(%Nb) compared to 4% and 1% Mn compositions. In particular, a composition can be seen that is entirely martensite-free but Fig. 4 -- Bend~break results at4% Mn on the WRC-1992 Diagram. Compositions that passed the lies within the region of the Schaeffler Di- 2 T bend test are shown as solid circles. Compositions that cracked during bending are shown as agram predicted to be completely open squares. Between the two parallel heavy lines, some compositions bent and some cracked. martensite. Clearly, the Schaeffler Dia- Above and to the right of these two lines, all compositions bent, except for a few very high fer- gram is inadequate for predicting rite compositions. Below and to the left of these two lines, all compositions cracked in bending. martensite in these high manganese compositions. Figure 6 plots the magnetically determined martensite-free 10% Mn compositions on the WRC-1992 Diagram, with 32 ,LI ' I a lower-left boundary for such composi- ~" 28 [: Uooe~I Marl : msit [ ~ °°1° _S°/, tions. It should be noted there are not a I • poundary, ~cor ling uste ,ire /" / I / 7~' lot of compositions available to act as a - i u ~. m~, ,~ basis for this boundary, so there must be \, ,/! I considerable uncertainty attached to it. + Ised )n F! k/I.,4" I i/ However, leftward shift and counter- =m,,,,,,,,,~. I ~./I 12o~ -- clockwise rotation of the boundary compared to that for the 4% and 1% Mn compositions is evident. Figure 7 plots the 2T bend test data at 10% Mn on the Schaeffler Diagram. As ,, 12 L I - . -d in the case of the 4% Mn results, there is •g 8 Y<::'v .-'../1" I I ..lOO~" no attempt to draw boundaries for compositions that all bend, or all break, be- UJ M.... te ,1~ + / ~ ~ ~ cause there is no intention to propose a ~4:\1 1 [ , ,.. correction to the Schaeffler Diagram. It o ! : 2"i I .. IT i i : 1 can be noted there are two compositions in the zone predicted by the diagram to 0 4 8 12 16 20 24 28 32 36 40 consist of 100% martensite that passed Cr Equiv. = %Cr + %Mo + 1.5(%Si) + 0.5(%Nb) the bend test. Figure 8 plots the 2T bend test data at Fig. 5 -- Martensite-free 10% Mn compositions on the 5chaeffler Diagram. Note one of these 10% Mn on the WRC-1992 Diagram. compositions is within the area considered to be 100% martensite according to the diagram, but Once again, there is a transition zone, it is martensite-free. indicated by heavy parallel lines, of mixed bend test behavior, and the magnetically determined martensite-free Discussion of Results filler metal. And the 10% Mn level might boundary lies within this zone of mixed be encountered when using stainless bend test behavior. Compositions above Three levels of manganese have been steel filler metals high in manganese (the and to the right of this transition zone all considered in stainless steel weld de- AWS 200 series filler metals). In all three bend. Compositions below and to the posits. The 1% Mn level, from the previ- cases, the Schaeffler Diagram has been left of this transition zone all break dur- ous part of this study, is normal for most shown to predict martensite in composi- ing the bend test. A further leftward shift common austenitic stainless steel weld tions that were magnetically determined and counterclockwise rotation of the claddings. The 4% Mn level, considered to be martensite-free, and which pass the transition zone, as compared to that for herein, might be encountered when pro- 2T bend test. The disagreement between 4% Mn, is evident. ducing buffer layers using 18 8 Mn or 307 the Schaeffler predictions and the exper-

WELDING RESEARCH SUPPLEMENT I 351-s determined martensite-free boundary and the lines bounding the extremes of the 18 transition zone between bend and break 16 behavior in the 2T bend test. The three shaded boundary zones, 14 corresponding to three manganese levels, are each drawn with parallel sides as 12 a practical matter. If the sides were not parallel, the edges would cross at some 10 point, which is absurd from a realistic point of view. The uncertainty associated with the width of each shaded zone is considered to be due mainly to uncertainty in chemical analysis. If a single sample of weld metal is analyzed repeat- edly, on successive days, the results reported from one day to the next for each element will vary. Then the calculated i0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 chromium equivalent and nickel equiva- Cr Equiv. = %Cr + %Mo + 0.7(%Nb) lent will vary as well. So one cannot say with certainty what the exact chromium equivalent and nickel equivalent are for a given weld sample. This uncertainty is Fig. 6 -- Martensite-free 10% Mn compositions on the WRC- 1992 Diagram. Many 10% Mn com- reflected in the width of the shaded positions, indicated by solid circles, are below and left of the 4% Mn boundary obtained by mag- boundary zone. In the case of the 10% netic measurements. A 10% Mn martensite-free boundary is indicated. manganese compositions, there are fewer data points, so the uncertainty (shaded boundary width) is indicated to be greater than that for the other two 32 I " manganese levels. Mart tniItl 0% 5% The strength of manganese relative to 28 PounPe~i:~Zccol~llnglaLllltellltll J• ~/~ !7 f that of nickel, with respect to stabilizing austenite against transformation to martensite, can be estimated from the + ~4 /B;lled')nF~ /./i/ I/ vertical displacement of the martensite ~ / @11%'1n /" / i I'~ ' " boundary obtained by increasing the Mn content from 1 to 4%. It can be seen from Fig. 9 that this vertical displacement due to the additional 3% Mn amounts to about 4 nickel equivalent near the right end of the 4% Mn martensite boundary (i.e., at a chromium equivalent of 16). This would mean a coefficient for man- i"' ..,,,,,.t.o!\ I/I l+ / / I ganese in the nickel equivalent of about 1.3 (4 nickel equivalent divided by 3% Mn) at 16% Cr. Near the left end of the 4 8 12 16 20 24 28 32 36 40 1% Mn martensite boundary (i.e., at a Cr Equiv. = %Cr + %Mo + 1.S(%SI) + 0.ti(%Nb) chromium equivalent of 10), the vertical displacement due to the additional 3% Mn amounts to about 5 nickel equiva- Fig. 7-- Bend~break results at 10% Mn on the 5chaeffler Diagram. Compositions that passed the lent. This would mean a coefficient for 2T bend test are shown as solid circles. Compositions that cracked are shown as open squares. manganese in the nickel equivalent of about 1.7 (5 nickel equivalent divided by 3% Mn) at 10% Cr. So manganese is more powerful than nickel in stabilizing imental results becomes greater at higher temperatures, and half as powerful as Ni austenite with respect to transformation manganese levels. in stabilizing austenite relative to marten- to martensite, not half as powerful as pro- There is no reason to expect that man- site formation at low temperatures. The posed by the Schaeffler Diagram, and the ganese should have exactly the same ef- WRC-1992 Diagram does not include power of manganese increases with defect (weighting factor relative to nickel) on manganese in the Nickel Equivalent at all, creasing chromium content. martensite formation at low temperatures which means that manganese has no ef- The observed leftward shifting and as it has on ferrite formation at high tem- fect on ferrite formation at high tempera- counterclockwise rotation of the marten- peratures. The Schaeffler Diagram, with a tures. So the way is clear to provide dif- site boundary as the manganese content coefficient of 0.5 for Mn in the Nickel ferent martensite boundaries for different increases is not really surprising. Self, et Equivalent, proposes that Mn is both half manganese levels. These are shown in al. (Ref. 7), predicted this shifting and ro- as powerful as Ni in stabilizing austenite Fig. 9 as shaded zones. Each shaded tation graphically, based upon the equa- with respect to ferrite formation at high boundary zone includes the magnetically tions of Andrews (Ref. 9). Self, et al., pro-

352-s I DECEMBER 2000 pose a coefficient for manganese in the

Nickel Equivalent with respect to austen- 32 I ite transformation to martensite that increases with decreasing chromium con- ~28 ,nsltq 0%_ 5%-- tent, as given in Equation 1 below. 24 ~ ~ ~ ling~s!el ,,te

Coefficient for Mn = 1/(0.083x%Cr + 0.5) (1) + "~ [//B' sed ' ,n FN[ /

/ The prediction of Self, et al. Ref. 7), gl.+ -- - / /~%" can be tested against the observed shift in J/.J f the martensite boundary. At 16% Cr, _, £ / / Equation 1 proposes the coefficient for Mn to be 0.547, vs. the observed value of 1.3. And at 10% Cr, Equation 1 proposes I"~/... i 100% i the coefficient to be 0.752, vs. the observed value of 1.7. There appears, therefore, to be qualitative agreement be- i Fer tte tween the predictions of Self, et al., in that the coefficient for manganese in- 0 12 16 20 24 28 32 36 40 creases with decreasing chromium con- Cr Equiv. = %Cr + %Mo + 1.5(%Si) + 0.5(%Nb) tent. However, there is not quantitative agreement -- the observed coefficients are about 2.3 times as large as predicted Fig. 8 -- Bend~break results at 10% Mn on the WRC-1992 Diagram. Compositions that passed by Self, et al. (Ref. 7). the 2T bend test are shown as solid circles. Compositions that cracked during bending are shown In a later review of microstructure pre- as open squares. Between the two parallel heavy lines, some compositions bent and some diction in austenitic stainless steel weld cracked. Above and to the right of the heavy lines, all compositions bent. Below and to the left metal, Olson (Ref. 10) reproduces a of the heavy lines, all compositions cracked in bending. martensite-start temperature relationship from Self, et al. (Ref. 11), that indicates manganese to be 1.7 times as powerful as nickel in stabilizing austenite, which is 18 much more consistent with the 1.3 to 1.7 factor observed herein. 16 It must be recognized there is a degree 14 of uncertainty in the exact location of the martensite boundary at any manganese 12 level. At all three manganese levels examined, this degree of uncertainty is in- 10 dicated by presenting the martensite boundary as a shaded zone. This shaded 8 boundary zone is on the order of 1.5 6 chromium equivalent, or 1.5 nickel equivalent, wide (more in the case of the 4 10% Mn level). Above and to the right of each martensite boundary zone, all com- 2 positions at the given manganese level 0 are martensite-free in the as-welded con- 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 dition, and these compositions pass a 2T bend test unless they contain excessive Cr Equiv. = %Cr + %Mo + 0.7(%Nb) ferrite. Below and to the left of each martensite boundary zone, all compositions at the given manganese level con- Fig. 9 -- The WRC-1992 Diagram, with martensite boundaries for I, 4 and 10% Mn. The bound- tain martensite in the as-deposited con- aries are shown as shaded bands to indicate a degree of uncertainty in their positions. Each bound- dition and fail a 2T bend test. Within the ary includes the extreme of martensite-free compositions as determined by magnetic measure- shaded martensite boundary zone, the ments, and the limits of mixed bend~break behavior in the 2T bend test. behavior is unpredictable.

Conclusions test. With the modified WRC-1992 Dia- fects of carbon, nitrogen and molybde- gram, the graphical methods used for num on the position of the martensite An experimentally determined modi- predicting ferrite in cladding or dissimi- boundary in the WRC-1992 Diagram. fication of the WRC-1992 Diagram has lar metal joining (Ref. 3) can now be ap- been developed, as shown in Fig. 9. This plied also to predicting martensite. Acknowledgments now provides the possibility to predict whether or not stainless steel clad layers, Future Work The author is grateful to The Lincoln over nonalloy or low-alloy steels, will be Electric Co. for the opportunity to pursue free of martensite and will pass a 2T bend Part 3 of this study will examine the ef- this interest and for the laboratory sup-

WELDING RESEARCH SUPPLEMENT I 353-s port necessary. Bill Spang was especially NB-2433.1-1. The American Society of Me- 10. Olson, D. L. 1985. Prediction of helpful in preparing the test welds and chanical Engineers, N.Y. austenitic weld metal microstructure and extracting test pieces. 5. Kotecki, D. J. 1999. A martensite bound- properties. Welding Journal 64(10): 281 -s to ary on the WRC-1992 Diagram. Welding Jour- 295-s. References nal 78(5): 180-s to 192-s. 11. Self, J. A., Olson, D. L., and Edwards, 6. Szumachowski, E. R., and Kotecki, D. J. G. R. July 1984. The stability of austenitic weld 1. Schaeffler, A. L. 1949. Constitution dia- 1984. Effect of manganese on stainless steel metal. Proc. oflMCC, Kiev, Ukraine. gram for stainless steel weld metal. Metal weld metal ferrite. Welding Journal Progress 56(11): 680 to 680B. 63(5):156-s to 161-s. 2. DeLong, W. T. 1974. Ferrite in austenitic 7. Self, J. A., Matlock, D. K., and Olson, stainless steel weld metal. Welding Journal D. L. 1984. An evaluation of austenitic Fe- 53(7): 273-s to 286-s. Mn-Ni weld metal for dissimilar metal weld- 3. Kotecki, D. J., and Siewert, T. A. 1992. ing. Welding Journal 63(9): 282-s to 288-s. WRC-1992 constitution diagram for stainless 8. Kotecki, D. J. 1986. Ferrite control in du- steel weld metals: a modification of the WRC- plex stainless steel weld metal. Welding Jour- 1988 diagram. Welding Journal 71 (5): 171 -s to nal 65(10): 273-s to 278-s. 178-s. 9. Andrews, K. 1965. Empirical formulae 4. ASME Boiler and Pressure VesselCode, for the calculation of some transformation 1995 Edition, Section II1, Division I, Figure temperatures. Jl51203:721 to 727.

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~¢A_~ I I~I:CI:MRI:R ")1"1(10 The Stress-Relief Cracking Susceptibility of a New Ferritic Steel Part 1: Single-Pass Heat- Affected Zone Simulations

The effects of energy input and postweld heat treatment temperature on the stress- relief cracking susceptibility of a new ferritic steel were investigated and compared to conventional 2.25Cr- 1Mo steel

BY J. G. NAWROCKI, J. N. DUPONT, C. V. ROBINO AND A. R. MARDER

ABSTRACT. The stress-relief cracking ductility and some microductility when fect on the ductility of HCM2S. The hard- (SRC) susceptibility of single-pass welds tested at 325 MPa. The ductility de- ness of the CGHAZ for 2.25Cr-1Mo steel in a new ferritic steel, HCM2S, has been creased significantly when tested at 270 decreased significantly after PWHT, but it evaluated and compared to 2.25Cr-1Mo MPa, but it was still higher than that of remained constant for HCM2S. The dif- steel using Gleeble thermal simulation HCM2S at each test condition. The stress- ferences in stress-relief cracking response techniques. HCM2S was found to be relief cracking susceptibility was based are discussed in terms of the differences more susceptible to stress-relief cracking on the ductility and resultant microstruc- in composition and expected carbide than 2.25Cr-1Mo steel. Simulated tures. Using these criteria, HCM2S is precipitation sequence for each alloy coarse-grained heat-affected zones considered "extremely" to "highly sus- during PWHT. (CGHAZ) were produced that corre- ceptible" to stress-relief cracking at each spond to the thermal cycles expected energy input and postweld heat treat- Introduction when depositing single-pass welds using ment, whereas 2.25Cr-lMo steel would a range of energy inputs and tested at var- only be considered "slightly susceptible" 2.25Cr-1Mo steel is commonly used ious simulated postweld heat treatment tested at 325 MPa. The 2.25Cr-1Mo steel for high-temperature applications in (PWHT) temperatures. Both alloys were samples tested at 270 MPa are consid- steam generators and pressure vessels for tested at a stress of 325 MPa. The 2.25Cr- ered "slightly" to "highly susceptible" to chemical and fossil power plants. Many 1Mo steel was also tested at 270 MPa to stress-relief cracking at each PWHT tem- components in these power plants oper- normalize for the difference in yield perature. The time to failure decreased ate at temperatures of approximately strength between the two materials. Light with increasing PWHT temperature for 300-600°C. New components fabri- optical and scanning electron mi- each material. There was no significant cated from 2.25Cr-1Mo steel may require croscopy were used to characterize the difference in the times to failure between welding at both the fabrication and in- simulated CGHAZ microstructures. The the two materials. Varying energy input stallation stages, and in-service material simulated as-welded CGHAZ of each and stress had no effect on the time to may be welded during repairs. In such alloy consisted of lath martensite or bai- failure. The ductility, as measured by re- applications, preheat and/or postweld nite and had approximately equal prior duction in area, increased with increas- heat treatment (PWHT) are often re- austenite grain sizes. The as-welded ing PWHT temperature for 2.25Cr-1Mo quired to improve heat-affected zone hardness of the simulated 2.25Cr-1Mo steel tested at both initial stress levels. (HAZ) mechanical properties and reduce steel CGHAZ was significantly higher However, PWHT temperature had no ef- susceptibility to hydrogen cracking. than that of the HCM2S alloy. Over the These preheat and PWHT steps represent range studied, energy input had little ef- a significant fraction of the overall fabri- fect on the as-welded microstructure or cation/repair costs. hardness of either alloy. The energy input Recently, a new ferritic steel, denoted also had no effect on the stress-relief KEY WORDS as HCM2S, was developed. HCM2S has cracking susceptibility of either material. been reported to exhibit improved me- Both alloys failed intergranularly along Stress-Relief Cracking chanical properties and resistance to hy- prior austenite grain boundaries under all Ferritic Steel drogen cold cracking compared to contest conditions. The 2.25Cr-1Mo steel Coarse-Grained HAZ ventional 2.25Cr-1Mo steel (Refs. 1-3). samples experienced significant macro- Alloy HCM2S Table 1 compares the allowable compo- Thermal Cycles sition ranges of both 2.25Cr-1Mo and the J. G. NAWROCKI, J. N. DUPONT and A. R. Postweld Heat Treat HCM2S alloy (Refs. 1, 4). The lowered MARDER are with the Department of Materi- Chrome-Moly carbon content improves weldability by als Science and Engineering, Lehigh Univer- Power Plant reducing hardenability and the as- sity, Bethlehem, Pa. C V. ROBINO is with Ma- welded hardness of the HAZ. Although terials Joining Dept., Sandia National the carbon content of HCM2S and Laboratories, Albuquerque, N. Mex.

WELDING RESEARCH SUPPLEMENT I 355-s Table I -- Allowable Composition Range of ..... Stress Profile ~ Temperature Profile 1400 , , , , , , , 400 HCM2S and 2.25Cr-1Mo Steel (wt-%) Peak Temp.131~C 350 1200 ...... Element HCM2S 2.25Cr-1Mo ,,' 300 (Ref. 1) (Ref. 5)

• " PWh'[T Sinnlhltion 250 = 800 C 0.04-0.10 <0.15 •" + 200 ~ Cr 1.90-2.602.00-2.50 600 g~ Mo <0.30 0.90-1.10 ." / W 1.45-1.75 -- 400 [.. ~ Simulation 100 V 0.20-0.30 -- 200 ,m Onsetof Stress ~ / 50 Nb 0.02-0.08 -- ,'A~' AppUeation ~/ B ~O.OO6 -- m~ l l I I ~I I I I 0 AI <0.03 -- 50 100 150 200 250 300 350 400 Si ~0.50 0.20-0.50 Time (seconds) Mn 0.30-0.600.30-0.60 P nO.030 <0.035 S ~0.010 ~0.035 Fig. 1 -- Schematic illustration of a stress-relief cracking test cycle.

1Mo steel (Refs. 1-3, 5). In addition, the alloy carbides (e.g. VC, NbC) preferen- ~, L7 / • maximum allowable C content is 0.1 and tially precipitate at dislocations in the 0.15 wt-% for HCM2S and 2.25Cr-1Mo prior austenite grain interiors, thereby steel, respectively. The creep rupture causing considerable strengthening. strength is improved by the substitution These carbides retard dislocation move- of Mo with W that acts as a solid-solution ment and do not allow residual stresses strengthening element. Vanadium and to relax through plastic deformation of niobium are added to improve creep the grains. The microstructure may also strength by way of carbide precipitation contain precipitate-free denuded zones strengthening. Boron is also added to im- adjacent to prior austenite grain bound- prove creep strength. It has recently been aries. These denuded zones may be due suggested that the improved weldability to grain boundary carbides that have de- from these composition modifications pleted the adjacent matrix of carbon and may permit elimination of costly preheat alloying elements (Refs. 11, 12)or the and/or PWHT requirements. Although formation of a second phase during cool- HCM2S has been shown to exhibit ex- ing after welding (Ref. 13). Along with cellent mechanical properties and resis- this, classical temper embrittlement can : =-~ T'¢ tance to hydrogen cracking, the stress- occur, which is the segregation of tramp relief cracking susceptibility had yetto be elements to prior austenite grain bound- investigated. aries during cooling or elevated temper- Many low-alloy, creep-resistant steels ature exposure. These segregants lower such as 2.25Cr-1Mo steel are known to the cohesive strength of the boundaries be susceptible to stress-relief cracking and, together with the presence of a de- (Ref. 6). Stress-relief cracking is defined nuded zone, can lead to brittle intergran- as intergranular cracking in the heat- ular failure. affected zone or weld metal that occurs Previous work has been conducted to during exposure of welded assemblies to understand the stress-relief cracki ng sus- postweld heat treatments or high-tem- ceptibility of 2.25Cr-1Mo steel. How- perature service (Ref. 7). Stress-relief ever, the stress-relief cracking response cracking occurs primarily in the CGHAZ of this HCM2S alloy is currently un- of a weldment. The general mechanism known. Therefore, the objective of this of stress-relief cracking is well docu- work is to evaluate the stress-relief crack- mented in the literature and has been ex- ing susceptibility of HCM2S relative to plained for low-alloy steels (Refs. 6-10). 2.25Cr-1Mo steel expected in single During typical fusion welding processes, pass welds deposited with a range of the unmelted base material surrounding heat inputs and several PWHT tempera- the weld pool is heated to a temperature tures. The results may be useful for determining the conditions under which Fig. 2 -- Representative coarse-grained heat- very high in the austenite phase field. During this time, pre-existing carbides ei- HCM2S may be used in the pressure ves- affected zone microstructure in the as- sel and utility industries. welded condition. A -- 2.25 Cr-I Mo; B -- ther dissolve or coarsen and austenite grain growth occurs. Due to the fast cool- ,?'++'?,iI~ HCM25. +III ing rates during fusion welding, supersat- Experimental Procedure uration of microalloying elements occurs 2.25Cr-1Mo can be identical, HCM2S is as the austenite transforms to martensite Stress-Relief Cracking Tests typically produced with a carbon content (provided the alloy has sufficient harden- of -0.06 wt-%, which is much lower than ability). When the newly formed CGHAZ The alloy compositions of the 2.25Cr- the typical carbon content of 2.25Cr- is exposed to elevated temperatures, 1Mo and HCM2S steels used in this re-

356-S I DECEMBER 2000 search are summarized in Table 2. Stress- Ioys at the test temperatures used in this Table 2 -- Chemical Composition of HCM2S relief cracking tests were performed research are unavailable and therefore and 2.25Cro1Mo Steels (wt-%) using a Gleeble 1000 thermomechanical the above values were chosen because simulator. Unnotched, cylindrical test 650°C is near the middle of the test tem- Element HCM2S 2.25Cr-1Mo samples (105 mm long and 10 mm di- perature range. The 2.25Cr-1Mo steel (Ref. 1) (Ref. 5) ameter) with threaded ends were used. A samples tested at 270 MPa were pro- C 0.06 0.13 schematic illustration of the stress-relief duced using an energy input of 2 kJ/mm. Si 0.25 O.2 cracking thermomechanical test cycle The maximum residual stress present in a Mn 0.48 0.5 can be seen in Fig. 1. Samples were sub- weldment is typically at or near the yield P 0.013 O.OO8 jected to single-pass weld thermal simu- strength (Ref. 16). Therefore, the lower S 0.006 0.001 Cr 2.4 2.3 lation cycles representative of 2, 3 and 4 stress was used because the yield Mo 0.09 1.04 kJ/mm energy inputs with a peak tem- strength of HCM2S is typically higher W 1.5 NM perature of 1315°C and a preheat tem- than that of 2.25Cr-1Mo steel and lower- V 0.24 0.004 perature of 93°C. The thermal cycles are ing the stress serves to help normalize the Nb 0.050 0.001 based on actual data from SMA welds on yield strength differences between the B 0.0036 NM carbon steel (Refs. 14, 15). A tensile stress two materials. A constant load test is AI 0.013 NM was imposed on the sample during cool- more severe than a constant displace- Sn 0.01 0.01 Sb 0.01 <0.001 ing and held for the duration of the test to ment or stress relaxation test because the As 0.01 0.006 simulate the residual stresses present in load is not allowed to relax and the sam- Fe balance balance an actual weldment. After cooling to ple is often taken to failure. However, the room temperature, the sample was then mechanism of stress-relief cracking was NM: not measured subjected to a simulated programmed effectively simulated and the constant postweld heat treatment temperature and load test is relatively easy to perform. samples in the as-welded condition and held at constant temperature and load These tests were performed under a vac- after SRC testing using a Knoop indenter (that corresponds to the initial stress uum of approximately 100 millitorr to and a 500-g load. Samples were etched level) until failure. The load is actually prevent decarburization and oxidation of using either 2% Nital or Vilella's reagent constant and not the stress because the the samples as well as decoherence of and observed using light optical mi- stress will change as the cross-sectional the thermocouples. The time to failure croscopy (LOM). Prior austenite grain area of the specimen changes. Therefore, was taken to be the time when the PWHT size measurements were made in accor- when the stress level is mentioned here- temperature was reached to the time of dance with ASTM E112-84. after, it corresponds to the initial stress rupture. The ductility was determined as level. The simulated postweld heat treat- the reduction in area during PWHT. Results ment temperatures ranged from One half of each fractured sample was 575-725°C. Both materials were tested reserved for fractographic examination Stress-Relief Cracking Tests at a stress of 325 MPa and the 2.25Cr- by scanning electron microscopy (SEM). 1Mo steel was also tested at a stress of The remaining half was electroless Ni- Typical as-welded CGHAZ mi- 270 MPa. The initial stress levels (325 coated to provide edge retention of the crostructures of each alloy are shown in MPa for HCM2S and 270 MPa for 2.25Cr- fracture surface. Longitudinal cross-sec- Fig. 2. Each thermal cycle produced a mi- 1Mo) were chosen based on the yield tional samples were then polished to a crostructure consisting of lath martensite strength of the alloys at -650°C. The 0.04 pm finish using colloidal silica. Mi- and/or bainite with similar prior austen- yield strengths of the CGHAZ of these al- crohardness traverses were performed on ite grain sizes (-50 pm). Hardness tra-

O 2.25Cr-lMo, 2 kJ/mm [] 2.25Cr-lMo, 3 kJ/ram Base Metal I ~ gnth-e HAZ--~ Base Metal 2.25CrolMo, 4 kJ/ram HCM2S,3 kJ/mm • HCM2S, 2 kJ/mm 2.2SCr-IMo,3 ItJImm • HCM2S, 3 kJ/ram • HCM2S, 4 kJ/mm 4'°1,oo 750 • E~R ,

700

ODDI~ ~650 O eL il O~U~)

200 0 S Distaln0ce(ram) IS 20 600

550 Fig. 3 -- Microhardness traverse across simulated heat-affected zones. 1 10 100 1000 10 4 l0 s The traverse was across the sample between the jaws of the Gleeble. Time to Failure (sec.)

Fig. 4 -- Postweld heat treatment temperature vs. time to failure at various energy inputs.

WELDING RESEARCH SUPPLEMENT [ 357-s • HCM2S(325MPa) G 2.25Cr-lMo(325 MPa) • 2.25Cr-lMo (270 MPa) ...... , ...... i ...... ;o ...... Q 2.25Cr-lMo, 2 k J/ram 750 [] 2.25Cr-lMo,3 kJ/mm ~o 2.25Cr-lMo, 4 kJ/mm i I) HCM2S, 2 kJ/mm 700 II HCM2S, 3 kJ/mm ~ I ~ ~o HCM2S, 4 k J/ram ~o E 650 <> ~ I 2 Z5Cr-IMo Did|not fai o | 600 a ! V • ,W.. • I eB 6 550 600 650 700 750 PWHT (°C) 550 10 100 1000 10 4 10 s Time to failure (sec.) ~ 1

Fig. 5 -- Postweld heat treatment temperature vs. time to failure for Fig. 6 -- Reduction in area as a function of PWHT temperature at various an energy input of 2 kJ/mm along with lowered stress values for energy inputs. I 2.25Cr- 1Mo steel.

• HCM2S(325 MPa) • 2.25Cr-lMo (325 MPa) "as-welded" ~],~---BaseMltal---~ 0 2.25Cr.iMo, 2kJ/mm, 675°C C~ 2,25Cr-lMo (270 MPa) 2-25Cr-1Mo,~A ' ~GHA~'I l / • HCM2S, 2U/mm, 67S°C 40 ...... i ...... t ...... "as-welded'~450 35 HCM2S % 400 30 350 ~ I 25 | 300 20 250 15 ,25 t o © 200 10 o ~ 0 2 4 6 8 10 12 14 16 5 Distance from Fracture Surface (mm)

0600 650 700 "/5O Temperature (°C) Fig. 8 -- Microhardness traces acquired from HAZ samples (2 kJ/mm) after failure during a PWHT of 675°C. Fig. 7- Reduction in area as a function of PWHT temperature for an energy input of 2 kJ/mm along with lowered stress values for W:!I 2.25Cr- 1Mo steel.

N verses from each alloy in the as welded is more likely to be martensite than bai- site formation) in these simulations was condition (energy input of 3 kJ/mm) are nite due to the large effect of carbon con- faster than the critical cooling rate for presented in Fig. 3. These traverses are tent on the as-welded hardness of the these materials. Figure 5 compares the across the entire region between the jaws CGHAZ. Figure 4 shows the postweld time to failure for both alloys tested at an of the Gleeble and represent the entire heat treatment temperature vs. time to energy input of 2 kJlmm and an initial HAZ along with unaffected base mater- failure for both alloys tested under an ini- stress of 325 MPa as well as 2.25Cr-I Mo ial. Although the base metal hardness of tial stress of 325 MPa and various energy steel tested at an initial stress of 270 MPa. W: each alloy is similar (-225 HKN), the inputs and postweld heat treatments. It is It can be seen the change in stress had no 2.25Cr-1Mo steel has a much higher important to note every failure occurred effect on the time to failure for the peak hardness in the CGHAZ (-470 in the CGHAZ. In general, as the PWHT 2.25Cr-1Mo alloy. The 2.25Cr-1Mo sam- HKN) than HCM2S (-375 HKN) due to temperature increased, the time to failure ples tested at 575°C (325 and 270 MPa) the higher C content. The CGHAZ ex- decreased for both materials. There is no did not fail after six hours and the tests tends from approximately 6.5 mm to discernable difference between the two were stopped. Figure 6 shows the varia- 13.5 mm in Fig. 3. The hardness of the materials, and the change in energy input tion in reduction in area as a function of simulated CGHAZ of HCM2S corre- is shown to have very little effect. Vary- postweld heat treatment temperature at sponds well with hardness values of ac- ing energy input also had no discernable various energy inputs for each alloy tual welds taken for comparison (-370 effect on the CGHAZ peak hardness, im- tested at 325 MPa. For 2.25Cr-1Mo, the HKN). The microstructure of the CGHAZ plying the cooling rate (for 100% marten- ductility increased considerably with in-

358-s J DECEMBER 2000 I Z I I 1,1.1 I I11 ILl IO I I ILII I I ~ I I ILII, I la I

It,.P I Fig. 9 -- Scanning electron microscopy photomicrographs of fracture surfaces. Samples produced using an energy input of 2 kJ/mm and tested at a I ~ I PWHT temperature of 675°C. A -- HCM2S; B -- 2.25Cr-IMo tested at 325 MPa; C -- 2.25Cr- 1Mo tested at 270 MPa. I @ I I~rJ I I I.LI I creasing PWHT temperature. In contrast, stress of 325 MPa and the sample shown HCM2S shows no clear variation in duc- in Fig. 9C was tested at 270 MPa (2.25Cr- Table 3 -- Steel-Relief Cracking tility with PWHT temperature. Again, 1Mo). Each of the samples failed inter- Susceptibility Criteria Developed by I ILl I there is no clear correlation between the granularly along prior austenite grain Vinckier and Pense (Ref. 18) ductility and the energy input for a given boundaries. These microstructural fea- PWHT. Figure 7 shows the variation in re- Susceptibility to % Reduction tures indicate the test conditions properly t m i duction in area as a function of PWHT for simulate the stress-relief cracking mech- Stress-Relief Cracking in Area both alloys tested at an energy input of 2 anism. In comparing the two samples I ~IB I Extremely susceptible <5% I 1,1.1 I kJ/mm and a stress of 325 MPa as well as tested at 325 MPa, the 2.25Cr-1Mo steel Highly susceptible 5-10% 2.25Cr-1Mo steel tested at 270 MPa. The exhibits some microductility on grain Slightly susceptible 10-15% Not susceptible >20% reduction in area at 270 MPa is much surfaces (Fig. 9B), whereas the HCM2S i w i lower than the reduction in area at 325 sample has primarily smooth, featureless MPa at each PWHT temperature for the grain surfaces -- Fig. 9A. However, the 2.25Cr-1Mo steel. Figure 8 compares 2.25Cr-1Mo steel sample tested at 270 I LI.I I typical hardness traverses acquired from MPa shows little signs of microductility macroscopic yielding. On the other I iii I each material after being subjected to an and closely resembles the HCM2S sam- hand, alloys that retain their strength at energy input of 2 kJ/mm, a PWHT of ple -- Fig. 9C. Figure 10 shows typical high temperatures and/or become locally 675°C and a stress of 325 MPa. The orig- cross-sectional LOM photomicrographs embrittled at the grain boundaries are [ iii inal CGHAZ extends approximately 3.5 acquired from fractured samples of each susceptible to low-ductility fracture t mm from the fracture surface. The hard- alloy corresponding to the samples in along the prior austenite grain bound- ness of the HCM2S is constant across the Fig. 9. The white layer on the fracture aries during stress relief. Vinckier and L B CGHAZ, but the hardness increases near edge is an electroless Ni-coating used to Pense (Ref. 18) developed a criteria for the end of the CGHAZ in 2.25Cr-1Mo preserve the microstructural features the susceptibility to stress-relief cracking i,M steel. It is unclear as to why this occurs, near the edge of the sample. Each sample of steels based on the percent reduction but it may be due to the increased elon- failed intergranularly along prior austen- in area of specimens subjected to HAZ gation of the 2.25Cr-1 Mo samples. Neck- ite grain boundaries. Secondary cracks simulations and tested at elevated tem- ing during the test may cause a tempera- are present behind the fracture surface, peratures (Table 3). The criteria were ture gradient to form, thereby causing the with each being approximately normal to found to agree with test results by Lundin, variation in hardness with distance. The the tensile axis. These samples are repre- et al. (Ref. 16), on low-alloy steels. peak hardness of the CGHAZ in the sentative of all energy inputs and PWHT The susceptibility criteria discussed 2.25Cr-1Mo steel was considerably used in this investigation. The cracks in above are to be used as a general guide higher than HCM2S in the as-welded the 2.25Cr-1Mo steel samples tested at for well-controlled laboratory experi- condition. However, the hardness of the 325 MPa (Fig. 10B) appear to have more ments. Using these criteria, HCM2S is I.LI i! 2.25 Cr-lMo steel decreased consider- elongated features as opposed to the rel- considered "extremely" to "highly sus- ably after PWHT (from 470 HKN to -325 atively undeformed grains seen for the ceptible" to stress-relief cracking at each HKN), while the HCM2S hardness ex- HCM2S in Fig. 10A and the 2.25Cr-lMo energy input and postweld heat treat- O hibits no detectable change although the sample tested at 270 MPa -- Fig. 10C. ment, whereas, 2.25Cr-1Mo steel would U.I times to failure (time of exposure to This corresponds well with the ductility only be considered "slightly susceptible" Ll,I PWHT) were equivalent. This behavior values presented in Fig. 7. tested at 325 MPa. The 2.25Cr-1Mo steel was typical of each sample tested at 325 samples tested at 270 MPa are consid- -r MPa. Discussion ered "slightly" to "highly susceptible" to t~ The HCM2S alloy generally showed stress-relief cracking at each PWHT tem- re' more evidence of brittle intergranular Ductility has been found to be a reli- perature. I~1 ¸ i failure. Figure 9 shows SEM photomicro- able indicator of stress relief cracking sus- The reason for the decrease in ductil- graphs of samples produced using a ther- ceptibility when Gleeble simulation ity of 2.25Cr-1Mo steel when using a 1.1,1 mal cycle representative of an energy techniques are used to compare alloys lower stress is that a higher stress corre- input of 2 kJ/mm and tested at 675°C. The (Ref. 17). In general, alloys that can ap- sponds to a greater initial strain. In other samples represented in Fig. 9A (HCM2S) preciably soften during PWHT are capa- words, during a constant stress test, the and 9B (2.25Cr-1Mo) were tested at a ble of relieving residual stresses by material is initially (prior to the time L

WELDING RESEARCH SUPPLEMENT I 359-s Fig. 10 -- Light optical microscopy photomicrographs of cross-sectioned failed samples produced using an energy input of 2 kJ/mm and tested at a PWHT temperature of 675°C. A -- HCM2S; B -- 2.25Cr- 1Mo tested at 325 MPa; C -- 2.25Cr-1Mo tested at 270 MPa. when embrittlement mechanisms are ac- tested at 270 MPa since, as discussed teristics of elemental segregation and tivated) elongated an amount that corre- above, a stress of 325 MPa for 2.25Cr- carbide precipitation and how these sponds to the stress and then the test es- 1Mo steel induces an artificial reduction processes, in turn, affect the tempering sentially becomes a creep test. Therefore, in area. The lower stress is a more accu- response and fracture modes during the use of a higher stress at a given tem- rate representation of the stress state the stress relief. perature will initially produce more 2.25Cr-1Mo steel would experience in Tramp element segregation (temper strain and the apparent ductility in- an actual weldment because it is closer embrittlement) typically occurs in car- creases. Figure 11 is a plot of displace- to the yield strength at the PWHT tem- bon and low-alloy steels when slowly ment vs. time for each material/stress test peratures used in this study. The result is cooled or isothermally aged in the tem- combination at a PWHT temperature of 2.25Cr-lMo steel appears to be slightly perature range of approximately 625°C. The data represents the time at less susceptible to stress-relief cracking 350-600°C (Ref. 19). When temper em- which the PWHT was reached to the time than HCM2S based on the criteria of brittled steels are reheated to tempera- of failure. The increase in stress in the Vinckier and Pense (Ref. 18). This is es- tures above approximately 600°C and 2.25Cr-1Mo steel has caused an increase pecially true since the reduction in area cooled rapidly, embrittlement is reversed in the slope of the steady-state portion of increased as the PWHT temperature in- (Refs. 19, 20). Therefore, with the excep- the curve. This is similar to the result of creased, but PWHT had no effect on the tion of the samples tested at 575 and increasing the stress in a creep test. While ductility of HCM2S. 625°C, failure was unlikely to be associ- the elongation initially increases rapidly Low ductility intergranular failure in ated with tramp element segregation. in each sample, only the 2.25Cr-1Mo the CGHAZ during PWHT can occur by The CGHAZ of the 2.25Cr-1Mo steel steel sample tested at 325 MPa continues two general mechanisms: 1) tramp ele- experienced significant softening during to significantly elongate during the re- ment segregation to prior austenite grain postweld heat treatment at 325 MPa mainder of the test. The 2.25Cr-1Mo boundaries and/or 2) precipitation whereas the hardness of the CGHAZ of sample tested at 270 MPa and the strengthening of grain interiors and de- each HCM2S sample after PWHT was es- HCM2S sample reach a given displace- nuded zone formation near the grain sentially identical to the hardness in the ment, then the displacement essentially boundaries (Ref. 6). In the former case, as-welded condition. The reason for this remains constant. In contrast, the 2.25Cr- the presence of tramp elements (P, S, Sn, difference can be explained by examin- 1Mo sample tested at 325 MPa continues As and Sb) along the prior austenite grain ing the chemical composition and the ex- to elongate and always had a greater rate boundaries lowers the cohesive strength pected carbide precipitation sequences of elongation than the other samples at across the boundaries and leads to brit- of these alloys. Baker and Nutting (Ref. all PWHT temperatures. The rate of elon- tle, intergranular fracture. In the latter 21) studied the carbide precipitation se- gation also increased with increasing case, alloy carbides (e.g. VC, NbC) pref- quence during tempering of 2.25Cr-1 Mo PWHT temperature similar to a conven- erentially precipitate in the prior austen- steel for a broad range of tempering tem- tional creep test. Therefore, even though ite grain interiors on dislocations and peratures (400-750°C) and times each sample failed due to stress-relief cause considerable strengthening. Along (0.5-1000 h). Their findings are illustrated cracking, the 2.25Cr-1 Mo samples tested with this, some carbides may precipitate in Fig. 12. The following general carbide at 325 MPa exhibited high reductions in in the prior austenite grain boundaries. precipitation sequence was determined: area and continued to elongate through- These carbides can deplete the adjacent out the test. The 2.25Cr-1Mo samples material of carbon leaving a thin precip- ~-carbide "--~" M3 C itate-free denuded zone (Refs. 11, 12). tested at 270 MPa and HCM2S samples (M02C + M3C) ~ M23C 6 ~ M6C experienced some elongation before Therefore, any stress will be concentrated maintaining a constant displacement and in these relatively soft zones leading to then elongated a small amount before intergranular failure. Thus, the operable failing due to stress-relief cracking. It is cracking mechanism of each alloy can be Cr7C3* t important to note HCM2S should be understood by examining the influence compared to the 2.25Cr-1Mo samples of chemical composition on the charac- where the M stands for Fe or Cr.

360-s I DECEMBER 2000 0.4 2.25Cr-iMa 3IS MI~ 62,5 de ~..cj 0.39

f 2.,lSCr 1Mo,2"70 MI:'n,( IS dellnm C • _ ~ .-~'--..~.~.£"~ 0.38 /f | / ~0,37 u f EIC34~ 3~ M]F L, fg,5 dellmm C J /

0.34 °° r 0 500 1000 1500 2000 ~i~,~ h CLoqsca~) Time(w.onds)

Fig. 11 -- Displacement as a function of time during a PWHT of Fig. 12 -- Isothermal diagram showing the sequence of carbide for- 625°C mation on tempering of a quenched 2.25Cr-1Mo steel (Ref. 21).

For the temperature range 0.05 Nb-0.006N-0.5Mn-0.004B system Work is now in progress using analytical 400-725°C, E-carbide and/or M3C al- (Ref. 24) indicated the stable phases at and transmission electron microscopy to ways precedes the formation of any Cr- or 2.5 wt-%-Cr and 0.06%C are ~ + VC + examine the microstructures so the pre- Mo-based carbides. From these results, it M6C. This is consistent with the long- cise failure mechanisms can be under- can be estimated that, due to the short term aging results. The relatively high stood in more detail. times, cementite should be the only car- susceptibility of HCM2S to stress-relief bide to form in the 2.25Cr-1Mo steel cracking is likely due to a combination of Conclusions samples under the conditions of this vanadium carbide precipitation strength- study. Therefore, the material should ening within the grain interiors and pos- The stress relief cracking response of soften relative to the as-welded condition sibly the formation of denuded zones in conventional 2.25Cr-1Mo and HCM2S because the mechanism of softening is the grain boundary regions. Denuded steels was investigated by Gleeble HAZ the release of carbon from the supersatu- zones formed in low-alloy steels are typ- simulation techniques. The HCM2S alloy rated matrix and concomitant relaxation ically only up to a few hundred nanome- was shown to be more susceptible to of lattice strain (Ref. 22). This would ac- ters wide (Ref. 13). Therefore, even if de- stress-relief cracking than 2.25Cr-1Mo count for the significant increase in duc- nuded zones had formed, the steel over the range of weld thermal sim- tility observed with increasing PWHT detectability is limited to transmission ulations and postweld heat treatment temperature and the low susceptibility to electron microscopy. Vanadium carbide schedules used in this research for single- stress relief cracking. This is also consis- is well-known to promote stress-relief pass weld CGHAZ simulation samples. tent with the hardness results in Fig. 8. cracking by forming a fine, uniform dis- HCM2S experienced brittle intergranular Because the material could soften appre- persion of very stable carbides (Refs. 25, failure along prior austenite grain bound- ciably during tempering, the stress would 26). Grain interior strengthening by VC aries under each set of test conditions. be relieved by macroscopic yielding would resist stress relaxation by macro- The 2.25Cr-1Mo steel also failed inter- rather than the concentration of strain at scopic yielding and lead to stress intensi- granularly along prior austenite grain the prior austenite grain boundaries. fication along the relatively weak prior boundaries, but exhibited significant The carbide precipitation sequence austenite grain boundaries that may con- macroductility when tested at a stress of during the tempering of HCM2S is ex- tain denuded zones. This proposed 325 MPa. Lowering the applied stress in pected to differ from 2.25Cr-lMo steel process would account for the retained the 2.25Cr-1Mo steel samples to normal- due to the presence of V and Nb, which hardness of the HCM2S after postweld ize for the yield strength resulted in lower are strong carbide forming elements. Pi- heat treatment and the relatively high ductility values from the stress-relief grova (Ref. 23), in a study on quenched susceptibility to stress relief cracking. cracking tests. Increasing the postweld and tempered Cr-Mo-V steels, found Another possible factor is the pres- heat treatment temperature increased the M3C (Fe and Cr-rich) and MC (V-rich) car- ence of B and AI in the HCM2S alloy. Ad- ductility for 2.25Cr-1Mo steel, but had no bides to be present after tempering from ditions of AI (Refs. 13, 27, 28) and B significant effect on HCM2S. The as- 450-700°C for up to 1000 h (depending (Refs. 10, 13, 29) to low-alloy steels have quenched hardness of the CGHAZ pro- on the temperature). Previous work has been shown to greatly increase the sus- duced at each energy input for 2.25Cr- shown normalized and tempered ceptibility to stress-relief cracking and 1Mo steel was -470 HKN and for HCM2S steel exhibits a fine dispersion of promote the formation of a denuded HCM2S was -375 HKN. This difference MC along with some M7C 3 inside the zone (Ref. 13), although the exact mech- in as-quenched hardness was attributed grains and M23C6 along grain boundaries anisms by which AI and B promote stress- to the higher carbon content of the (Ref. 24). The MC carbide was found to relief cracking are unclear. Therefore, the 2.25Cr-1Mo steel. The hardness of the be V-rich with some Nb present. After differences in composition between CGHAZ after tempering decreased to aging for 1000 h at 600°C, MC remained 2.25Cr-1Mo steel and HCM2S and their -325 HKN for 2.25Cr-lMo steel, but re- stable, but M23C 6 and M7C 3 transformed effect on the carbide precipitation kinet- mained the same as the as-quenched to M6C (Ref. 24). Calculation of phase ics and grain boundary characteristics hardness of the CGHAZ for HCM2S. equilibria at 600°C using Thermo-Calc apparently are the reason for the contrast With the tempering temperatures and routine for the C-Cr-1.6W-0.1 Mo-0.25V- in the stress-relief cracking behavior. times used in this study, E-carbide and

WELDING RESEARCH SUPPLEMENT I 361-s Fe3C are expected to precipitate in 3. Prager, M., and Masuyama, F. 1994. Zhou, G., Khan, K. K., and Prager, M. 1996. 2.25Cr-1Mo steel. The concomitant re- Conference Proceedings Maintenance and WRC, Bulletin 411, pp. 1-215. lease of carbon from the supersaturated Repair Welding in Power Plants V. Orlando, 18. Vinckier, A. G., and Pense, A. W. 1974. Fla., EPRI and AWS, pp. 16-30. WRC Bulletin 197. structure and precipitation of Fe3C results 4. Metals Handbook, 8th ed., Vol. 1. ASM 19. Steven, W., and Balajiva, K. 1959. Jour- in a decrease in lattice strain and soften- International, Materials Park, Ohio. nal of the Iron and Steel Institute 193: ing of the CGHAZ. In HCM2S, V-rich MC 5. Creep Rupture Data of HCM25 Steel 141-147. is expected to form, which retards soft- Tubes, Pipes, Forgings and Plates. 1997. Sum- 20. Pugh, S. F. 1991. An Introduction to ening and ultimately leads to the higher itomo Metal Industries, Ltd. and Mitsubishi Grain Boundary Fracture, The Institute of Met- SRC susceptibility. Heavy Industries, Ltd. als, London. 6. Meitzner, C. F. 1975. WRC Bulletin 211 21. Baker, R. G. and Nutting, M. A. 1959. pp. 1-17. Journal of the Iron and Steel Institute (7): Acknowledgments 7. Dhooge, A., and Vinckier, A. 1992. 257-268. Welding in the World 30: 44-71. 22. Honeycombe, R. W. K., and The authors would like to gratefully 8. Swift, R. A. 1971. Welding Journal50(5): Bhadeshia, H. K. D. H. 1996. Steels: Mi- acknowledge the sponsors of this re- 195-s to 200-s. crostructure and Properties, 2rid ed. Halstead search including Sumitomo Metal Corp., 9. Swift, R. A., and Rogers, H. C., Welding Press, New York, N.Y. Mitsubishi Heavy Industries, Ltd., Foster Journal 50(5): 357-s to 373-s. 23. Pigrova, G. D. 1996. Metallurgical Wheeler Development Corp. and Penn- 10. McPherson, R. 1980. Metals Forum Transactions A, 27A(2): 498-502. 24. Miyata, K., Igarashi, M., and Sawaragi, sylvania Power and Light Co. The authors 3(3): 175-186. 11. Asbury, F. E., Mitchell, B., and Tort, L. H. Y. 1997. ICOPE-97, Tokyo, Japan, pp.13-17. would also like to thank Dr. Bruce Lind- 1960. British Welding Journal (11 ): 667-678. 25. Bentley, K. P. 1964. British Welding sley for his contributions to this research. 12. Irvine, K. J., Murray, J. D., and Picker- Journal (10): 507-515. ing, F. B. 1960. Journal of the Iron and Steel In- 26. Stone, P. G., and Murray, J. D. 1965. References stitute (10): 166-179. Journal of the Iron and Steel Institute (11 ): 13. Edwards, R. H., Barbaro, F. J., and 1094-1107. 1. Masuyama, E, Yokoyama, 1-., Sawaragi, Gunn, K. W. 1982. Metals Forum 5(2): 27. Viswanathan, R., and Beck, C. G. Y., and Iseda, A. 1994. Materials for Advanced 119-129. 1975. Metallurgical and Materials Transac- Power Engineering. D. Coutsouradis, et al. 14. Nippes, E. F., Merrill, L. L., and Savage, tions A 6A(11 ): 1997-2003. eds., Part 1. Kluwer Academic Publishers, W. F. 1949. Welding Journal (28): 556-s to 28. Ratliff, J. L., and Brown, R. M. 1967. Netherlands, pp. 173-181. 564-s. Transactions of the ASM 60:176-186. 2. Masuyama, E, Yokoyama, T., Sawaragi, 15. Nippes, E. F., and Nelson, E. C. 1958. 29. Presser, R. I., and McPherson, R. 1977. Y., and Iseda, A. 1994. Service Exposure and Welding Journal (37): 289-s to 294-s. Scripta Metallurgica 11 : 745-749. Reliability Improvement: Nuclear, Fossil, and 16. Welding Handbook, 8th ed., Vol. 1. Petrochemical Plants, PVP, Vol. 288. ASME, 1991. American Welding Society, Miami, Fla. pp.141-146. 17. Lundin, C. D., Liu, P., Qiao, C. Y. P.,

Call for Papers

The 6th International Seminar on Numerical Analysis of Weldability will be held October 1-3, 2001, in Graz, Austria. This seminar is held under the sponsorship of IIW Commission IX, Working Group "Mathematical Modeling of Weld Phenomena." Papers are invited on the following topics: • Melt Pool and Arc Phenomena • Solidification • Microstructural Modeling in Weld Metal and HAZ • Microstructure and Mechanical Properties • Influence of Postweld Heat Treatment • Crack Phenomena and Testing Methods • Residual Stresses and Distortion • Modeling Tools and Computer Programs Individuals interested in presenting a paper should prepare an abstract no more than a half page in length. Include the title of the paper, name of the author(s) and affiliation. Deadline for abstract submission is April 1, 2001. Send it to Bernhard Schaffernak, TU Graz, Institute for Materials Science, Welding and Forming, Kopernikusgasse 24, A-8010 Graz, Austria; FAX +43 316 873 7187; e-mail [email protected].

362-s I DECEMBER 2000 Control for Weld Penetration in VPPAW of Aluminum Alloys Using the Front Weld Pool Image Signal The study shows the feasibility of implementing weld formation control of VPPAW of aluminum in real time

BY B. ZHENG, H. J. WANG, Q. I. WANG AND R. KOVACEVIC

Abstract. This paper presents a technique Compared with other welding processes, welding (PAW): inaccessibility of the for real-time, closed-loop feedback con- VPPAW can generate high weld quality weld pool because of the limited torch trol of weld penetration based on the and high productivity at relatively low stand-off distance and the interference of front image signal of the weld pool in cost. These attractive features are attrib- the arc radiation. PAW technology in the variable polarity plasma arc welding uted mainly to a fully penetrated one-keyhole-per-pulse mode can be (VPPAW) of aluminum alloys. The for- keyhole-mode weld pool, inside which fairly well applied to steels, so the arc mation of an image can be acquired hydrogen cannot be trapped, and to the sound or the arc efflux light from the back when the arc light reflects off the con- removal of tenacious oxide film on the side of the workpiece can be used to de- cave, mirror-like surface of the depressed workpiece surface, which guarantees tect the size of the keyhole. Based on this keyhole weld pool and passes through a better fluidity of the metal in the weld principle, a full-penetration weld bead band-pass filter onto the image sensor. pool. However, keyhole collapse and has been guaranteed in real-time feed- The image of the visual keyhole (nominal melt-through may occur during a weld- back control (Refs. 6-9). However, this keyhole) is a two-dimensional projected ing process if disturbances such as type of technology is not applicable to picture of the actual keyhole weld pool. abruptly varying thermal conditions aluminum alloys. Also, detecting the The determination of the geometrical exist, especially when welding plates keyhole from the back side of the work- size of the nominal keyhole is also de- ranging from 4.0 to 25.4 mm. Thus, se- piece is not feasible in some cases, such scribed according to the consecutive lecting process parameters and providing as in the welding of pressure vessels. To frames of the image. The variation in size control of the stability of weld formation date, constant parameter open-loop con- of the nominal keyhole is closely corre- during welding to produce a satisfactory trol of weld formation is still being used lated to the bottom diameter of a key- weld remains a challenge. in PAW of aluminum alloys by the keyhole. A model of the relationship be- One effective approach is to monitor hole mode. tween the bottom diameter of a keyhole the keyhole weld pool. Recently, it was In recent years, welding researchers and the geometrical size of the nominal found the presence or absence of a key- have focused on using machine vision keyhole weld pool in the image is estab- hole could be determined by measuring systems to sense the weld pool for con- lished and examined using the BP artifi- the ratio of hydrogen to argon in the trolling the full penetration state in gas cial neural network theory. A cutting or a plasma arc column with an optical spec- tungsten arc welding (GTAW) and gas keyhole collapse phenomenon is suc- trometer (Ref. 5). However, the size of the metal arc welding (GMAW) (Refs. cessfully avoided and uniform weld for- keyhole cannot be determined and the 10-15). The arc light filtering solution has mation is obtained in a welding process welding process cannot be distinguished been investigated through coaxial view- using the model to control both the wire from the cutting process according to the ing of the weld pool in GTAW (Ref. 16). feed and the welding current when the signal. At present, two difficult problems These approaches are based on the prin- thermal conditions of the butt-jointed are associated with front-face sensing of ciple the diffuse reflection of arc light workpieces are changed. The results the keyhole weld pool in plasma arc from the mirror-like weld pool surface is achieved show a feasible way to imple- weaker than that from the surrounding ment the real-time weld formation con- area. Thus, in the image, the weld pool trol into the aluminum VPPAW. produces a dark area, while the solid part of the workpiece appears as a bright area. Introduction Key Words Some researchers used a pulsating laser synchronized with a high-shutter-speed Variable polarity plasma arc welding Aluminum Alloys camera to overcome the arc light inter- (VPPAW) of aluminum alloys in the key- VPPAW ference in GTAW of stainless steel (Refs. hole mode has been used successfully in Front Image Sensing 17-19). With this approach, a clear production, such as in fabricating the Weld Pool image of the weld pool is captured and space shuttle external tanks (Refs. 1-4). Keyhole Diameter the weld pool boundary is calculated in Neural Networks Model real time using a developed image- Penetration Control B. ZHENG, H. J. WANG and R. KOVACEVIC processing algorithm. The geometrical are with Southern Methodist University, Dal- Weld Formation appearance of the weld pool is charac- las, Tex. Q. I. WANG is with Harbin Institute terized by the rear angles and the length of Technology,, Harbin, P. R. China.

WELDING RESEARCH SUPPLEMENT I 363-s aluminum alloys is the transition from a Travelling Camaera keyhole welding process to a cutting mechanism cco I Powersource I Imageprocessing for wire feeder I software process or to a melt-in-mode welding process without a keyhole. Although lots I •t of factors influence the stability of the E Z!!!l I r--- weld formation, variation in thermal con- W!;!I / Computersystem for Frame grabber ditions of the workpiece (which is an un- ~!!!1 weld monitoring and control controllable factor in application) is 0,!!1 mainly responsible for the transition if the ~11;iI Plasmatorch [ 1 optimized welding parameters are ap- Video recorder I plied. Therefore, to avoid this transition, ~;!iI U ~eS~d:ngngdases and monitor the guarantee of the dynamic presence of soorceVPPAWsystom p .... a keyhole weld pool in a plasma arc 11 Cooling water system welding process with a varied thermal condition is one of the biggest challenges ~1 Storagefor data ..__.]Motion control in the control of a quality weld. I I system ~ il Currently, the real-time feedback con- Wi;I trol of the weld formation using a keyhole signal in PAW of aluminum alloys is still Fig. 1 -- Schematic of the monitoring and control system in VPPAW. not available, despite its applications to some key products. Therefore, explo- ~1 ration of this research issue is crucial to achieving a quality weld. This paper will Oiii!l of the weld pool. For the full-penetration focus on front imaging the weld pool to i~ii!;I Wiii~;I case, the back weld bead width could be achieve the required signal of a keyhole; ~ii;i!i] _!, ,I related to the geometrical features of the establishing the model of the relationship ~i;!ii~;!l front side of the weld pool. Infrared ther- between the bottom diameter of a key- ='I I mography has also been extensively in- hole and the geometrical size of a weld a vestigated (Refs. 20-22). It was found the pool in the image and implementing the 0!!;/ @;i!i!l interference of the bright arc light could real-time feedback control of the weld @:i!1 _!, '1 be prevented, and the depth of the joint penetration. penetration could be determined using ~il;il =ll -L [ ~!;!iI the characteristics of the temperature Experimental Procedure ;i=i!!!l profiles of steel in GTAW. The instanta- neous decrease of the welding current Experimental System Z:I has also been used to weaken the inten- ~i!!l Fig. 2 -- Schematic of workpieces. A -- Or- sity of the arc light in order to capture a The image sensing system used is ~:i!iI dinary conditions; B -- varied thermal con- ! LIII ditions with a slot. clear weld pool image during welding shown in Fig. 1. It consists of a commer- Oiiii!l (Ref. 23). However, in some cases, this cial CCD camera (15 mm in diameter :~,Ji:![ approach may not be acceptable be- and 100 mm in length) with a band-pass W!ii:~l cause of the poor weld bead that occurs, filter, a monitor, an image processing Wi:l such as in PAW of aluminum alloys using card, a PC-Pentium computer and a video recorder. The parameters of the fil- A Top the keyhole mode. ii~ii:i:ii] Besides the inaccessibility of the weld ter are the following: center wave length ,Oiill pool and the arc radiation interference in 658 nm, half wave width 10 nm, trans- PAW, a common problem existing in the missivity 27% and background depth of ....~:!i::il ,' )R,4---..~ Botl= welding of aluminum alloys is that nearly field 1/1000. These specific filter para- no color change occurs when the plate is meters are selected because the intensity / X t~ melted. Consequently, the weld pool of the arc light when using argon as the / shielding gas is much weaker within the :iNi::i!l I/ cannot be easily distinguished from the solid base metal using the visible spec- above spectrum. The welding system ~:!:iI trum range. Thus, processing a weld pool also shown in Fig. 1 consists of a vari- Fig. 3 -- Three-dimensional schematic of a ~:iiiiI image in the case of aluminum alloys is able-polarity welding power source, keyhole. much more difficult than in the case of programmable sequence controller, steel welding. plasma gas controller, CNC positioning mi!:il ConvexTop FaceWeld Bead Another problem in the welding of system, computer-controlled wire feeder WI:II i aluminum alloys is the tenacious oxide and plasma arc torch. The camera is at- film on aluminum strongly impedes the tached to and positioned in front of the i!!~iit flow of the weld pool in the welding plasma arc torch with its axis at an angle ! j~l:i!il] process so that a very poor weld forma- (43 deg) from the workpiece surface tion with oxide inclusion is easily gener- plane. Convex ated. A cutting process with an oxidizing ill iii~ i!1 Bead with ...... e, Experimental Conditions ;I:Z i],1,1!!1 Concave-downwardsBottom Weld Bead surface cut may also occur if the plates without Wire Feeding are melted through in a plasma arc welding process by the keyhole mode. Actu- Variations in the keyhole size can be Fig. 4 -- Schematic of a weld bead cross sec- ally, the main representation of an unsta- effected by changing some of the weld- tion. ble weld formation in VPPAW of ing conditions such as the welding cur-

364-s J DECEMBER 2000 rent, the wire feed speed and the thermal conditions of the plates (the shape of the workpiece, for instance). Since variation in the thermal conditions is crucial to ~Highlight I × :~(. o, Yo) J stability of weld formation in the welding of aluminum products, all the exper- H 0¢~~.~::iii::iii::::ii~:. iments were conducted using work- I~e~ole pieces with varied thermal conditions, ~ arlla except the experiments done for com- J: w (XR,~'R) parison. Butt-joint welds were made with wire feeding. Two shapes of 5-mm- thick 2024 aluminum plates are shown Fig. 5 -- 5chematic of the normal keyhole weld pool viewed from the top. (5 is the front pe- in Fig. 2. The welding current in the start- riphery of the keyhole weld pool; R is the right periphery of the nominal keyhole; H is the up segment reaches 80-90 A within 5 s, length of the nominal keyhole; L is the left periphery of the nominal keyhole; W is the width which increases up to 90-120 A within of the nominal keyhole; and ~ is the angle between L and R.) 5-10 s from the termination of this segment to the beginning of the main body segment. Other parameters have the following values: a direct current electrode negative (DCEN) to direct current elec- A B trode positive (DCEP) time ratio of 22 to 3.0 ms, DCEN current 80-100 A, DCEP current 110-120 A, pilot arc current 15 A, plasma gas flow rate 4.5 L/min, shielding gas flow rate 6 L/min, welding speed 100 mm/min, torch stand-off dis- (o,99) ~ f I ~,99) (0,eo) ~ ~o~o) tance 5 mm, angle of workpiece surface b(zOo,eo) plane to the horizontal plane equal to 85 deg, orifice diameter 3.2 mm, orifice length 3.5 mm and a tungsten electrode Fig. 6 -- Periphery tracing for the nominal keyhole. A -- Without wire feed; B -- with wire setback of 3.2 mm. feed. Image Features of the Keyhole Weld Pool Image Features curves (L, R and S) are not in the same Keyhole Profile spatial plane (L and R are not parallel to To better understand a keyhole image, A schematic of a keyhole weld pool the workpiece surface). The area a three-dimensional schematic of a key- without wire feeding and with wire feed- bounded by lines L and R and the pe- hole is shown in Fig. 3. The keyhole is ac- ing is shown in Fig. 5. The main features riphery S is a type of keyhole area tually a cavity through the weld pool, of the image are as follows: through which the plasma arc passes. 1) The images are two-dimensional with a profile resembling a trumpet. The This area is defined in this paper as the profiles of the keyhole weld pools pro- nominal keyhole. With wire feeding, the cross section of this cavity varies both in jected onto the target plane of the cam- lines L and R become a smooth curve, diameter and shape (irregular ellipse). era, which is defined in this paper as the and the middle segment of the periphery The maximum cross-sectional diameter visual (nominal) keyhole weld pool. This S is blocked by the cold wire. occurs at the top surface of the workpiece means only a single viewpoint of the key- 4) A highlighted area behind the nom- (top section diameter). The cross section hole weld pool can be captured by the inal keyhole exists in the image during a with the smallest diameter is located camera, and the curves in the image are normal welding process. The highlighted about 1.5-2.5 mm up from the bottom generally in different spatial planes. The area is not the image of the bright arc, but surface of the workpiece (throat section pattern of the keyhole weld pool in the the reflected light from the arc on the rear diameter). The diameter of the cross sec- image is deformed with respect to the surface of the weld pool. The area of the tion on the bottom surface of the work- pattern of the actual keyhole weld pool. nominal keyhole will increase with an in- piece is larger than the throat diameter 2) The front periphery (S) of the nom- crease in the welding current, but the but less than the top section diameter. In inal keyhole weld pool is clear, but the highlighted area will decrease with an in- uphill welding without wire feeding, the portion of it at the location with the crease in welding current. This is because shape of a back-side weld bead is largest weld bead width cannot be the size of the actual keyhole increases. concave-downward along the entire clearly distinguished from the solid area The area of the nominal keyhole inweld path -- Fig. 4. Therefore, the key- of the base metal. The rear periphery of creases to a maximum until the high- hole weld pool is a deformed weld pool, the nominal keyhole weld pool cannot lighted area vanishes (because there is no and is much different from a weld pool in be seen in the image. surface to reflect the arc light) when the GTAW and GMAW (Refs. 17-19). How- 3) The lines L and R are projected lines welding process becomes the cutting ever, with wire feeding, the concave- of the actual periphery of the keyhole. process. downward shape in the back side of a They may be the periphery of the keyhole 5) The bright arc cone cannot be seen weld bead will be filled into the convex throat (at the throat cross section [Fig. 3]). directly from the image because of the shape that is a normal full-penetration However, the periphery S is on the work- shielding of the torch gas cup. weld bead. piece surface. So, actually, the three 6) Besides other dimensions of the

WELDING RESEARCH SUPPLEMENT I 365-s 8500 | 8 [ iI 8 5o _ ~ 5000 ~! 3250

"i i 1 i i I i r ~ i ~ l i i i i i i i i i i 3~, [ ,~ ,~ ' I [ I I I I I I I I I I I I I J I I I I ! 1500 0 30 60 90 120 150 30 60 90 120 150 Time (s) Time (s) b

210 '~_A=. , 70.o =I- [.--o~ ordinarywod~e |1 ,~ --O--ordinary workl~Ce i 170 I -~" 50 .c ~ 40 :30 130 Z 20~ u :- I ,' ~ I I I I I I I ! 110 0 30 60 90 120 150 0 30 80 90 120 150 Time (s) Time (s) c

Fig. 7 -- Variation of keyhole parameters. A -- Bottom diameter of a keyhole; B -- nominal keyhole area; C -- nominal keyhole width; D -- nominal keyhole length.

Fig. 8 -- Back side photographs of weld beads in butt joints with wire feed. A -- Ordinary workpiece; B -- varied heat sink workpiece.

nominal keyhole, there are three charac- tracted, as shown in Fig. 6A. fied algorithm is taken to acquire the area teristic points with coordinates (X,, YL), The periphery of the nominal keyhole of a nominal keyhole: (XR, YR) and (Xo, Yo) in the image. is determined as follows: 1) Within the predefined window, an 7) The quantity of the molten metal in • Find the vertical centerline of the image frame is divided into two areas the weld pool with wire feeding is much highlighted area in the image. separated by the dotted line ab, which is more than in the case of no wire feeding, • Determine the starting point for shown in Fig. 6B. The data points to the so the bottom weld bead profile is con- tracing the periphery of the nominal key- left of line ab are processed in a sequence vex. This will make the highlighted area hole. from left to right and from top to bottom. in the image become larger than that in • Trace the periphery of the nominal In buffer 1, if the gray of a point (x, y) is the case with wire feeding. However, the keyhole. greater than fifty and the gray difference image is not as clear as in the case with- • Determine the front periphery of the between this point and the other point out wire feeding. nominal weld pool. (x+5, y+5) is between zero and ten, the gray of the point (x, y) is changed to zero. Extracting the Nominal With Wire Feeding Otherwise, the original gray of the point Keyhole Periphery (x, y) is saved. The same operation for the To process the image of a nominal data points to the right of line ab is done, Without Wire Feeding keyhole weld pool, one buffered area of but the sequence is from right to left and the RAM in the computer is preserved for from top to bottom. Because the image of the nominal storing the data of a whole frame of the 2) The first point with a gray value of keyhole weld pool is clear and the dif- image sampled per second. The same zero in each column is searched by scan- ference in grayness between the periph- size area of RAM is preserved for a copy ning the image frame from top to bottom. ery of the nominal keyhole and the other of the data stored in the area of buffer 1. The left intersecting point between curve area is large, no image preprocessing is During the data processing of a new sam- S and the nominal keyhole periphery arc needed in the case of no wire feed. The pled image, the data in buffer 1 are L can be located according to the fol- characteristic points and the lines of the changed, but the data in buffer 2 are kept lowing: to the left of line ab in the image nominal keyhole can be directly ex- as the initial value. The following simpli- frame, if the ordinates y of the points with

366-s J DECEMBER 2000 I~yhd= W 0.15 B Learning J Testing I 0.1 .... =yw iJJ

-- Inputmyer

Aru ~ H~ht x~t Y~l x~ YR~ XC=t= YC~Iw 3 8 9 12 15 18 PE number of the hidden layer

Fig. 9 -- Architecture of the BP neural network mode/of the key- Fig. 10 -- Error comparison of the BP neural networks. hole diameter.

the gray value of zero consecutively de- of the prerequisites for ~8 crease and the last point among these achieving a uniform --~--- Measured points has the same abscissa as that of and stable weld forma- g7 [•-I~.- N.N. output line ab, the first point (xu YL) among these tion. points is the left terminal point of the In essence, the rea- nominal keyhole periphery L. The right son for generating a ~ 5 terminal point (xR, YR) of the nominal key- cutting process is that hole periphery R can also be acquired by not enough metal ex- £4 m the same method. ists in the weld pool v 3 I i I I I I I I I I J I I I 3) A straight line Yu with ordinate YL and too much energy is 30 80 9O to the left of line ab and perpendicular to deposited in the work- the Y axis, is drawn. Another straight line, piece. The experiments Time ($) YR, can be drawn in a similar way. The reported in this paper area I, surrounded by lines ab, L and YL, show that under con- a and the area il, surrounded by lines ab, R stant energy input, and YR, are added together to represent when the thermal con- .~8 the nominal keyhole area. dition of a workpiece is g7 l--Jr-- Measured The other geometrical size (width and changed due to the --~--N.N. Output j length) of a nominal keyhole and the co- buildup of heat, the ordinates of the points (Xu YL), (XR, YR) keyhole size becomes m and (Xo, Xo) can also be calculated ac- larger as the weld pool ~ 5 cording to their number of pixels and becomes wider. When £4 their corresponding gray values in the the keyhole size is

, i , , , , , , , , , , , , , ...... image frame. larger than a certain " 3 value, a cutting 0 30 60 90 120 150 Variation of a Keyhole process will be gener- Time (s) ated. To avoid this Many factors -- arc stability, energy melt-through mode input of a workpiece, flow rates of gases, cutting process, the b position and speed stability of the wire quantity of the filler feed, thermal condition variations gen- metal should be in- ~8 erated by the workpiece structure and creased, which will de- heat buildup because of the continuous crease the size of the g7 L,, welding process itself- may influence keyhole even though ~6 I the transition from a normal keyhole the width of the weld m welding process to a cutting process or a bead generated will =8 5 melt-in mode welding process. The vari- probably be larger than ation in thermal conditions is the most that of a normal key- £4 crucial and complex among these fac- hole weld bead. Figure I I I I J r i I i h i i i L L i ~ i i i i i i i tors because of its variability, immeasur- 7 shows the relation- ability and uncontrollability. In keyhole ship of the bottom di- 0 30 60 90 120 150 welding, the cutting process usually oc- ameter of a keyhole Time (s) curs more easily than in the melting-in and the nominal key- mode welding process. Once a cutting hole size to the time c process occurs, the weld bead is not ac- using the workpieces ceptable and must be repaired. Thus, shown in Fig. 2, in Fig. 11 -- Bottom diameters of a keyhole from neural net output and avoiding a cutting process resulting which the origin of the actual measurement. A -- Constant welding parameters; B -- vari- mainly from a variation in thermal con- time axis represents the able welding current; C -- variable wire feed speed. ditions is a high priority. This is also one instant when the work-

WELDING RESEARCH SUPPLEMENT [ 367-s Table I -- Welding Parameters for BP Neural Network Modeling of the Bottom Diameter of a ~e ~ed ~peod Keyhole with Wire Feeding

Number of Slot length Welding current Wire feed speed experiment (ram) (A) (mm/s) 1 0 97 14 2 0 97 15 3 6 97 15 4 6 97-87-97 15 5 6 97-92-97 15 6 6 97 15-17-15 7 6 97 15-19-15 8 6 97 15-21-15 9 6 97-92-97 15-19-15 DE DDI D~2 D~3--~o~ 10 6 97-92-97 15-21-15 11 6 97-87-97 15-17-15 12 6 97-87-97 15-19-15 Fig. 12 -- Control model of the bottom diameter of a keyhole. piece movement is initiated after the key- the cutting process. hole size reaches a certain value. Be- 2) The geometrical size (the cause it is not currently possible to syn- area, width and height are shown, respectively, in Fig. 7B-D) of the chronously measure the bottom diameter 0.24 of a keyhole in a welding process, the off- nominal keyhole in an image has line measured width between the bottom the same trend as the bottom di- 0.235 oxide films along a weld bead, which is ameter of the keyhole, for both the 0.23 the trace of the arc efflux, is used for rep- ordinary and the varied heat sink resenting the bottom diameter of a key- workpiece, even though there are 0.225 hole. To accurately acquire the data, some slight differences between 0.22 marks with an interval of 1.0 mm are them. The change in the area 3 6 g 12 15 18 made on the top and bottom faces along shows the largest variation among PE numberof the hidden layer the butt-jointed workpieces before weld- these characteristic sizes. How- ing. The cycle of image sampling is 1.0 s ever, all this size data cannot represent the variation in the bottom and the welding speed is 6.48 m/h. Fig. 13 -- Training error of the BP neural network. Therefore, the measuring interval is 1.8 diameter of a keyhole, which is ac- mm. Associated with the corresponding tually a measurement of the full- photos given in Fig. 8, the following re- penetration state. Thus, to avoid sults were obtained: the cutting process, the bottom di- 1 ) The bottom diameter of the keyhole ameter of a keyhole should be cor- on the ordinary workpiece increases with related with the geometrical size time during the first 20 s-- Fig. 7A. How- of the nominal keyhole. ever, at the nearby origin, it is about 3) The allowable magnitude of 4.5-5.0 mm because of the arc preheat at the variation in the bottom diame- the start location, and then decreases to ter of a keyhole is not large (+ 2.0 3.8 mm because of the better heat trans- mm). The time interval required for fer conditions of the workpiece after the welding process to become the torch motion is initiated. From that in- cutting process for nominal weld- stant, the bottom is nearly constant in the ing velocities of 100 mm/min Fig. 14 -- Output of the controlling model of the wire range of 3.8 to4.0 mm up until 90 s. From shows the response time for both feed speed. (Note: curve I is the output of the model about 90 s, it increases to 4.5 mm be- acquiring and processing the using the data from open-loop control experiments; cause of the heat buildup and maintains image and for controlling the full curve 2 is the output of the model using the data from 4.5 mm after 110 s. Therefore, the key- weld penetration should be less closed-loop control experiments.) hole welding process can enter a stable than 20 s. state after 20 s from the start, during which the variation of the keyhole diam- Modeling the Keyhole 4) Varied heat sink workpiece with a eter is 0.2 mm up to 100 s. For the varied Diameter variation in welding current. heat sink workpiece, it can also be seen 5) Varied heat sink workpiece with the keyhole diameter has nearly the same The following experiments were variations in both the welding current variation as that of the ordinary work- made for mapping the relationship of the and the wire feed speed. piece up until 30 s, even though there ex- bottom diameter of a keyhole with the The purpose of the variations in the ists a small difference during the first 10 geometrical size of the corresponding welding current and/or the wire feed s. Because the thermal condition is get- nominal keyhole in an image: speed is to maintain a continuous weld- ting worse after 30 s (the arc is reaching 1) Ordinary workpiece with constant ing process and prevent an occurrence of the area with a slot machined on each welding parameters. a cutting process. The parameters ap- workpiece), the variation of the keyhole 2) Varied heat sink workpiece with plied are shown in Table 1. As an exam- diameter rapidly increases to more than constant welding parameters. ple of experiment 4, the welding current 6.8 mm at the instant of 72 s. After that, 3) Varied heat sink workpiece with a is maintained at an initial value of 97 A the keyhole welding process becomes variation in wire feed speed. until the area with the varied heat sink is

368-s [ DECEMBER 2000 reached. Then the welding current is stepped down to 87 A. When the area with the varied heat sink is passed, the welding current is stepped up again to 97 A. In experiment 6, the initial wire feed speed is maintained at a value of 15 cm/s ~put VV~d.g J Pararmters I ul until the area with the varied heat sink is ~re F~a~ Speed ! Calculation and regulating J reached. Then it is increased to a maxi- I mum value of 17 cm/s according to a Welding Current I0 "lbreshold Sw itching J i / slope at the middle location of the area Start WeU~g I with the varied heat sink. After that, it is I decreased to the initial value of 15 cm/s I uu according to a slope. Every experiment is J TirmCounter=O , m repeated four times. The first three of the Start Tm-e Counter same four experiments are used for model recognition, and the last experi- N Y I ~[ ment is for verifying the accuracy of the I .1 m~e Acq~s~x)n I if) model established based on the three ex- I ILl and Processing periments. Every group of parameters associated with the results of the image processing is recorded once a second, 20 I ILl seconds after the weld initiation. From J Keyhole Dia~ I DataStorage the three groups of experiments in Table Calculat~n 1 (from 1 to 4, 5 to 8 and 9 to 12), 3855 i i groups of data were acquired. I uJ An artificial BP neural network of three layers with nine parameters as in- I uJ puts and the bottom diameter of a key- Fig. 15 -- Block diagram of the program for closed loop control of full penetration in butt-jointed i I hole as an output, which can implement plates. I c.) any map from m dimensions to n dimensions, was used to model the system -- Fig. 9. As the number of hidden layers is guarantee full penetra- I ILl 10.5 23 not easily determined using current the- tion control and --O.-measu~d ke'/h@e dianlet~" I 22 v~O.5 ~ N.N. output keyho~ diw'neterll ories, the BP models with one hidden achieve a uniform •-O-~re fcedlr~~ 12021 l 0.5 layer consisting of elements of 3, 6, 9, 12, weld bead, the quan- i m 15 and 18 are respectively examined tity of the weld pool ~ "/.5 10 ~ i b ~ 6.5 I uJ using the Gauss initiation procedure and metal should be con- 16 '= '~ the Delta rule (Ref. 24). Figure 10 shows trolled. Based on the ~ 5.5 '14 4.5 the error comparison of the models with fact the keyhole size 13 different layers. A comparison of the may be regulated by 3.5 ' ' , , , , 12 2O 35 50 65 80 95 110 125 140 I uJ neural network output with the measured adjusting the wire feed T~me(s) results is given in Fig. 11. It can be seen speed and the heat the training error of the model is the input may be con- Fig. 16 -- Bottom diameter of a keyhole and wire feed speed vs. the smallest value of 6.77%, and the corre- trol led by changing the time in the full penetration control of a weld bead in a butt joint sponding error of the experiment exam- welding current, the using wire feed speed as a control variable. ined is 6.64% when the number of the wire feeding speed hidden layer element is selected as six. was selected as the first Also, the corresponding curves measured control ling variable for I uJ and output from the model agree well full weld penetration. t with each other. Thus, the model with a six-element hidden layer was selected as Controlling Model I ILl the mapping model between the bottom diameter of a keyhole and the geometri- To model the rela- cal size of a corresponding nominal key- tionship between the ',w.~ hole, as well as the three pairs of coordi- wire feed speed and nates in the image schematically shown the bottom diameter of in Fig. 5. However, the model should be a keyhole by the black- I ii1 retrained using new experimental data if box method, the artifi- the thickness of a workpiece and differ- cial BP neural network ent welding parameters are applied. theory was applied. Because the welding < I Real-time Feedback Control of the process is a time delay III - Full Weld Penetration process (the response W of the weld pool status As stated above, the reason for the oc- to the adjustment of Fig. 17 -- A weld bead with closed loop control of full penetration currence of a cutting phenomenon is not the controlling para- in a butt joint using wire feed speed as a controlling variable. A -- enough metal is inside the weld pool. To meters takes a longer Top face; B -- bottom face.

WELDING RESEARCH SUPPLEMENT I 369-s 9.5 22 I -,~ ~umd k~o~ d~ I 21 ~.~.~ ~N.N. output keyhole dl~me~er| 95 g 9o 7.5 85 5.5 i ~ 14 4.5

4.2 4.5 4.8 Ke~ole diameter (ram) "nrne ($1 | !

Fig. 18 -- 5chematic of the welding current regu- Fig. 19 -- Bottom diameter of a keyhole, welding current and wire feed speed vs. la tion. the time in the full penetration control of a weld bead in a butt joint using wire feed speed and welding current as controlling variables.

time), the previous data values for the first four experiments input should be utilized in the establish- are for constant weld- ~~~.~ I ment of a model using current data value. ing current; the second . ,~ A model of three layered BP neural net- four experiments are works was established, with the current for a decrease in weld- i wire feed speed as the output and the ing current by 5 A I current and previous bottom diameters of when the area with a the keyholes as the input. The number of slot is reached; the last hidden layer elements is selected from four experiments are the experiments. In the beginning, the for a decrease in weld- I~ ~'~ -::, training sample data are acquired from ing current by 10 A ~::i the experiments in Table 1 when the wire when the heat sink of ~['~-~ feed speed was changed. So, two cate- thecreased.Workpieces is in- ~.~-T~ gories of data (associated with the varied heat sink workpiece and the ordinary According to the workpiece, respectively) are selected ac- feedback control the- ,~,~:~Z~ cording to the standard: there is no ap- ory, it can be seen the ~.~ parent concave or undercut in a weld regulator in Fig. 12 bead. The bottom diameter of a keyhole, can regulate the wire Fig. 20 -- A weld bead in a butt joint with the closed-loop control which is the input for the controlling feed speed to change of weld formation using both wire feed and welding current as con- model shown in Fig. 12, is the output in the keyhole size de- trolling variables• A -- Top face; B -- bottom face. Fig. 9. From the comparison of the output pending on the varia- results of the neural networks model with tion in the keyhole di- the training sample data, illustrated in ameter, so an occurrence of the cutting etration when the thermal condition of Fig. 13, it can be seen the model with process may be avoided. the workpiece changes• three elements in the hidden layer has the • In the areas with a poorer heat sink smallest error. Also, the difference be- Full Penetration Control because of the slots, the width and height tween the output results of the neural net- of the bottom weld bead are apparently works model and the training sample The block diagram of the program for wider and higher than those in other data is large. The reason for this is the controlling full penetration of a weld areas with a better heat sink. The corre- changes in the wire feed speed are lim- bead for the butt-joint plates is shown in sponding width of the top bead is a little ited and the standard for an acceptable Fig. 15. Because a welding process needs wider and the corresponding height of weld bead is not very strict. Conse- about 20 s to enter the stable main body the top bead is a little reduced. However, quently, contradictory data are included segment from the start-up segment, the there are no concave or undercut defects in the training data sample collection. control process of the full penetration be- in the weld bead. In Fig. 14, curve 1 is the model output gins at the 20th cycle of the image sam- • The weld formation is not uniform. of the wire feed speed regulator based on pling (i.e., the control strategy is applied ~t the above data sample collection used after the variable I equals 19 s in Fig. 15). Optimization of the for training the model. The correspond- The wire feed speed and the bottom Weld Formation r~ ing initial and terminal data values, as diameter of a keyhole are recorded, mea- well as the increment value of the bottom sured and calculated, the relationships of To achieve a uniform weld formation diameter of a keyhole are respectively which, versus time, are shown in Fig. 16. during the full weld penetration control 3.0, 8.0 and 0.1 mm. Curve 2 is the out- The corresponding photograph of a weld process, the welding current should be put of the same regulator trained using bead is given in Fig. 17. It shows the fol- control led for regulating the heat input to lowing: the workpiece. Although the experiments NA~;:: the new data sample collection acquired from the feedback experiments done • The cutting process can be avoided show the cutting process can also be under the condition of the varied heat reliably using the wire feed speed as a avoided by adjusting only the welding sink according to curve 1. These experi- controlling variable in the real-time current, there often exist undercut and ments are divided into three groups: the closed loop control of the full weld pen- concave defects in the top weld bead.

370-s J DECEMBER 2000 A solution that includes the regulation 3) The model, established between the Study on arc sound in TIG and plasma of the wire feed speed is shown in Fig. 18. bottom diameter of a keyhole and the geo- processes. IIW Doc. 212-610-85. Three thresholds of the bottom keyhole metrical size of a nominal keyhole weld 9. Hu, B. X. 1980. The study of controlling diameters of 4.3, 4.6 and 5.1 mm are re- pool in the image, effectively and accu- system of welding quality at all-positions by spectively matched with the welding cur- rately reflects the keyhole variation. The using the arc sound in pulsed plasma arc weld- rent of 97, 92 and 87 A. The changing bottom diameter of a keyhole can be used ing of steel. Welding 3:17-20 mode of the welding current is designed as a characteristic parameter to monitor 10. Agapakis, J. E., and Bolstad, J. 1991. Vi- into the following: and control the full weld penetration. sion sensing and processing system for moni- 1) When the bottom diameter of a key- 4) The model for controlling the full toring and control of welding and other high hole increases to a threshold, the welding weld penetration can be applied to a luminosity processes. Proc. of the Interna- current is decreased according to the top welding process using the wire feed tional Robots & Vision Automation Confer- downstairs-shaped curve in Fig. 18. speed as a control variable to reliably ence, pp. 23-29. 2) When the bottom diameter of a avoid an occurrence of a cutting process 11. Nakata, S, Huang, J., and Tsuruha, Y. keyhole decreases to a threshold, the or a melt-in mode. However, a uniform 1988. Visual sensing system for in-process welding current is increased according to weld bead may not be obtained by using control of arc welding process. Welding Inter- the bottom upstairs-shaped curve. only the wire feed speed as a single con- national 12:1086-1090. 3) When the bottom diameter of a trolling variable. 12. Hoffman, T. 1991. Real-time imaging keyhole changes between the two neigh- 5) Uniform weld formation can be for process control. Advanced Materials & boring thresholds and does not reach achieved using a combination of the wire Processes 9:37 to 43. those thresholds, the welding current is feed speed regulation with welding cur- 13. Guu, A. C., and Rokhlin, S. I. 1989. held constant. To weaken the influence rent adjustment according to the varia- Computerized radiographic weld penetration of any noise during an on-line control tion in the bottom diameter of a keyhole control with feedback on weld pool depres- process, an average-weighted filtering in the full weld penetration control of a sion. Materials Evaluation 10:1204-1210. method is applied to the determination of weld bead. 14. Guu, A. C., and Rokhlin, S. I. 1992. Arc the bottom diameter of a keyhole: the 6) The approach used in this paper weld process control using radiographic sens- weighted coefficients are 0.5, 0.3 and should be further explored when thicker ing. Materials Evaluation 11 : 1344- 1348. 0.2, respectively, for the current diame- materials are applied. The influence of 15. Rokhlin, S. I., and Guu, A. C. 1990. ter, the former diameter and the diameter the arc light intensity should be a greater Computerized radiographic sensing and con- before the former diameter. condition when designing a filtering sys- trol of an arc welding process. Welding Jour- Figure 19 shows the responses of the tem under the condition of a high weld- nal 69(3): 83-s to 95-s. welding current and the wire feed speed ing current. 16. Richardson, R. W., and Gutow, D. A. to the variation in the bottom diameter of 1984. Coaxial arc weld pool viewing for a keyhole during a real-time feedback Acknowledgments process monitoring and control. Welding Jour- control process. Compared with the re- nal 63(3): 43-s to 50-s. sults in Fig. 1 6, it can be seen the bottom The authors wish to acknowledge the 17. Kovacevic, R., and Zhang, Y. M. 1993. diameter becomes significantly smaller financial support from the National Key Three-dimensional measurement of weld pool in area with a poorer heat sink because Laboratory of Advanced Welding Pro- surface. Proc. of the International Conference of the slots and the quantity of wire feed duction Technology at Harbin Institute of on Modeling and Control of Welding is decreased to avoid a cutting process. Technology, P. R. China, and from the Processes, Fla. The corresponding photograph of the National Science Foundation (Project 18. Kovacevic, R., and Zhang, Y. M. 1995. weld bead (Fig. 20) also shows the bead Nos. DMI-9900011 and DMI-9700102). Vision sensing of 3D weld pool surface. Proc. is more uniform than that in Fig. 17. of the 4th International Conference on Trends Therefore, a combination of the wire feed References in Welding Research, Gatlinburg, Tenn. regulation with welding current adjust- 19. Kovacevic, R., and Zhang, Y. M. 1996. ment can further improve the weld for- I. Nunes, A. C. 1984. Variable polarity Monitoring of weld penetration based on weld mation in VPPAW of aluminum alloys by plasma arc welding on space shuttle external pool geometrical appearance. Welding Jour- the keyhole mode. tank. Welding Journal 63(4): 27-s to 35-s. nal 75(10): 317-s to 329-s. 2. Woodward, H. A. 1996. U.S. contractor 20. Nagarajan, S., Chen, W. H., and Chin Conclusions for the international space station. Welding B. A. 1989. Infrared sensing for adaptive arc Journal 75(3): 35-s to 40-s. welding. Welding Journal 68(11 ): 462-s to The following conclusions can be 3. Torres, M. R. 1992. Gas contamination 466-s. made based on the results of this study: effects in variable polarity plasma arc welded 21. Nagarajan, S., Banerjee, P., Chen, W. 1 ) A clear image of the keyhole weld aluminum. Welding Journal 71(4): 123-s to H., and Chin, B. A. 1990. Weld pool size and pool can be obtained using a band-pass 130-s. position control using IR sensors. Proceedings filtering method. The nominal keyhole in 4. Martinez, L. F. 1994. Effectof weld gases of NSF Design and Manufacturing Systems the image is a part of the actual keyhole, on melt zone size in VPPA welding of A12219. Conference. Arizona State University. the geometrical features of which can re- Welding Journal 73(10): 50-s to 55-s. 22. Chen, W., and Chin, B. A. 1990. Mon- flect the variation in the bottom diameter 5. Martinez, L. F. 1992. Front side keyhole itoring joint penetration using infrared sensing of a keyhole regardless of whether there detection in aluminum alloys. Welding Journal techniques. Welding Journal 69(4): 181-s to is wire feed or not. 71 (5): 49-s to 52-s. 185-s 2) The main reason for an occurrence 6. Steffens, H. D. 1972. Automatic control 22. Oshima, K., and Morita, M. 1992. of a cutting phenomenon is not enough for plasma arc welding with constant keyhole. Sensing and digital control of weld pool in metal is appropriately added to the weld Welding Journal 51 (6): 40-s to 45-s. pulsed MIG welding. Transactions oftheJapan pool during a welding process. The devel- 7. Metcalfe, J. C., and Quigley, M. B. C. Welding Society 23(4): 36-42. opment of a cutting process from a keyhole 1975. Keyhole stability in plasma arc welding. 23. Hagan, M. T., Demuth, H. B., and welding process takes some time, which Welding Journal 54(11): 401-s to 404-s. Beale, M. 1996. Neural Network Design. PWS allows full weld penetration control. 8. Zhang, J. H., and Wang, Q. L. 1985. Publishing Co., pp. 1--43.

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