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505 OAKWOOD RD LAKE ZURICH. ILLINOIS 60047 PH 847 5500033 FX 847 5500444 CMINDUSTRIES.COM EMAIL SALES C MINDUSTRIES COM For Info go to www.aws.org/ad-index CONTENTS July 2010 • Volume 89 • Number 7 Features 28 Artists Think' in Metal Metal and welding go hand-in-hand for this group of AWS Web site www.aws.org creative individuals K. Campbell, M. R. Johnsen, and H. Woodward Departments 38 Precision Laser Welding of Thin Structures A combination of preplaced powder filler material and laser welding addressed the problems of distortion and melt Press Time News 4 through on 0.25-mm-thick foils Editorial 6 A. Deceuster, G. Stewardson, and L. Li News of the Industry 8 42 Tips to Improve GTAW Arc Starts Controlling the variables as consistently as possible leads to International Update 12 positive arc starts Stainless Q&A 14 J. Luck Book Review 16 47 A Summary of Revisions in the New D1.1:2010, Structural Letters to the Editor 18 Welding Code — Steel The significant changes in the new 2010 issue are explained RWMAQ&A 20 J. L. Gayler and D. D. Rager New Products 24 50 Homes for Haiti Welding Workbook 56 Metal cargo containers, a welding class, dedicated workers, Coming Events 58 and an actress with a compassionate heart combine to help those left homeless in Haiti Conferences 62 K. Campbell and H. Woodward Society News 63 Tech Topics 66 Official Interpretations 01.1,01.5,017.1 66 015.1 67 Welding Research Supplement Guide to A WS Services 89

133-s Effects of Nb, V, and W on Microstructure and Abrasion New Literature 90 Resistance of Fe-Cr-C Hardfacing Alloys Personnel 92 Different compositions in self-shielded flux cored electrodes Classifieds 95 were tested to determine the best formula for wear-resistant deposits Advertiser Index 98 Q. Wang and X. Li

140-s Hybrid Laser Arc Welding Process Evaluation on DH36 and EH36 Steel Experiments were conducted to determine the most effective arc and laser power for hybrid welding of DH36 and EH36 C. Roepke et al. Welding Journal (ISSN 0043-2296) is published monthly hy the American Welding Society for $120.00 per year in the United States and posses- 151 -s Effect of Continuous Cooling Transformation Variations sions, $160 per year in foreign countries: $7.50 on Numerical Calculation of Welding-Induced Residual per single issue for domestic AWS members and Stresses $10.00 per single issue for nonmembers and $14.00 single issue for international. American Variations in continuous cooling transformation behavior were Welding Society is located at 550 NW LeJeune Rd., studied to find their influence on welding-induced residual stress Miami, FL 33126-5671; telephone (305) 443-9353. J. Caron et al. Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2

Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or re- sale. Permission is granted to quote from articles, On the cover: Wolves, The Messengers, was created by Canadian Artist Hilary provided customary acknowledgment of authors Clark Cole, who welded the sculpture out of weathering steel. (Photo courtesy and sources is made. Starred (*) items excluded of Hilary Clark Cole.) from copyright.

WELDING JOURNAL PI7E55 TIME NEWS WELJMMBi Publisher Andrew Cullison American Welding Society Purchases New Headquarters Buiiding Editorial Editorial Director Andrew Cullison The American Welding Society Editor Mary Ruth Johnsen (AWS) recently purchased a 122,482-sq- Associate Editor Howard M. Woodward ft building in the Doral area of greater Associate Editor Kristin Campbell Miami, Fla., to serve as its future head- Peer Review Coordinator Erin Adams quarters. Office space is being built out, and it's expected the move will be com- Publisher Emeritus Jeff Weber pleted by late 2011. Graphics and Production The recently renovated five-story Production Manager Zaida Chavez office building on a five-acre parcel is Senior Production Coordinator Brenda Flores located at 8669 NW 36th St., Doral, Fla., about seven miles northwest of the cur- Advertising rent headquarters. Initially, the Society National Sales Director Rob Saltzstein The American Welding Society's future head- will occupy about 50% of the building, Advertising Sales Representative Lea Gatrigan Badwy quarters building (shown in the above photo) is and 15% is already leased out. Senior Advertising Production Manager Frank Wilson located in the Doral area of greater Miami, Fla. "The American Welding Society The move is set to be completed by late 2011. has grown significantly in recent years, Subscriptions and we need increased space for meet- Subscriptions Representative Edalia Suarez ing rooms with state-of-the-art audio/visual capabilities," said AWS President John [email protected] Bruskotter. "The new building provides us with the space we need to continue to grow and to expand our services in the best interest of our members." American Welding Society 550 NW LeJeune Rd., Miami, PL 33126 The purchase reflects expansion opportunities for the Society, which has a rising (305) 443-9353 or (800) 443-9353 membership of 63,000. Present commercial real estate conditions made purchasing this building the best option, but many possibilities were reviewed over the past two years, Pubiications, Expositions, Marketing Committee including expanding its current facility, purchasing adjacent land, and constructing a D. L. Doench, Chair new building. Hobart Brothers Co. "From a financial standpoint, AWS was in a position of a solid financial base with S. Bartholomew, Vice Chair the growth of our reserves. This enabled us to purchase the building outright without fi- ESAB Welding & Cutting Prod. nancing it," said AWS Treasurer Robert Pali. J. D. Weber, Secretary The Society has changed its headquarters location only a few times, from the Engi- American Welding Society neering Societies Building in 1919 to the United Engineering Center, both in New York D. Brown, Weiler Brush City, followed by the move to Miami in 1971. J. Deckrow, Hypertherm D.DeCorte, RoManMfg. J. R. Franklin, Sellstrom Mfg. Co. Motoman and Yaskawa Eiectric America Join Forces D. Levin, Airgas E. C. Lipphardt, Consultant Motoman Inc., Dayton, Ohio, and Yaskawa Electric America, Inc., Waukegan, 111., J. Mueller, Thermadyne Industries will combine to form Yaskawa America, Inc. The Motoman operations will form the J. F. Saenger Jr., Consultant Motoman Robotics Division of Yaskawa America, and the Yaskawa Electric America S. Smith, Weld-Aid Products operations will form the Drives & Motion Division. Both will continue to operate as in- D. Wilson, Wilson Industries dependent divisions, retaining the same management structures, and operating in the P. Wittke, Lincoln Electric Co. same geographical regions that are currently in place. J. C. Bruskotter, Ex Off., Bruskotter Consulting Services "The global economy is recovering, and we believe this is the perfect time to com- H. Castner, Ex Off., Edbon Welding Institute bine the brand name strength of Yaskawa and Motoman. Using the name Yaskawa on a L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems global basis will strengthen our corporate identity and emphasize the strong global con- S. Liu, Ex Off., Colorado School of Mines E. Norman, Ex Off., Southwest Area Career Center nection between drives, motion control products, and robotics," said Gen Kudo, Yaskawa R. G. Pali, Ex Off., /. P. Nissen Co. America's chairman and CEO. R. W. Shook, Ex Off, American Welding Society Steve Barhorst, president and COO of the Motoman Robotics Division, and Jody Kurzhalts, president and COO of the Drives & Motion Division, believe users will real- ize benefits from better alignment of their divisions. "Our combined capabilities will lead to more innovative products. We are particularly excited about the prospects for developing advanced controls technology utilizing the expertise and experience of both divisions," added Barhorst. Copyright © 2010 by American Welding Society in both printed and eiec- tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors int'i Thermai Spray Association Offers Schoiarships of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the The International Thermal Spray Association Scholarship Program, a contributer to part of potential users. the growth of the thermal spray community, especially the development of new technol- ogists and engineers, offers up to three graduate scholarships worth $2000 each to be awarded each calendar year. Applications are now accepted annually May 1 through BPA July 15, and winners will be announced in August. Visit the scholarship area at www.thermalspray.org for details and a printable application form.

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7950 Dixie Highway Florence KY 41042 USA General Office Phone 859 3710070 Fax 859 371 5210 Email kiswel@kiswelusa com EDITORIAL American Welding Society Founded in 1919 to Advance the Science, Technoiogy and Appiication of Weiding The Key to Avoiding Donor Officers President John C. Bruskotter Fatigue: Don't Stop Believing Bruskotter Consulting Services, LLC Vice President John L. Mendoza Lone Star Welding It has been said that volunteers are the lifeblood of AWS. Over the years, I have come to appreciate the truth of that observation. I continue to be amazed by the achievements Vice President William A. Rice Jr. of long-time AWS members, especially our Life Members. Even more remarkable is that OKI Bering many of these long-time members do not assume passive roles but are actively involved Vice President Nancy C. Cole with various AWS activities. Dedication at that level and depth deserves special commendation. NCC Engineering At last count, there were more than one-million organizations registered with the Treasurer Robert G. Pali Internal Revenue Service as nonprofit entities. With so many choices, why is AWS wor- J. P. Nissen Co. thy of receiving your time and resources? Long-time members state they continue giving because they believe in AWS. They support its core values and mission. They are con- Executive Director Ray W. Shook vinced that AWS is the world's premier welding organization. American Welding Society This passion for AWS on the part of its members should not be taken for granted. Countless charitable organizations have ceased to exist because their donors stopped believing in the mission. Doubt erodes motivation and gradually donor fatigue sets in. Directors To help overcome donor fatigue consider the following suggestions. B. P. Albrecht (At Large), Miller Electric Mfg. Co. • Remember the mission. AWS continues to advance the science, technology, and appli- J. R. Bray (Dist. IS), Affiliated Machinery, Inc. cation of welding and allied joining and cutting processes including brazing, soldering, D. B. DeCorte (At Large), RoMan Mfg. Inc. and thermal spraying. Since 1919, this core concept has not altered. All AWS strategic plans and initiatives are specifically developed to support this objective. This unswerv- G. Fairbanks (Dist. 9), Fairbanb Inspection & Testing Services ing focus serves to reinforce your resolve to continue your support. T. A. Ferri (Dist. 1), Thermadyne Industries • Attend Section meetings. By attending meetings, you witness firsthand the positive D. A. Flood (Dist. 22), Tri Tool, Inc. effect AWS has on the lives of real people. Listen as students tell you with enthusias- M. V. Harris (Dist. 15), Vallej' National Gases tic voices about the education they are receiving because of an AWS scholarship. Hear others relate how they were able to buy their first house or how they secured gainful R. A. Harris (Dist. 10), Consultant employment because they attained a welding-related certification. This interaction D. C. Howard (Dist. 7), Concurrent Technologies Corp. will do wonders to rejuvenate your commitment to volunteering. J. Jones (Dist. 17), Thermadyne Industries • Reflect on what AWS has done for you. When you thoughtfully reflect on the positive W. A. Komlos (Dist. 20), Arc Tech, LLC benefits you have received from your association with AWS you will be impelled, yes, I believe even driven, to want to help others achieve similar benefits. You will redis- D. Landon (Dist. 16), VemeerMfg. Co. cover the inward drive to stay the course. R.C.Lanier(Dist.4),HttC.C. As is true with so many long-time members, may the passing of time not diminish G. E. Lawson (Past President), ESAB Welding & Cutting Prod. your zeal. Remember, AWS and its success are totally dependent on the generosity of members like you. Keep volunteering. Continue giv- T. J. Lienert (At Large), Los Alamos National Laboratory ing. Don't stop believing. J. Livesay (Dist. 8), Tennessee Technolog}' Center D. L. McQuaid (At Large), DL McQuaid & Associates V. Y. Matthews (Past President), Lincoln Electric Co. (ret.) S. Mattson (Dist. 5), Mattson Repair Service S. P. Moian (Dist. 12), PDM Bridge, LLC T. C. Parker (Dist. U), Miller Electric Mfg. Co. (ret.) K. A. Phy (Dist. 6), KA Phy Services, Inc. W. R. Polanin (Dist. 13), Illinois Central College

John L. Mendoza N. Saminich (Dist. 21), Ninyo & Moore AWS Vice President N. S. Shannon (Dist. 19), Carbon Testing of Portland T.A.Siewert(AtLarge),iW5r E. Siradakis (Dist. U),Airgas Great Lakes K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv D. R. Wilson (At Large), Wilson Industries M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute

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Florence-Darlington Technical College Holds First Welding Rodeo

Florence-Darlington Technical Col- lege (FDTC), Florence, S.C., held its first Welding Rodeo April 30 and May 1 at the college's Southeastern Institute of Manufacturing and Technology. Five teams of professional welders and five teams of welding students, made up of four welders each, created welded sculptures fitting a motion theme. They were given eight hours to create artwork using a pile of scrap material. Planning for the event began more than one year ago when the college's Educational Foundation met with leaders from ESAB Welding and Cutting Products of Florence. "This was a true partnership between the college and ESAB," said Jill Heiden, executive director of the FDTC Foundation. Ross Gandy, director of the college's Advanced Welding and Cutting Center, headed up all compliance issues and Welders turned scrap metal into artwork at Florence-Darlington Technical College's first oversaw the building and equipping of Welding Rodeo. As shown above, a welding student from Central Carolina Technical the welding competition area. College, Sumter, S.C., works on the group's entry. The completed figure of an eagle catching The sculptures were judged by an in- a fish won the amateur division and an $800 grand prize. (All photos courtesy of Jerry dependent panel of local sculptors. The Uttrachi.) team from Nucor Steel of Darlington County won the professional division and a $1600 grand prize with their moving dolphin. Honda of South Carolina in Timmonsville took second place and $1200 with a curvy, free-form sculpture mounted on a giant "H." Welding students from Central Carolina Technical College, Sumter, S.C, won the amateur division and an $800 grand prize for their portrayal of an eagle catching a fish. ESAB donated $10,000 worth of welding equipment to the winning amateur team and gave welding helmets and gloves to each of the participants. Florence Career Center students finished second with their sculpture, "The Vortex," and the Florence-Dar- lington Technical College's Advanced Welding and Cutting Center team took the Honorable Mention prize for their motorcycle interpretation. ESAB donated $25,000 to the college's Foundation for the event. Nucor Steel Vice President Mike Gurley made the winning bid of $2000 for the dolphin made by the company's team. Hoyt Wood of Lake City, S.C, bought Cen- tral Carolina's creation for $800. ESAB purchased its team's entry of bull riders in a rodeo ring and will put it on permanent display at the Southeastern Insti- tute of Manufacturing and Technology on the Florence campus. The auction raised just more than $10,000 for the FDTC scholarship program. Plans are underway to make next year's competition bigger with room for more teams to compete and with the possible addition of a car show in con- junction with the rodeo. For more in- In the competition's professional division, Nucor Steel of Darlington County took top formation on the Welding Rodeo, visit honors, and a $1600 grand prize, for its moving dolphin sculpture. www.fdtc.edu.

JULY 2010 Hydrex Performs Dry Underwater Welding on a Tanker in Port of Gaiveston, Tex. GRIND TUNGSTEN PRECISELY MillQpi^lkMlw

A Hydrex class certified welder works underwater in one of the company's propriety mobile drydocks. (Photo courtesy of Hydrex LLC, Clearwater, Fla.) HEAVY DUTY TUNGSTEN GRINDER FOR 3/16"-.040" SAFETY; Enclosed diamond wheel grinding area Hydrex recently dry underwater welded an insert plate on a WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability tanker as a permanent ship hull repair in-situ. A five-person team PRODUCTIVITY: Longitudinal diamond grind your tungsten under 30 seconds of certified technicians and divers from the company's U.S. office went to the vessel in the Port of Gaiveston, Tex., to do the VALUE: Diamond flat, grind & cut your tungsten economically work. DIAMOND GROUND PRODUCTS, INC. v(<,.A The tanker required an insert of 800 x 490 mm for the hull's 2550 Azurite Circle Newbury Park CA 91320 \ f Phone (805) 498-3837 • FAX (805) 498-9347 V^, bottom. After ascertaining the cargo and ballast tanks were free Email: [email protected] of chemicals and fumes, and the atmosphere was safe for welders Visit our website: www.diarnondground.corn and hot work, the Hydrex team used its propriety mobile mini drydock technology to create a dry environment for performing For info go to www.aws.org/ad-index the welding and completing the permanent hull repair while the tanker remained in the water. Ultrasonic testing confirmed the weld. Also, the company's team coordinated with the Houston Det Norske Veritas office, and the American Bureau of Shipping supervised and approved the job site. Welder Bob Dedicated as Hobart Institute Celebrates 80 Years

At the dedication ceremony for Welder Bob, sculptor Gregory John- son (left), Hobart Institute of Welding Technology President Andre Odermatt, and William H Hobart Jr. pose with the bronze sculpture.

Welder Bob, a bronze sculpture erected at the entrance to the Hobart Institute of Welding Technology (HIWT), Troy, Ohio, was formally unveiled at a May 15th ceremony as part of activi- World's Leading Brand of Anti-Spatter For info go to www.aws.org/ad-index

WELDING JOURNAL ties celebrating the institute's 80th anniversary. The sculpture is Following the dedication ceremony, the institute held an open 43 in. tall and weighs in at 360 lb, not counting the 450-lb base house where people from the community as well as prospective on which it stands. The honor of unveiling the sculpture went to students toured the facilities. — Information provided by Dan Lea Elmer Swank, the institute's most senior welding instructor. and Martha Baker, Hobart Institute of Welding Technology. Welder Bob was named in honor of Robert C. Bercaw, the first instructor at the Hobart Trade School, which later became HIWT Sheet Metal Welding Conference XIV Draws It is dedicated to all past, present, and future Hobart instructors. In 1930, Bercaw was personally recruited by William H. Hobart High Turnout for Sessions, Vendor Display Sr. from the New York Central Railroad to teach welding in a corner of the Hobart Brothers Co. factory. Bercaw was also in- strumental in writing the first Hobart training manuals. Noted artist Gregory Johnson of Cumming, Ga., was commissioned to create the sculpture that was cast by Eagle Bronze Foundry of Lander, Wyo. Typical of Johnson's works, the sculpture is realistic, including details such as eyelets on the safety shoes, hems on the gloves, and seams on the trousers. One person seeing the piece for the first time immediately identified the gas metal arc welding gun in the sculpture's hand. The sculptor took care to pose the figure in a realistic position for welding. The bronze portion stands on a steel base designed and fabricated by the institute's staff, under the direction of Ron Scott, vice president of Hobart Institute. The base was then powder coated by Aesthetic Finishers, Piqua, Ohio. Present at the sculpture dedication were Andre Odermatt, During the technical program of Sheet Metal Welding Conference the institute's president; William H. Hobart Jr., Robb F. Howell, Xllf presenters covered a variety of topics including recent develop- and Greg Schaffer, members of Hobart Institute's board of di- ments in resistance welding and other sheet metal joining processes. rectors; Dr. Richard Adams, Ohio 79th District State Represen- The event, hosted by theAWS Detroit Section and cosponsored by tative; and Troy Mayor Michael L. Beamish. the Edison Welding Institute, took place May 12-14. American Welding Society Executive Director Ray W Shook, who served as HIWT president from 1991 to 1993, was unable to attend the ceremony, but sent a letter that stated in part, "On The American Welding Society's (AWS) Detroit Section re- behalf of the American Welding Society and its 63,000 members cently hosted Sheet Metal Welding Conference (SMWC) XIV from around the world, I want to congratulate you and HIWT at Schoolcraft College's VisTaTech Center, Livonia, Mich. The for achieving this major milestone." event attracted nearly 150 people from the United States, Canada,

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Members oftheAWS Detroit Section and guests attended the conference's large vendor display on the evening of May 13. Lynnes Welding Training started a facility in Bismarck, N.Dak., of- Mexico, Europe, Japan, China, and India. fering many types of hands-on classes. A student named Cord (left) Edison Welding Institute (EWI), Columbus, Ohio, cospon- from Fishtail, Mont, is shown with instructor Carl Tengesdal. sored the event as well as coordinated the technical program and registration. "The Sheet Metal Welding Conference is an important con- our training system would fit a niche for certain students who did tribution the Detroit Section makes to fulfilling the AWS mis- not want to go to a traditional technical college for welding," sion to advance the science and technology of welding," said Con- said owner Dave Lynnes, who occasionally teaches at both cam- ference Chairman Mike Palko from Ford Motor Co. "With the puses in addition to running a manufacturing company. quality of the technical presentations, the consistent attendance, The school offers gas metal arc, gas tungsten arc, shielded and dependable sponsors, SMWC clearly fills a need in our weld- metal arc, pipe, and combination welding courses. Both locations ing industry." provide custom training to businesses in industry. Students can On May 11, Dr. Sivakumar Ramasamy of Emhart Fastening sign up for one to two week basic courses up to advanced courses Teknologies guided a day-long tutorial on weld quality. that last a couple of weeks. Classes are ongoing throughout the During the three-day conference held from May 12 to 14, year. 38 papers were presented. Its six sessions and the session leaders Training allows students to spend approximately 15% of their included the following: Resistance Welding (Weldability), Dr. time in class learning about safety, protective gear, equipment Michael Karagoulis of General Motors; Other Joining Processes, maintenance, troubleshooting, power sources, and gases. The re- Dr. Jerry Gould of EWI; Resistance Welding (General), Dan maining 85% of time is spent in the welding booth working, learn- Galiher of Tower Automotive; Laser Welding, Arnon Wexler of ing, and practicing on the specific process being studied. Ford Motor Co.; Resistance Welding Equipment, Joe Beckham Carl Tengesdal, the main instructor at the Bismarck campus, of Chrysler Co. LLC; and Arc Welding, Rus Little of Honda. is an American Welding Society (AWS) Certified Welding In- An evening vendor display held on May 13, coordinated by spector, AWS Certified Welding Supervisor, and AWS Certified Susann Morfino of MJM Sales, Inc., also served as the Detroit Welding Educator. On occasion, Chad Erickson, the main in- Section's monthly meeting. Members and guests visited booths structor at the Fargo campus, will teach at the new location. For featuring 50 welding equipment and technology vendors. more information, visit www.learntoweld.com. Dr. Mark Gugel of General Motors served as vice chairman of this year's event and will be conference chairman for SMWC Conference Attendees Discussed Weider XV in 2012. A CD with the entire archive of technical papers from all Sheet Training Needs Metal Welding Conferences is available from the AWS Detroit Section. For more information about the biennial conference, More than 25 educators, suppliers, and welding industry lead- visit its link at www. awsdetroit. org or contact smwc@awsdetroit. org. ers convened at the Tulsa Welding School (TWS) campus in Jack- sonville, Fla., for the Super Training and Employment Advisory Committee Conference on April 8. Carl Peters, director of tech- Lynnes Welding Training Opens New nical training for Lincoln Electric, gave the keynote address at a Location in Bismarck, N.Dak. dinner held the previous evening. The conference represented the first time in the 60-year his- Lynnes Welding Training, Inc., recently expanded to a second tory of Tulsa Welding School that industry leaders and educators campus in Bismarck, N.Dak. The location was chosen due to a combined to review the overall curriculums for both of the growing number of students and inquiries from the western part school's campuses. Also in attendance were representatives from of North Dakota; the current oil industry boom predominant in the American Welding Society, Lincoln Electric, and Texas State the western part of the state; and the fact that the pipelines, power Technical College. Some of the topics discussed included the plants, and coal mines in western North Dakota need welders. need for more in-depth metallurgy training, the physics of weld- The school's original location is in Fargo. ing, and training on more complicated welding positions repre- The new 4800-sq-ft space features a training classroom; of- sentative of real-world environments. fice; work space; eight welding booths equipped with multiprocess Larry Brown, CEO and founder of Beam Reach Education, welding machines and custom-built with a unique pedestal ap- the parent company of TWS, hosted and moderated the confer- proach allowing for more room; and expansion capabilities avail- ence. There was lively discussion regarding the welder training able with room to add another five welding booths. needs of the industry and how the school might incorporate some "The success and acceptance of Lynnes Welding Training has of them into its programs as well as refine its current offerings. been both fun and rewarding, but not without a lot of hard work. In addition, the conference addressed training needs that may We knew that the market for training welders was there and that be more specific to the regions where the campuses are located.4

WELDING JOURNAL INTERNATIONAL UPDATE

New Laser Hall Opened to Conduct and Russia, celebrated the start of construction Welding Research with the symbolic welding together of two pipes The GKSS Research at Portovaya Bay, north- Centre, in collaboration east of St. Petersburg. with Airbus Deutschland The pipeline will span r^p^-^M GmbH, recently opened 1224 km (760.5 miles) — a new laser hall that in- the longest subsea cludes a laser system that pipeline in the world — will be used to research and will run straight laser beam welding of through the middle of new lightweight con- the Baltic Sea to Ger- struction alloys. The many's port of Greif- laser hall will be part of swald. It will consist of The laser welding hall at the GKSS the planned GKSS two parallel lines; the Research Centre. Lightweight Materials first to be completed in Assessment, Computing, 2011 and the second in and Engineering Centre. 2012. The laser hall is lo- Three pipelay barges cated at the GKSS Re- will be used on the proj- search Centre in ect. The Castoro Sei will Geesthacht, Germany. In a symbolic act to celebrate the start perform the majority of The company invested of construction on the Nord Stream the offshore construc- more than $1.2 million in pipeline at Portovaya Bay, Russia, pipes tion. In German waters, the facility, which was representing the Russian and European the shore approach of opened April 19 by rep- natural gas networks were welded both pipelines will be resentatives of GKSS together. built by the Castoro and Airbus. The materi- Assembly of the laser welding head. Died, and in the Gulf of als researchers from Finland, the Solitaire will be used. Geesthacht are taking During the opening ceremony, Russian President Dmitry over the system from the Airbus location in Nordenham, Medvedev said, "I am confident that the Nord Stream gas pipeline Germany. will become another link between Russia and Europe. Its con- While the research in Nordenham focused on laser beam weld- struction meets our long-term goals — and I would like to em- ing of length-stiffened profiles known as stringers for the exter- phasize this point — it corresponds to the objective of develop- nal skin of the aluminum fuselage structure of aircraft, the focus ing our national economies. And, of course, this is our contribu- in Geesthacht will be welding of sample models and test compo- tion into Europe's energy security." nents for aircraft fuselage shells. "The system is ideal for our research in the area of strength and reliability of laser welded lightweight structures," said Nor- Energy, Shipbuilding, and Construction to bert Huber, head of material mechanics at GKSS. Drive Growth In the Indian Welding Market

Swagelok Opens India Technology Center While the Indian welding market is currently dominated by the use of manual welding equipment, this situation is expected Swagelok Co., a developer and provider of fluid system solu- to change as several end-user industries have started demanding tions headquartered in Solon, Ohio, recently opened a new tech- automated equipment to support higher productivity, according nology center in Pune, India. Swagelok will operate the Swagelok to a new analysis from Frost & Sullivan. Strategic Analysis of the India Technology Center, a division of Bombay Fluid System Indian Welding Equipment Market (www.industrialautomation. Components Pvt. Ltd., and will provide product assembly serv- frost.com) finds that robust expansion of the Indian shipbuilding, ices, technical service, education, training, and development di- construction, and energy — particularly wind power — sectors rectly to customers in the region. It is the company's fifth tech- will underline strong growth of the Indian welding market over nology center worldwide; it also has centers in the United States, the medium and long term. Japan, China, and Switzerland. According to the report, the market earned revenues of $208 India represents a growing region for Swagelok, where the million in 2008, and it is estimated this will reach $311.5 million company has two authorized sales and service centers that serve in 2015. a diverse number of industries. "While the financial meltdown has adversely affected most end user industries for welding equipment in India, energy, con- Construction Begins on Nord Stream struction, and shipbuilding sectors have, to a large extent, been Subsea Russia-Germany Pipeline recession-proof and have been generating moderate demand," noted Frost & Sullivan Senior Research Analyst Archana Construction recently began on the Nord Stream Pipeline Chauhan. "A key driver boosting market revenues has also been from Russia to Germany through the Baltic Sea. Nord Stream, the gradual move from manual to automatic and semiautomatic along with shareholders and guests from the European Union welding equipment."^

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Q: An inspector recently noticed an er- ther from the grain boundary austenite, trode when AC H-F is used for arc initia- rant arc strike from an E2209-16 elec- the ferrite grains are loaded with tion. In my experience, addition of nitro- trode inside a 2205 duplex stainless steel chromium nitride precipitates. In fact, the gen to the GTAW shielding gas normally tank we are fabricating. The inspector in- microstructure of the HAZ is remarkably requires more frequent dressing of the sisted that we not only grind off the bump similar to that of the resistance welds in tungsten electrode for effective arc initia- but also insisted that we excavate (by 2205 shown in my May 2010 Stainless tion using AC H-F than when pure argon grinding) below the surface at least Yu in. Q&A column. is used as the shielding gas. This made the base metal thickness less Chromium nitrides have the approxi- Sargeant et al. found that the pitting- than the specified minimum, so we had to mate chemical formula C^N, which means sensitive depth of the GTAW arc strike deposit a repair weld to rebuild the exca- that one atom of N will remove 2 atoms of HAZ was less than with SMAW in their vation from the arc strike. I can under- Cr from the ferrite. The effect of Cr re- study, but they still needed to excavate stand such a requirement when the steel moval is compounded by the difference in 0.34 mm (0.013 in.) to remove the pitting- is hardenable, but I cannot understand atomic weight between Cr and N — the sensitive HAZ. such a requirement for a stainless steel atomic weight of Cr is about 52 while that I personally have witnessed the results that is not hardenable. I think the inspec- of N is about 14, so the Cr atom is about 3.7 of arcing between a 2205 stainless vessel tor should have allowed us to just grind times as heavy as the nitrogen atom. and a copper block used for the current re- the bump smooth at the arc strike. Was Therefore, on a weight-percent basis, for- turn (ground) to the power source when the inspector justified in insisting on the mation of chromium nitrides removes the copper block was not clamped and a excavation? about 7.4 times as much Cr as N from the worker inadvertently stumbled over the ferrite. In addition, Cr, being a larger atom copper block while welding was occurring. A: In a word, yes. than N, diffuses much more slowly than N. This produced a trail of arc strikes on the You are correct that 2205 base metal The result is that the ferrite around each stainless as the copper block slid along. All (nominally 22% Cr, 5% Ni, 3% Mo, 0.18% nitride particle is severely depleted in Cr, of these arc strikes had to be excavated. N) is not hardenable, so one wouldn't be and therefore is susceptible to corrosion. Good practice is to rigidly clamp the cur- worried about martensite formation in the Sargeant et al. further examined the rent return to the workpiece to prevent heat-affected zone (HAZ) of the arc strike tendency for pitting corrosion to occur at this sort of event from occurring. that could lead to hydrogen-induced an arc strike in 2205, and found that the From the above discussion, it should be cracking. That is a serious concern with HAZ containing chromium nitride pre- apparent that precautions should be taken carbon steels and low-alloy steels, but not cipitates is highly susceptible to pitting. In to prevent arc strikes on duplex stainless with duplex stainless steels. But there is their study, they determined that the arc steel. (In fact, precautions should be taken another concern that justifies the inspec- strike area needed to be excavated by to prevent arc strikes on any metal.) If an tor's requirement that you remove not grinding to a minimum depth of 0.89 mm arc strike occurs on a duplex stainless only the deposit from the arc strike but (0.035 in.) below the original surface of steel, the arc strike should be excavated to also the HAZ of the arc strike. the plate in order to remove the pitting- a depth sufficient to be sure that any de- The concern stems from the fact that, sensitive HAZ of the arc strike. posited metal at the arc strike, and the when duplex stainless steel is heated to a Duplex stainless steels like 2205 are HAZ, have been removed.4 temperature close to the melting temper- commonly used in environments where ature, the metal transforms to virtually pitting tends to occur, so removal of the Reference 100% ferrite. This happens in the HAZ. pitting-sensitive HAZ as well as the arc Under normal weld cooling conditions, strike deposit seems prudent. Your in- 1. Sargeant, D. A., Bradshaw, R., the HAZ cools slowly enough that austen- spector demanded excavation at the arc Walker, M. I., and Cottis, R. A. 1994. In- ite can nucleate and grow in the HAZ. strike to nearly double the depth deter- vestigation of the effects of arc strikes on This requires time for the nitrogen in the mined by Sargeant et al., no doubt to be on duplex stainless steel using scanning refer- ferrite to diffuse to the growing austenite the conservative side. I expect that your inence electrode techniques. Proceedings of phase regions. But under the extremely spector was either aware of this study or the Fourth International Conference — Du- rapid cooling conditions associated with his requirement for excavation was set by plex Stainless Steels, Vol. 1, Paper 98. an arc strike, the HAZ of the arc strike is someone else aware of the study. I think Woodhead Publishing, Cambridge, UK. quenched and nearly 100% ferrite re- the inspector was correct in demanding mains until cooling progresses to a tem- the excavation. perature that is too low for austenite to nu- Arc strikes are not isolated to shielded DAMIAN I. KOTECKI is president, cleate and grow. Then the nitrogen metal arc welding. In the same study, Damian Kotecki Welding Consultants, Inc. trapped in the ferrite is no longer soluble Sargeant et al. examined gas tungsten arc He is a past president of the American Weld- in the ferrite, but the nitrogen has no (GTA) metal arc strikes, as can occur ei- ing Society, currently treasurer and a past austenite it can reach by diffusion. So, on ther when AC high-frequency arc initia- vice president of the International Institute further cooling, the nitrogen precipitates tion is not used, or when a welder has dif- of Welding, andamemberoftheAWSASD as chromium nitrides within the ferrite. ficulty with AC H-F arc initiation because Subcommittee on Stainless Steel Filler Met- The issue of arc strikes on duplex stain- the tungsten electrode has become con- als, and the AWS D1K Subcommittee on less steel was investigated a number of taminated. I note here that addition of on Stainless Steel Structural Welding. He is a years ago by Sargeant et al. (Ref. 1). They the order of 2% nitrogen to the argon member and past chair of the Welding Re- showed that, in the HAZ of the arc strike, shielding gas in GTA welding is often rec- search Council Subcommittee on Welding very large ferrite grains are found, with ommended to counteract tendencies for Stainless Steels and Nickel-Base Alloys. E- just traces of austenite along the ferrite nitrogen loss from the weld pool during mail your questions to Dr. Kotecki at grain boundaries. Then, just beside the GTAW. While this is beneficial to the weld, [email protected], or send to grain boundary austenite, the ferrite it is somewhat damaging to the arc initia- Damian Kotecki, do Welding loumal, 550 grains are free of chromium nitrides. Far- tion characteristics of the tungsten elec- NWLeleune Rd., Miami, FL 33126.

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Welding Metallurgy and Weldability of cessing plants; aerospace rocket nozzles; Nickel-Base Alloys is a well-organized text and pollution-controlled flue gas desul- WELDING and a must read for students interested in furization systems statistically or pictori- METALLURGY the industry as well as practicing profes- ally illustrating the importance of nickel- sionals. John N. DuPont, John C. Lippold, based alloys would have been a nice AND WELDABILITY OF and Samuel D. Kiser have done a com- addition. NICKELBASE ALLOYS mendable job taking a "snapshot in time The text starts off with general classifi- MMM N Ot#OMf • JOM* C HPfOtO of the field." Current and future new cations of nickel and nickel-based alloys IAHU«1 0 MMt nickel-based alloy development efforts and then gets more specific with fruitful dis- are underway and will encourage future cussions on alloy producer history, trade editions. It is also on par with a similar names (i.e., Inconel®, Hastelloy®), and text, Weldability of Steels, by R. D. Stout. unified number system designations. The The text is heavy on the high-temper- phase equilibria discussions are excellent, ature nickel-based alloy side and light on and the accompanying bibliography is suf- the corrosion-resistant nickel-based alloy ficient to provide direction for readers to and application sides. A more thought out delve further into key areas. The authors discussion/chapter on applications would provide good coverage of the physical met- have provided the novice reader with a allurgy and weldability of solid-solution- more vivid description of nickel-based strengthened and precipitation-strength- alloy usage. The mention of "power gen- ened nickel-based alloys. Although impor- eration, petrochemical, chemical process- tant, I was surprised to see a discussion on ing, aerospace, and pollution control" is brazing and other joining processes in the too general and leaves a lot for the imag- oxide dispersion-strengthened alloys and ination. A more vivid description of nickel aluminide sections of the text. Ex- power generation (fossil, solar, nuclear, amples of brazing, a method also used for Welding Metallurgy and Weldability of fuel cells, bioenergy, with examples); su- joining solid-solution-strengthened and Nickel-Base Alloys, by John N. DuPont, perheater tubing in the petrochemical precipitation-hardening nickel-based al- John C. Lippold, and Samuel D. Kiser, is plants; shell/tube heat exchangers and mi- loys, was rightfully excluded from the text hardcoverwith 440 pages. Published by John crochannel reformers in chemical pro- and is well covered in other texts such as Wiley & Sons, Inc., Newark, N.J., www.wiley.com ISBN 978-0-470-08714-5. Price is $125.00 U.S.

Brazing Footprints by Robert Peaslee. Discussions on repair welding were extensive for precipitation-strengthened REAL SAVINGS! and single crystal alloys, yet very brief for solid-solution-strengthened alloys. The No matter the size of your shop or the equipment section on dissimilar welding was concise, you use, our revolutionary EWR system can offer you: and the included case studies are a must read. Practitioners will probably be skep- • a 40% - 60% reduction in shielding gas use tical about the overall content in the text • improved weld quality, manual or robotic as there is limited guidance on welding procedure. Voltage, current, and travel • reduced environmental impact speed affect the metallurgy of the weldment and are rarely mentioned in the text. r Call, OP visit our web site/ Energy input discussions were limited to the electron beam welding process, weld- to learn more . / ing of precipitation-strengthened nickel- based alloys, repair welding of single crystal superalloys, and description of Vare- straint-type testing. Also, while gas metal and gas tungsten arc welding are addressed, discussions on shielded metal arc welding, a common process used for joining nickel-based alloys, was noticeably ab- sent from the text. The appendices provide a quick reference (i.e., composition, etching formula) for practitioners and the Distributorships academe.* available to qualified companies HENRY J. WHITE, PhD, PE, is a market manager at Haynes International, Inc., Kokomo, Ind. 41G Gallimope Dairy Road, Suite I / Greensbopo, NC 27403 / 336 G05 1880 / www.peguiasystemsusa.com

For Info go to www.aws.org/ad-lndex M JULY 2010 AWS FELLOWSHIPS

To: Professors Engaged in Joining Research Subject: Request for Proposals for AWS Fellowships for the 2010-2011 Academic Year The American Welding Society (AWS) seeks to foster university research in joining and to recognize outstanding faculty and student talent. We are again requesting your proposals for consideration by AWS. 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 September 15, 2010. New AWS Fellowships will be announced at the AWS Annual Meeting, November 2010. THE AWARDS The Fellowships or Grants are to be in amounts of up to $25,000 per year. A maximum of two students are funded for a period of up to three years of research at any one time. However, progress reports and requests for renewal must be submitted for the second and third years. Renewal by AWS will be contingent on demonstration of reasonable progress in the research or in graduate studies. 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 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. DETAILS The Proposal should include: 1. Executive Summary 2. Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.) 3. Matching Funding or Other Support for Intended Research 4. Duration of Project 5. Statement of Problem and Objectives 6. Current Status of Relevant Research 7. Technical Plan of Action 8. Qualifications of Researchers 9. Pertinent Literature References and Related Publications 10. Special Equipment Required and Availability 11. Statement of Critical Issues Which Will Influence Success or Failure of Research In addition, the proposal must include: 1. Student's Academic History, Resume and Transcript 2. Recommendation(s) Indicating Qualifications for Research must include one or more letters of recommendation from the sponsoring professor or others acquainted with the student's technical capabilities 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. 4. Statement Regarding Probability of Success The technical portion of the Proposal should be about ten typewritten pages; maximum pages for the Proposal should be twenty-five typewritten pages. Maximum file size should be 2 megabytes. It is recommended that the Proposal be typed in a minimum of 12-point font in Times, Times New Roman, or equivalent. Proposal should be sent electronically by September 15, 2010 to:

Vicki Pinsky (vpinsky(a),aws.org) Manager, AWS Foundation American Welding Society 550 N.W. LeJeune Rd., Miami, FL 33126 Yours sincerely, Ray W. Shook Executive Director American Welding Society LETTERS TO THE EDITOR

Reader Corrects Article on thinnest layer has a silvery color, while a aries in the HAZ. Pickling cannot save Stainless Steel Welds slightly thicker oxide layer gives a straw such a weld. Only solution annealing and yellow color. Darker colors result from quenching can. A discussion is presented about the "Tips still thicker oxide layers. The hotter the for Welding Stainless Steel" article (pages metal is when it reaches the air, the darker Damian J. Kotecki 46-48) in the May 2010 Welding Journal will be the oxidation layer color. These AWS Past President by Brent Williams, a technical contributor, colors happen whether or not carbide pre- President, Damian Kotecki Welding Weldcraft. cipitation has occurred. Consultants, Inc. The possibly dangerous part of the quoted paragraph results if a person weld- We would like to acknowledge Dr. I read with interest the "Tips for Weld- ing a non-low carbon grade of stainless, Kotecki for his comments regarding the pres- ing Stainless Steel" article, and while it such as 304 or 316, thinks the weld cannot ence of carbide precipitation in stainless has some interesting points, I find the fol- suffer carbide precipitation if the silver or steel welds. Our intention was to simplify lowing paragraph about GTAW of stain- straw yellow color is achieved. If a weld this key consideration associated with the less wrong and possibly dangerous: in a higher carbon stainless is put, with- welding of stainless steels. However, the gen- "Good austenitic stainless steel welds out subsequent solution annealing and eralized relationship between weld discol- are straw colored, whereas those in which oration and carbide precipitation in the de- quenching, into service in a corrosive en- carbide precipitation has occurred are scribed situation could be misleading. As vironment, or even into water, corrosion black. Welds that have the potential for stated by Dr. Kotecki, discoloration in stain- along grain boundaries will likely take carbide precipitation are generally blue less steel welds is indicative of the oxide layer place. The factor that determines carbide or purple. By considering these colors, you and minimal discoloration does not indi- precipitation is not the color but the car- should be able to determine whether you cate the absence of carbide precipitation — are achieving the correct heat input and bon content of the base metal. The shop especially in alloys with higher carbon con- travel speeds when welding austenitic accepting the color statement quoted tent. More correctly, the procedures de- stainless steel." above is asking for trouble with corrosion. scribed by Dr. Kotecki should be followed What is wrong is that the color on the Whatever the oxidation color, if the to ensure weld quality with minimal pres- surface of the weld has absolutely noth- base metal is low carbon (maximum ence of carbide precipitation. This clarifi- ing to do with whether or not carbide pre- 0.03%), pickling to completely remove the cation and insight from Dr. Kotecki is ap- cipitation has occurred. The surface color surface oxidation colors will render the preciated and will be applied to this and fu- is only an indication of the temperature weld corrosion resistant. But if the base ture references regarding the key differences of the metal surface when it reached the metal is higher in carbon, regardless of between oxidation and carbide precipitation air outside of the shielding gas coverage. the oxidation color of the surface, it will in stainless steels. The various colors are the result of the experience carbide precipitation and may thickness of the oxidation layer. The experience corrosion along grain bound- Weldcraft

CAN WE TALK? The Welding Journal staff encourages an exchange of ideas with you, our readers. If you'd like to ask a question, share an idea or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with the right person. Publisher Production Mnager Senior Advertising Production Andrew Cullison Zaida Chavez Manager [email protected]. Extension 249 [email protected], Extension 265 Frank Wilson Article Submissions Design and Production [email protected], Extension 465 Advertising Production Editor Senior Production Coordinator Mary Ruth Johnsen Brenda Flores Peer Review Coordinator [email protected], Extension 238 [email protected]. Extension 330 Erin Adams Feature Articles Production [email protected]. Extension 275 Peer Review of Research Papers Associate Editor Advertising Sales Director Howard Woodward Rob Saltzstein [email protected]. Extension 244 [email protected]. Extension 243 Advertising Sales Society News, Personnel Welding Journal Dept. Advertising Sales & 550 N.W LeJeune Rd. Associate Editor Promotion Coordinator Miami, FL 33126 Kristin Campbell Lea Garrigan Badwy (800) 443-9353 [email protected], Extension 257 [email protected], Extension 220 FAX (305) 443-7404 New Products Production and Promotion News of the Industry

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www.logodogz.net/aws RWMA Q&A er ROGER 6. HIRSCH

Q: I install weld nuts on panels using a ing machine that uses a fixture-type and will not pass OSHA requirements. The pilot pin in the lower electrode as a loca- transformer operating on 440-V single- only system available that is passive uses tor. I have noticed that some of the threads phase power. The operators are complain- continuity measurement between elec- in the nuts are distorted. What could be ing about receiving little shocks when they trodes to see if the electrodes are touching the cause? touch the electrodes. A meter placed metal. The electrodes close under low force between the electrode and ground reads and only go to high force when metal is de- A: There can be two causes for this prob- 230 V. Does this mean that the trans- tected. Your resistance welding supplier lem. First, if the pilot pin is conductive former needs replacement? should have no problem in finding a con- you can have arcing on the threads. This trol with this type of safety system that will can be eliminated by using fully insulated A: Probably not. If the transformer had operate your welding machine. guide pins. The current technology uses a breakdown between the primary and ceramic guide pins to eliminate arcing. secondary sides your operators would get Q: When I join an 18-gauge cold rolled The second cause could be using a weld- more than "little" shocks. I would bet that steel (CRS) plate that has three projec- ing schedule that is too long or with too the secondary of the welding transformer tions to a 14-gauge CRS part I have a hard low of a force between electrodes. This is not grounded. There should be a ground time getting all three projections to be ac- causes the nut to become plastic and wire, sized about Vi the size of the incom- ceptable. Usually one projection is good, changes the thread pitch. Just increase ing power wires, that should be connected one is borderline, and one just falls apart. force, reduce weld time, and then increase from either of the welding machine's sec- What am I doing wrong? welding current until the desired pull-off ondary pads. If installing this ground wire strength has been developed. causes arcing between the part and the A: Projection welding can drive you crazy. welding table or fixture, you can leave the The problem is that the welding machine Q: I have had no problem finding weld- secondary floating and install a ground- will pass current through the projection ing schedules in the RWMA Resistance ing reactor on the machine secondary. that has the best contact force and might Welding Manual to join most of the parts Your resistance welding supplier should not even start passing current through an- we manufacture. The only thing I do not be able to supply this inexpensive device. other projection until much of the weld see on the schedules is how to set the time has expired. To make all of the welds HOLD TIME. What does this function do, Q: I use my spot welding machine to sil- successful, you have to do two things: and what number should I set? ver solder brass and copper parts to- 1. The upper and lower electrodes gether. The electrodes are copper-tung- should be flat and absolutely parallel. This A: Hold time is the time after the end of sten and I can get good results. However, means that the welding machine has to be weld heat and the opening of the welding the operator must continually adjust the very rigid. Don't try to do this type of weld- electrodes. It keeps the metal under force welding control to maintain flow of the ing using a rocker arm welding machine. until the molten metal of the weld nugget silver solder. Any ideas? Be sure to measure the absolute parallel of solidifies. If the hold time is too short, the the electrodes under full welding force since welds will not be at full strength. If the A: The problem is that you are using the all welding machines will flex under me- hold time is too long, production time will electrodes as external heating blocks, and chanical load. One trick is to put the ma- be wasted. As a rule of thumb, set hold the amount of heat produced has to do chine in no weld, place a piece of a self-car- time to 03 cycles for metal thicknesses of with the starting temperature as well as boning form under the projection part, and 0.070 in. or thinner, and 05 cycles for the height of the copper-tungsten face on come down with full welding force. Adjust thicker metals. If joining two thicknesses, the electrodes. The answer is to use a weld- the electrodes as needed to make the same use the thinner of the pair to determine ing control that incorporates an infrared print on all three projections. the hold time. temperature instrument that will monitor 2. Once you have this set, you will need temperature at the outside of the joint and to use a welding schedule that has lower Q: I am trying to make a weld on a panel continually compensate to produce the heat, lower force per projection, and a that must be as clean and flat as possible same temperature and time sequence. longer time than would be used for weld- on the outside of the finished product. The These controls are readily available from ing a single projection. The Resistance welds are strong enough, but the weld lo- your resistance welding supply company. Welding Manual has a very nice chart on cations have deep dents that are almost projection welding with separate settings impossible to sand out. Q: Two of our operators have had finger for a single projection, two to three pro- accidents involving our spot welding ma- jections, and more than three projections. A: First, be sure that the electrode on the chines in recent months. One common op- Set the electrode force and weld time per "show" side of the part is flat and ab- eration involves inserting weld nuts on the chart, and then adjust the weld heat solutely parallel to the back surface of the top of a locator pin. This requires that the until you achieve the desired results.4 panel. While some recommend the use of operator place her fingers near the pinch swivel electrodes, I am a fan of solid flat point between the electrodes. One of the ROGER B. HIRSCH is president, Unitrol electrodes with a diameter at least twice accidents happened when the operator Electronics, Inc., Northbrook, III, and chair that of the upper electrode. Then use full was installing a new set of electrodes. How of the RWMA committee of the American electrode force, short time, and high weld- can we guard these welding machines Welding Society. Hirsch holds a degree in electrical engineering from the University of ing heat to get a nugget without exces- without affecting production or putting mechanical probes in the welding area? Illinois and in mechanical engineering from sively heating the surrounding area. Using IIT. He has worked in the metals manufac- too low electrode force will actually in- turing industry since 1965 and has a list of crease weld indentation. Try to use a weld A: There are various systems available to patented inventions for this industry and oth- schedule from the Resistance Welding guard resistance welding machines, but ers. Send your comments I questions to Manual for the alloy you are welding. most require adjustments to the safety sys- [email protected], or Roger tem to make the pinch-point zone safe. Hirsch, do Welding loumal, 550 NW Q: I have a custom single-point spot weld- This renders the safety process nonpassive Leleune Rd, Miami, FL 33126.

JULY 2010 Become Certified in Robotic Arc Welding and Join the Ranks of the Elite in the Robotics Industry

AWS understands that the certification of individuals in robotic arc welding is important to the industry, and has developed a program, based on the AWS QC19 standard and AWS D16.4 specification, that defines the requirements for personnel to be considered qualified to test for certification.

Depending on the level of experience, individuals who pass a written exam and performance test can be certified as either Robotic Arc Welding Technicians on Operators. For more information regarding this program, including how to become an AWS Approved Test Center, visit our website today at www.aws.org/certification/CRAW or call (email [email protected]).

To schedule training and testing to become certified in robotic arc welding, contact one of these AWS Approved Test Centers. Colorado // //4600 Innovation Drive //Fort Collins, CD 80525 // Iowa // //8900 Harrison Street//Davenport, IA 52806// 63) 445-" Michigan// /1250 Brown Road//Auburn Hills, Ml 48326// 1-8421 Ohio// Lincoln Elect //22221 St. Clair Ave. //Cleveland, DH 44117 // 383-8542 Wisconsin // /1200 South 71 st Street//West Allis.WI 53214// (414] 297-6996

Week of: AWS Approved Test Center 8/2/2010 , Mich. 9/13/2010 , _ . Collins, Colo. 9/13/2010 Genesis-Systems, Davenport, Iowa 10/4/2010 ABB, Inc., Auburn Hills, Mich. 10/4/2010 Genesis-Systems, Davenport, Iowa 10/25/2010 The Lincoln Electric Co., Cleveland, Ohio 10/25/2010 Genesis-Systems, Davenport, Iowa 11/1/2010 ABB, Inc., Auburn Hills, Mich. 11/1/2010 Genesis-Systems, Davenport, Iowa On request Milwaukee Area Technical College, Milwaukee, Wis. THE WORLD OF r; r WELDING'S GREATEST C August 31 - September 1,2010 San Diego, CA

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WELDING JOURNAL 3 ^asss ^Gitok OEI m^m Whether they work with stainless steei, weathering steel, brass, copper, or scrap mild steel, metal and welding are the preferred media of these artists

BY KRISTIN CAMPBELL, MARY RUTH JOHNSEN, AND HOWARD WOODWARD

Artists who sculpt using welding work she knew she had "found the material that in a fundamentally different manner than says what I want to say." Cole believes those who create using other materials she's a pioneer in many ways. Although and methods, explained Canadian artist not the first woman to sculpt with metal, Hilary Clark Cole. "People who weld work when she began her professional career from the inside out; sculptors who work in the late 1960s, she didn't see too many in wood, stone, and sometimes in bronze other women doing what she was. "I knew work from the outside in." what I wanted to do, but there was no one Following are profiles of six artists who to show me how to do it," she recalled. "I have chosen metals and welding as the had to figure out how to do things myself. media to create art that ranges from the I had to innovate. The equipment was whimsical to the monumental. large and the materials were heavy." Clark Cole got her first taste of metal- Hilary Clark Cole work while a student at the Ontario Col- lege of Art and Design in a jewelry-mak- Fig. 2 — Northern Ontario Bull Moose When Hilary Clark Cole (Fig. 1) first ing class. They taught welding next door, was the first piece Clark Cole built from began working with metals and welding however, and she quickly moved over. In COR-TENsteel. The moose stands 9 ft tall, and weighs 1200 lb, about the height and weight of a real moose.

Fig. 3 — Muskox took a year and a half to complete and weighs 1600 lb. The individual steel strips that make up his coat were cut with a plasma cutting machine, shaped (often using Clark Cole's own body weight Fig. 1 — Canadian artist Hilary Clark Cole poses with the maquette or study model of to bend the metal), and individually welded Muskox and the then-unfinished sculpture. into place.

MARY RUTH JOHNSEN ([email protected]) is editor and KRISTIN CAMPBELL ([email protected]) and HOWARD WOOD- WARD ([email protected]) are associate editors of the Welding Journal.

JULY 2010 Fig. 4 — Clark Cole said she "lay under- neath, sat beside, and climbed on top" to weld the hair on Muskox The pieces of hair range in size from 'A-in. square to 30 in. long x 3 in. wide. Fig. 5 — Here, Hilary Clark Cole shares the spirit of her sculpture titled Windswept Sil- some ways, she believes her affinity for houette, which is rooted on a piece of metal is ingrained. "Fifteen years into my Muskoka granite. The sculpture took a year professional career I asked my father what to complete, is Wift tall, and weighs 4'/2 tons. my grandfather did for a living, and it Cole considers it one of her masterworks. turned out he was a blacksmith." Fig. 6 — Clark Cole began work on Ironica Since 1971, Clark Cole has lived and lanuary 27, 2009, and completed the work worked in Muskoka, Ont., Canada. "I don't really have anyone to help me, in May 2010. She built the life-sized figure Today's modern welding and cutting and I don't really want anyone to," she from the feet up. equipment has been a boon to her career said. "I want it to be a work of my own because of its light weight and capabilities hands." She does have a friend she turns for cutting and welding thicker materials. to if she needs something with especially "Until 1992,1 wasn't working in heav- accurate dimensions, but overall, "I don't ier materials and most of my pieces were like perfect circles. I like my hands to indoor sculptures," she said. "I couldn't show." lift the sheets, let alone cut them. I used Clark Cole does extensive research be- a lot of scraps at first and looked for hours fore building a sculpture in order to get the to find the shapes I needed." anatomy and movement correct for the Today, she uses oxyacetylene and gas creature she is creating. That was true for metal arc welding (GMAW) and plasma Ironica, the life-size female figure wearing arc cutting equipment. She creates large, a suit of armor that she has spent the past realistic, three-dimensional animals such year and a half creating—Fig. 6. Clark Cole as Northern Ontario Bull Moose (Fig. 2) enjoys chronicling her creations and has ex- and Muskox (Figs. 3, 4) and fanciful fig- tensive write-ups and photos of her pieces ures such as Windswept Silhouette (Fig. 5), on her Web site at www. hilaryclarkcole. com, as well as small, intimate studies of flow- including a complete diary of the building ers, wildlife, and humans. For the large of Ironica. She believes people need to pieces, she starts with a maquette, or study know how artworks are created and that it model, in light steel in order to establish helps with their understanding and enjoy- the anatomy, dimensions, personality, and ment of the piece. message of the life-sized work. Today she is still in "Ironica recovery The Moose, Muskox, and Windswept Sil- mode" and is enjoying working on some houette were all created with Vs-in. COR- small pieces that take only two or three TEN® steel plate. This nickel-steel alloy, weeks to complete rather than a year or commonly known as weathering steel, rusts more. This series will be displayed at The until it achieves a certain color and patina, Algonquin Art Centre at Algonquin Fig. 7—Kevin Stone enjoys making unique but does not corrode, making it ideal for Provincial Park in Central Ontario. sculptures out of stainless steel with mirror creating outdoor sculptures. Clark Cole finishes. His detailed work includes two cuts the metal with the plasma cutting ma- Kevin Stone large-scale bald eagles and a dragon. chine; she uses a Beverly shear for lighter materials. She bends the metal through Since childhood, Kevin Stone has loved hammering, heating, or as with the pieces to draw cartoon and fantasy art. Now, Chilliwack, B.C., Canada — Fig. 7. that make up Wuskox's long coat, putting thanks to the help of a full-time investor, "My pieces are designed to inspire awe the cut metal strips in a vise grip and using he's able to spend his days sculpting as and simply amaze spectators upon view- her body weight to make the bends. owner of Metal Animation Studio, Inc., ing," Stone said.

WELDING JOURNAL Fig. 8 — A gargoyle, built out of leftover scrap material, became one of the first stainless steel sculptures Stone made.

Fig. 9 — Power and Authority boasts an impressive 31-ft wingspan.

Fig. 10 — Power of Flight offers a domi- neering presence combined with grace all in a wingspan covering more than 40 ft.

Fig. 11 — Stone, shown welding the Fig. 12 - The 85-ft-long Chinese Imperial Water Dragon took nearly two years to dragon's head, made approximately two complete. miles of gas tungsten arc weld beads while putting together the dragon. (Photo courtesy of Miller Electric Mfg. Co.)

With more than 20 years of metal fab- can be reflected off of them. presence. Its public unveiling, held in rication experience, he started sculpting Stone cuts the stainless steel with a 2006, came after ten months of work. stainless steel about SVi years ago after an power sheer or grinder with a cut-off "Inspired by the positive feedback employer asked him to build a gargoyle wheel; fits and tacks parts together; pri- from friends and the public who have seen for the company's rooftop. He completed marily uses gas tungsten arc welding be- my work, I decided to make another eagle, the 6.6-ft-talI, 8.5-ft-wide, 300-lb creature cause the process does not spatter or spark bigger and with even more detail," he said. in about three months working with left- and enables fine detail work; grinds down Power of Flight, Stone's second bald over shop scraps — Fig. 8. the welds; and follows a multistep process eagle, captures the bird's streamlined ef- "I thought it would be fun to challenge of polishing with fine-grit polishing pads ficiency and grace — Fig. 10. Unveiled in myself to try sculpting in metal," Stone until achieving a mirror finish. 2007, it weighs 6000 lb and is 11 ft high said. "The result was that I found stain- with a wingspan of more than 40 ft. less steel to be a wonderful and beautiful Letting Eagles Soar material to work with for making art." Each of Stone's three-dimensional cre- Stone's first large-scale sculpture, the Creating the Chinese Imperial ations is hand made with 16-gauge surgi- bald eagle Power and Authority, strikes an Water Dragon cal-grade stainless steel. The metal's attack pose with extended legs and its eyes longevity qualities include no rust or cor- focused on the prey — Fig. 9. The 20-ft- Stone's next piece came from an early rosion. He also intends for his sculptures high sculpture with a 31-ft wingspan cap- liking of fantasy art with heroes fighting to be mounted in or above water so light tures the bird's dominating, powerful dragons and monsters to save the king-

JULY2010 dom or a damsel in distress. The Chinese Imperial Water Dragon has been his most challenging project, taking almost two years to complete. "It was a test of perseverance," Stone said. Approximately two miles of gas tungsten arc weld beads were made while putting together the masterpiece — Fig. 11. The dragon's body features two large coils, and an enameled ball is held in one of its claws. Stone believes it is the world's largest stainless steel Chinese dragon standing 12 ft tall, 14 ft wide, more than 85 ft long, and weighing 6000 lb — Fig. 12. In 2009, the dragon unveiling attracted a turnout of almost 2000 people with support from the City Council, Chilliwack tourism, local art groups, and a speech from Chilliwack Mayor Sharon Gaetz.

Additional Projects

In August 2009, Stone assembled a rap- tor dinosaur using a scaled-up version of a wood puzzle model. It stands more than 7 ft tall and 11 ft long from head to tail. The sculpture's metal bones were cut using a plasma machine, boxed with 1-in. flat strips, and welded for added strength. All four sculptures (the two eagles, dragon, and dinosaur) are on display at Stone's studio in Chilliwack, which is located in the yard of his home and open seven days a week for the public to view these pieces before they sell. Eventually, Stone would like to work with a Native American carver to create a large totem pole using his chosen medium of stainless steel with a mirror Fig. 13 —Jennifer Costa heat treats metal parts to intensify the colors. Heating cast aluminum finish. To learn more about the artist, visit coated with linseed oil produces various attractive colors. "Depending on when I stop the www. metalanimation. com. heating," Costa said, "the linseed oil takes on shades of yellow, orange, red, brown, or black." Jennifer Costa

Jennifer Costa (Fig. 13) is the gallery curator and an assistant professor of art at Illinois Central College, East Peoria, III., where she has taught for ten years. Some of her artistic inspiration has become reality by taking artistic advantage of her own scrap metal. Costa mused, "I often found myself thinking what a waste of all of these pieces of steel that I am cutting away to make the larger pieces. I started saving the smaller pieces and then welding them together to create interesting patterns that would play with light." Most interesting, she said, "I have created sculptural pieces that just happened to have places for a person to sit, thus making them functional as well. My chairs made way for tables, and the tables made way for mirrors, and the mirrors made way for wall pieces with little drawers to pique the interest of the viewer" — Figs. 14—16. fig. 14 — The whimsical Nothing to Hide blanket chest shows what Jennifer Costa created She credits her inspiration to the Art Deco from four pieces of steel and a hinged lid made from cast-aluminum and a patina produced and Art Nouveau artists Eileen Gray, using her linseed oil technique. The inside-bottom of the chest is lined with fabric. She used Charles Rennie Mackintosh, Louis Ma- a plasma torch to make the clean-cut edges on the design.

WELDING JOURNAL AWS Illinois Central College Student ing," Costa explained, "is the process of Chapter, worked with Costa on several burying an item carved out of a piece of AWS-related projects. He also has at- foam and then pouring molten aluminum tended Costa's classes. He said, "Jennifer down a tube to the foam piece. The alu- Costa is a good welder. She taught me how minum instantly vaporizes the foam and to work out my ideas using a sketchbook fills the void. The piece of steel placed in and the construction of maquettes. A hun- the foam is used for welding the legs to a dred of my sketches would usually yield steel frame. Sometimes, I cast the alu- only a couple good ideas, but they embod- minum around bolts and use the bolts to ied the best features of the other 98 weld to the frame. For welding, I use a sketches that were rejected." Ocker- Lincoln Electric Weld Pak 100 shielded hausen concluded, "Creating good art is with CO2, and for cutting I use a Miller a lot of work!" Spectrum 375 Cutmate DC plasma arc system." For cutting, she prefers to use plasma arc for its ability to give cleaner Fig. 15 — One of a series, this Little Table Some Tricks of Her Trade is a 36- x 24- x 18-in. corner table that dis- edges than is possible with oxyacetylene. plays a number of Costa's metalworking Costa said, "The sculpture lab has a Costa exhibits her work locally and na- techniques. fully equipped woodworking shop and a tionally, and anyone can view her portfolio small welding area. We have a foundry at www.jennifercostastudio.com. outside with a Speedy Melt Furnace that is capable of melting 30 lb of aluminum Bob Doster and 90 lb of bronze. We are capable of doing lost-wax casting, and resin-bonded Bob Doster (Fig. 17) first tried his hand sandcasting. Most of my artwork incorpo- at welding when he was eight years old. rates some variation of aluminum casting, His father owned a furniture business, welding, and woodworking. The tables then added metalwork when furniture have cast aluminum legs in which I use sales slowed. "Fifty-two years later, here vapo casting and cast the aluminum di- I am still welding," Doster said. rectly around a piece of steel. Vapo cast- Doster initially learned to weld from

Fig. 16 — This 36- x 36- x 18-in. Launch table is made from welded steel with cast aluminum legs. The intricate design is fash- ioned from scrap steel pieces. Costa allowed the table to rust to develop a natural patina, then sealed the surface of the piece with spar varnish.

jorelle, Emile Galle, and others who also made amazing sculptural objects that served practical purposes.

Combining Materials for Effect

"Now," Costa explained, "I am working on combining materials. I'm not rely- ing solely on wood or on steel, but using both within one piece of artwork in addition to other materials. I love detail and using the natural colors of various woods by having them contrast and complement one another." Costa, who holds a master's degree in fine arts — sculpture, is currently affiliated with VagnHall Galleri, Prairie Arts Center, Bishop Hill, 111. She teaches 3D Design and Sculpture I at Illinois Central College. Her students learn to braze and weld with the gas tungsten arc process. "My students learn how to do bronze and aluminum casting and can further their welding experience by practicing basic beads using the Lin- coln Electric Weld Pak." Fig. 17 — Bob Doster is shown looking through one of his many portal sculptures. This one Eric Ockerhausen, advisor for the is now in a private collection in Washington, D.C (Photo by Aaron Stevenson.)

JULY 2010 Fig. 18 — During his time as the featured artist at the University of South Carolina Upstate, Doster created eight large metal sculptures for the campus, including this Suspended Portal. Doster has created many portals over the years, "Hike the shape and form, but there's also a transitional meaning, the passing through from one point of time to another." Fig. 19 — Doster enjoys the challenge of creating something to fit a specific space, such as Cascade for the Saks Fifth Avenue store in Atlanta. the guys in the shop, but after receiving a master's degree in fine arts from Clemson arc, and shielded metal arc (SMA) weld- quired it be no deeper than 4 ft, no wider University, he enrolled in welding classes ing processes, as well as both manual and than 10 ft, and no taller than 40 ft. Erect- at York Technical College, Rock Hill, S.C. CNC plasma arc cutting systems. He also ing the piece on site took IVi nights and "When I got out of college, I immediately utilizes a variety of hand tools and light the services of structural engineers and took a welding course so I could make bending equipment. Any pieces greater riggers to hang it safely. Shoppers view it pretty welds," he recalled. "Mine would than 12 ft tall, he takes to a friend's fab from different angles as they ride the stick, but they looked terrible." shop to take advantage of the cranes and store's escalators. Today Doster continues working in his heavier-duty equipment there. Doster is also clearly passionate about hometown of Lancaster, S.C, where he When creating a large-scale piece, he working with children. Thirty years ago he owns Bob Doster's Backstreet Studio, likes to build a small model beforehand. was named to the roster of the Arts in Ed- Gallery, and Garden, where he not only The model allows him to create a visual rep- ucation program of the South Carolina shows his own work but that of other resentation of his ideas and helps him work Arts Commission, and he estimates he has artists, including wife. Cherry. Among the out any difficulties he might encounter in worked with more than 100,000 students honors he has received are the 2006 Eliz- developing the full-scale artwork. since then. The program gives students abeth O'Neill Verner award, a governor's the opportunity to work with professional award that is the highest recognition given Passions and Challenges artists. The pieces the students make to artists in South Carolina. Doster was range from small artworks they can carry the featured artist for the 2008-09 aca- What is Doster passionate about? home with them to large pieces to deco- demic year at the University of South Car- "Usually the next piece I'm working on," rate their schools or communities. The olina Upstate in Spartanburg. During that he said. "My passions vary from piece to plasma cutting equipment has been help- year, he created eight large metal sculp- piece. I'm like a tree, I go from branch to ful to Doster's educational endeavors be- tures that are located throughout the cam- branch." More seriously, Doster explains cause even the youngest children can cut pus — Fig. 18. that one of his most enjoyable challenges their own pieces with his hand guiding Doster uses COR-TEN® or stainless is "when someone says 'This is the space, theirs. steel for much of his work. "I like the rusty make something to fit it.'" "Most of the time I do the actual weld- material because of the way it looks in the An example of that is Cascade, a 40-ft- ing, but at schools with a metal shop, the environment. Neither one (weathering or tall stainless steel sculpture he created for students do it," he said. Doster lamented stainless steel) has any upkeep." the Saks Fifth Avenue department store the loss of so many vo-tech programs say- He uses the gas tungsten arc, gas metal in Atlanta, Ga. — Fig. 19. The space re- ing there are many students who would

WELDING JOURNAL Pamela Olin Art Featuring the Human Form

Human figures recur throughout Portal, a steel archway that comes apart Pamela Olin's artwork. "I like how the in three pieces, is a pivotal piece to Olin human form can express emotion and at- — Fig. 23. "That was my very beginning titude," she said. of using human shapes," she said. The owner of Olin Design Studio, Its three-month construction phase Chicago, 111., finds inspiration in life. Her took place in 1995. She used GMAW for love of art began as a child, and she grew the archway's inner walls to provide struc- up as a creative person, thinking outside tural ability; hand cut human shapes down the box. its sides with a plasma cutting machine; Olin (Fig. 22) works with mild steel. It welded those cut-out figurines in a circle is versatile, easily found in leftover scraps, at its top; and applied a clear coating. The and gives weight to sculptures. To make structure stands 8 ft wide x approximately pieces look solid, she uses copper, bronze, 10 ft tall x 2 ft front to back. It is placed brass, and pewter coatings, or allows a at a camp's outdoor chapel. patina to develop. Two steel sculptures. Going Forth and Primarily, she performs GMAW for Fullfill, were made at the same time in the tight control it provides, and also uses 1998 over a span of four months. a plasma arc cutting machine and a sup- Going Forth (Fig. 22), signifying man's ply of hand tools including drills, ham- efforts to explore beyond our sphere of mers, and sanders. reference, features three spiral arms of Olin has enjoyed making welded art people with the center having smaller Fig. 20—One ofDoster's commissions was during the past 17 years. "It's a great rush spheres "born" from it, then getting larger a series of Cotton Boll sculptures for manipulating material," she said. "It'll as they get farther away. Olin made an ar- l Founders Federal Credit Union offices. last. It's not going to break or go away." mature with A-m. rod as its base, used

Fig. 21 — Doster uses a computer- controlled plasma arc cutting machine to cut the pieces for his series of small collectibles, which includes palmetto trees. benefit from taking welding. Doster's goal has always been to make a living as an artist. To that end he relies heavily on commissions such as a series of Cotton Boll sculptures for Founders Fed- eral Credit Union — Fig. 20. He took their corporate logo and turned it into 8- or 12- ft-diameter three-dimensional metal sculptures. He also creates a variety of functional pieces such as benches as well as collectables such as stainless steel palmetto trees and angel oaks — Fig. 21. He began making palmettos — the state tree of South Carolina — because of one of his five sisters. "She was having a barbecue and said, 'If you'll make me a palmetto tree, I'll sell ten of them that night.' She sold 100 of them, and I decided I needed to make palmetto trees." At first he cut them by hand, but now does them on the CNC plasma cutting machine. For more information on Bob Doster and his Backstreet Studio and Gallery, Fig. 22 — Pamela Olin stands beside Going Forth. The piece represents man's efforts to visit www.bobdoster.com. explore beyond our sphere of reference.

JULY 2010 Fig. 23 — Olin, standing under Portal, likes the idea that a person can walk through the archway and come out changed.

Fig. 25 — The four figures in Guardians of Peace (from left) are Native American, Asian, Caucasian, and African American.

Fig. 24 — The Fullfill vase, painted in sil- Fig. 27— Olin, shown above using GMAW ver, has many human shapes welded on it. Fig. 26 —A recent line of work featuring to finish a cube sculpture, teaches female extended figures with gas metal arc wire welders at Harper College. used as a medium includes Seeker.

GMAW to place the human figures, and made with a mosaic of recycled stainless continuing education, noncredit course let the metal rust before applying a clear- steel, and constructed using SMAW. Olin provides 12 h of instruction. Using coat finish. The 36-in.-diameter piece was worked on the project for three months in GMAW, plasma arc cutting, and a variety installed at Congregation Etz Chaim, 2002 with a Brazilian artist. of tools, the women create projects such Lombard, 111., as a confirmation class gift. For new extended figures inspired by as steel garden accents. Olin constructed Fullfill using a wire Alberto Giacometti, texture can be seen Next, Olin plans to create decorative frame of %-m. rod, built up as a vase, to painting with gas metal arc wire. To cre- steel tangled vines for the outside window provide support for the human shapes that ate the line, Olin made an armature with frames of Pamela's Parkside Grill, her were laser cut and gas metal arc welded thin steel rod and laying weld bead along restaurant in Arlington Heights, 111. She — Fig. 24. The piece measures 72 in. tall the rods to form the musculature. This would like to continue making custom, x 36 in. in diameter and appears shiny welding creates the gentle curves as the commissioned, and public fine art along from silver paint. "It illustrates by heat draws the steel to it. Seeker, sculpted with paintings and home furnishings. To working together, we can do something," using molten steel with spatter added for learn more, visit www.PamelaOlin.com. she said. texture, holds a 3-in.-diameter sphere and The four Guardians of Peace stand at is 12 in. diameter x 52 in. tall — Fig. 26. Sandra Garcia-Pardo Highland Park High School, Highland Park, 111. — Fig. 25. The Native American fea- Guiding Women Welders Sculptor Sandra Garcia-Pardo (Fig. 28) tures an eagle; the Asian wears a hat; the maintains her own studio in South, Florida, Caucasian carries a shield; and the African For the past VA years, Olin has taught where she creates art works and teaches American holds an instrument. Each of the Welding for Women at Harper College, art classes. Her works cover a wide range hollow figures is approximately 15 ft tall. Palatine, 111. — Fig. 27. The four-week of topics and materials — Figs. 29, 30.

WELDING JOURNAL ture. Garcia-Pardo said, "I grew up in a working middle-class family. Since childhood, my inclination for art was evident and was always a passion. I wanted to become a professional, but this was not easy for me. The hardest part was getting no support from my parents." Her parents were afraid that she would starve to death should she pursue art as a career. They urged her to study something more pro- ductive. So, Garcia-Pardo studied publishing design at the Barranquilla School of Fine Arts, but was not content. Her big breakthrough came when "I was fortunate to receive a government Fig. 28 - Sandra Garcia-Pardo displays her enigmatic Many of You Shall Betray Me scholarship to study art at the prestigious sculpture. School of Fine Arts Prilidiano Pueyrre- don in Buenos Aires, Argentina. It was there I discovered the marvelous world of Women Love to Weld Finding Her Niche talking with art," she explained. "It was great to find a college to attend in a for- Much of her training involves the use "One day," she said, "I found my part- eign country. All these years of study at of welding equipment, and she finds it ner in steel. Steel is a great partner to work the Fine Arts School and far from my fam- amusing that most of her students are with. Steel gives character to my pieces ily were really worthwhile. I expected to women. She utilizes a variety of materials which are both strong and delicate, and I become a painter artist, but I discovered and media to create art objects that em- am always committed to simplicity — no the sculpture world was just so much more body her ideas "regarding human rela- ornaments —just honest expression and fascinating, seeing I could make anything tionships (on a personal level) and politi- telling of new stories through my art." Her out of nothing." cal ideas (on a broader level)." She has hope is that viewers will personally iden- After graduating as a sculptor, Garcia- become successful creating art from steel tify with her creations. Pardo came to the United States where pieces she salvages mostly from junkyards, "When I start a project," she mused, she displayed her art in galleries nation- "giving them a new life" using her talents. "I think about the great masters of steel wide. Now, her works are exhibited in pri- "In addition to exploring diverse media like Weissman, Di Suvero, David Smith, vate collections in the United States, Do- such as bronze, paints, engraving, pho- and Antony Caro. I feel inspired by their minican Republic, Puerto Rico, Spain, tomontage, collage, and carving," she said, dedication to their art with no limits." and Argentina. she is comfortable painting canvas, draw- She said her appreciation for art was ing, and using whatever materials and awakened in the city where she was born, Inspirations for the Art skills that are necessary to contribute to Barranquilla, Colombia. It is a land rich the evolution of the piece. in pre-Hispanic and African art and cul- When asked about how she goes about

JULY 2010 Fig. 30 — Sandra Garcia-Pardo's unique Education sculpture consists of a series of nine school desk chairs, perhaps to remind kids what they are therefor.

making her creations, she stated, "I am self- demanding, and I do not let traditions over- rule my intentions. I create with no fears, letting the thoughts being captured as they first appear in my mind to later transform them in my art — plenty of simplicity, no ornaments, just honest." She added, "I decided to make art in an unusual way. I involved myself in welding — an exclusive world for men. The challenge was how to make something beautiful out of rusted, heavy, and ugly junk. My sculptures keep their delicacy regardless of their size or shape. They are graceful because my hands have given new life to the metal skin." Now living the life that she loves, Gar- cia-Pardo currently teaches a hands-on art course she calls Wild Welding Women Workshops. The main topics include electric arc welding, oxyacetylene cutting, and gas metal arc welding. Her shop is well equipped with SMA and GMA welding machines, oxyacetylene torches, grinders, an air-compressor, sand blaster, drill press, and a variety of hand tools for the detail work. Her new provocative line of satirical art works titled, The Bags of the Vanities, are stunning — Fig. 31. They portray in steel the delicate pricey handbags sold by Chanel, Hermes, and Louis Vuitton to their wealthy clientele. She intends them to serve as a criticism of the astronomical prices the famous brands ask for their products. Hopefully, she said, "This series of sculptures will be an invitation to think about the fetishes surrounding a luxurious article, so when we have some of them on our shoulders, they do not fit so well with the words in Ecclesiastes, 'Van- ity of vanities; all is vanity.'" Fig. 31 — This welded metal sculpture is just one in the Vanity of Vanities; All Is Vanity Visit http://sandragarciaart.com to view series of ingenious Sandra Garcia-Pardo's works inspired by luxurious handbags. Note the her portfolio and learn more about her delicate distressed metal surfaces and her signature rust patina. classes.4

WELDING JOURNAL Precision Laser Welding of Thin Structures Joining of foii materiais to produce thin lattice structures was achieved using a iaser with preplaced powder fiiler materiai

BY ANDREW DECEUSTER, GARY STEWARDSON, AND LEIJUN LI

The common technologies used to join Arc welding is readily used when lat- Rather than joining a support rod and large-scale lattice structures include fu- tice-structured components are designed wire/strip together, the incorporation of sion and resistance welding, brazing, sol- with thicker sections. Typically, resistance the support rod into the wire/strip could dering, and adhesive bonding. However, welding has been used on thinner sections. be produced by incorporating the con- the use of these processes for joining lat- In the production of well sieves, resistance cepts of solid freeform fabrication, where tice structures utilizing foil materials on welding has been limited to thicker sec- the weld bead would act as the integrated the order of 0.25 mm (0.010 in.) or thin- tions that would not qualify as foil mate- support rod — Fig. IB. A laser could be ner has proven difficult. When subjected rials. Resistance welding requires high used to join foil materials by forming a to the traditional joining technologies, pressure and electrical flow; the pressure solid bead with a powder material, as an these foil materials tend to melt through, would cause foil materials to deform. Au- integrated support rod, while simultane- distort, or form weak bonds. Because of togenous laser beam welding has also be- ously tying the foil materials into the bead, the limitations of current joining tech- come popular for welding foil materials, similar to the selective laser sintering nologies, the material's size has become but is limited to certain joint geometries (SLS) process — Fig. 2. a limiting factor in the design of lattice- with tight tolerances (Refs. 1, 2). Welding Several problems are associated with structured components. provides the advantage of a complete met- the SLS process using a pure powder bed: A majority of the joining issues have allurgical bond that would allow for bet- When the laser initially scans the surface come from the traditional manufacturing ter heat transfer in thermal management of the cold powder bed, there is an initial technique of welding a support rod and structures. However, the main drawback ball that forms from the high surface ten- wire/strip together as two separate pieces to any welding process is the distortion as- sion of the bed (Refs. 3, 4). The surface to form the lattice structure — Fig. 1A. sociated with the high temperatures tension creates a steep contact angle, lim- The traditional joining techniques have needed for welding. The process charac- iting the wettability of the liquid pool (Ref. required thicker joining materials to avoid teristics of arc welding decrease its feasi- 5). The oxides in the powder add to the defect formations. While increasing the bility for joining foil materials. surface tension (Refs. 6, 7). The high sur- component thickness allows for proper To optimize the materials and/or de- face tension causes the bead to form on joining, optimization of materials or designs of foil lattice structures, a new join- the surface of the powder bed instead of sign properties cannot be fully utilized. ing and fabrication technique was needed. penetrating into the bed. The initial

B Laser Bead Stainless Steel Foil- - > 0.25mm Stainless Steel Powder Filler ^%^ ? Copper Support Material

Wire/Strip Wire/Strip Integrated Support Rod Secondary Support Rod

Fig. I —A graphic representation showing the use of a secondary sup- Fig. 2 — Laser joining of the foil materials with a powder filler mate- port rod (A) vs. integrating the support rod into the foil structure (B). rial with the spacing of the structure maintained by the fixturing foil material.

ANDREW DECEUSTER ([email protected]), GARY STEWARDSON ([email protected]), and LEIJUN LI ([email protected]) are with Utah State University, Logan, Utah.

JULY 2010 balling and any other balling that occurs in the track will deplete powder from the surrounding powder bed, which leads to more problems with nonuniform density and track continuity. A hybrid laser processing technique based on the idea of solid freeform fabrication using SLS, with the incorporation of solid foil materials, was hypothesized as a means of joining foil material into lattice structures. The incorporation of the foil material into the powder bed helps the process overcome many of the problems associated with SLS using a pure powder bed. The use of this laser processing technique would benefit many applications that use fragile thin structures in several industries such as wastewater remedia- tion, filtration, biomedical, and thermal management. The process would allow engineers to design higher surface area biological contactors, higher efficiency sieves, cardiovascular stents, higher height-to-width-ratio heat sinks, and a number of other products that would benefit from the use of foil materials. This article discusses the use of laser beam welding with powder filler as a hybrid technique for joining foil material into lattice- style structures. Process Setup Selective laser sintering is a solid freeform fabrication process that uses a laser to fuse powder materials together. The goal of this solid freeform fabrication process is to produce a finished product from a three-dimensional CAD model in a single manufacturing process. Due to limitations of SLS, foil structures cannot be produced based on the laser spot size L and other effects. The incorporation of Fig. 3 — The experimental setup and laser beam processing of the foil material with powder foils into the process would allow it to pro- filler material placed in the gaps between each foil. duce foil structures of similar material with complete metallurgical bonds. The support material was the thickness of the top of the copper support material. Once main concept that can be taken from the desired gap spacing for the structure and the fixture was set up, a laser was used to SLS process is the ability to produce a was recessed below the surface of the foil join the foil structure in the desired solid structure from a powder material. If materials. The foil and support materials design. this idea is combined with normal laser were placed into a clamping fixture that welding, then a hybrid laser process that held the materials securely to avoid any Laser Processing incorporates foil and powder material can distortion during processing. The powder provide an alternative technique for pro- filler was added to the surface to fill the After the foil materials are placed into ducing foil lattice structures. The powder gaps produced by the staggering of the foil the fixture, a laser is selected and joining material forms the support rod while the and recessed secondary materials and was can begin — Fig. 3. Argon shielding is pro- traveling melt pool bonds the foil materi- scraped even with the top of the foil vided through an external nozzle similar als together. materials. to a gas tungsten arc welding gas cup with In the development of this hybrid laser The recess of the support materials was the laser traveling through the center. process, fixturing was found to be highly necessary to create a pocket for the pow- Laser processing of the foil materials is important. Without proper fixturing, the der filler to be placed to form the bead in versatile. Depending on the desired bead slightest distortion of the foil materials the gaps. The depth of recess for the sup- profile either a continuous or pulse laser caused the powder filler material to sink port material was based on the desired can be used in processing. The continu- into the gap in between the foils. This de- profile of the bead. The recess was in- ous laser can produce a variety of contin- crease in powder level caused the foils to creased if a larger bead or deeper pene- uous profiles based on power input, travel not join properly. To overcome this prob- tration was required. Figure 2 shows the speed, and focal spot size, while the pulse lem, a temporary support material was processing of a stainless steel foil struc- laser can produce either continuous or in- added in between the foil materials. The ture with stainless steel powder placed on termittent profiles based on power, pulse

WELDING JOURNAL Continuity of Beads for Continuous Laser

500 ooooooooooooooooo^m XXX 400 ooooooooooo o '^^^"^ 300 O O O O O O O OJ. ^ , 200 o o 100 x x x x x iliTiiliiiilll'!! lli« II 5 10 15 20 25 Travel Speed (mm/sec)

O Continuous Beads x Discontinuous Beads

Fig. 4 — Plot of the boundary between continuous and discontinuous beads using a continuous laser.

Continuity of Beads for Pulse Laser Fig. 5 —A bead produced with a continuous laser. A — The top- down orientation of the bead; B — the parallel to bead direction 4.5 section of the sample; C — the perpendicular to the bead direction 4 X X section of the sample in the powder fdler region; D — the perpen- 3.5 X X dicular to the bead direction section of the sample in the thin foil 3 x x material. 2.5 X X 2 x x 1.5 0 2 4 6 8 10 Pulse Duration (ms) O Continuous Beads x Discontinuous Beads

Fig. 6 — Plot of the boundary between continuous and discontinuous beads using a pulse laser.

Fig. 7 — Detailed photos of a bead produced with a pulse laser. Fig. 8—A — The screen section of a biological contactor using a A — The top-down orientation of the bead; B — the parallel to foil thickness of 0.25 mm with matching gap spacing. The beads bead direction section of the sample; C — the perpendicular to the act as the support rods for holding the structure together. B — a bead direction section of the sample in the powder filler region; heat sink that was formed by overlapping the beads of the pulse D — the perpendicular to the bead direction section of the sample laser, utilizing a shallow bead penetration. in the thin foil material. duration, frequency, and focal size. The Continuous Laser results that the boundary between contin- pulse laser has the advantage of produc- uous and discontinuous beads seemed to ing point profiles where two foil materi- Processing be based on the energy input (J/mm) and als in any location can be joined, allowing In evaluating the parameter effects on the rate of energy input (watts). The re- for more freedom in structure design. bead continuity with a continuous laser, sults showed that a rate of more than 100 A set of experiments was carried out numerous experiments were conducted to W, with an energy input of 33.3 J/mm or to fully characterize the laser processes map out the laser power vs. travel speed higher, was needed to maintain a contin- and show their process capabilities. Due parameter space. The resulting process- uous bead. to limited literature on the hybrid laser zone boundary can be seen in Fig. 4. The The sectioned profiles and top-down welding and solid freeform fabrication results from other studies showed similar views of a continuous bead can be seen in process, the study dealt with process pa- results for the boundary; however, the Fig. 5. The measurements for the bead rameter effects, bead profiles, and distor- studies were performed on pure powder profiles varied with the parameter set- tion of the foil substrates. beds (Ref. 8). It was determined from the tings. The range for the penetration depth

JULY 2010 was from 0.28 to 1.45 mm. The range for Summary ens, P. M. 2003. Investigation of fully the width of the bead was 1.27 to 2.07 mm. dense laser sintering of tool steel powder The range of achievable measurements Using the data gathered from the ex- using a pulsed Nd:Yag (neodymium- for the profiles shows the versatility of the periments, a section of a biological con- doped yttrium aluminium garnet) laser. process to adapt to a variety of products. tactor and a heat sink were produced and Proceedings of the Institution of Mechani- The distance between the foil materi- can be seen in Fig. 8. The joining of foil cal Engineers, Part C, Journal of Mechani- als was measured to determine how much materials for the purpose of producing cal Engineering Science 217(1): 127-138. distortion the laser processing caused. The thin lattice structures was achieved using 4. Tolochko, N. K., Mozzharov, S. E., distortion of the gap between the foil ma- a laser with preplaced powder filler ma- Yadroitsev, I. A., Laoui, T, Froyen, L., terials was measured and found to have a terial. The boundary between continuous Titov, V. I., et al. 2004. Balling processes tolerance of ± 0.02 mm. The lack of dis- and discontinuous beads was found and during selective laser treatment of pow- tortion in the samples was due to the com- the factors for maintaining a continuous ders. Rapid Prototyping Journal 10(2): bination of the laser process and the setup. bead were found to be a function of laser 78-87. The use of a laser for joining as compared power input and travel speed. The results 5. Agarwala, M., Bourell, D., Beaman, to traditional joining methods produces showed that the laser process is capable J., Marcus, and H., Barlow, J. 1995. Di- much lower energy input, and therefore of joining foil materials into lattice struc- rect selective laser sintering of metals. less distortion. The fixture also provided tured components. This process will help Rapid Prototyping Journal 1(1): 26-36. rigidity to keep the foils from becoming engineers in the designing of foil lattice- 6. Morgan, R., Sutcliffe, C. J., and distorted from the laser processing. Due structured components by allowing the O'Neill, W. 2004. Density analysis of di- to the laser process and fixture, distortion support structure to be integrated into the rect metal laser remelted 316L stainless was minimal across the parameter settings. component.4 steel cubic primitives. Journal of Material Distortion did not appear to be an issue Science 39: 1195-1205. when considering parameter selection. References 7. Simchi, A. 2006. Direct laser sintering of metal powders: Mechanism, kinet- Pulse Laser Processing 1. Li, Z., Gobbi, S. L., Norris, I., Zolo- ics and microstructural features. Materi- tovsky, S., and Richter, K. H. 1997. Laser als Science and Engineering: A 428, The parametric effect of a pulsed laser welding techniques for titanium alloy 148-158. was studied, due to the increased control sheet. Journal of Materials Processing Tech- 8. Childs, T H. C, Hauser, C, and of the pulsed laser over process parame- nology 65: 203-208. Badrossamay, M. 2004. Mapping and ter. Increased control of heat input by a 2. Xie, J., and Kar, A. 1999. Laser weld- modeling single scan track formation in pulsed laser would be beneficial for even ing of thin sheet steel with surface oxida- direct metal selective laser melting. CIRP thinner materials or exact placements of tion. Welding Journal li: 343-348. Annals-Manufacturing Technology 53(1): the laser for structural designs. Similar to 3. Su, W. N., Erasenthiran, P., and Dick- 191-194. the continuous laser process. Fig. 6 shows the boundary between continuous and discontinuous bead formation based on process parameters. To maintain continuous tracks, the minimum energy input needed to be above the zone of 64 to 72 J/mm. Associated with the amount of energy input, the resulting track profiles and top- down views of foil material processed with the pulse laser can be seen in Fig. 7. The measurements showed that the range for foil profile penetration was 0.50 to 0.63 mm. The range for the microfoil profile width was 1.12 to 1.51 mm. The range for the powder profile penetration was 0.56 to 0.67 mm. The range for the powder profile width was 1.15 to 1.57 mm. The range of measurements shows the capability of the process to conform to a variety of applications. Distortion of the gaps in the micro-foil materials was measured for each parameter setting. The mean and standard deviation were calculated for the gaps before and after joining. Distortion was present in the samples; however, the distortion was similar regardless of parameter settings. The distortion had a tolerance range of ± 0.01 mm. As with using a con- TG-Woek F3rogram. tinuous laser, distortion did not appear to • On-Campus Dorm and IS/loal FMan Availabla be an issue when considering parameter selection. COMMERCIAL DIVING ACADEMY

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WELDING JOURNAL Grmw Arrj s

New high-frequency and GTAWarc starting technology enables welders to eliminate the root cause of many rejected welds while consistently starting a DC GTAW arc at 1 A.

Promoting consistent, positive arc starts and maintaining arc stability depends upon controiiing the variabies

BY JOHN LUCK

As welders familiar with AWS D17.1, current that melts through thin metal or GTAW arc start tests conducted during Specification for Fusion Welding for Aero- melts the knife-edge of small parts. the R&D phase of technology develop- space Applications, and other aerospace To combat these issues, aerospace ment produced new insights into condi- codes know, gas tungsten arc welding welders often use a "run-on tab" (a small tions that promote better arc starts and (GTAW) requires the use of noncontact block of brass or other metal) on which to weld quality. The following series of pho- or high-frequency (HF) arc initiation start the arc and then carry it over to the tos provides new insights into improving techniques to eliminate a potential source workpiece. While solving problems, a run- DC GTAW arc starts and reinforces the of inclusions in the weld bead. on tab doesn't eliminate the root cause of importance of some existing best practices High frequency provides a path of least rejected welds, nor can it be used in all for aerospace welding. resistance for the welding current to fol- situations. low. However, in conditions where the arc Fortunately, new HF technology — Point Root Opening Problems fails to positively initiate, the HF current coupled with new GTAW arc starting tech- sometimes "dances" around the weld- nology — now enables aerospace welders Traditional GTAW machines feature a ment, producing uncontrolled arc start to eliminate the root cause of many re- set of HF arc starting points that function marks on the workpiece, which then must jected welds while positively and consis- in a manner similar to a spark plug gap. be rejected. Uncontrolled arc starting tently starting a DC GTAW arc at 1 A (see Any variability (such as grinding dust, dirt, conditions may also cause a burst of weld lead photo). In addition, the thousands of or high humidity) changes the amount of

/OfflVLt/C^ (www.millerwelds.com.) is product manager, Miller Electric Mfg. Co., Appleton, Wis.

JULY 2010 resistance required to bridge the root More Variables Controlled opening — Fig. 1. Inverter technology better managed this variable, but it didn't Old DC GTAW arc starting technology eliminate the source of erratic arc starts. controlled one variable: amperage. New technology controls four variables: amperage, time at amperage, slope time, and minimum amperage. More control eliminates the current overshoots that cause melt-through.

Automatic Simplicity

Obtaining consistent arc starts with new technology is as simple as selecting the size of the tungsten you're using from a built-in menu — Fig. 3. A "general" category allows users to create a custom program for unique applications, such as un- Fig. 5 — Smooth current flow. usually long weld cables with increased resistance. 2% Lanthanated for DC GTAW

Use a 2% lanthanated tungsten (AWS EWLa-2, as indicated by the blue band in Fig. 1 — Root opening. Fig. 6) for welding stainless steel, In- conel®, nickel and cobalt alloys, titanium, and most other aerospace alloys. Lan- Consistent Capacitors thanated tungstens provide excellent arc starting and current-carrying capabilities, The newest inverters designed for are nonradioactive, and can deliver up to aerospace welding, tool/die welding, and 200 arc starts without significant tip ero- other low-amperage GTAW applications sion (vs. 70 arc starts for 2% thoriated). feature solid-state circuitry (Fig. 2) and hardware that functions much like a ca- Fig. 3 — Built-in menu selection. pacitor with an output controlled by a high-speed power-switching transistor. This circuit provides more consistent HF Shun Cheap Tungstens arc starts because it eliminates sources of variability. No welding machine in the world can compensate for the poor arc starts and erratic arcs caused by tungstens with poor Fig. 6 — Blue band indicates 2% lan- grain structures. This problem, often thanated tungsten. caused by improper annealing, manifests itself when the tungsten bends (Fig. 4) and/or shatters instead of breaking Avoid a Frosted Tungsten cleanly. After a few dozen arc starts, tungsten forms a "frost," as shown in Fig. 7. This frost insulates the tungsten and degrades arc starts, so dress the tungsten as often as necessary.

Fig. 4 — Poor-quality tungsten. Fig. 7 — Tungsten "frost."

One Acceptable Method Pay for Performance

Ouality tungstens promote smooth Whenever the tungsten becomes concurrent flow (Fig. 5) and better arc starts taminated, the only acceptable method of because they have a fine, evenly distrib- removing the contaminated portion is Fig. 2 — Solid-state circuit board. uted grain structure and evenly distrib- with a high-speed cut-off wheel (Fig. 8) uted doping elements (e.g., lanthanum). (vs. the "garage" practice of snapping off

WELDING JOURNAL the tungsten end on a table edge, which flows perpendicular to the grind angle. As most notably with titanium. For critical can lead to splintering and cracking). seen in Fig. 10, use a longer taper for shal- applications, wear nitrile gloves (Fig. 12) lower penetration and a blunter taper for when handling the tungsten and welding deeper penetration. wire. Clean these items with acetone prior to welding. Pointed Tungsten for Low Amperage Back off the Gas i HE Sharply pointed tungstens (Fig. 11) re- For welding at 10 A or less, reduce gas [i*S* duce resistance and improve arc starts in flow from 15 to 12 ft3/h (Fig. 13) to pre- - low-amperage applications. In applica- vent the gas flow from extinguishing the tions above 20 or 25 A, consider putting a arc. ^^^= ae very small land on the end of the point to prevent it from melting and becoming in- Fig. 8 — High-speed cut-off wheel. cluded in the weld pool. IP Grind with the Grain 1 Use a special tungsten sharpener (Fig. 9) that grinds the tungsten longitudinally 1 (which promotes current flow) and elimi- 1 nates any rough spots that could interrupt smooth current flow.

i Fig. 11 - Sharply pointed tungsten helps i Fig. 9 — Tungsten sharpener. arc starts. -

The Impact of Point Angles Fig. 13 — Gas flow control. Avoid Oils Contrary to popular belief, a pointed tungsten does not provide deeper pene- The oil from your fingers can affect arc Go with the Flow tration (but it does provide better direc- starts and lead to weld contamination. tional control). The reason is that current Using a gas lens smoothes gas flow and promotes better gas coverage — Fig. 14A. Without a gas lens, the gas flow becomes

• Fig. 12 — Keep the tungsten contaminate Fig. 10 — Grind angle effect on the weld. free. Fig. 14A — Gas lens.

JULY 2010 Fig. 15 — Collet body.

and provide poor conductivity, leading to hot spots on the torch and poor arc starts. Control the Variables

As this article shows, promoting consistent and positive arc starts and maintaining arc stability depends upon elimi- nating and controlling every variable pos- Fig. MB — no gas lens. sible. The old adage "prior planning pre- vents poor performance" certainly comes turbulent. The swirling current could pull to mind. Manufacturers of GTAW invert- in atmospheric contaminants — Fig 14B. ers for aerospace applications are working hard to control machine-related vari- Pay Attention to Consumables ables for the arc starts and low-end arc performance critical to aerospace weld- Cups, collets, and collet bodies (Fig. ing. When welders work equally as hard 15) don't last forever. Worn cups can to manage the variables within their con- cause gas turbulence, while worn collets trol, they can be confident that better arc and collet bodies create excess resistance starts and arc performance will follow.4

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WELDING JOURNAL S WELDER KUU WELDERS keep pace with the evolving needs of Iders, the American Welding Society (AWS) has created a Membership exclusively for welders,,. AW **e AWS Welder Membership,

Welders who are committed to making their Jobs, as well as their lives easier, are candidates for the AWS Welder Membership. The AWS Welder Membership will allow you to save on welding equipment that you use every day, give you direct access to a health insurance program that fits your needs, provide you with the latest information in the industry and much more You'll connect with the materials joining community through educational seminars, informal get-togethers and special events You'll be tuned into the latest happenings and trends You II get the discounts and benefits that you ve been looking for O Discounts on welding equipment and tools of the trade offered by participating GAWDA distributors O Health Insurance Program O Publications exclusively for welders O Discounts on auto and home insurance O Discounts on dental, vision and pharmacy programs O The Welder s Exchange bulletin board on the AWS web s

Call: (800) 443-9353. ext 480. Visit: www.aws.org/membership or(305)443-9353, ext 480 American Welding Society A Summary of Revisions in the New D1.1:2010, Structural Welding Code - Steel

Poised to go on a five-year publication cycie, the 2010 Code has some significant changes explained

BY JOHN L. GAYLER AND DONALD D. RAGER

The AWS Dl Structural Welding Com- mittee Chair Duane Miller announced in his editorial in the March 2010 issue of the Welding Journal that Dl.l would move to a five-year publication cycle. This will be the first time since 1986 that Dl.l will not be published on a two-year cycle. Aside from this significant change in publication frequency, the Dl.1:2010 edition has several other changes that the Struc- tural Welding Committee feels the industry will welcome. Described here are the most significant changes from the 2008 to the 2010 editions of Dl.l. Some explana- tions and rationale behind a few noted changes are also included. Fig. 1 — Groove weld profiles inside comer joints. Understanding a New Table

The most noticeable change that most such as wire feed speed and submerged lowable convexity. These requirements are users of the code will see in the 2010 edi- arc welding electrode parameters, to categorized into four schedules (Schedule tion is the addition of a new table in the name two. The listing of the other vari- A, Schedule B, Schedule C, and Schedule prequalification section. The new table, ables in the new table is not a change in D) in the new table as a means to separate Table 3.8, lists which variables must be in- the requirements of previous editions of different criteria depending on the type of cluded on a prequalified WPS, and how the code in writing a prequalified WPS, weld and type of weld joint to be welded. changes beyond certain parameters would rather they are a clarification that changes Along with redrafting these figures, the require a new or revised WPS to be writ- to those variables require writing a new code committee has made slight modifi- ten. Subclause 3.6 introduces the new or revised prequalified WPS. It is the cations to the code's requirements such as table, and users of the code will notice that Structural Welding Committee's consen- larger weld reinforcement is now permit- this subclause no longer references Clause sus that reorganization and consolidation ted for welds in thicker members. By ex- 4, Table 4.5, for the requirements and the of the instructions on how to establish a panding Figure 5.4, the code now shows ranges for amperage, voltage, travel prequalified WPS will assist code users. specific weld profiles for groove welds in speed, and shielding gas flow rate. The corner and T-joints, shelf bars, and welds code also includes commentary on the Weld Profiles between butt joint welded members of un- new Table 3.8 that helps clarify many open equal thickness. Some of the new weld pro- questions on prequalified procedures and Probably the next greatest change in files are shown in Figs. 1-4. explains how to use the new table. Code the code is the redrafting of the well- users should be aware that some of the known weld profile figures, Figure 5.4. The prequalification ranges of the four vari- number of illustrations has been increased New Thermal Cut ables mentioned previously have also to better clarify what weld profiles are re- Roughness Requirements been revised with the establishment of this quired in different types of weld joints. A new table. In addition, specific ranges new table accompanying the redrawn fig- Also of note is the elimination of spe- have been placed on other variables not ure lists weld profile dimension require- cific thermal cut roughness values as given required in previous editions of the code ments, such as weld reinforcement and al- in previous editions in Subclause 5.15.4.3

JOHN L. GAYLER ([email protected]) is director, national standards activities, American Welding Society, Miami, Fla. DONALD D. RAGER ([email protected]) is president, Roger Consulting, Inc., Coles Point, Va.

WELDING JOURNAL and measured to the requirements of AS ME B46.1. Now, the new thermal cut roughness values are tied solely to the comparison samples found in AWS C4.1, Oxygen Cutting Surface Roughness Gauge. The requirements in previous code editions have been deemed overly prescrip- tive, and the code committee thought it appropriate to change the requirements to a comparative standard. Access Holes and Beam Copes

Requirements for weld access holes and beam copes are revised in this edition. Weld access hole dimensions have been modified, and mandatory minimum and recommended maximum depth dimensions of access holes have been set to Fig. 2 — Groove weld profiles in T-joints. prevent those that are unnecessarily deep or that are too shallow. The new code also uNncccmau permits a smaller radius on reentrant cor- ners in connection material and beam copes, as the 1-in. (25-mm) radius re- >Kr quirement of previous codes is not sup- ported by research and is excessive for 2Q >C3 } many connection details. Beam copes in ^— -e*>0M0tOQ( flOCIXAtC galvanized sections must now be ground to bright metal to reduce the possibility of cracking. Preheating before thermal cutting of beam copes and weld access holes in heavy shapes is now mandatory to reduce the formation of a hard surface ] u i layer and the tendency to initiate cracks.

AP*1 f C *J>P»»« Revised Backing Requirements

The code committee has revised the re- Fig. 3 — Fillet weld profiles for outside comer joints. quirements for backing, found in Sub- clause 5.10, to allow for discontinuous backing in some limited statically loaded DESIFUSLE ACCCPTAflLE hollow structural steel (HSS) applications. There are limiting factors including diameter and wall thickness of the HSS shape that control when noncontinuous backing may be permitted, and there are, of course, a few code exceptions to these limitations. Prequaiification and Qualification SHELF BAR Mi.f HAH Under Subclause 3.3, the matching and undermatching table has been revised to clarify that a filler metal chosen for joining a combination of two different strength base materials need only match either of the two materials for the selection to be considered "matching." Like- wise, "undermatching" was clarified to 1 mean a selection of filler metal whose SHCLFaAR SMELF BAR strength is less than either of the base metals being joined. The requirements of Subclause 3.7.3 Fig. 4 — Typical shelf bar details. have been expanded to include all weath-

JULY2010 ering steels, not just ASTM A 588. ASTM allow manufacturers to produce products Other Changes A 709 HPS50W has been added as a pre- that comply with both international and qualified material in Group II of Table 3.1 American standards. These tolerance • The code no longer requires the Type and Group B of Table 3.2. ASTM A1043 changes do not adversely affect the physi- III W UT Reference Block; any of the IIW Grades 36 and 50 have been added to cal or mechanical properties of the studs. "type" blocks may be used. Table 4.9. • Cracks or bursts in headed studs are A new subclause under 3.13 (CJP Commentary on ESW, now covered in detail, and the maximum Groove Weld Requirements) has been length of these cracks has been established. added to clarify that only steel backing is EGW, and UT considered prequalified for nontubular • A definition for "tubular" has been New commentary on electroslag and welds made from one side only. The use added to Annex K along with a revised of material other than steel for backing in electrogas welding (ESW and EGW) has definition for "pipe." been added as assistance to users in im- a one-sided nontubular weld may be used • Annex N, Form N-3 (ESW/EGW) plementing these welding processes. Also, if qualified by test in accordance with has been completely revised. Clause 4 (Qualification). commentary to alert users when applying ESW and EGW on quench and tempered • Some guidance has been added to The code clarifies by revisions to 4.35.3 steels, thermomechanical control the introductory page of the commentary that if an existing qualified WPS is to be processed steel, and precipitation hard- to assist users in distinguishing commen- used for applications requiring impacts tary on code from items supporting but CVN tests were not done during the ened steels subjected to cyclic loading applications has been added. Both potential commentary. initial qualification of that WPS then a and current users of these processes procedure test plate needs to be per- • The words "thorough fusion" have formed but only impact tests are required should read through the new commentary been changed to "complete fusion" in to better understand potential pitfalls and to be run. The other tests associated with Table 6.1 (visual acceptance criteria) to possible remedies suggested there. a WPS being qualified by test, having been match the terminology used in AWS A3.0, Additional commentary has been completed during the original WPS Qual- Standard Welding Terms and Definitions. added to emphasize that the ultrasonic ification need not be repeated. testing (UT) acceptance criteria shown in Many other changes, mostly minor, Tables 6.2 and 6.3 have been established have been made to this new edition of the Stud Size within specific testing parameters and that Dl.l Code. The new foreword has a com- using testing equipment or procedures, prehensive but succinct list of all changes. A Ys-in. (10-mm) stud size has been such as transducers of a different size or Most changes are also identified in the added to the code, and the tolerances on angle shown in these tables, may invali- published code by underlined text or ver- existing stud sizes have been revised to date the results. tical lines in the margins of the page>

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WELDING JOURNAL Homes for Haiti

AWS is working with the Give Love Foundation and a Miami welding schooi to buiid housing units from steel cargo shipping containers

BY KRISTIN CAMPBELL AND HOWARD WOODWARD

Fig. 1 —Artist's sketch of how the housing units will look on location. The units employ modified steel shipping containers with prefabri- cated steel doors.

It's not often individuals invest their time and money to better the lives of others, especially when long-term needs are involved, but that's exactly what actress Patricia Arquette is doing. Through the Give Love Foundation she founded along with fashion designer Rosetta Getty, a col- laborative project will rebuild communities, homes, and livelihoods for survivors of the magnitude 7.0 earthquake that struck Haiti Jan. 12. It left millions of people in the Cite Soleil, Port-au-Prince, area forced to live in tents and endure the rav- ages of flooding and water-borne diseases. The Give Love Foundation's initial goal is to provide 54 housing units constructed from refurbished steel cargo shipping containers — Fig. 1. Architect Christopher Robertson (Fig. 2) designed the housing structures, which cost about $5000 each to complete, to withstand the rigors of hurricanes and earthquakes. The exteriors will be protected with a reflec- tive ceramic barrier paint to keep the dwellings cooler. Additional foundation goals include developing an ecologically sound sanitation, hygiene, and compost- ing system to support a 400-person village at Bois Neuf Field. The project includes Fig. 2 — Architect Christopher Robertson (left) confers with welding instructor James the installation of a water-reclamation Brantley at the Robert Morgan Educational Center Welding Lab.

KRISTIN CAMPBELL ([email protected]) and HOWARD WOODWARD ([email protected]) are associate editors of the Welding Journal.

JULY 2010 Fig. 3 — Student Enoch Montgomery puts the finishing touches to a steel doorframe assembly at Robert Morgan Educational Center. and filtration system to provide the village complete and meets Monday through cluding T-, lap, inside and outside corner, with potable water. Thursday from 5:00 to 11:00 pm and on and butt joints. The American Welding Society (AWS) Friday from 5:15 to 8:30 pm. As of press time, about 25 doors have assisted Arquette in finding a welder been completed with many more ready to training facility where the door frames Sorting Out Project Details be processed. Once the door assemblies could be assembled for the dwellings. The arrive in Haiti, they can be quickly in- Robert Morgan Educational Center in Since early April, Brantley (Fig. 2) has stalled on the prepared shipping contain- Miami, Fla., was selected. Over the past worked alongside his students demon- ers to complete the living quarters. couple of months, welding students at the strating how the doors are to be con- center have been working to fabricate and structed. The ongoing project has been a Student Point of View weld door frames — Fig. 3. nice addition to the curriculum. The 7-ft-tall doors have widths of 54, Student David Hunsberger gained nu- Creating the Door Frames 32, and 22 in. "Each container will have merous skills by working on the project, three doors. By us doing manual labor including GMA welding in difficult posi- Sixteen welding students at Robert here cuts down on the time of having to tions, proper preparation, and perfecting Morgan, led by welding instructor James do it there. It makes it a lot easier," Brant- cuts with no slag. "It's really an awesome Brantley (Fig. 4), have been making three ley explained. An additional job for the feeling. Being able to help them while sizes of steel door frames for installation welding students includes making steel learning in school is great," Hunsberger on the housing units. roofing trusses for the structures using 2 said. He likes working on this project that When offered the assignment, Brant- x 2 in. square tubing. results in a product with significant value. ley said, "I jumped at the opportunity be- Working on the doors provides the stu- "Building so many doors, my welding cause the students will get experience dents with many educational benefits. has gotten a lot better," Hunsberger from doing these things." This practical They are required to interpret blueprints; added. "It's given me a lot of real-world experience will help them prepare to go accurately measure, cut, hammer, and experience." The former graphic artist has to work. Fabrication takes place during grind steel; precisely perform gas metal found his calling with welding. He antici- the regular class hours. The night school arc (GMA) and shielded metal arc weld- pates graduating by the end of this year welding program takes about a year to ing; and make different types of welds in- and is interested in pursuing underwater

WELDING JOURNAL Patricia Arquette Discusses Her Experiences in Haiti

ground. The experience has left her emotionally drained. "It looks like the earthquake happened just yesterday," Arquette said. "It's an absolute living-hell nightmare." She recognized the essential needs for fresh water and plumbing. Arquette has engaged experts to set up systems to purify drinking water and collect and treat wastes to kill pathogens. "There's no sanitation there," she said, adding that maybe 3% of the population had water and flushing toilets. The number-one problem in Haiti now is malnutrition, and the next most-serious problem is roundworm in kids. It is not enough to just treat the kids for the worms. The worm eggs can live in waste for ten years on the ground, and people can be reinfected simply though contact with contaminated ground or drinking the water. Compounding this problem, Arquette said, is every canal ultimately empties into the river where the people bathe and get their drinking water, and these canals are full of trash and human waste. Another concern is unemployment is sky-high in Haiti. Ar- quette expressed several ideas for relieving their financial dilemma. For example, starting pilot projects, like collecting trash and recycling, for which they can earn money. Another sugges-

Not one to let the welding students have all the fun, Patricia Arquette put on the gloves and leathers to try her hand at cutting steel plate.

Patricia Arquette made a special appearance at the Robert Morgan Educational Center Welding Lab in Miami, Fla., May 24, to personally thank the students for their hard work in assem- bling door frames that will help transform refurbished large steel cargo shipping containers into sturdy shelters for Haitians left homeless by the Jan. 12 earthquake. The project is funded by the Give Love Foundation that Arquette established. "It blows my mind," Arquette said of the efforts these welding students have put into the project. She pointed out that their Patricia Arquette told the Welding Journal of the deplorable condi- work shows a beautiful mixture of American generosity, abun- tions in Haiti that prompted her to establish the Give Love Founda- dance, and good-will extended to the Haitian people in their time tion to provide relief. of great need. Arquette watched the students cutting steel and welding door frames, and she examined a number of the completed units. Im- tion is to till vegetable byproducts back into the soil to improve pressed with the quality and quantity of work they had done, she its suitability to grow crops and trees. If successful, it could stim- looked forward to seeing the completed shelters erected on-site ulate agriculture and create new jobs, she said. in Haiti. "I can't wait to get pictures of them on location with peo- Her foundation's work cannot be handled alone, and to take ple living in them," she said. on all of Haiti is impossible, but many individuals are working to- After watching the students working, Arquette wanted to try gether to serve its greater purpose. "Believe me, it's definitely an her skills at cutting steel plate. She suited-up in protective gear, re- uphill battle. It's going to take longer than I ever imagined, but ceived a training session, then did a respectable job using the oxy- it's definitely needed," Arquette said. "The great people who I've acetylene process. Her appearance at the welding lab came as a brought onboard and the experts who know what they're talking pleasant surprise to the students who were in awe that she wanted about have already done some incredible things. I'm just really to meet them and try her hand at the work they do for the project. excited about it." Earlier, Arquette spoke to the Welding Journal about what she Arquette's ambition for her foundation is to continue building saw during the two weeks she recently spent touring the earth- additional homes after the initial 54 units are completed. "I'm hop- quake-devastated regions of Haiti. ing that (will happen). I want it to be a success," she said. "The hous- She graphically described the gut-wrenching scenes she wit- ing will help hundreds of people, but an efficient sanitation system nessed in Haiti. She told of children with red hair — a result of would help tens of thousands of people, ultimately." Once these malnutrition — trash piled up everywhere, pancaked buildings, housing units are on the ground with people living in them, more rubble all over the streets, dead bodies left exposed for days, col- benefactors will see what is being done and assist in this undertak- lapsed kindergartens with piles of little shoes outside, and the ing. "Then," Arquette said, "I think it will be easier to source land homeless people living in unstable tent shelters erected on soggy and to get more funding and get more housing created."^

JULY 2010 Fig. 4 — Students at the Robert Morgan Educational Center welcome the opportunity to work on the Haitian-relief project. welding and operating his own shop. oping sustainable cooking fuel alterna- Haiti," said Ray Shook, executive direc- For Haitian student Jean Ladouceur, tives to charcoal; organizing cleanup and tor of the American Welding Society. "We this project to help Haiti is a double win as environmental programs for communities hope to continue working with Ms. Ar- he's helping himself and his countrymen at in Cite Soleil; beginning communal gar- quette and Give Love to make the dream the same time. He said the earthquake has dening programs to supplement food of providing safe living environments for taken an emotional toll on his family in needs; and revitalizing local agriculture the Haitian people a reality." Haiti. "I've seen how bad it was before. It's and livelihoods. The AWS and the Give Love Founda- even more of a devastating blow now. No tion offer opportunities for welding one was expecting something like that to schools and individuals to participate in happen," Ladouceur said. How Others Can Share the project. Schools and training centers When Ladouceur graduates this Octo- the Love interested in participating as Robert Mor- ber, he would like to get into fabricating, gan Educational Center is now may con- designing, or building work. "I was defi- "The American Welding Society is tact Cindy Weihl at [email protected], nitely surprised to even be a part of this. honored to be able to assist Give Love in (800/305) 443-9353, ext. 416. For informa- I came here to be a welder, and the hands- its efforts to improve the lives of the many tion about the Give Love Foundation, visit on experience has definitely taught me to families devastated by the earthquake in www.givelove. org. • do a lot of different things," Ladouceur said. The other Robert Morgan Educational Center welding students working on the project are Liston Bailey, Joseph Camp- DO YOUR OWN TESTING bell, Stephen Fowler, Zaire Henry, Omari Moodie, Runako Moodie, Matias Naulin, Nathaniel Pruitt, Roselio Abreu, Diego Bend Testers - Bend Specimen Cutting Grullon, Enoch Montgomery, John Fixtures - Coupons -Tensile Testers

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WELDING JOURNAL The AWS Foundation is proud to announce its 2010-2011 ••••••••••••••••••• National Scholarship Recipients ifititirifififititir ••••••

fLHCh >car. the American WclJm^ SiKict) Koundatiiw prov i*krs tchtilurship funds to help huiklreds of students \sho otherwise uould he un.ihk ID .ill Mil a weldmy cduealioo Wc are tlte (Wily milustn. liKindaluNi vsith the ^pceifie niis\u>fi nl helping u> fund the ediKaliiKi of welding \tudenl> In v> doing. »e create the careerx that suNlain and grim our imhnlry.

Wc gel ifK-se IUIKN from ytm contn hut ions. The more you contnhute. the nK>n: students we can help educate To make a scholarship contrihulion K* to set up sour own District. vaion or National Named Vliolarship. contact Sam (ienti> at the AWS Foundation. Call 1 ICJim lSII.« email t.. NJ< mi v ,i aws.org.

Hunk sou lot your continued support.

jjj. Foundation, Inc. WELDING WORKBOOK Datasheet 316 Master Chart Classifies the Latest Allied Process Developments

In the latest edition of A3.0, Standard Welding Terms and (Fig. 1), thermal gouging has been added as a separate category. Definitions, Including Terms for Adhesive Bonding, Brazing, Sol- Figure 2 shows the joining method chart. A3.0 is available dering, Thermal Cutting, and Thermal Spraying, the Master Chart through World Engineering Xchange (WEX), Ltd., at of Allied Processes has been revised to classify the latest process www. awspubs. com. developments and enhancements. In this new version of the chart

THERMAL OOWQINO (TGi SPRAYINO fTMSPj ALLIED cwbon arc gouging CAG B'C ASP wygtngougng OQ PROCESSES FLSP arc gougwig PAG FLSPW Mgh wHocxy oryfcal tpraytng HW PSP

curnMorrci

OPIYCtN CUTTINO 10CJ CUTTINO (HEBCl ARC CUTTMQ (M D kacuMng OC* CJTrg EBC caiton arc euiang CAC MMM powdar ouang OC-P :yrrc. iec mt cartwi arc ounng CAC-A on** ga* cunng OFC LBCA ga* ma«« arc cwnmg GUAC OKfWOtAfltOt CUtttftQ OfC-A LBC-EV gM Mtgtian arc cutting GTAC OFC H LflC-KS plairna arc cunng PAC o^nalunl gas cuang OFC-N LK 0 •h*a*dad mtM arc cutting SMAC o«VP»ocart» cunng OFC P ony^trt ftfc cutting OAC caygMt tanca ounng OLC

Fig. 1 — Master chart of allied processes.

C.i'.-.iVf.1t.-r Chart

Mtcftantcttl S«e Figura A.4

Jonir-^ SM Figurg A.5

MhMlM Saa Figure A 6

Fig. 2 — Joining method chart.

Excerpted from A3.0M/A3.0:2010, Standard Welding Terms and Definitions, Including Terms for Adhesive Bonding, Brazing, Solder- ing, Thermal Cutting, and Thermal Spraying.

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American Welding Society The Alumtnum Association COMING EVENTS NOTE: A DIAMOND (*) DENOTES AN AWS-SPONSORED EVENT.

63rd Annual Assembly and Int'l Conf. of the Int'l Institute of • FABTECH. Nov. 2-4, Georgia World Congress Center, Atlanta, Welding (IIW). July 11-17, Swissotel The Bosphorus, Istanbul, Ga. This show is the largest event in North America dedicated to Turkey. Leading researchers to share recent advances in welding showcasing the full spectrum of metal forming, fabricating, tube and joining sciences and technologies to achieve cost-effective, and pipe, welding equipment, and technology. Contact American environment-friendly, safe, and long-lasting welded systems in Welding Society, (800/305) 443-9353, ext. 455; or visit construction, energy, and transportation. Visit www.iiw2010.com. www.aws.org.

• Trends in Welding Conf. Aug. 2-5, Cherry Valley Lodge, Manufacturing Innovations — Medical Canada. Nov. 3, 4, Inter- Newark, Ohio. Cosponsored by American Welding Society and national Centre, Hall #6, Toronto, Ont., Canada. Sponsored by Edison Welding Institute. Contact George Ritter (614) 688-5199; the Society of Manufacturing Engineers. Visit www.sme. [email protected]. org/canmedical.

• ICWJM 2010, Third Int'l Conf. on Welding and Joining of Ma- ASNT Fall Conf. and Quality Testing Show. Nov. 15-19, Houston terials, and Int'l Welding Show Peru. Aug. 9-11, Lima, Peru. To Convention Center, Houston, Tex. Visit www.asnt.org. feature weldability of advanced alloys, modeling processes, distortion, advanced NDE of welds, welder training, special welding Underwater Welding & Inspection Technology, Third Annual and joining processes, technology transfer, etc. Sponsored by the Workshop. Nov. 17-19, Houston, Tex. Organized by Profs. AWS Peru Section, organized by Soldexa S.A. and Pontifical Stephen Liu and David Olson, Colorado School of Mines. Topics Catholic University of Peru in collaboration with the University of to include new and advanced technology for welding and repair, Chicago. Visit www.pucp.edu.pe/icwim/ingles/index.html. problems, engineering, practice, and reliability for welding and inspection, and review of certifiers and regulators of welding, cut- 21st World Energy Congress. Sept. 12-16, Palais des Congres, ting, and inspection. Visit www.mines.edu/Educational_Outreach. Montreal, Que., Canada. Visit http://montreal2010.ca. Power-Gen Int'l. Dec. 14—16, Orange County Convention Center, IMTS, Int'l Manufacturing Technology Show. Sept. 13-18, Orlando, Fla. Visit www.power-gen.com. McCormick Place, Chicago, 111. Visit www.imts.com. 13th Int'l Symposium on Tubular Structures. Dec. 15-17, Hong Asiamold 2010, Int'l Trade Fair for Moldmaking and Tooling, De- Kong. Sponsored by the Subcommission for Tubular Structures sign and Application Development. Sept. 15-17, Poly World Trade XV-E of the IIW. Visit www.hku.hk/civil/ISTS13/. Centre Expo, Guangzhou, China. Visit www.asiamold-china.com. SSPC Annual Meeting, Technical Conf., and Expo. Jan. 31-Feb. Atlantic Manufacturing Technology Show. Sept. 21-23, Exhibi- 3,2011, Mandalay Bay Resort, Las Vegas, Nev. Sponsored by The tion Park, Halifax, Nova Scotia. Sponsored by the Society of Man- Society for Protective Coatings. Visit www.sspc.org. ufacturing Engineers. Visit www.sme.org/amts. ILSC® Int'l Laser Safety Conf. March 14-17, 2011. Doubletree ICALEO®, The 29th Int'l Congress on Applications of Laser & Hotel San Jose, San Jose, Calif. Visit www.laserinstitute.org. Electro-Optics. Sept. 27-30, Anaheim Marriott Hotel, Anaheim, Automate (formerly Int'l Robots, Vision & Motion Control Calif. Visit www.icaleo.org. Show). March 21-24, 2011. McCormick Place, Chicago, 111. Colo- eating with ProMat® 2011. Visit www.promatshow.com. GAWDA, Gases and Welding Distributors Assn., Annual Con- vention. Oct. 3-6, Maui, Hawaii. Visit www.gawda.org. AeroDef Manufacturing Expo. April 5-7, 2011. Anaheim Con- vention Center, Anaheim, Calif. Sponsored by Society of Manu- Canadian Manufacturing Week 2010. Oct. 5-7, Toronto Congress facturing Engineers. Visit http://aerodef.sme.org. Centre, Toronto, Ont., Canada. Sponsored by Society of Manu- facturing Engineers. Call (888) 322-7333; [email protected]. • JOM-16,16th Int'l Conf. on the Joining of Materials & ICEW- 7,7th Int'l Conf. on Education in Welding. May 10-13,2011. LO- MS&T 2010, Materials Science & Technology. Oct. 17-21, Hous- skolen Conference and Hotel, Helsing0r, Denmark. Contact ton, Tex. Cosponsored by NACE, AIST, ASM Int'l, TMS, and JOM Institute, Gilleleje, Denmark. Phone +45 48 35 54 58; ACerS. Visit www.nace.org. jom_aws@postl0. tele. dk.

Manufacturing Innovations — Aerospace/Defense. Oct. 20, 21, IIW 64th Annual Assembly and Int'l Conf. on Global Trends in Gaylord Palms, Orlando, Fla. Sponsored by the Society of Manu- Joining, Cutting, and Surfacing Technology. July 17-22, 2011. facturing Engineers. Visit www.sme.org/aerospacedefense. Chennai Trade Center, Chennai, India. Visit www.iiwindia.com.

EuroBLECH 2010, 21st Int'l Sheet Metal Working Technology Weld India 2011, Int'l Expo on Joining, Cutting, and Surfacing. Exhibition. Oct. 26-30, Exhibition Grounds, Hanover, Germany. July 21-23, 2011. Chennai Trade Center, Chennai, India. Visit Visit www.euroblech.com. www. iiwindia. com.

26th ASM Heat Treating Society Conf. and Expo. Oct. 31-Nov. 2, • Fray Int'l Symposium on Metals and Materials Processing in a Duke Energy Convention Center, Cincinnati, Ohio. Visit Clean Environment. Dec. 4-7, 2011, Hilton Cancun Golf & Spa www. asmintemational. org. Resort, Cancun, Mexico. Sponsored by the American Welding So- ciety and many other technical organizations. Visit 5th Conf. on Uses of Steel and Expo. Nov. 1-4, Rosario, Santa Fe, www.flogen.com/FraySymposium, or e-mail Chairman Florian Argentina. Visit www.siderurgia.org.ar/conflO/index_english.html. Kongoli fkongoli@flogen. com.

JULY 2010 Educational Opportunities

AWS CWI Seminar and Exam. Offered July 25-31, Oct. 17-23. Call Lincoln Electric Welding School (216) 383-8325, or visit www. lincolnelectric. com.

Basics of Nonferrous Surface Preparation. Online course, six hours includes exam. Offered on the 15th of every month during 2010 by The Society for Protective Coatings. Members $145, nonmembers $245. Register online at www.sspc.org/training.

Basic Plate and Sheet Metal Welding. A six-week course offered Aug. 2-Sept. 10, Sept. 13-Oct. 22, Oct. 25-Dec. 3. Call Lincoln LINEAR or RADIAL Electric Welding School (216) 383-8325, or visit www.OULLCa.CCIM HIGH DEPOSrT RATE www. lincolnelectric. com. QUICK SETUP TIME Blodgett Welding Design Technical Training Course. Oct. 12-15. Call Lincoln Electric Co. (216) 383-2409, or visit KAX OSCILLATOR www. lincolnelectric. com.

Brazing Fundamentals Training Seminars. Oct. 5-7, Embassy Motoflivd «»ld c*nt«r lin* odjirtmwnt Suites, Greenville, S.C. Covers furnace, torch, induction, etc., as well as all filler metal types (Ni, Cu, Ag, Al, etc.). Contact Kay & Motorlltd ttrok* width Associates (860) 651-5595, ox visit www.kaybrazing.com. Ovrillofion tp**d control

Comprehensive Arc Welder Training. A 15-week course offered Stor • up 10 10 w*lding Aug. 2-Dec. 3, Sept. 13-Jan. 28, Oct. 25-March 11. Call Lincoln p'ogronvv Electric Welding School (216) 383-8325, or visit www. lincolnelectric. com. GULLCO INTERNATIONAL INC. • U.S.A Flux Cored Arc Welding/Semiautomatic. A one-week course rt AHitjwidw RIMKJ - 0>»rt»nd - Oho - 44144 offered weeks of July 26, Sept. 7, Oct. 18, Nov. 29. Call Lincoln For Info go to www.aws.org/ad-index WELD TRAINING Hobart Institute of Welding Technology offers our comprehensive Technical Training courses throughout the year! Prep for AWS Certified Welding Supervisor Exam C.W.I. TRAINING Prep for AWS Welding Inspector/Educator Exam At your fingertips! Visual Inspection

Welding for the Non Welder completely online NdT Arc Welding Inspection & Quality Control tmmg program! Weldability of Metals, Ferrous & Nonferrous

Liquid Penetrant & Magnetic Particle Inspection Visit us at ww.ivorMspec.org today! Visit www. welding, org or call toll free: for course dates or call 1-877-506-7773 1-800-332-9448 Save $100 dollars instantly, for more information. enter the discount code: EO 2010 Hobart Institute of Welding UOBART INST1TUT Technology, Troy, OH 11 OF WELDING TECHNOLOGY aws59c2 St. of OH Reg. #70-12-0064HT For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

WELDING JOURNAL Electric Welding School (216) 383-8325, or visit Sulphur, La. Call Real Educational Services, Inc. (800) 489-2890, www. lincolnelectric. com. info @realeducational. com.

Gas Metal Arc Welding/Semiautomatic. A one-week course Consumables: Care and Optimization. Free online e-courses offered weeks of July 19, Aug. 30, Sept. 27, Oct. 11, Nov. 1, Nov. presenting the basics of plasma consumables, designed for plas- 22, Dec. 6, Dec. 13. Call Lincoln Electric Welding School (216) ma operators, distributor sales and service personnel, etc. Visit 383-8325, or visit www.lincolnelectric.com. www. hyperihermcuttinginstitute. com.

Gas Tungsten Arc Welding. A one-week course offered weeks of Crane and Hoist Training. Safety courses and operator training July 12, Aug. 2, Aug. 23, Sept. 13, Oct. 4, Nov. 15, Dec. 6, Dec. for users of overhead cranes and hoists. For schedules, contact 13. Call Lincoln Electric Welding School (216) 383-8325, or visit Konecranes Training Institute, Springfield, Ohio; (262) 821- www. lincolnelectric. com. 4001; or visit www.konecranesamericas.com.

Introduction to Welding. One-week course beginning July 19, EPRINDE Training Seminars. EPRI offers NDE technical skills Oct. 18. Call Lincoln Electric Welding School (216) 383-8325, or training in visual examination, ultrasonic examination, ASME visit www.lincolnelectric.com. Section XI, and UT operator training. Call Sherryl Stogner (704) 547-6174, e-mail [email protected]. Pipe Welding. A six-week course offered Aug. 2-Sept. 10, Sept. 13-Oct. 22, Oct. 25-Dec. 3. Call Lincoln Electric Welding School Environmental Online Webinars. Free, online, real-time semi- (216) 383-8325, or visit www.lincolnelectric.com. nars conducted by industry experts. For topics and schedule, visit www. augustmack. com. Plasma, Oxyfuel, Alloy & Hardening. A three-week course offered Aug. 2-20, Sept. 13-Oct. 1, Oct. 25-Nov. 12. Call Lincoln Essentials of Safety Seminars. Two- and four-day courses are Electric Welding School (216) 383-8325, or visit held at numerous locations nationwide to address federal and www. lincolnelectric. com. California OSHA safety regulations. Call American Safety Training, Inc. (800) 896-8867, or visit www.trainosha.com. Preparation and Exam for AWS Certified Welding Inspector/ Educator. Two-week-long courses beginning Aug. 9, Sept. 20, Fabricators and Manufacturers Assn. and Tube and Pipe Assn. Nov. 1, Nov. 29 in Troy, Ohio. Call Hobart Institute of Welding Courses. Call (815) 399-8775, ox visit www.fmanet.org. Technology (800) 332-9448; [email protected]; or visit www. welding, org. Firelighter Hazard Awareness Online Course. A self-paced, ten- module certificate course taught online by fire service profes- Preparation and Exam for AWS Certified Welding Supervisor. sionals. Fee is $195. Call Industrial Scientific Corp. (800) 338- One-week-long course begins Oct. 18 in Troy, Ohio. Call Hobart 3287, or visit www.indsci.com. Institute of Welding Technology (800) 332-9448; [email protected]; or visit www.welding.org. Gas Detection Made Easy Courses. Online and classroom courses for managing a gas monitoring program from gas detection to ASM Int'l Courses. Numerous classes on welding, corrosion, fail- confined-space safety. Call Industrial Scientific Corp. (800) 338- ure analysis, metallography, heat treating, etc., presented in 3287, or visit www.indsci.com. Materials Park, Ohio, online, webinars, on-site, videos and DVDs. VisA www.asmintemational.org, search for "courses." Hellier NDT Courses. Hellier, 277 W Main St., Ste. 2, Niantic, CT 06357; (860) 739-8950; FAX (860) 739-6732. Automotive Body in White Training for Skilled Trades and Engineers. Orion, Mich. A five-day course covers operations, Inspection Courses on ultrasonic, eddy current, radiography, dye troubleshooting, error recovery programs, and safety procedures penetrant, magnetic particle, and visual at Levels 1-3. Meet SNT- for automotive lines and integrated cells. Call Applied Mfg. TC-1A and NAS-410 requirements. Call TEST NDT, LLC, (714) Technologies (248) 409-2000, or visit www.appliedmfg.com. 255-1500, or visit www.testndt.com.

Basic and Advanced Welding Courses. Cleveland, Ohio. Contact Laser Safety Online Courses. Courses include Medical Laser The Lincoln Electric Co. for schedules, www.lincolnelectric.com. Safety Officer, Laser Safety Training for Physicians, Industrial Laser Safety, and Laser Safety in Educational Institutions. Call Boiler and Pressure Vessel Inspectors Training Courses and Laser Institute of America, (800) 345-3737, or visit Seminars. Columbus, Ohio. Call (614) 888-8320 or visit www. laserinstitute. org. www. na tiona Iboard. org. Laser Safety Training Courses. Courses based on ANSI Z136.1, CWI/CWE Course and Exam. Troy, Ohio. This is a two-week Safe Use of Lasers, presented in Orlando, Fla., or at customer's preparation and exam program. For schedule, call Hobart site. Call Laser Institute of America, (800) 345-3737, Institute of Welding Technology (800) 332-9448, or visit www. laserinstitute. org. www. welding, org. Machine Safeguarding Seminars. Call Rockford Systems, Inc., CWI/CWE Prep Course and Exam and NDT Inspector Training. (800) 922-7533, or visit www.rockfordsystems.com. Courses. An AWS Accredited Testing Facility. Courses held year- round in Allentown, Pa., and at customers' facilities. Call Welder Machining and Grinding Courses. Visit TechSolve, Training & Testing Institute (800) 223-9884, [email protected]; or www. TechSolve.org. visit www.wtti.edu. NACE Int'l Training and Certification Courses. Call National CWI Preparatory and Visual Weld Inspection Courses. Classes Assoc. of Corrosion Engineers (281) 228-6223, or visit presented in Pascagoula, Miss., Houston, Tex., and Houma and www.nace.org.

JULY 2010 AWS Certification Schedule Certification Seminars, Code Clinics and Examinations Application deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee. Certified Welding Inspector (CWI) Certified Welding Supervisor (CWS) LOCATION SEMINAR DATES EXAM DATE LOCATION SEMINAR DATES EXAM DATE Miami, FL EXAM ONLY Jul. 15 Minneapolis, MN Jul. 19-23 Jul. 24 New Orleans, LA Jul. 11-16 Jul. 17 Miami, FL Sept. 13-17 Sept. 18 Phoenix, AZ Jul. 11-16 Jul. 17 Norfolk, VA Oct. 4-8 Oct. 9 Orlando, FL Jul. 18-23 Jul. 24 CWS exams are also given at all CWI exam sites. Milwaukee, WI Jul. 18-23 Jul. 24 Los Angeles, CA Jul. 18-23 Jul. 24 Certified Radiographic Interpreter (CRI) Sacramento, CA Jul. 18-23 Jul. 24 LOCATION SEMINAR DATES EXAM DATE Kansas City, MO Jul. 25-30 Jul. 31 Miami, FL Jul. 26-30 Jul. 31 Cleveland, OH Jul. 25-30 Jul. 31 Miami, FL Oct. 18-22 Oct. 23 Louisville, KY Jul. 25-30 Jul. 31 Radiographic Interpreter certification can be a stand-alone credential or Denver, CO Aug. 1-6 Aug. 7 can exempt you from your next 9-Year Recertification. Philadelphia, PA Aug. 1-6 Aug. 7 Chicago, IL Aug. 8-13 Aug. 14 Certified Welding Sales Representative (CWSR) San Diego, CA Aug. 8-13 Aug. 14 LOCATION SEMINAR DATES EXAM DATE Miami, FL Aug. 8-13 Aug. 14 Miami, FL Aug. 25-27 Aug. 27 Charlotte, NC Aug. 15-20 Aug. 21 Indianapolis, IN Sept. 22-24 Sept. 24 San Antonio, TX Aug. 15-20 Aug. 21 Atlanta, GA Nov. 2-4 Nov. 4 Bakersfield, CA Aug. 15-20 Aug. 21 CWSR exams will also be given at CWI exam sites. Rochester, NY EXAM ONLY Aug. 21 Certified Welding Educator (CWE) Portland, ME Aug. 22-27 Aug. 28 Seminar and exam are given at all sites listed under Certified Welding Inspector. Salt Lake City, UT Aug. 22-27 Aug. 28 Seminar attendees will not attend the Code Clinic portion of the seminar (usually Seattle, WA Aug. 22-27 Aug. 28 first two days). Corpus Christi, TX EXAM ONLY Sept. 4 Senior Certified Welding Inspector (SCWI) Pittsburgh, PA Sept. 12-17 Sept. 18 Exam can be taken at any site listed under Certified Welding Inspector. No Houston, TX Sept. 12-17 Sept. 18 preparatory seminar is offered. Minneapolis, MN Sept. 12-17 Sept. 18 St. Louis, MO Sept. 19-24 Sept. 25 Certified Robotic Arc Welding (CRAW) Miami, FL Sept. 19-24 Sept. 25 LOCATION WEEK OF: CONTACT New Orleans, LA Sept. 19-24 Sept. 25 Wolf Robotics, Ft. Collins, CO Jul. 19 (970) 225-7736 Anchorage, AK EXAM ONLY Sept. 25 Genesis-Systems, Davenport, IA Jul. 26 (563) 445-5688 Nashville, TN Oct. 3-8 Oct. 9 ABB, Inc., Auburn Hills, MI Aug. 2 (248) 391-8421 Tulsa, OK Oct. 3-8 Oct. 9 Genesis-Systems, Davenport, IA Aug. 2 (563) 445-5688 Long Beach, CA Oct. 3-8 Oct. 9 Genesis-Systems, Davenport, IA Aug. 9 (563) 445-5688 Newark, NJ Oct. 3-8 Oct. 9 Genesis-Systems, Davenport, IA Aug. 16 (563) 445-5688 Portland, OR Oct. 17-22 Oct. 23 Genesis-Systems, Davenport, IA Aug. 23 (563) 445-5688 Roanoke, VA Oct. 17-22 Oct. 23 Genesis-Systems, Davenport, IA Aug. 30 (563) 445-5688 Cleveland, OH Oct. 17-22 Oct. 23 Genesis-Systems, Davenport, IA Sept. 13 (563) 445-5688 Miami, FL EXAM ONLY Oct. 28 Wolf Robotics, Ft. Collins, CO Sept. 13 (970) 225-7736 Corpus Christi, TX EXAM ONLY Oct. 30 Genesis-Systems, Davenport, IA Sept. 20 (563) 445-5688 Atlanta, GA Nov. 14-19 Nov. 20 Genesis-Systems, Davenport, IA Sept. 27 (563) 445-5688 Dallas, TX Nov. 14-19 Nov. 20 ABB, Inc., Auburn Hills, MI Oct. 4 (248) 391-8421 Sacramento, CA Nov. 14-19 Nov. 20 Genesis-Systems, Davenport, IA Oct. 4 (563) 445-5688 Spokane, WA Nov. 14-19 Nov. 20 Genesis-Systems, Davenport, IA Oct. 11 (563) 445-5688 St. Louis, MO EXAM ONLY Dec. 4 Genesis-Systems, Davenport, IA Oct. 18 (563) 445-5688 Los Angeles, CA Dec. 5-10 Dec. 11 Genesis-Systems, Davenport, IA Oct. 25 (563) 445-5688 Houston, TX Dec. 5-10 Dec. 11 Lincoln Electric, Cleveland, OH Oct. 25 (216) 383-8542 Syracuse, NY Dec. 5-10 Dec. 11 ABB, Inc., Auburn Hills, MI Nov.l (248) 391-8421 Reno, NV Dec. 5-10 Dec. 11 Genesis-Systems, Davenport, IA Nov.l (563) 445-5688 Miami, FL Dec. 5-10 Dec. 11 Genesis-Systems, Davenport, IA Nov.8 (563) 445-5688 Corpus Christi, TX EXAM ONLY Dec. 18 Genesis-Systems, Davenport, IA Nov. 15 (563) 445-5688 Genesis-Systems, Davenport, IA Nov.29 (563) 445-5688 9-Year Recertification Seminar for CWI/SCWI ABB, Inc., Auburn Hills, MI Dec. 6 (248) 391-8421 LOCATION SEMINAR DATES EXAM DATE Genesis-Systems, Davenport, IA Dec. 6 (563) 445-5688 San Diego, CA Jul. 12-17 NO EXAM Genesis-Systems, Davenport, IA Dec. 13 (563) 445-5688 Orlando, FL Aug. 23-28 NO EXAM Denver, CO Sept. 20-25 NO EXAM International CWI Courses and Exams Dallas, TX Oct. 4-9 NO EXAM Please visit http://www.aws.org/certification/inter_contact.html Miami, FL Nov. 29-Dec. 4 NO EXAM For current CWIs and SCWIs needing to meet education requirements without For information on any of our seminars and certification programs, visit taking the exam. If needed, recertification exam can be taken at any site listed our website at www.aws.org/certification or contact AWS at (800) 443- under Certified Welding Inspector. 9353, Ext. 273 for Certification and Ext. 455 for Seminars. Please apply early to save Fast Track fees. This schedule is subject to change without notice. Please verify the dates with the Certification Dept. and confirm American Welding Society" your course status before making final travel plans.

©AWS 2010 CER1324-07 CONFERENCES

The World of Energy — ovens when not in use, a practice not always observed in fabricating plants throughout America. The main thrust here is in Welding's Greatest Challenge ASME code work, shipbuilding, off-highway equipment, and in San Diego, Calif. the chemical industry and power plants. The introduction of du- August 31, September 1 plex stainless steels and the higher-strength versions of same require new filler metals to answer the needs of many plants that This conference will explore many topics, including the im- weld these corrosion-resistant materials. The roles of heat treat- portant aspects of coal-powered plants, the present and future ment and shielding gases will also be discussed. states of nuclear power, activities in pipeline construction, land- based and offshore work in liquefied natural gas (LNG), solar energy, and wind power. Metals will be emphasized, especially Weld Repair and the Strengthening of Grade 91 steel, 2205 and the many other duplex stainless steels, Welded Structures and nickel-based alloys. New welding processes are already play- November 3 ing major roles in these arenas and cladding is becoming more important than ever. Some of the world's largest operations, like Two of the most important concerns in welding are the repair the $10-billion, 3000-MW solar-powered facility in India and the of faulty welds and the prevention of failures from occurring in expansive Gorgon gas fields in Australia, are expected to be on the first place. These topics will be featured at one of the most the agenda. Much of welding's future depends on industry's abil- important conferences at FABTECH. ity to adapt and promote its technologies. Duane K. Miller of The Lincoln Electric Co. will be the keynoter. He will discuss the new AWS D1.7, Guide for Strength- ening and Repairing Existing Structures. Other speakers will in- 13th Aluminum Welding Conference clude Bob Terrell of the National Board of Boiler and Pressure Seattle, Wash. Vessel Inspectors, who will describe what is needed to obtain an September 21,22 "R" certificate; David J. Barton of PCI/WEC, who will comment on weld repairs in the nuclear industry; and Brent M. Williams of Miller Electric, who will discuss the use of GTAW inverter A panel of aluminum industry experts will survey the state of technology for aircraft engine repair work. the art in aluminum welding technology and practice. Attendees will have the opportunity to network with speakers and other participants, as well as to visit an exhibition showcasing products and services available to the aluminum welding industry. New Developments In Thermal Spray Aluminum lends itself to a wide variety of industrial applications Coatings, Processes, and Applications because of its light weight, high strength-to-weight ratio, corrosion November 3 resistance, and other attributes. However, because its chemical and physical properties are different from those of steel, welding of alu- This one-day event, organized by the American Welding Soci- minum requires special processes, techniques, and expertise. ety and the International Thermal Spray Association, will intro- duce the thermal spray process and its uses to new users with sessions focusing on actual applications and new developments in thermal spray technology. It will include a half-day tutorial on 2010FABTECH thermal spray fundamentals titled "What Is Thermal Spray" spon- Conference Schedule sored by the International Thermal Spray Association. Atlanta, Ga. The Welding and Cutting National Welding Education Conference of Pipe and Tubing November 2 November 4

Highlighting the conference on pipe and tubing will be Ian D. What's New In Weld Consumables? Harris of the Edison Welding Institute, who will discuss three November 2 processes: DeepTIG•, narrow groove tandem GMAW-P, and hybrid laser welding. Robert J. Pistor of Liburdi Automation will A low-hydrogen weld deposit is obviously the result of proper discuss the role of orbital welding in the new combined-cycle gas use of low-hydrogen filler metals. Much has been done and is turbine power plants in Canada, and Eric Carlson of CRC-Evans still being done in the development of low-hydrogen manual arc will talk about the past and present in automatic pipeline electrodes. It has become imperative that the relatively new welding. Grade 91 steel be welded using low-hydrogen filler metals, and From the standpoint of cutting, Jeff Bennett of Vernon Tool work is under way to develop new chemistries for these elec- will discuss the benefits and considerations via automating pipe trodes. Many of the gas metal arc welding technologies also pro- and tube cutting and profiling processes. Joe Sorvaag of ESAB duce low-hydrogen weld deposits, as does submerged arc weld- will also be on hand with a comparison of thermal cutting ing. Industry still has to learn to store these electrodes in rod options.4

For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext. 462. You can also visit the Conference Department at www.aws.orglconferences for upcoming conferences and registration information.

JULY 2010 BY HOWARD M. WOODWARD AWS Nominates National and District Officers for 2011

John L. Mendoza William A. Rice Jr. Nancy C. Cole Dean R. Wilson president vice president vice president vice president

The 2009-2010 Nominating Committee has an- ence with power plant maintenance and training nounced its slate of candidates who will stand for welders for CPS Energy, San Antonio, Tex. In 1996, election to AWS national offices for the 2011 term, he earned his Craft Instructor certification from which begins January 1, 2011. the National Center for Construction Education Nominated are the following candidates: John and Research and was hired as a welding instruc- L. Mendoza, for president; William A. Rice Jr., tor at Texas A&M University. In 2005, he was Nancy C. Cole, and Dean R. Wilson for vice presi- elected to the State of Texas board of directors for dents; and Tony Anderson and David L. McQuaid the SkillsUSA college/postsecondary division. He for directors-at-large. Three vice presidents and chaired the Texas SkillsUSA welding competition; two directors-at-large are to be elected. is a 34-year member of the International Brother- The National Nominating Committee was hood of Electrical Workers, Local 500; a past chair chaired by Past President Gene E. Lawson. Serv- of the St. Philip's College welding advisory coming on the committee with Lawson were H. R. Cast- mittee; and has received the District Dalton E. ner, D. A. Flood, R. A. Harris, D. C. Howard, J. F. Hamilton Memorial CWI of the Year Award. Key, R. C. Lanier, T. M. Mustaleski, R. L. Norris, Tony Anderson R. G. Pali, W. R. Polanin, D. D. Rager, N. S. Shan- Nominated for Vice President director-at-large non, and G. D. Uttrachi. G. Manalich served as William A. Rice Jr. Secretary. The Nominating Committees for Dis- Rice, an AWS member for more than 25 years, tricts 2, 5, 8, 11, 14, 17, and 20 have selected the is currently completing his second term as a vice following candidates for election/reelection as Dis- president. He serves as CEO for OKI Bering Sup- trict directors for the three-year term Jan. 1, 2011, ply, president of Dadco of West Virginia, president through Dec. 31, 2013. The nominees are H. W. of West Side Real Estate, and is on the boards of Thompson, District 2; S. Mattson, District 5; J. A. trustees for several health and financial organiza- Livesay, District 8; R. P. Wilcox, District 11; R. L. tions in West Virginia. Rice worked for Airgas from Richwine, District 14; J. Jones, District 17; and W. 1993 to 2001, where he served as its president and A. Komlos, District 20. COO. From 1971 to 1992, he was president of Vir- ginia Welding Supply Co. and president of sev- Nominated for President eral other welding-related companies, which he John L. Mendoza later sold to Airgas. He served as chairman of Mendoza, currently completing his third term the state VICA welding contests from 1979 to as an AWS vice president, is with Lone Star Weld- 1983. Rice holds a degree in business marketing in San Antonio, Tex. He is a Certified Welding ing with postgraduate work in journalism, psy- Inspector, Certified Welding Educator, and a jour- chology, and labor relations. He also has com- neyman welder qualified to ASME Section IX in pleted numerous welding-related courses pre- David L. McQuaid SMA and GTA welding. He has extensive experi- sented by AWS and other organizations. director-at-large

WELDING JOURNAL Nominated for Vice President Nominated for Vice President for numerous AWS technical committees re- Nancy C. Coie Dean R. Wiison sponsible for publishing the aluminum stan- Cole is completing her first term as a vice Wilson is completing his first year as a di- dards. He is a registered Chartered Engi- president. She is an AWS Fellow, a Life rector-at-large. He is vice president, weld- neer with the British Engineering Council Member, and a registered Professional En- ing business development, at Jackson Safety and a Fellow of The Welding Institute gineer in the state of Tennessee. She has Products where he has worked since 2007. (TWI). He is the author of Welding Alu- been a member of the Northeast Tennessee, From 1987 to 2007, he served as president, minum Questions and Answers, 2nd Edition, Chattanooga, and Northeast Florida Sec- CEO, and owner of Wilson Industries, Inc., and a coauthor of Welding Aluminum The- tions. She served as chair of the AWS Tech- in Pomona, Calif., a manufacturer of indus- ory and Practice, 4th Edition. Anderson is nical Activities, Fellows, and C3 Brazing and trial safety-related products. He has com- also a member of the welding technology ad- Soldering Committees, and has served on pleted graduate studies in business at San visory board at Ferris State University. Prior the International Standards, Awards, Re- Diego State University and at Stanford Uni- to joining ITW, he served as corporate tech- search and Development, Technical Paper versity in executive management. Wilson is nical training manager for ESAB North Selection, and National Nominating Com- a Laser Institute of America director-at- America in Florence, S.C. mittees. Cole also served on the Welding Re- large, and a member of Gases and Weld- search Council Brazing Research Commit- ing Distributors Assn., Industrial Fabrics Nominated for Director-at-Large tee, Materials Advisory Group, Marine Assn., Specialty Tools & Fasteners Dis- David L. McQuaid Board, National Research Council, Ad- tributors Assn., and Safety Equipment McOuaid, an AWS member since 1975 and vanced Joining Committee, and National Distributors Assn. a past chair of the Pittsburgh Section, is Materials Advisory Board. She has received presently completing his first three-year term the Wasserman Award, McKay-Helm Nominated for Director-at-Large as a director-at-large. He has been an AWS Award, AWS Honorary Member Award, and Tony Anderson member since 1977, and is a past chair of the Outstanding Alumni Award from University Anderson, well known to Welding Jour- Dl Structural Welding Committee and the of Tennessee. She holds three brazing- nal readers for his bimonthly column Alu- Technical Activities Committee (2002-2004). related patents. Cole worked at ABB Com- minum O&A that he has authored for the He received his civil engineering degree from bustion Engineering where she developed past eight years, recently joined the ITW West Virginia University in 1964 then joined welding electrodes, fluxes, and flux cored Global Welding Technology Center as direc- the American Bridge Division of U.S. Steel wires, and wrote computer programs for the tor of aluminum technology. He is an AWS Corp. where he held various positions in the process. Before forming her own company, Certified Welding Engineer, Certified Weld- Construction Department including senior she was program manager and contract man- ing Inspector, and Certified Welding Edu- welding engineer and corporate applications ager at Oak Ridge National Laboratories. cator. He has served as chair or vice chair engineer. He received the prestigious Ameri- can National Standards Institute 2009 Fine- gan Standards Medal that "honors an individ- Nominations Sought for National Officers ual who has shown extraordinary leadership AWS members who wish to nominate can- Tuesday, Nov. 2, 2010, at the Georgia World in the actual development and application of didates for President, Vice President, and Di- Congress Center, Atlanta, Ga., during the 2010 voluntary standards." Currently, he heads D. rector-at-Large on the AWS Board of Direc- FABTECH show. Nominations must be accom- L. McOuaid and Associates, Inc., a consult- tors for the term starting Jan. 1, 2012, may: panied by biographical material on the candi- ing company he formed in 1999 to serve the 1. Send their nominations by Sept. 22, 2010, date, including a written statement by the can- steel construction industry. to Gricelda Manalich, [email protected], c/o didate as to his or her willingness and ability to Victor Y. Matthews, chairman. National Nom- serve if nominated and elected, letters of sup- Nominated for District 2 Director inating Committe or port, plus a 5- x 7-in. color portrait. Note: Per- Hariand W. Thompson 2. Present their nominations in person at the sons who present their nominations at the show Currently vice chairman for the Long Is- open session of the National Nominating Com- must provide 20 copies of the biographical ma- land Section, Thompson is senior project en- mittee meeting scheduled for 2:00 to 3:00 PM, terials and written statement. gineer and welding supervisor for Under- writers Laboratories (UL), Inc., in Melville, AWS Bylaws Article IX, Section 3. Nominations. N.Y. He received his degrees in business Nominations, except for Executive Direc- with signatures of at least 20 members from management at Lyndon State College, and tor and Secretary, shall proceed as follows: each of five Districts, provided such petitions industrial engineering from the University (a) Nominations for District Directors shall are delivered to the Executive Director and of Vermont. Prior to joining UL in 2006, he be made by the District Nominating Commit- Secretary before August 26 for the elections worked in engineering and quality assurance tees [see Article III, Section 2(c)]. The Na- to be held that year. A biographical sketch of positions at Belle Transit Div., Bohemia, tional Nominating Committee shall select the nominee (and acceptance letter) shall be N.Y.; the Long Island Rail Road; Breda nominees for the other offices falling vacant. provided with the petition. Any such nominee Transportation, Inc., San Francisco, Calif.; The names of the nominees for each office, shall be included the election for such office. Thompson Transit Services, Inc., with a brief biographical sketch of each, shall A District Director may be nominated by Ronkonkoma, N.Y.; and LTK Engineering be published in the July issue of the Welding written petitions signed by at least 10 mem- Services in Blue Bell, Pa. Journal. The names of the members of the Na- bers each from a majority of the Sections in the District, provided such petitions are deliv- tional Nominating Committee shall also be Nominated for District 5 Director ered to the Executive Director and Secretary published in this issue of the Welding Journal, before August 26 for the elections to be held Steve Mattson along with a copy of this Article IX, Section 3. that year. A biographical sketch and accept- Mattson is currently completing his first (b) Any person with the required qualifi- ance letter of the nominee shall be provided term as District 5 director. He began his ca- cations may be nominated for any national of- with the petition. Any such nominee shall be reer in the welding industry in 1986 after fice by written petitions signed by not less than included in the election. serving in the military. He started a weld- 200 members other than Student Members, ing equipment service and repair facility

JULY 2010 m* *s^^ t JKA fa Harland W. Thompson Steve Mattson Joe A. Livesay Robert P. Wiicox District 2 director District 5 director District 8 director District 11 director business in Jacksonville, Fla., that has operated for metallurgy. He was promoted to program chair in more than 20 years. Mattson has been active in the 1997. Among his many District awards are CWI of North Florida Section for more than 20 years the Year, Meritorious, Private Sector Educator, and where he has served in all executive positions. Cur- the District Director Award. He has received the rently, he serves as its chairman and secretary. Ivy Tech Technology Division Advisor of the Year in 2006 and 2008, the Mid-West Team Welding Tour- Nominated for District 8 Director nament's Clifford Hunt Award for his work in edu- Joe A. Livesay cation, and was appointed to the Honorable Order Livesay is currently completing his first term as of Kentucky Colonels. District 8 director. In the U.S. Navy, he served as a hull technician, then continued his studies at Ten- Nominated for District 17 Director nessee Technological University and worked as a J. J. Jones welder at the Hartsville, Tenn., nuclear power plant. Jones, currently completing his first term as Dis- He later worked as a fitter-welder in Louisiana off- trict 17 director, has worked 26 years as a welding shore operations, then served 13 years at Crossville instructor with industry, secondary, and higher- Robert L. Richwine Ceramic as a maintenance welder. During this time education institutes. He is currently a technical District 14 director he became an AWS Certified Welding Educator. sales manager for Region 300 of Thermadyne In- Livesay taught evening welding classes at the Ten- dustries. At the age of 12, Jones was introduced to nessee Technology Center and later became the full- welding by his father. He pursued metalworking and time instructor. He has been active in AWS and has welding in high school and then went on to earn an helped implement the welding accreditation pro- AAS degree in welding technology from Eastfield gram for the state of Tennessee. He has hosted College where he became an AWS Student Mem- numerous welding competitions and his teams ber in 1982. He later received a bachelor's degree have ranked high in the SkillsUSA contests. and his Texas Lifetime Teaching Certificate in vocational trades. He contributed to the AWS Weld- Nominated for District 11 Director ing Handbook, ninth edition, where he authored Robert P. Wiicox welding processes. He has held all of the Section An AWS member since 1974, Wiicox has served officer positions, and worked on the 2005 AWS in many Detroit Section officer positions including Welding Show Committee. chair. He received his bachelor's degree at Spring Arbor College and a MS at Central Michigan Uni- Nominated for District 20 Director versity. He has worked in the automobile industry Wiiiiam A. Komios J. J. Jones as a cost estimator, buyer, and quality manager. An AWS member since 1979, Komios is currently District 17 director Wiicox serves on the advisory committees for completing his first term as District 20 director. He William D. Ford Vocational High School and is a Senior Certified Welding Inspector and a Cer- Schoolcraft Community College where he received tified Welding Educator. Komios is president of Arc his early education in industrial welding and fabri- Tech, LLC, Salt Lake City, Utah, providing project cation technology. Currently, he owns and operates support to manufacturing and steel-erection com- Warriors of Faith Martial Arts Academy where he panies. Earlier, he worked as a welding engineer conducts classes in self-defense. with Autoliv ASP, and as project manager and quality assurance manager for Mark Steel Corp. From Nominated for District 14 Director 1980 to 1995, he served as a welding instructor at Robert L. Richwine Salt Lake Community College and worked from An AWS Distinguished Member, active in the 1985 to 1991 at United Precision Machine and En- Indiana Section, Richwine has served as assistant gineering Co. in Salt Lake City. Komios served on District 14 director for the past three years. In 1994, the AWS Bl Committee on Nondestructive Exami- he joined Ivy Tech State College teaching courses nation of Welds as first vice chair for four years. He in welding, plumbing, pipefitting, print reading, and holds a MBA and a master's in civil engineering. • William A. Komios District 20 director

WELDING JOURNAL Tech Topics Two Official Interpretations: D1.1, Structural Welding Code — Steel Subject: Pipe diameters qualified for fillet D1.1/D1.1M:2004, Table 4.10, the qualified threaded studs or non-threaded studs. When welds production material thickness is 'A in. [3 invoked by the position of stud application Code Edition: D1.1/D1.1M:2004 mm] to unlimited and the diameter is un- the qualification studs may be tested by any Code Provision: Tables 4.9, 4.10 limited for fillet welds on tubular connec- suitable means to achieve the Application AWS Log: D1.1-04-I06 tions {Clause 4.28). Qualification. Clause 7.7 deals with produc- Inquiry: Table 4.9 indicates that a tion control of stud application using the welder who successfully completes a qual- procedure developed by 7.6.5. Its purpose is ification test on fillet weld test plate as Subject: Threaded stud and torque testing to verify the procedure developed elsewhere shown in Figure 4.36 in the 2F position is Code Edition: D1.1/D1.1M:2006 will produce sound stud attachment. Bend- also qualified to weld pipe fillets in the flat Code Provision: 7.6.5, 7.7.1.4 ing the threaded stud for production testing and horizontal positions. Table 4.10 shows AWS Log: D1.1-06-I14 on fabricated parts may distort the threads the qualified (thickness) dimension would Inquiry: Do all threaded studs have to to the point that the thread will not engage be Ys in. to unlimited. be torque tested and cannot be tested by properly. Therefore, for production testing Given there are no diameters stated, the bend test technique? under Clause 7.7.1.4, bend testing of does one interpret that the welder's qual- Response: Clause 7.6.5 deals specifically threaded studs is prohibited. ifications must include fillet welding of to Application Qualification test require- Bend testing is allowed for Stud Appli- pipe of all diameters and thickness? ments for special cases as noted. It is a pro- cation Qualification testingper 7.6.5. Bend Response: For performance qualifica- cedure test and not conducted on produc- testing is prohibited for Production Control tion, tests on plate in compliance with AWS tion work. The clause is not specific to testing of applied threaded studs per 7.7.1.4.

Four Official Interpretations: D1.5 Bridge Welding Code Subject: Butt joint welds in girder webs ration such as a B-L2c-S, weld one side, Does this mean that a minimum weld pass Code Edition: D1.5M/D1.5:2008 turn the qualification plate over, back- of 30 kJ/in. is all that can be made? Code Provision: Subclauses 6.11, 6.26.3 gouge with either a grinder or air carbon Response: The code does not provide AWS Log: D1.5-08-I01 arc torch, and then grind the backgouge preheats for fracture-critical welding using Inquiry: Is it the intent of the AWS to bright metal prior to welding the sec- a heat input of less than 30 kJ/in. Welding D1.5:2008,finrfge Welding Code, that when ond side? Or take the qualification test on outside of the parameters of Table 12.3 evaluating the NDE results of beam or a test plate prepared with a joint configu- would require agreements of required pre- girder web vertical butt joint welds that ration such as a B-L2a-S, remove the back- heat between the Contractor and Engineer. the applicable RT or UT acceptance cri- ing after welding the first side, backgouge teria for welds subject to tensile stress by air carbon arc torch or grinding and under any condition of load be used to de- then weld the backgouge prior to RT or Subject: Maximum heat input termine acceptance, regardless of the lo- bend testing? Code Edition: D1.5M/D1.5:2002 cation of the tested area? Response: Afo. Reason: Prequalified or Code Provisions: 5.12.1, 5.12.3.2 Response: Yes, unless the region is specif- production weld joints, other than those AWS Log: D1.5-02-I09 ically shown on the design drawings as sub- listed in Figures 5.1 and 5.2, are not intended Inquiry: What is the intent of the word- ject only to compressive stress (see 6.26.2.2). to be used for qualification of production ing in 5.12.1 in regard to the "highest heat welders or welding operators. input" requirement? Subject: Welder operator requirements Response: Individual weld passes on a Code Edition: D1.5M/D1.5:2008 Subject: Fracture-critical weld size and PQR test plate should be made at the same Code Provisions: 5.21.2, 5.23.1.2, 5.23.1.5 heat input specific welding variables (i.e., volts, amps, AWS Log: D1.5-08-I05 Code Edition: D1.5M/D1.5:2002 travel speed, which will produce the maxi- Inquiry: Is it the intent of the AWS Code Provision: Clause 12 and Table 12.3 mum heat input) given due consideration D 1.5:2008, Bridge Welding Code, that an AWS Log: D1.5-02-I08 for normal process variation. Increased vari- individual may take a qualification test on Inquiry: The heat input ranges identi- ability can be anticipated for root and cap a test plate prepared with a joint configu- fied in Table 12.3 start at 30 to 50 kJ/in. passes.

Two Official Interpretations: D17.1, Specification for Fusion Welding for Aerospace Applications Subject: Extended validity and disqualifi- 2. Can the Engineering Authority spec- ual "used the process" [D17.1, 4.2.3.2]? cation ify its "prescribed standards" for the "ap- Proposed replies (both possibilities): Code Edition: D17.1:2001 plication normally welded" in lieu of the a) A reply of "No" to Question 1 would Code Provision: Paragraphs 4.2.3.2, 4.2.3.3 "criteria for Class A welds" [D17.1, confirm that "used the process" equates to AWS Log: D17.1-01-I02 4.3.8.1]? what is commonly known as a "Record of Inquiry: 1. Does the phrase "...to doc- 3. Is it required that the "application Activity," wherein only welding is done, but ument welder performance." [D17.1, normally welded" meet the "prescribed it does not include requirements to inspect 4.2.3.3(2)] require that each "application standards" prior to any rework or repair, the "application normally welded" and normally welded" [D17.1, 4.2.3.2] for the i.e., at its soonest planned inspection? confirm its conformance to the "prescribed purpose of meeting the Extended Validity 4. Does the "auditable record" [D17.1, standards." (This would then relegate any requirements has to "meet prescribed stan- 4.2.3.2] need to include evidence of con- replies to Questions 2-4 as inconsequen- dards" as implied by the A3.0 definition of formance to the "prescribed standards" in tial.) To clarify this, 4.2.3.2(2) of D17.1 "welder performance qualification"? addition to the evidence that the individ- should delete the phrase "...to document

JULY 2010 welder performance". Otherwise, the "in- prospect of Disqualification. A "Yes" to Code Provision: Paragraphs 4.3.7.5,4.3.7.6 dividual's performance required by Questions 2-4 would logically follow. AWS Log: D17.1-01-I03 4.2.3.2" [4.2.3.3(2)] would contradict Consequently, this would require an ex- Inquiry: When a special application "welder performance" as implied by the panded system for acquiring and main- qualification is performed per Paragraph definition of "welder performance quali- taining inspection records from sources 4.3.7.5, are the limitations stated by Para- fication" in A3.0. that are not common to qualification test graph 4.3.7.6 imposed on the qualifica- b) A reply of "Yes" to Question 1 records, e.g., from manufacturing records tion, or is Paragraph 4.3.7.5 a stand-alone would mean that each "application nor- of delivered hardware (paper or elec- requirement with the qualification spe- mally welded" for the purpose of Ex- tronic), with the added outlay of time and cific to the special application test? Pro- tended Validity in a six-month period money to do so. posed reply: Define if Paragraph 4.3.7.6 would be purposely equivalent to an ini- Response: No. is a requirement for special applications. tial qualification test, including its inspec- Response: JVo. Paragraph 4.3.7.6 is not tion and evidence of conformance to pre- Subject: Qualification limitations a requirement for special applications. Yes. scribed standards, and invokes the Code Edition: D17.1:2001 4.3.7.5 is a stand-alone paragraph.

Official Interpretation: D15.1, Railroad Welding Specification for Cars and Locomotives Subject: Technique Alloy, and Stainless Steel Sheet Metal) — rent since Amperes is a current and volt- Document: D15.1/D15.1M:2007 Technique age is not? An amp is the unit of measure- Code Provisions: Page 184: Sample Form Inquiry: Form D-ll and Form D-13A: ment of an electric current or intensity. for Welding Procedure Qualification Test Under Technique where it states Welding Voltage is the electrical potential for an Record (PQR) — Technique, and Page Current, it covers Amperes and Volts. electric field, 187: Sample Form for Welding Procedure Shouldn't this be designated as Electrical Response: Replace "Welding Current" Specification (WPS) (For Carbon, Low- Characteristics instead of Welding Cur- with "Electrical Characteristics".

Revised Standard Approved by ANSI A5.34/A5.34M:20XX, Specification for of Industrial Mill Rolls. This standard pro- B2.2/B2.2M:2010, Specification for Nickel-Alloy Electrodes for Flux Cored Arc vides guidance for preparing, building up, Brazing Procedure and Performance Qual- Welding. The composition, soundness, and and overlaying by welding, postweld heat ification. Approved 4/22/2010. properties of weld metal from ten grades treating, finish machining, inspecting, and of flux cored electrodes are specified. record keeping of new and reconditioned Revised Standard for Public Review Standard electrode sizes together with industrial mill rolls. Stakeholders: Ma- C3.8M/C3.8:20XX, Specification for the their package forms and package sizes are chinery and equipment industry. Call M. Ultrasonic Pulse-Echo Examination of detailed. This specification makes use of Rubin, ext. 215. Brazed Joints. $25. Review expired both U. S. customary units and the Interna- D16.2M/D16.2:20XX, Guide for Com- 6/28/2010. tional System of Units (SI). Stakeholders: ponents of Robotic and Automatic Arc AWS was approved as an accredited Welding industry. R. Gupta, ext. 301. Welding Installations. This guide provides standards-preparing organization by the D9.1M/D9.1:20XX, Sheet Metal Weld- performance recommendations for eval- American National Standards Institute ing Code. This code covers the arc and uating components of a typical robotic or (ANSI) in 1979. AWS rules, as approved braze welding requirements for nonstruc- automatic welding installation. Emphasis by ANSI, require that all standards be tural sheet metal fabrications using the is placed on the role of the welding inter- open to public review for comment dur- commonly welded metals available in face. A pin arrangement and specific pin ing the approval process. Draft copies may sheet form. Requirements and limitations function for each location in a standard- be obtained from R. O'Neill, ext. 451, governing procedure and performance ized 37-pin connector are proposed. roneill@aws. org. qualification are presented, and work- Stakeholders: Robotic welding industry. manship and inspection standards are sup- Call M. Rubin, ext. 215. ISO Draft Standards for Public Review plied. The informative annexes provide G2.5/G2.5M:20XX, Guide for the Fu- ISO/DIS 12932, Welding — Laser-arc useful information on materials and sion Welding of Zirconium and Zirconium hybrid welding of steels, nickel and nickel processes. Stakeholders: Those involved Alloys. This guide provides instructions alloys — Quality levels for imperfections in the production and qualification of non- for the welding of zirconium and zirco- ISO/DIS 15609-6, Specification and structural sheet metal applications such nium alloys. It explains processes, equip- qualification of welding procedures for metal- as heating, ventilating, and A-C systems. ment, materials, workshop practices, joint lic materials — Welding procedure specifica- Call A. Alonso, ext. 299. preparation, welding techniques, tests, tion — Part 6: Laser-arc hybrid welding D14.4/D14.4M:20XX, Specification for and the repair of defects. Stakeholders: Copies of the above draft standards are Welded Joints in Machinery and Equipment. Equipment fabricators worldwide, engi- available for review and comment through This specification establishes common ac- neering companies, maintenance welders, your national standards body, which in the ceptance criteria for classifying and ap- chemical companies using zirconium United States is ANSI, 25 W 43rd St., plying carbon and low-alloy steel welded equipment, repair welders, etc. Call S. Fourth Fl., New York, NY 10036; (212) joints used in the manufacture of ma- Borrero, ext. 334. 642-4900. Any comments regarding ISO chines and equipment. It covers weld joint documents should be sent to your national design, workmanship, quality control re- standards-preparing body. In the United quirements and procedures, welding op- Technical Committee Meetings States, contact Andrew Davis, ext. 466, erator and welding procedure qualifica- July 22, Committee on Personnel & Fa- [email protected]. tion, weld joint inspection (visual, radi- cilities Qualification. Pittsburgh, Pa. Con- ographic, ultrasonic, magnetic particle, tact J. L. Gayler, ext. 472. New Standards Projects liquid penetrant), repair of weld defects, Aug. 11,12. Technical Activities Com- Development work has begun on the and heat treatment. Stakeholders: Ma- mittee. Chicago, 111. Contact J. L. Gayler, following revised standards. Affected in- chinery and equipment industry. Call A. ext. 472. dividuals are invited to contribute to their Alonso, ext. 299. Aug. 11, 12. International Standards development. To participate, contact the D14.7M/D14.7:20XX, Recommended Activities Committee, Chicago, 111. Call staff engineer listed with the document. Practices for Surfacing and Reconditioning A. R. Davis, ext. 466.

WELDING JOURNAL Weldmex Was a Great Show

John Bruskotter, American Welding So- ciety president, is shown presenting his speech welcoming the attendees to the 2010 AWS Weldmex exhibition. The event was held May 11-13, at the Centro Banamex exhibition hall in Mexico City, Mexico. Weldmex now is colocated with Metal- form Mexico, COATech, and FABTECH Mexico. The exhibition space totaled 44,000 sq ft, with the AWS Weldmex contributing 20,000 sq ft and 140 welding-related ex- hibitors. More than 7900 visitors attended the exhibition. The combined show has grown to the point where it is now the largest annual metalworking event in Latin America. The next Weldmex combined show is scheduled for May 11-13, 2011, at Cinter- mex, Monterrey, Mexico.

Candidates Sought for Technical Committees Seek Your Expertise M.I.T. Award Surfacing Industrial Mill Rolls cation for the Application of Thermal Spray D14H Subcommittee on Surfacing Coatings (Metallizing) of Aluminum, Zinc, November 2, 2010, is the deadline for and Reconditioning of Industrial Mill and Their Alloys and Composites for the submitting nominations for the 2011 Rolls to revise AWS D14.7, Recom- Corrosion Protection of Steel. Contact R. Prof. Koichi Masubuchi Award, spon- mended Practices for Surfacing and Re- Starks, [email protected], ext. 304. sored by the Dept. of Ocean Engineer- conditioning of Industrial Mill Rolls. ing at Massachusetts Institute of Tech- Contact M. Rubin, [email protected], Labeling and Safe Practices nology (M.I.T). ext. 215. SH4 Subcommittee on Labeling and This award, including an honorarium Safe Practices to update F2.2, Lens Shade of $5000, is presented each year to one Robotic and Automatic Welding Selector, F4.1, Safe Practices for the Prepa- person who has made significant contri- D16 Committee on Robotic and Au- ration of Containers and Piping for Weld- butions to the advancement of materials tomatic Welding to update D16.1, Speci- ing and Cutting, and the AWS Safety and joining through research and develop- fication for Robotic Arc Welding Safety; Health Fact Sheets. S. Hedrick, ment. The candidate must be 40 years old D16.2, Guide for Components of Robotic [email protected], ext. 305. or younger, may live anywhere in the and Automatic Arc Welding Installations; world, and need not be an AWS member. D16.3, Risk Assessment Guide for Robotic Magnesium Alloy Filler Metals The nomination package should in- Arc Welding; D16.4, Specification for Qual- A5L Subcommittee on Magnesium clude the candidate's background, ex- ification of Robotic Arc Welding Personnel. Alloy Filler Metals. This subcommittee is perience, publications, honors, and Contact M. Rubin, [email protected], ext. responsible for updating AWS AS.19-92 awards, plus at least three letters of rec- 215. (R2006), Specification for Magnesium ommendation from fellow researchers. Alloy Welding Electrodes and Rods. Con- The award was established to recog- Thermal Spraying tact R. Gupta, [email protected], ext. 301. nize Prof. Koichi Masubuchi for his nu- C2 Committee on Thermal Spraying merous contributions to the advance- to update C2.16, Guide for Thermal Spray Welding Sales Representatives ment of the science and technology of Operator Qualification; C2.18, Guide for Volunteers are invited help set the welding, especially in the fields of fabri- the Protection of Steel with Thermal qualification requirements in AWS B5.14, cating marine and outer space struc- Sprayed Coatings of Aluminum and Zinc Specification for the Qualification of Weld- tures. Send your nominations to Prof. and their Alloys and Composites; C2.19, ing Sales Representatives. Contact J. John DuPont at [email protected]. Machine Element Repair, C2.23, Specifi- Gaylei, [email protected], ext. 472.

District Director and Student Chapter Awards Announced District 22 Director, Dale Flood, nom- The AWS Sierra College Student The AWS Board of Directors estab- inated the following members for this Chapter, Sacramento Section, District 22, lished the Student Chapter Member award: Tom Smeltzer (San Francisco), and Robert Purvis, Student Chapter Ad- Award to recognize those whose activities Tom Erichsen (Santa Clara), Charles visor, have selected Russell Jordan to re- have produced outstanding school, com- Bookout (Fresno), Matt Wysocki and ceive the Student Chapter Member munity, or industry achievements. This Melvin Johnson (Sacramento), Randy Award. Jordan, with the Sierra College award also provides an opportunity for Naylor, Gaylord Rodeman, and Scott Hol- Student Chapter, is finishing his second Student Chapter advisors. Section offi- comb (Sierra Nevada). The District Di- year at the college, served this year as the cers, and District directors to recognize rector Award provides a means for Dis- Chapter chairman, and is qualified to outstanding Students Members. The cri- trict Directors to recognize individuals weld pipe on the 6G position. He enthu- teria and nomination form can be down- who have contributed their time and ef- siastically volunteered to repair bicycles, loaded from www.aws.org/sections/awards/ fort to the affairs of their local Section lawn mowers, and other items, during the student_chapter.pdf, or call the Member- and/or District. recent open house. ship Dept. at (800) 443-9353, ext. 260.

JULY 2010 Shanghai Welding Society Representative Visits Miami

Ding Fubao, general secretary, The national Agent in August 2008. Shown and certification programs; Peter Howe, Shanghai Welding Society (SWS), visited above are (from left) Melissa Gomez, sen- managing director. Certification Dept.; AWS headquarters May 7. The SWS ad- ior coordinator, international certifica- Donald Llopis, coordinator, international ministers AWS certification programs in tion programs; Cassie Burrell, deputy ex- business and certification programs; and Shanghai, China. It is an AWS Accredited ecutive director; Secretary Ding Fubao; Emil Pagoaga, senior coordinator for Ac- Test Facility that became an AWS Inter- Priti Jain, director, international business credited Test Facilities.

Israeii Certification Secretary Visits AWS Headquarters Chaim Daon, a member of the Israeli Examination and Certification Committee for Welding Inspectors and secretary of the Israeli National Welding Committee (INWC), an AWS International Section, visited AWS headquarters in May. Busi- ness included discussion about reciprocity for Israelis holding AWS CWI certifica- tions to gain INWC certification. Shown are (from left) Priti Jain, director, international business and certification programs; Cassie Burrell, deputy executive director; Secretary Chaim Daon; Peter Howe, managing director. Certification Dept.; and Rhenda Kenny, director. Member Services Department.

AWS Foundation Visits PSEG Fossii Training Center in Bridgeport, Conn.

Shown at the PSEG Welding Lab in Bridgeport, Conn., are (front, from left) Monica Pfarr, corporate director, solutions opportunity squad (SOS); and Elizabeth Fray; (back, from left) Sam Gentry, executive director, AWS Foundation; and welding students Jenifer Martin, Emery Laber- trandie, and Justine MacLean. The group visited with District 2 Director Ken Stock- ton, then toured the training center. The center presents an eight-week course stressing welding safety and troubleshooting submerged arc welding machines. It offers certification in submerged arc pipe welding. Fray is an AWS Foundation donor who is interested in welder education and development programs in the state of Connecticut.

WELDING JOURNAL New AWS Supporters

New Sustaining Companies Supporting Companies Floyd County High School Campbell's Welding & Machinery, Inc. 721 Baker St. Alta Vista Solutions, Inc. PO Box 8555 Floyd, VA 24091 6475 Christie Ave., Ste. 425 Landing, NJ 07850 Emeryville, CA 94608 Garden City Representative: Jlnesh Mehta Davlan Engineering Community College www. altavistasolutions. com 3644 Scarlett Oak Blvd. 801 Campus Dr. Alta Vista Solutions is a specialty St. Louis, MO 63122 Garden City, KS 67846 engineering firm that provides construction engineering and inspection Diamond Ground Products, Inc. Inland Empire services for infrastructure projects. Its 2550 Azurite Cir. Job Corps Center offices in California, Europe, and Asia Newbury Park, CA 91320 3173 Kerry St. have highly skilled technical staffs to San Bernardino, CA 92407 bring cost-effective construction sup- Penn Iron Works, Inc. port to speed project delivery. 700 Old Fritztown Rd. Los Fresnos High School Sinking Spring, PA 19608 1 Mile N. Arroyo Blvd. Los Frenos, TX 78566 Bucyrus International Rai Industrial Fabricators, LLC 1100 Milwaukee Ave. 199 Paradise Valley Rd. Meridian PTC South Milwaukee, WI 53172 Athens, GA 30607 Meridian High School Representative: Dale A. Gllbertson 1900 W. Pine www. bucyrus. com Wearresist Technologies Pvt. Ltd. Meridian, ID 83642 Bucyrus International designs and 749/9 G.I.D.C., Makarpura manufactures high-productivity mining Vadodara, Gujarat 390010 Metropolitan equipment for surface and under- India Community College ground mining. Its surface equipment Business and Technology is used for mining coal, copper, iron World International Testing, Inc. 1775 Universal Ave. ore, oil sands, and other minerals. Its 2228 Sunset Blvd., Ste. One Kansas City, MO 64120 underground equipment is used prima- Steubenville, OH 43952 rily for mining coal. It also manufac- North Pole High School tures high-quality OEM parts and pro- Affiliate Companies 601 NPHS Blvd. vides world-class support services for Calhoun Super Structures North Pole, AK 99705 its equipment. 7453 Willington Rd. 18 RR 1 Elora, ON N0B1S0, Canada Palo Duro High School 1400 N. Grant Hershberger Bros. Welding Amarillo, TX 79106 PO Box 97336 AWS Las Vegas, NV 89193 Pusan Membership Counts National University Interra Inc. Jangjeon Dong 6501 E. Greenway Pkwy. # 527 Kumjeong Ku Pusan 609735, Korea Member As of Scottsdale, AZ 85254 Grades 06/01/10 Rowe Inspection Services and Royal High School Sustaining 514 Consulting, LLC Welding Dept. Supporting 312 17775 W. Columbine Dr. 34499 Royal Rd. Educational 541 Surprise, AZ 85388 Brookshire, TX 77423 Affiliate 477 R Z Contractors, Inc. South West I.S.D. Welding distributor 48 PO Box 726, Condo Los Pinos 108 11914 Dragon Ln. Total corporate members 1,892 Caguas, PR 00726 San Antonio, TX 78252 Individual members 53,593 Student + transitional members.... 9,424 Educational Institutions Spring Hill High School American Technical Publishers Welding Program Total members 63,017 10100 Orland Pkwy. 3101 Spring Hill Rd. Orland Park, IL 60467 Longview, TX 75605

AWS Mission Statement Denison High School The Steel Yard 1901 S.Mirick Ave. 27 Sims Ave. The mission of the American Denison, TX 75020 Providence, RI 02909 Welding Society is to advance the science, technology, and application of Erie Institute of Technology Western Nevada College welding and allied processes, includ- 940 Millcreek Mall 2201 W. College Pkwy. ing joining, brazing, soldering, cut- Erie, PA 16565 Carson City, NV 89703 ting, and thermal spraying.

JULY 2010 District 1 Thomas Ferri, director (508)527-1884 tferri @ thermadyne. com BOSTON MAY 3 Activity: The Section members met at Ass- abet Valley Regional Technical School in Marlboro, Mass., for a demonstration of the safe use of industrial abrasives. Pferd Abrasives representatives Phil Benincaso, Jim Ballon, Christian Hansen, and Bill Fahlin performed the demos.

BOSTON AND Presenters at the Boston Section program are (from left) Phil Benincaso, Christian Hansen, CENTRAL MASS./R.I. Jim Ballou, and Bill Fahlin. APRIL 12 Activity: The two Sections met for a tour of Pierce Aluminum Co. in Franklin, Mass., to study its metal processing, waterjet cutting, and welded fabrication of aluminum components. Jim Pringle, vice president, conducted the program.

CONNECTICUT APRIL 20 Activity: The Section held an executive board meeting to plan for the upcoming CWI seminar in Hartford, Conn., the June District 1 conference, and future events. Attendees included District 1 Director Tom Ferri, Vice Chair Bob Cullen, Chair- man Al Moore, Secretary Joe McGloin and Treasurer Walter Chojnacki. Shown are (from left) District 1 Director Tom Ferri, Pierce Aluminum Vice President Jim Pringle, and Doug Desrochers, chairman, Central Massachusetts/Rhode Island Section. District 2 Kenneth R. Stockton, director (908)412-7099 [email protected] LONG ISLAND MAY 13 Activity: The Section discussed the welding of structures for the MTA tunnel and 2nd Avenue station. The meeting was held at The Nook Restaurant in Wantagh, N.Y.

District 3 Michael Wiswesser, director (610)820-9551 Shown at the Connecticut Section hoard meeting are (from left) Bob Cullen, Chairman Al mike @ welderinstitute. com Moore, Joe McGloin, District 1 Director Tom Ferri, and Walter Chojnacki.

WELDING JOURNAL Reading Section first-level welding contest Shown at the Long Island Section meeting are (from left) Tom Gartland, Harland Thomp- winners included (from left) Shantilly Smith, son, Barry McQuillen, Ray O'Leary, Alex Duschere, and Brian Cassidy chairman. Frank Mohr, and Wesley Hess. District 4 Roy C. Lanier, director (252)321-4285 [email protected]

SOUTHWEST VIRGINIA MAY 1 Activity: The Section hosted its annual fish fry outing at Green Hill Park in Salem, Va. Tom Wenrich was presented his Silver Membership Certificate Award for 25 years of service to the Society by Section Reading Section second-level welding contest winners included (from left) Jake Watson, Chairman Wayne Johnson. Alan Millinder, Zachary Shippling, and Cory Stuebner. District 5 Steve Mattson, director (904) 260-6040 [email protected] FLORIDA WEST COAST MAY 1 Activity: The Section hosted its annual Shrimp-A-Roo outing at Sons of Italy Lodge in Tampa, Fla., for nearly 100 members and guests. Scholarship Chair Alan Shissler presented Section scholarships for $750 each to Richard Perkins and Shane Holland, welding students at Traviss Career Center in Lakeland, Fla. Robert Brewington received his past chairman's plaque from Steve Mattson, District 5 Shown at the Southwest Virginia Section fish fry outing are (from left) Ted Alberts, Tom director. Wenrich, and Chairman Wayne Johnson. READING welding instructors, students, and guests NORTH FLORIDA APRIL 23 at Reading-Muhlenberg Career and Tech- APRIL 16 Speaker: Mike Wiswesser, District 3 di- nology Center in Reading, Pa. Awards Speaker: Leo Herns, Scientia Solutions rector were presented on three levels. The top Topic: Hexavalent chromium exposure Affiliation: Welder Training and Testing scorers were Wesley Hess, Frank Mohr, limits Institute, vice president Shantllly Smith, Cory Stuebner, Zachary Activity: The program was held in Jack- Topic: The importance of being an AWS Shippling, Alan Millinder, Nicholas sonville, Fla. Attending were Jerry member and how it helps welders Vazquez, Jake Watson, James Norman, Thomas, director. Plumbers Pipe Fitters Activity: The Section hosted an awards- Alex Ferrara, Ben Dehoff, Jeremy Mar- Training Facility; and Steve Mattson, Dis- presentation program for 52 members, tin, and Victor Torres. trict 5 Director.

JULY 2010 Jolene Molitoris discussed transportation Shown at the Florida West Coast Section outing are (from left) Alan Shissler, scholarship issues at the Columbus Section program recipient Richard Perkins, and Edwin Harrell, welding instructor at Traviss Career Center. in March.

Speaker Leo Herns (left), District 5 Direc- tor Steve Mattson (center), and Jerry Robert Brewington (left) is shown with Steve Shown at the South Carolina Section event Thomas participated in the North Florida Mattson, District 5 director, at the Florida are (from left) Gale Mole, Ben Magrone, and Section program. West Coast Section Shrimp-A-Roo. Steve Mattson, District 5 director.

SOUTH CAROLINA Topic: Transportation and rail develop- APRIL 15 ment in Ohio Activity: The Section held its annual Pig Activity: Members of the local chapters of Pickin' Social at Haselden Co., Inc., in SWE, ASME, ASM International, HE, Wando, S.C. Incoming officers were in- AIAA, ISA and NACE, attended the pro- stalled and Ben Magrone, outgoing chair, gram, held in Columbus, Ohio. received a plaque of appreciation. Attend- ing were Gale Mole, vice chair; and Steve APRIL 22 Mattson, District 5 director. Activity: The Columbus Section joined members of the local chapters of SWE, ASME, ASM International, HE, AIAA, District 6 ISA, and NACE to tour the facilities of the Kenneth Phy, director National Board of Boiler and Pressure (315)218-5297 Vessel Inspectors in Columbus, Ohio. The KA Phylnc ©gmail. com guides were engineering staff members Robert Schueler, James Keenan, Francis Speaker Robert Zimmerman (left) is shown Brown, and Robert Terrell. with AIAA Chair Tom Ramsay at the Columbus Section meeting in May. District 7 MAY 6 Don Howard, director Speaker: Robert Zimmerman, author DAYTON (814)269-2895 Topic: Stories of the early American and MAY 11 [email protected] Russian space programs Speaker: Edd Turner, senior sales repre- Activity: The Columbus Section met with sentative COLUMBUS members of the local chapters of SWE, Affiliation: Nelson Stud Welding MARCH 23 ASME, ASM International, HE, AIAA, Topic: Advances in stud welding Speaker: Jolene Molitoris, director ISA, and NACE, at Arlington Banquets in Activity: The meeting was held at Amber Affiliation: Ohio D.O.T., Columbus Columbus, Ohio. Rose Restaurant in Dayton, Ohio.

WELDING JOURNAL PITTSBURGH JULY 13, 2009 t - Activity: The Section held an executive board meeting to plan for the upcoming 8 r year's programs. * *Ji District 8 V ^vtaSF^ Joe Livesay, director (931)484-7502, ext. 143 mi joe. livesay @ ttcc. edu ^ CHATTANOOGA Shown at the Pittsburghu Section executive board meeting are (from left) Tom White, Dave APRIL 20 Dougherty, George Kirk, Carl Spaeder, Roger Hilty, and Brad King.^1 Speaker: Craig Eppley Affiliation: The Lincoln Electric Co. Topic: Controlling weld fumes Activity: The program was held at Ko- matsu America Corp. in Chattanooga, Tenn.

GREATER HUNTSVILLE APRIL 20 Activity: The Section members met to discuss the national SkillsUSA contest, Sec- tion scholarship program, and the District conference. The meeting was held at Mar- shall Technical School in Huntsville, Ala. Chair Rayburn Johnson conducted the meeting. Speaker Edd Turner (right) is shown with Speaker CraigEppley (left) chats with Buster Steve Whitney, Dayton Section chair. Hales at the Chattanooga Section program. HOLSTON VALLEY APRIL 13 Activity: The Section hosted its fifth annual students' night program at Tennessee Technology Center in Surgoinsville, Tenn. Welding instructor Jerry Sullivan presented a talk and also cooked the barbecue dinner. The welding skills contest included 20 students. The two top winners received $100 savings bonds, the runners- up received $50 bonds.

NASHVILLE Winners in the Holston Valley welding contests included (from left) John King, Jordan Law- APRIL 8 son, Paul Brandon, and D. J. Littlefield. Speaker: John Kahl Affiliation: The Lincoln Electric Co. Topic: The services Lincoln provides for industrial robots and power sources Activity: The Section presented $500 scholarships to welding students Barry Paul, Bruce Threet, Les Cornet, Ryan Boyd, and Sean Jones. Dave Brumley demonstrated a virtual reality welding simulator. Everyone enjoyed experimenting with the new training technology. Forty- one members and guests attended the meeting and barbecue dinner. District 9 George D. Fairbanks Jr., director The Nashville Section presented scholarships to (from left) Barry Paul, Bruce Threet, Les (225) 473-6362 Cornet, Ryan Boyd, and Sean Jones. fits ©bellsouth.net

JULY 2010 New Orleans Section past chairs are (from left) James Watts, Travis Moore, Paul Hebert, Matthew Howerton, Tony DeMarco, AWS Presi- dent John Bruskotter, and Bruce Halilla. NEW ORLEANS MAY 18 Speaker: Matthew Howerton Affiliation: The Lincoln Electric Co. Topic: Welding engineering for non-welding engineers Activity: The Section hosted its past chair- men's night program at Boomtown Casino in Harvey, La., for 70 attendees. Wesco Gas and Welding Supply hosted the meeting. Todd Taranto of Wesco and Chairman Donald Berger organized the event. Stu- dent Elliot Hardln, Local 58, was recog- Todd Taranto (left) and speaker Matthew Shown at the New Orleans Section program nized for attending the most meetings. Howerton are shown at the New Orleans are (from left) Aldo Duron, Elliot Hardin, Section program. and Donald Berger, chairman. District 10 Richard A. Harris, director (440) 338-5921 richaharris @ windstream.net District 10 DRAKE WELL MAY 11 Activity: The Section members met to discuss plans for the upcoming year's activities. The meeting was held at Cozumel Mexican Restaurant in Cranberry, Pa.

MAHONING VALLEY Shown at the Drake Well Section meeting are (from left) Treasurer Ward Riser, past AWS District 10 Conference Treasurer Earl Lipphardt, Chairman Mike Owens, and Jason Fry, vice chair. MAY 6 ~ The Mahoning Valley Section hosted the District 10 conference at Youngstown His- torical Center in Youngstown, Ohio, presided by District 10 Director Richard Harris. Past AWS President Victor Matthews presented the Life Membership Award to Ray DeBonis for 35 years of service to the Society, and a chairman's appreciation award to Huck Hughes. The AWS staff representative was Brian McGrath. District 11 Eftihios Siradakis, director At the District 10 conference, Ray DeBonis receives the Life Membership award from past (989)894-4101 President Victor Matthews. Shown in the back, from left, are Kenny Jones, Chuck Moore, ft.siradakis @ airgas.com District 10 Director Richard Harris, and Brian McGrath, AWS staff representative.

WELDING JOURNAL District 12 conference attendees are shown at the May 7program. District 12 Sean P. Moran, director (920) 954-3828 [email protected]

District 12 Conference MAY 7 Activity: The Milwaukee Section hosted the meeting chaired by District 12 Direc- tor Sean Moran. Participating were Theresa Wiles, Dave Ramseur, Dan Cri- Eight welding contestants pose at the Detroit Section-sponsored event. fase, Karen Gilgenbach, Chuck Frederick, Cory Satka, Ken Karwowski, Gerald DETROIT Blaski, Ben Newcomb, Craig Wentzel, Bob MAY 1 Bruss, Sue Silverstein, Randall Consel- Activity: The Section hosted a high school man, Dan Roland, and Steve Hedrick, welding contest at Schoolcraft College in AWS manager, safety and health. The Livonia, Mich. Guest speakers were Chair- event was held at Graingers Pub and Grill man Mark Rotary and Robert Wilcox. in Milwaukee, Wis. Eight schools participated. The winners were Alex Cudnohufsky, Jorden Nier- grath, and Shane Clark. Attendees MADISON-BELOIT learned how to use the Lincoln Electric APRIL 14 virtual welding teaching equipment. Work- Activity: The Section members toured the ing the contest were Gail White, Ben Kuhn North America facilities in Brod- Fontana, Paul Wilcox, Mark Rotary, Steve head, Wis., to study the manufacture of in- Slavic, Rodney Johnson, Tom Rumsey, dustrial agricultural equipment. The din- John Ludwig, Tim Hurley, Mike Bennett, ner and meeting were held at Silver Dol- Fred Ellicott, Viji Kuruvilla, and Melissa lar Steakhouse and Saloon. Chair Ben Machnee. Newcomb presented Rob Stinson the Dis- trict Director's Award, District Meritori- Hack Hughes receives a chairman's appre- ous Award, and his Life Member Certifi- ciation award from Victor Matthews at the NORTHWEST OHIO cate for 35 years of service to the Society. District 10 conference. APRIL 1 David Diljak presented Ben Newcomb an Activity: Adam Webb of Lincoln Electric award for his services as chairman. gave attendees a chance to show their welding skills using a virtual reality weld simulator. A contest was held, and the win- MILWAUKEE ner received a Lincoln welding machine. APRIL 22 Karl Hoes discussed the materials and Activity: The Section sponsored a vendors' welding processes used in the fabrication night program at Milwaukee Area Techni- of competition vehicles and offered a num- cal College in Oak Creek, Wis., titled Lat- ber of tips to make fabrication easier. est Trends in Technology. Participating More than 30 competition vehicles were companies included Eutectic, Lincoln on display to view their construction. Electric, Miller Electric, Fronius, Pana- Aaron Oyster and Jim Zywocki gave weld- sonic, Mavrix, IGM Robotics, Walter, Nor- ing and cutting demonstrations using Lin- ton Abrasives, and Airgas. A full-size robot coln's mobile demonstration unit. The pro- performed for the 74 attendees. John gram, attended by about 1500 people, was Hinrichs was presented the District Rob Stinson (right) is shown with Ben New- held at Owens Community College in Meritorious Award by Sean Moran, Dis- comb, Madison-Beloit Section chair. Toledo, Ohio. trict 12 director.

JULY 2010 Shown at the Milwaukee Section program are (from left) Brion Kluge, Terry Kitzrow, Joe Villa, Bryan Hackbarth, Dale Gilbertson, and Ami Quackenbush.

Jim Renner (left) receives the Private Sector Instructor Award from Dale Lange, Upper Peninsula Section chair. Shown at the Racine-Kenosha Section program are (from left) Chair Daniel Crifase, Mike Kessel, speaker Damian Kotecki, and Ken Karwowski. RACINE-KENOSHA MAY 19 Speaker: Damian J. Kotecki, a past AWS president Affiliation: Damian Kotecki Welding Con- sultants, Inc., president Topic: How to turn good filler metal into poor welds Activity: The program was held at Cardi- nal Ale House and Bowl in Columbus, Wis.

UPPER PENINSULA APRIL 13 The sponsors for the J.A.K welding rodeo were (from left) Mark Stevenson, John Willard, Activity: The Section members toured Fred Mancuso, Justin Tibbetts, and Will Hemphill. Verso Paper in Iron Mountain, Quinnesac, Mich. Karl Bauman, maintenance specialist, conducted the tour. Following the tour, the members held a business meeting to determine officer nominations and section award candidates. Chair Dale Lange received an appreciation certificate for his services. Jim Renner, a weld instructor at Marinette Marine Corp., received the Pri- vate Sector Instructor Award. District 13 W. Richard Polanin, director (309) 694-5404 Participants in the J.A.K. welding rodeo included (from left) Ian Walton, Alex Yamo, Spencer rpolanin @ icc.edu Blum, Clayton McDowell, Tony Syrgas, Justin Tibbetts, and Mark Stevenson.

WELDING JOURNAL Tully Parker (right). District 14 director, re- Shown at the Peoria Section welding contest are (from left) instructor Shane Seals with ceived the Clifford Hunt Award from Mike SkillsUSA welding participants Jimmy Baxter, NickDeig, and Shane Markham. Anderson at the Indiana Section Mid-West Team Welding Tournament. District 14 Tully C. Parker, director (618)667-7795 [email protected] INDIANA APRIL 13-15 Activity: The Section hosted its 32nd annual Mid-West Team Welding tournament at new Castle High School in New Castle, Ind. Twenty-six teams competed for trophies, $8000 in prizes, and a $6000 scholarship to Ohio Technical College. Pike Central High School, Petersburg, Ind., won the team title. The runner-up teams were Kentucky Tech, Nelson County, Ky.; Fountain Central, Veedersburg, Ind.; New First-place team members at the Indiana Section's Mid-West Team Welding Tournament Castle Career Programs, New Castle, Ind.; are (from left) Aaron Hopt, Dan Kreilein, Zack Wood, Devin Tegmeyer, and Kory Voelkel. and Franklin County High School, Frank- fort, Ky. Tully Parker, District 14 director, J.A.K. received the Clifford Hunt Award for his APRIL 17 "outstanding contributions to the Mid- Activity: The Joliet-Aurora-Kankakee West Team Welding Tournament." Section hosted a welding rodeo at Kanka- kee Community College in Kankakee, 111. APRIL 17 Josh Karalevlcz turned in the best per- Activity: The Indiana Section conducted formance for the day. Others participat- the Indiana SkillsUSA welding contest at ing were Ian Walton, Alex Yarno, Spencer Walker Career Center in Indianapolis. Blum, Clayton McDowell, Tony Syrgas, Aaron Hopt, Pike Central High School, Pe- and sponsors Mark Stevenson, John tersburg, Ind., won the secondary contest. Willard, Fred Mancuso, Justin Tlbbetts, Greg Carper, Ivy Tech C. C, Anderson, and Will Hemphill. Ind., won the postsecondary event. Artists (from left) Robert Ham, James Odum, and Yvonne Ham displayed their APRIL 24 works at the Peoria Section event. PEORIA Activity: The Indiana Section conducted APRIL 10 the first Indiana SkillsUSA fabrication Activity: The Section joined with Illinois welding contest at J. Everett Light Career Central College to present an artists' show- Center in Indianapolis. Dave Koutz of Lin- case at the college. Nine artists displayed coln Electric chaired the event. The top their works, and Tom and Vicky Schertz teams were New Castle High School, Pike demonstrated their blacksmithing talents. Central, and Whitewater Career Center. The winning team members were Zach APRIL 16 Cheesman, Logan Pool, and Brandon Activity: The Peoria Section sponsored Johnson. contestants for the Illinois SkillsUSA contest. Shane Seals is the welding instructor. Winners in the Indiana SkillsUSA fabrica- Jimmy Baxter placed fifth in the state post- LEXINGTON tion contest are (from left) Zach Cheesman, secondary class, Nick Deig placed fourth, APRIL 22 Logan Pool, and Brandon Johnson. and Shane Markham placed seventh. Activity: Incoming Chair Tim Pinson pre-

JULY2010 Shown at the St. Louis Section students' night program are (from left) speaker Gailyn Cornell, Mark Borchardt, Jessica Gourley, Michael Hawks, Geordi Sievert, Lewis Green, Robert Lipscomb, Chris Newton, and Nick Wiltsee.

Chair Jason Miles (left) presents a speaker award to Howard Rinne at the Kansas City Section tour. The first-place welding team poses with their trophies at the Lexington Section program. sented James Mattox with an appreciation award for serving as chairman. The winners in the recent SkillsUSA welding contest were presented.

ST. LOUIS APRILS Speaker: Gailyn Cornell, branch services director Affiliation: ILMO Products Co. Topic: The welding career tree Activity: The Section hosted a students' night program at Granite City, III. Awards and scholarships were presented to outstanding students.

Incoming Lexington Section Chair Tim Pin- son (right) is shown with James Mattox, Diane Steadham and Marc Childs are District 15 chairman. shown at the Kansas Section baseball event. Mace V. Harris, director (612)861-3870 KANSAS MAY 18 macevh @ aol.com APRIL 15 Activity: The Kansas Section members Activity: The Section hosted the state met with family and friends for a picnic SkillsUSA welding competition at Wi- lunch then attended the season game District 16 chita Area Technical College in Wichita, opener of the Wichita Wingnuts baseball David Landon, director Kan. Thirty-five Section members partic- team in Wichita, Kan. Chairman Diane (641)621-7476 ipated and 54 secondary and postsec- Steadham was presented an appreciation [email protected] ondary school students competed. award for her services.

WELDING JOURNAL Kansas Section members and guests are shown at the Wingnuts baseball game outing in May.

The Kansas City Section members pose at SPX Cooling Towers in April. KANSAS CITY APRIL 8 Activity: The Section toured SPX Cooling Towers in Olathe, Kan. Howard Rinne discussed cooling tower fabrication and led the program. Following the tour, the incoming slate of officers was announced: Jason Miles, chairman; Mike Vincent and Michael Williams, vice chairs; Joey Bleam, secretary; and Brian McKee, treasurer.

MID-PLAINS APRIL 7 Activity: The Section members toured Troyer Enterprises in North Platte, Neb., to learn about and see demonstrations of plasma arc cutting. The presenters were Kyle Troyer and Bob Hardy. District 17 Central Arkansas Section members working the SkillsUSA contest are, from left, (front row) J. Jones, director Jim Ryan, Matt Fair, Dennis Pickering, and Chuck LeBlanc; (back row) James Templet, (940)368-3130 George Seahom, Jimmy Brewer, and Chris Newell. jjones @ thermadyne. com

M JULY 2010 Win Great Prizes in the 2010-2011 AWS Member- Get-A-Member Campaign*

-A-JBOCJT* AWS is looking for individuals to become part of an exclusive group of AWS Members who get involved and win. Give back to your profession, strengthen AWS and win great limited-edition prizes by participating in the 2010-2011 Member-Get-A-Member Campaign. By recruiting new members to AWS, you're adding to the resources necessary to expand your benefits as an AWS Member. Year round, you'll have the opportunity to recruit new members and be eligible to win special contests and prizes. Referrals are our most successful member recruitment tool. Our Members know first-hand how useful AWS Membership is, and with your help, AWS will continue to be the leading organization in the materials joining industry.

To recruit new Members, use the application on the reverse, or visit www.aws.org/mgm PRIZE CATEGORIES SPECIAL PRIZES LUCK OF THE DRAW President's Honor Roll: Recruit Participants will also be eligible to win For every new member you sponsor, 1-2 new Individual Members and prizes in specialized categories. Prizes your name is entered into a quarterly receive an AWS Sportpack bag. will be awarded at the close of the drawing. The more new members campaign (June 2011). you sponsor, the greater your President's Club: Recruit 3-8 new chances of winning. Prizes will be Sponsor of the Year: The individual awarded in November 2010, as well Individual Members and receive an who sponsors the greatest number of as in February and June 2011. AWS hat and an AWS Sportpack bag. new Individual Members during the campaign will receive a plaque, a trip to Prizes Include: President's Roundtabie: Recruit the 2011 FABTECH Show, and •* Complimentary AWS 9-19 new Individual Members and recognition at the AWS Awards Membership renewal receive an AWS polo or denim shirt, Luncheon at the Show. • AWSt-shirt hat and an AWS Sportpack bag. Student Sponsor Prize: AWS • AWS hat Members who sponsor two or more President's Guild: Recruit 20 or Student Members will receive an AWS SUPER SECTION CHALLENGE more new Individual Members and Sportpack bag. The AWS Section in each District receive an AWS Messenger Bag, an that achieves the highest net AWS polo or denim shirt, a one-year The AWS Member who sponsors the percentage increase in new free AWS Membership, the "Shelton most Student Members will receive a Individual Members before the June Ritter Member Proposer Award" free, one-year AWS Membership, an 2011 deadline will receive special AWS polo shirt, hat and an AWS Certificate and membership in the recognition in the Welding Journal. Winner's Circle. Sportpack bag. International Sponsor Prize: Any The AWS Sections with the highest Winner's Circle: All members who member residing outside the United numerical increase and greatest net recruit 20 or more new Individual States, Canada and Mexico who percentage increase in new Members will receive annual sponsors the most new Individual recognition in the Welding Journal Individual Members will each receive Members will receive a complimentary the Neitzel Membership Award. and will be honored at the FABTECH AWS Membership renewal. Show.

•The 2010-2011 MGM Campaign runs from June 1, 2010 to May 31, 2011. American Welding Society Prizes are awarded at the close of the campaign. Visit www.aws.org *k PLUS... Get a popular welding publication for only $25 ($192 value) AWS MEMBERSHIP APPLICATION BOOK/CD-ROM SELECTION 4 Easy Ways to Join or Renew: (Pay Only $25... up to a $192 value) 3 Mail this form, along with your payment, to AWS NOTE: Only New Individual Members are eligible for this selection. Be sure to add $25 to your total payment. S Call the Membership Department at (800) 443-9353, ext. 480 ONLY ONE SELECTION PLEASE. • Fax this completed form to (305) 443-5647 • Jefferson's Welding Encyclopedia (CD-ROM only) B Join or renew on our website • Design and Planning Manual for Cost-Effective Welding • Mr. • Ms. • Mrs. • Dr. Please print • Duplicate this page as needed • Welding Metallurgy • Welding Handbook (9th Ed., Vol. 3) Last Name • Welding Handbook (9th Ed., Vol. 2) • Welding Handbook (9th Ed., Vol. 1) First Name_ M.I. For more book choices visit www.aws.org/membership Title Birthdate Learn more about each publication at www.awspubs.com Were you ever an AWS Member? • YES • NO If "YES," give year and Member # a New Member a Renewal A free local Section Membership is included Primary Phone ( ) Secondary Phone ( ) _____ with all AWS Memberships. Section Affiliation Preference (if known): FAX( ) ^E-Mail Did you learn of the Society through an AWS Member? • Yes • No Type of Business (Check ONE only) A Q Contract construction If "yes," Member's name: Member's # (if known): B Q Chemicals & allied products C Q Petroleum & coal industries From time to time, AWS sends out informationai emaiis about programs we offer, new Member benefits, savings opportunities and D Q Primary metai industries changes to our website. If you would prefer not to receive these emails, please check here • E O Fabricated metai products F Q Machinery except elect, (inci. gas welding) ADDRESS NOTE: This address will be used for all Society mail. G Q Electrical equip., supplies, electrodes H Q Transportation equip. — air, aerospace Company (if applicable) i Q Transportation equip. — automotive J Q Transportation equip. — boats, ships K Q Transportation equip. — railroad Address L • Utilities M Q Welding distributors & retail trade Address Con't. N Q Misc. repair services (inci. weiding shops) 0 O Educational Services (univ., libraries, schools) P Q Engineering & architectural services (incl. City_ State/Province _Zip/Postal Code _ Country assns.) NOTE: This data wiil be used to deveiop programs and services to Q Q Misc. business services (inci. commercial labs) PROFILE DATA R Q Government (federal, state, local) serve you better. S • Other 0 Who pays your dues?: • Company • Self-paid © Sex: • Male • Female Job Classification (Check ONE only) © Education level: • High school diploma • Associate's • Bachelor's • Master's • Doctoral 01 Q President, owner, partner, officer 02 Q Manager, director, superintendent (or assistant) PAYMENT INFORMATION (Required) 03 • Sales 04 Q Purchasing ONE-YEAR AWS IlVDfflDUAl MEMBERSHIP J80 05 Q Engineer — weiding 20 Q Engineer — design TWO-YEAR AWS IlVDfflDUAl MEMBERSHIPt .|ttCQ $135 21 Q Engineer — manufacturing 06 Q Engineer — other New Member? Yes No 10 • Architect designer 12 • Metallurgist If yes, add one-time initiation fee of $12 f 13 • Research & development International Members add $50 for optional hard copy of Welding journal (note: digital deliver)' of IF/ is slandard)tttt $50 (Optional) 22 • Quality control 07 Q Inspector, tester 08 Q Supervisor, foreman I Domestic Members add $25 for book selection ($192 value), and save up to 87%tt I (optional) 14 Q Technician \ International Members add $75 for book selection (note: $50 is tor international shipping) ff..! (Optional) 09 Q Welder, welding or cutting operator 11 • Consultant I (Note: Book Selection applies to new Individual Members only - Book selections on upper-right corner) 15 • Educator 17 • Librarian TOTAL PAYMENT $ 16 • Student 18 • Customer Service AWS STUDENT MEMBERSHIP ttt NOTE: Dues include $18.70 for We/ding Journal 19 • Other • Domestic (Canada & Mexico incl.) |15 subscription and $4.00 for the AWS Foundation, Technical Interests (Check all that apply) • International f50 A Q Ferrous metais TOTAL PAYMENT f B Q Aluminum C Q Nonferrous metais except aluminum Payment can be made (in U.S. dollars) by check or money order (international or foreign), payabie to the American Weiding Socidy, or by charge card D Q Advanced materials/lntermetaiiics E Q Ceramics • Check • Money Order • Bili Me F Q High energy beam processes G Q Arc weiding Q American Express Q Diners Club Q Carte Bianche Q MasterCard Q Visa Q Discover Q Other H Q Brazing and soldering i Q Resistance welding L J L J Q Thermal spray Your Account Number K • Cutting Expiration Date (mm/yy) L • NDT M • Safety and health Signature of Appiicant: _ Application Date: N Q Bending and shearing Office Use Only 0 • Roll forming Check #_ Account # P Q Stamping and punching Source Code WJ Date Amount Q Q Aerospace tTVo-year Individual Membership Special Offer; applies only to new AWS Individual Merabeis, ftDiscount Publication R Q Automotive „, American Welding Society S Q Machinery Offer; applies only to new AWS Individual MerabeB, Select one of tbe six listed publications for an additional $25; International T Q Marine Xs^ P.O. Box 440367 Members add 175 (|25 for book selection and 150 for International shipping); Multi-iear Discount; First year Is S80, each U O Piping and tubing Miami, FL 33144-0367 additional year Is (75. No limit on years (not available to Student Members). ^Student Member; Any individual who attends V Q Pressure vessels and tanks Telephone (800) 443-9353 a recognized college, university, technical, vocational school or high school Is eligible. Domestic Members are those students resid- W • Sheet metai X • Structures FAX (305) 443-5647 ing In Norh America (incl. Canada & Mexico). This membership Includes the Weidmgpumai magazine. Student Memberships Y • Other Visit our website: www.aws.org do not Include a discounted publication, ttttlntemational hard copy Welding journal option: applies only to Z Q Automation Member Services Revised 12/12/08 International AWS Welder Members (excludes Canada and Mexico). Digitized delivery of WJ Is standanl 1 • Robotics 2 Q Computerization of Welding The participants in the East Texas Section welding and cutting contest are shown in April.

British Columbia Section members pose at the Covanta Energy facility.

CENTRALARKANSAS APRIL 12 Activity: The Section participated in the state SkiilsUSA competition. The event was held at Hot Springs Summit Arena.

EAST TEXAS APRIL 17 Activity: The Section hosted a welding and cutting contest at Tyler Junior College in Longview, Tex. The top performers were Martin Toppia, Brent Jonson, and Colton The top performers at the East Texas weld- Clark. ing contest are (from left) Brent Jonson, Martin Toppia, and Colton Clark. Shown at the British Columbia Section tour TULSA are (from left) Helmut Bott, Treasurer APRIL 27 Brenda Moe, and Tim Benko. Speaker: Paul Wittenbach, principal metallurgical and welding engineer Affiliation: Conoco Phillips District 19 Topic: Welding challenges faced when Neil Shannon, director jacking up the Ekofish offshore North Sea (503)419-4546 oil platform neilshnn @ msn.com Activity: The program was held in Tulsa, Okla. BRITISH COLUMBIA APRIL 29 Activity: The Section members toured Covanta Energy, Inc., in Delta, B.C., District 18 Canada. Tim Benko and Helmut Bott John Bray, director presented an overview of the incinera- (281)997-7273 tor and how it works before conducting Tulsa Section Vice Chair David Gilliam sales @ affiliatedmachinery.com tours of the facility. (left) is shown with speaker Paul Wittenbach.

WELDING JOURNAL Presenters at the Puget Sound Section program are (from left) William Vossler, Yim Mens, Bryan Hayes, Philip Obers, Derric Fothersill, instructor Ken Johnson, Steve Gaworski, Starr Gaworski, Tom Ferguson, and instructor Dan Aragon.

Shown at the Puget Sound Section program are speaker Mike Weaver (left) and Vice Chair Ken Johnson. Awardees are shown at the Colorado Section program.

OLYMPIC APRIL 20 District 20 Speaker: Ken Alrick, application special- William A. Komlos, director ist (801)560-2353 Affiliation: Thermadyne-Thermal Arc bkoz@arctechllc. com Topic: Plasma arc welding Activity: Following the talk, Alrick held a ALBUOUERQUE question-and-answer session then offered APRIL 29 the students hands-on demonstrations of Speaker: Fred Hooper, owner the equipment. Affiliation: Speed of Light Topic: Laser beam welding Activity: Following the talk. Hooper Olympic Section Chair Rob Rothbauer (left) PUGET SOUND demonstrated laser beam welding. Schol- is shown with speaker Ken Alrick. MAY 6 arships were presented. Activity: The Section hosted a students' day program at Stanwood High School in Seattle, Wash. Mike Weaver of Weaver En- gineering, discussed stress analysis of COLORADO welds, and several students presented MAY 13 talks. Darryl Main received the Educator Speaker: Glenn Washer, assistant profes- of the Year award. sor Affiliation: University of Missouri Topic: Nondestructive evaluation of high- SPOKANE way bridges APRIL 27 Activity: Jay Voth, Lynn Sturgill, Alan Bar- Speaker: Rick Pfeifer ber, and Dave Murphy received Private In- Affiliation: Pfeifer Sales, Inc. structor Awards, Wade Lutz and Mike Topic: Autodarkening welding hoods Rinow received CWI of the Year Awards, Rick Pfeifer demonstrated autodarkening Activity: The program was held at Oxarc and John Steele received the Instructor of welding hoods at the Spokane Section event. Training Center in Spokane, Wash. the Year Award.

JULY 2010 Albuquerque Section members pose for a group shot in April.

A WCIWT Student Chapter presenters pose with District 21 Director Nanette Samanich at the Green Welding symposium. UTAH APRIL 27 Activity: The Section honored Mason Win- ters for earning the silver medal win in the SkillsUSA 2009 competition and his winning the Donald and Shirley Hastings Scholarship. District 21 Nanette Samanich, director (702)429-5017 [email protected] AWCIWT Student Chapter FEBRUARY 5 Activity: The Arizona Western College In- stitute of Welding Technology (AWCIWT) Student Chapter hosted the Region 1 Shown at the Utah Section presentation are (from left) Don Arbon, Tony Sanchez, and SkillsUSA welding competition in Yuma, Mason Winters. Ariz. Thirty-five students from area high schools participated in the event. toured the Free-McMoRan Copper and contests, robotic welding, 3-D virtual weld Gold Mine in Bagdad, Ariz., to study ex- simulation and many welding processes MARCH 10 tractive metallurgy and see the heavy sponsored by Miller, Lincoln, MK Prod- Activity: The AWCIWT Student Chapter equipment in action. ucts, ESAB, Thermadyne, Hobart, hosted its annual welcome back welders Stoody, Victor, Tweco, and others. torch cutting skill competition for 75 at- MARCH 30-APRIL 1 tendees. Featured was a regional Skills- Activity: The Student Chapter hosted the APRIL 12,13 USA welding competition. tenth anniversary Welders without Bor- Activity: Students from the college com- ders event titled Green Welding: The Fu- peted in Phoenix, Ariz., at the SkillsUSA MARCH 18 ture Is Now. Running from 8 a.m. to 5 state competitions for extemporaneous Activity: The Student Chapter members p.m. daily, the activities included welding speaking and welding fabrication.

WELDING JOURNAL The Arizona Western College Institute of Welding Technology Student Chapter members are shown at the Green Welding event.

Welding students and instructors are shown at the Los Angeles I Inland Empire Section program in April.

The Sacramento Section event in April produced a big turnout.

L.A./INLAND EMPIRE SACRAMENTO APRIL 28 District 22 APRIL 21 Activity: The Los Angeles/Inland Empire Dale Flood, director Speakers: John Madri, ordinance welding Section hosted a students' night activity in (916)288-6100, ext. 172 instructor, U.S. Army; and Lincoln Elec- Lost Angeles, Calif. [email protected] tric sales representative David Kilburn.

JULY 2010 The Sierra Nevada Section members are shown during their May tour.

Sam Cophrun detailed off-road vehicle con- Shown at the Sacramento Section event are (from left) Trevor Robinson, Emmanuel Ezenwa, struction at the Sierra Nevada Section event. Mark Feuerbach, District 22 Director Dale Flood, Mark Reese, and Chair Matt Wysocki.

Shown at the Santa Clara Section program Speaker Jimmy Hollison (right) is shown Speaker Jeff Hicks is shown with Tom Erich- are (from left) Tony DeSousa, District 22 Di- with Tom Smeltzer, San Francisco Section sen, Santa Clara Section chairman. rector Dale Flood, and Alex Gutierrez. chairman. Topic: Flame spraying tungsten carbide SANTA CLARA SIERRA NEVADA and use of hardfacing electrodes MAY 11 MAY 13 Activity: Madri presented a demonstra- Speaker: Jeffrey Hicks, principal scientist Activity: Following a pizza repast, the Sec- tion of flame spraying for the 105 atten- Affiliation: Exponent, Inc. tion members toured SamCo Fabrication dees. District 22 Director Dale Flood pre- Topic: Hexavalent chromium in weld fume in Sparks, Nev., to study the manufacture sented achievement awards to Section of- Activity: Chair Tom Erichsen, Vice Chair of off-road race cars, trucks, and rock ficers Trevor Robinson, Emmanuel Alex Gutierrez, and Secretary Tony De- crawlers. Sam Cophrun, founder and Ezenwa, Mark Feuerbach, Mark Reese, Sousa received plaques in appreciation owner, and David Kilburn, technical sales and Chair Matt Wysocki. The Sierra Col- for their services. representative, conducted the program. lege Student Chapter sponsored the event.

SAN FRANCISCO How to Order Copies of AWS Publications MAY 5 Speaker: Jimmy Hollison, QA manager Contact Rhonda Brown, Foster Purchase American Welding Society Affiliation: Performance Mechanical, Inc. Printing Services, rhondab@fosterprint- standards, books, and other publica- Topic: Details about the certified fabri- ing.com, for electronic and printed tions from WEX (World Engineering cator designation Welding Journal articles in quantities of Xchange). Place your orders online at Activity: Sixty-eight members attended 100 or more. www.awspubs.com; call (888) 935-3464, this final meeting for the season. The pro- Contact Ruben Lara, [email protected], (305) 824-1177; FAX (305)826-6195; gram was held at Spenger's Restaurant in for copies of Welding Journal articles. e-mail [email protected]. Berkeley, Calif.

WELDING JOURNAL Member-Get-A-Member Campaign

Listed below are the AWS members who are participating in The following standings are as of May 17, 2010. Call the AWS the 2009-2010 MGM campaign. See page 81 in this Welding Jour- Membership Dept. (800/305) 443-9353, ext. 480, for information nal or visit www.aws.org/mgm for the rules and prize list. on your member-proposer status.

G Euliano, Northwestern Pa. J. Roberts, Sacramento — 18 Winner's Circle M. Haynes, Niagara Frontier D. Vranich, N. Florida — 18 Sponsored 20+ new members. K. Hurst, Kansas City K Carter, Tri-River — 17 The superscript indicates the number S. Johnson, Lexington R. Schmidt, Philadelphia — 17 of times the member has achieved Win- R. Jones, Houston G. Smith, Lehigh Valley — 17 ner's Circle status since June 1, 1999. D. Mandina, New Orleans B. Wenzel, Sacramento — 17 V. Matthews, Cleveland N. Baughman, Stark Central — 16 J. Compton, San Fernando Valley7 J. Medina, International J. Daugherty, Louisville — 16 E. Ezell, Mobile7 J. Miller, Lancaster A. Reis, Pittsburgh — 16 J. Merzthal, Peru2 T Moffitt, Tulsa G. Seese, Johnstown-Altoona — 16 G. Taylor, Pascagoula2 B. Morgan, Kern W Garrett, Olympic — 15 L. Taylor, Pascagoula2 F Nguni, New Jersey M. Vann, South Carolina — 15 S. Esders, Detroit1 T Rowe, Tulsa R. Vann, South Carolina — 15 B. Mikeska, Houston1 M. Rudden, Colorado B. Benyon, Johnstown-Altoona — 14 W Shreve, Fox Valley1 R. Sewell, International J. Ciaramitaro, N. Central Florida — 14 M. Karagoulis, Detroit1 J. Sims, Syracuse T Garcia, New Orleans — 14 S. McGill, NE Tennessee1 S. Siviski, Maine J. Kline, Northern New York — 14 T Weaver, Johnstown-Altoona1 M. Stevenson, J.A.K. R. Munns, Utah — 14 G. Woomer, Johnstown-Altoona1 T Thomas, St. Louis W Seyfarth, N. Central Florida — 14 R. Wray, Nebraska1 S. Mattson, N. Florida — 12 M. Haggard, Inland Empire1 4+ Student Member Sponsors H. Thompson, New Orleans — 12 D. Saunders, Lakeshore — 56 G. Rodeman, Sierra Nevada — 12 C. Rogers, San Antonio — 49 C Fomby, Auburn — 11 President's Guiid G Kirk, Pittsburgh — 47 R. Ledford, Birmingham — 11 Sponsored 20+ new members. H. Hughes, Mahoning Valley — 44 J. Stallsmith, South Carolina — 11 B. Chin, Auburn-Opelika — 24 D. Berger, New Orleans — 38 H. Browne, New Jersey — 10 J. Morash, Boston — 37 D. Howard, Johnstown-Altoona — 10 President's Roundtabie S. Miner, San Francisco — 36 S. Kuntz, Pittsburgh — 10 Sponsored 9-19 new members. C. Hardbarger, Mid-Ohio Valley — 35 G. Putnam, Green & White Mts. — 10 R. Ellenbecker, Fox Valley — 17 R. Durham, Cincinnati — 34 R. Rummel, Central Texas — 10 J. Compton, San Fernando Valley — 13 G Gammill, NE Mississippi — 34 C Schiner, Wyoming — 10 A. Sumal, British Columbia — 11 D. Ketler, Willamette Valley — 34 P. Swatland, Niagara Frontier — 10 H. Thompson, New Orleans — 10 C. Lindquist, Central Michigan — 32 V. Harthun, Northern Plains — 8 G. Moore, San Diego — 9 D. Zabel, SE Nebraska — 32 J. Hill, Puget Sound — 8 T Palmer, Columbia — 30 M. McLaughlin, Reading — 8 President's Ciub J. Carney, West Michigan — 29 J. Fitzpatrick, Arizona — 7 Sponsored 3-8 new members. M. Anderson, Indiana — 28 A. Mattox, Lexington — 7 S. Keskar, India — 8 D. Kowalski, Pittsburgh — 27 D. Roskiewich, Philadelphia — 7 E. Young, Tri-River — 7 D. Pickering, Central Arkansas — 27 J. Smith, Greater Huntsville — 7 J. Hennessy, Fox Valley — 6 A. Stute, Madison-Beloit — 27 J. Grossman, Central Michigan — 6 J. Price, Detroit — 6 R. Hutchison, Long Bch./Or. Cty. — 25 M. Hayes, Puget Sound — 6 D. Berger, New Orleans — 5 M. Boggs, Stark Central — 24 E. Hinojosa, L.A./Inland Empire — 6 J. Ciaramitaro, N. Central Florida — 5 A. Duron, New Orleans — 24 R. Jones, Puget Sound — 6 E. Ezell, Mobile — 5 S. Siviski, Maine — 24 R. Madrigal, L.A./Inland Empire — 6 J. Hope, Puget Sound — 5 D. Aragon, Puget Sound — 23 A. Badeaux, Washington, D.C. — 5 G. Baldree, Rio Grande Valley — 4 A. Baughman, Stark Central — 23 T Bridigum, Northwest — 5 B. Cebery, Fox Valley — 4 R. Wahrman, Triangle — 23 S. Colton, Arizona — 5 J. Fitzpatrick, Arizona — 4 T Gerber, Allegheny — 22 D. Kearns, Northern Michigan — 5 E. Ravelo, International — 4 T Geisler, Pittsburgh — 21 S. Liu, Colorado — 5 J. Rodenbarger, Nebraska — 4 S. Burdge, Stark Central — 20 R. Richwine, Indiana — 5 D. Scott, Mobile — 4 R. Evans, Siouxland — 20 T Strickland, Arizona — 5 S. Singh, Indian — 4 E. Norman, Ozark — 20 J. Boyd, San Diego -4 T Baber, San Fenando Valley — 3 G Marx, Tri-River — 20 G. Callender, San Fernando Valley — 4 G Burrion, S. Florida — 3 K Rawlins, Columbia — 20 R. Davis, Syracuse — 4 T Morris, Tulsa — 3 B. Suckow, Northern Plains — 20 S. Hansen, SE Nebraska — 4 P. Newhouse, British Columbia — 3 R. Cook, Utah — 19 S. Henson, Spokane — 4 M. Pelegrino, Chicago — 3 C. Donnell, NW Ohio — 19 R. Hilty, Pittsburgh — 4 J. Durbin, Tri-River — 19 R. Irving, Spokane — 4 President's Honor Roii V. Facchiano, Lehigh Valley — 19 G. Kimbrell, St. Louis — 4 Sponsored 2 new members. W Galvery, Long Bch./Or. Cty. — 19 A. Kitchens, Olympic Section — 4 J. Barber, Connecticut W Harris, Pascagoula — 19 J. Lynn, Idaho/Montana — 4 T Blakeney, Green & White Mts. J. Theberge, Boston — 19 S. MacKenzie, Northern Michigan — 4 C. Bridwell, Ozark M. Arand, Louisville — 18 D. Newman, Ozark — 4 G Callender, San Fernando Valley J. Boyer, Lancaster — 18 M. Pelegrino, Chicago — 4 K. Carter, Tri-River R. Boyer, Nevada — 18 J. Pummer, Long Bch./Or. Cty. — 4 J. Cooley, Birmingham W Davis, Syracuse — 18 S. Robeson, Cumberland Valley — 4 R. Davis, Utah J. Fox, NW Ohio — 18 M. Stevenson, J.A.K. — 4 J. Gerdin, Northwest — 18 R. Wilcox, Detroit — 4

JULY 2010 550 NW LeJeune Rd., Miami, FL 33126; (800/305) 443-9353; FAX (305) 443-7559; iviviv.aivs.org Staff extensions are shown in parentheses.

AWS PRESIDENT PUBLICATION SERVICES Director, National Standards Activities John C. Bruskotter Department Information (275) John L. Gayler.. [email protected] (472) jbruskotter@eplweb. com Personnel and Facilities Qualification, Computer- Bruskotter Consulting Services Managing Director, Publication Services ization of Welding Information 14254 Hwy. 23, Belle Chasse, LA 70037 Andrew Cullison.. [email protected] (249) Manager, Safety and Health Welding Journal Stephen P. Hedrick.. [email protected] ... .(305) ADMINISTRATION Publisher Metric Practice, Safety and Health, Joining of Plas- Executive Director Andrew Cullison.. [email protected] (249) tics and Composites, Welding Iron Castings Ray W. Shook., [email protected] (210) Editor Senior Manager, Technical Publications Deputy Executive Director Mary Ruth Johnsen.. [email protected] (238) Rosalinda O'Neill., [email protected] (451) Cassle R. Burrell.. [email protected] (253) AWS publishes about 200 documents widely used National Sales Director throughout the welding industry. Senior Associate Executive Director Rob Saltzstein.. [email protected] (243) Jeff \Nebet.. [email protected] (246) Staff Engineers/Standards Program Managers Society and Section News Editor Annette Alonso.. [email protected] (299) Associate Executive Director Accounting Howard VlooA\[email protected] .(244) Automotive Welding, Resistance Welding, Oxy- Gesana VxWegas.. g\[email protected] (252) fuel Gas Welding and Cutting, Definitions and Welding Handbook Symbols, Sheet Metal Welding Executive Assistant for Board Services Editor Gricelda ManaWch.. [email protected] ... .(294) Annette O'Brien., [email protected] (303) Stephen Borrero.. [email protected] (334) Joining of Metals and Alloys, Brazing and Solder- Administrative Services ing, Brazing Filler Metals and Fluxes, Brazing Managing Director MARKETING COMMUNICATIONS Handbook, Soldering Handbook Jim Lankford..y(m/@flM«.o^ (214) Director Ross Hancock., [email protected] (226) Rakesh Gupta., [email protected] (301) IT Network Director Filler Metals and Allied Materials, Int'l Filler Met- Armando Campax\[email protected].. .(296) Public Relations Manager als, Instrumentation for Welding, UNS Numbers Cindy VleVn\[email protected] (416) Assignment Director Hidail [email protected] (287) Webmaster Brian McGrath . [email protected] (311) Jose Sa\ga

WELDING JOURNAL NEW LITERATURE

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Carell Corp. www. carellcorp.com (251) 937-0948 Laser Hazard Standard issued THE LEADING MANUFACTURER AND MASTER DISTRIBUTOR OF BRASS, BRONZE, AND COPPER ALLOYS IN THE USA The standard Z136.4-2010, Recom- mended Practice for Laser Safety Measure- ments for Hazard Evaluation, provides For info go to www.aws.org/ad-index JULY 2010 guidance for optical measurements asso- Companion D1.1 Standards of hazardous-duty-rated devices, PF high- ciated with laser safety requirements. The current devices (up to 600 A), and a wide information is intended to assist those who Document Published variety of multipin devices up to 37 con- conduct laser hazard evaluations to en- tacts. The Decontactor Series allows quick The 565-page, ASTM Standards for sure the appropriate control measures are change-out of motors, welding machines, Welding, second edition, includes the 60 implemented. It contains clearly written and other electrical equipment, approved ASTM standards referenced by the latest definitions, examples, and other practical for branch-circuit and motor-circuit dis- edition of the American Welding Society, information for manufacturers, laser connect switching up to 200 A or 60 hp. D1.1/D1.1M:2010, Structural Welding safety officers, technicians, and other The units feature integral switching capa- Code — Steel. These documents provide trained laser users. This document su- bility to ensure the contacts are deener- the practical information needed for weld- percedes the 2005 standard and harmo- gized before the plug can be withdrawn ing any type of structure constructed from nizes with the revised ANSI Z136.1, Safe from the receptacle. the commonly used carbon- and low-alloy Use of Lasers, standard. The document in- steels. The included resources can assist cludes updated figures, tables, and charts, Meltric Corp. quality professionals, inspectors, supervi- as well as revised and new sections www. meltric. com sors, as well as quality-conscious engineers throughout the standard. The document, (800) 433-7642 and managers with interpretation of spec- available in electronic format, may be pur- ifications and the test methods used every chased by phone or online. day in the field. The volume is available PMA Launches Improved on CD or soft-cover edition for $475. Laser Institute of America Web Site www. laserinstitute. orglstore ASTM International (800) 345-2737 Metal-forming technology news is now www.astm.org easier to access at the company's re- (610) 832-9585 designed Web site. Notable improvements Portable Fume Collectors include enhanced navigation to Hot Off Pictured In Brochure Catalog Pictures Industrial the Press features, new product announcements, and exclusive online arti- Plugs and Receptacles cles. The updated multimedia center features editorial videos prepared by the staff The company's new 224-page product to help illustrate the print articles catalog features the Decontactor Series switch rated plugs, receptacles, and con- nectors, plus information on its new line — continued on page 94

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WELDING JOURNAL PERSONNEL

TRUMPF Fills Two Sales press Incentive Services. Marshall previ- and retractile cables, has appointed Louis ously was the marketing communications Garriga III industrial business unit leader. Posts specialist in the Biosystems division of Since 1998, Garriga has served the com- Leica Microsystems, Inc. pany as director of manufacturing. Lincoln Electric Promotes Scott Process Systems Two to Global Positions Appoints President

The Lincoln Elec- Scott Process Systems, Inc., Hartville, I trie Co., Cleveland, Ohio, a wholly owned subsidiary of the I Ohio, has named CIC Group, Inc., has named Thomas E. I Peter Fletcher direc- Bach president. Scott Process is a fabrica- Mike Morissette Chris McMillin tor, global consum- tor of process, power, and nuclear piping able development, systems used primarily in the power- TRUMPF Inc., Farmington, Conn., and Ferry Naber di- generation industry. Bach, a 30-year has named Mike Morissette finance man- rector, global ma- veteran of the fabrication, erection, and ager for TRUMPF Finance. Chris chine development. construction industry, most recently McMillin replaces him as regional sales Fletcher, based in served as director of operations for the manager, based in Arizona. Morissette Peter Fletcher Cleveland, previously CIC Group. has been with the company for 15 years served as business di- serving in various managerial positions. rector, offshore. Naber will continue to be Wlttke Recognized by McMillin previously was a salesman for based at Smitweld, Nijmegen, The Icon Machine Tool, a distributor of fabri- Netherlands. Cambridge Who's Who cation equipment. Phillip Wittke, director of marketing. The Lincoln Electric Co., Cleveland, Genesis Names Two Execs Ohio, has been recognized by Cambridge Thermadyne Adds to Its Who's Who for "demonstrating dedica- Genesis Systems tion, leadership, excellence in general, and Sales Force Group, Davenport, marketing management." Wittke, a mem- Iowa, has named ber of the AWS Cleveland Section since Chuck Keibler exec- 1996, previously served the company as 1 utive vice president managing director Greater China, based — business develop- in China. He has been honored with a ment, and Patrick number of awards from the welding in- ^^ Pollock chief operat- dustry, including the Australian Metal I ing officer. Keibler is Trades Person of the Year. ^^^ * ^^^ responsible for all as- Patnck Pollock pects of business development, client dis- Human Resource Manager Tony Coco Bill Wehrman covery, service, and training. The position Named at Harris Products includes administering the company's web of domestic partner relationships with The Harris Products Group, Mason, Thermadyne In- supplier partners, original equipment Ohio, a Lincoln Electric company, has ap- dustries, Inc., St. manufacturers, and distributors. pointed Cathey Sexton human resource Louis, Mo., has ap- manager at its Gainesville, Ga., facility. pointed Tony Coco di- Previously, Sexton worked for auto parts rector of channel MetalForming Names supplier Unisia Steering Systems, a wholly marketing and na- Publisher owned subsidiary of Hitachi. tional accounts for North and South Precision Metalforming Assn., Cleve- America. Bill land, Ohio, has named Andy Flando pub- Brooks Receives SME's Wehrman joins the lisher of its official publication, Metal- Highest Honor Vickie Marshall company in support Forming magazine. Flando previously of Coco to define and served as associate publisher of Cleveland Rodney Brooks, chairman and chief direct the marketing communication magazine and publisher of Pulse maga- technology officer of Heartland Robotics, strategy for the Americas. Vickie Mar- zine, both published by Great Lakes Pub- Inc., has received Honorary Membership shall, working for Wehrman, is responsi- lishing in Cleveland, Ohio. in the Society of Manufacturing Engineers ble for the visual design, layout, interface, (SME). In presenting the society's highest and graphic production for Web-based award, Mark C. Tomlinson, SME execu- products within the company. Coco previ- Northwlre Technical Cable tive director and general manager, said, ously worked for Honeywell Analytics as Names Business Leader "The society reserves this recognition for vice president of sales. Wehrman most re- those who have exhibited professional em- cently was director of marketing and cor- Northwire, Inc., Technical Cable, inence in our industry. Brooks's work in porate communications for American Ex- Osceola, Wis., a manufacturer of technical robotics has achieved international promi-

JULY2010 nence and his passion and genius are welding engineer and metallurgist for Ar- nSearles, Ala., where known throughout the science, engineer- mour Research Foundation, Standard Oil his father was a fore- ing, and manufacturing worlds." Brooks of Indiana (Amoco), DuPont, and Foster man working for the was a former director of both the Massa- Wheeler. At Foster Wheeler he was di- coal mines. He was chusetts Institute of Technology (MIT) rector of welding engineering during the ten years old when Artificial Intelligence Laboratory and the era of nuclear power plant construction the mines played out MIT Computer Science and Artificial In- for utilities and the U.S. Navy. As an ad- and his family moved telligence Laboratory, and held research junct professor, he taught courses in weld- to Whitwell, Tenn., and faculty positions at Carnegie Mellon ing technology at Kean University in New where mining re- and Stanford Universities. Brooks also Jersey and in welding metallurgy at the mains the main in- founded iRobot Corp., manufacturer of New York Polytechnic Institute graduate JimSnow dustry After gradu- the consumer-oriented Roomba® robot. school. Winsor served as chairman of the ating from Whitwell AWS New Jersey Section and worked on High School as president of his class, he Single Source Appoints the education committee supervising Cer- studied pre-med at the University of Ten- tified Welding Inspector examinations. He nessee, Knoxville, before World War II President also chaired a subcommittee of the AWS disrupted his studies. He worked many A5 Committee on Filler Metals and Allied years for the Chattanooga Armature Single Source Technologies (SST), Processes. He was an active member of the Works and Jones-Sylar Supply. In 1963, he Mississauga, Ont., Canada, has appointed Welding Research Council and ASM In- founded the T J. Snow Co., Inc., that con- Juergen Moeglich president of SST ternational. AWS recognized his contribu- tinues today, selling resistance welding Canada. The company is a distributor of tions with the Samuel Miller Memorial equipment. In 2003, the Resistance machinery brands such as Makino, Mu- Medal in 1991, and the District Meritori- Welder Manufacturers Assoc. honored ratec, Cinetic Landis, and Metris. Previ- ous Award in 2007. He is survived by his him with its Elihu Thompson Award to ously, Moeglich served as director of the wife Gertrude, four children, four grand- recognize his contributions to the indus- Canadian Machine Tool Dealer Associa- children, and many nephews and nieces. try. He was a member of the Chattanooga tion for more than ten years. Yacht Club and was a longtime Shriner. He is survived by a son, two daughters, Bruce Dean Weisman seven grandchildren, and four great- grandchildren. Obituaries Bruce Dean Weis- man, 68, died May 1 Mike Harris in Anchorage, Alaska. He was a Mike Harris, 77, member of the died May 15 in American Welding Uxbridge, Ont., Society for 33 years Canada. Born in and served several WELJUMgREPRINTS Letchworth, Eng- terms as chairman of land, he immigrated the Alaska Section. to Canada in 1953. Bruce Weisman Born in Los Angeles, Take Advantage of your Associated for many Calif., he served in years with Gullco In- the U.S. Navy Seabees from 1960 to 1963. Editorial Exposure ternational, he was a He was a self-taught welder who owned Reprints of Welding Journal are a simple way long-time member of Mike Harris Ornamental Iron and Welding and taught to put information directly into the hands of the Welding Equip- welding at Lake Tahoe, Nev., before mov- your target audience. Having been featured in a ment Manufacturers Committee ing to Alaska in 1977. He was employed by well-respected publication adds the credibility (WEMCO), and was an icon in the weld- Welding and Testing Institute of Alaska, of a third-party endorsement to your message. ing industry. Harris is survived by his wife, Veco, and CH2M Hill as an instructor, Ann, a daughter, a sister, and several shop foreman. Certified Welding Inspec- Reprints are ideal for: grandchildren. tor, and quality assurance expert. He was — PR Materials and Media Kits also a member of BP's emergency response team, the Porsche Club of Alaska, Direct Mail Enclosures Frederick J. Winsor and the Petroleum Club. He was a found- Trade Shows/Promotional Events ing member of the Mat-Su Borough Conferences/Speaking Engagements Frederick J. Win- School District Welding Advisory Board. Recruitment and Training Packages sor, 88, an AWS Life His involvement and commitment re- Member, died at his sulted in the creation of a modern welding . Customer and Prospect home in Fanwood, lab and certification program for the stu- Communications/ Presentations N.J., May 25 follow- dents and summer welding and certifica- ing a long illness. tion classes for Alaska instructors. Weis- Born in the Mohawk man is survived by a daughter, a brother, a River Valley in up- nephew, and several cousins. state New York, he earned his PhD in For additional information, please contact Frederick Winsor metallurgical engi- FosteReprints, the official reprint provider neering at Rensselaer T. J. (Jim) Snow for Welding Journal. Polytechnic Institute. He was a Profes- Email: [email protected] sional Engineer in the states of Delaware, T. J. (Jim) Snow, 90, died May 27 in or call 866-879-9144 Illinois, and New Jersey. He worked as a Chattanooga, Tenn. Snow was born in

WELDING JOURNAL NEW LITERATURE controlled laser beam to create the proper interference color patterns for each color. Additional videos are scheduled for re- — continued from page 91 lease on laser beam welding, cutting, and published in MetalForming magazine. engraving of handset metals. Other additions include podcasts, down- loadable white papers, and an archive of Laird Technologies sponsored Webinars. The site will be of www. lairdtech. com particular interest to personnel concerned (636) 898-6100 with precision metal forming, stamping, fabricating, spinning, slide- and roll-form- Construction Estimating ing technologies, and other value-added Handbook Published processes. The Construction Estimating Complete Precision Metalforming Assn. Handbook is designed for building and www. metalformingmagazine. com construction professionals. It covers all (216) 901-8800 aspects of the construction estimating process and is useful for both experienced Hazardous Pollutants professionals and students studying con- Chart Offered struction management. The guide covers key industry profit-making factors, includ- A 12-page, pocket-size Hazardous Air ing bid planning, scope review, quantity Pollutants (HAPS) monitor chart pro- take-off for all trades and divisions, cost counts available. Visit the Web site or call vides details on the chemical abstracts analysis, value engineering, and Excel for more information. service (CAS) registry numbers, corre- spreadsheet estimating tutorials. The sponding HAPS compounds, and the cal- book focuses on construction estimating Hypertherm ibration gases the company can provide how-to essentials for those who need www. hypertherm. com for accurately monitoring emissions of straightforward answers to on-the-job (603) 643-3441 those compounds. The chart will be of problems. It includes tips, checklists, value to regulators and owners of HAPS- worksheets, and data tables that provide emitting facilities to help them easily de- Fundamentals of Tool the tools needed to effectively navigate termine whether a calibration gas can be Design Updated the estimating process risk assessment and produced for measuring a specific pollu- mitigation, mark-up analysis, increasing tant to avoid using a surrogate chemical The sixth edition of Fundamentals of bit-hit success ratio, value engineering, re- for calibration. The technique can save Tool Design includes revised geometric di- ducing estimating mistakes, meeting proj- considerable time and expense in comply- mensioning and tolerancing information ect management turnover, and improving ing with Title V emissions permits. Call to include ASME Y14.5-2009, an instruc- labor productivity. Purchase of the book the phone number for a copy of the chart. tor's guide with answers to the review includes access to online resources. questions in the book and information on Airgas how to incorporate the DVDs into class- DeWALT® www.airgas.com room or online instruction. It includes ex- www. dewalt. com/guides (610) 675-6854 panded broaching examples and concepts, (603) 643-3441 revised tool material and mechanical def- Plasma Arc Technology initions and reference tables, an in-depth review of brushing applications, new ap- Dear Readers: Curriculum Developed pendixes that provide sources for tool design components, related Web sites and The Welding Journal encour- Plasma Cutting Technology: Theory reference charts, and more review ques- ages an exchange of ideas through and Practice includes lessons, exercises, tions at the end of each chapter. The 464- letters to the editor. Please send interactive presentation slides, compre- page textbook and nine DVDs are avail- hensive facilitator's guide, and models of your letters to the Welding Jour- able as a package or individually. The real plasma torches and consumables. It nal Dept., 550 NW LeJeune Rd., book lists for $ 110, $90 for SME members. is designed for implementation in high Miami, FL 33126. You can also schools, colleges, unions, the military, in- reach us by FAX at (305) 443-7404 Society of Manufacturing Engineers house training departments, and welding or by sending an e-mail to Kristin www.sme.org and cutting distributors who want to offer (800) 733-4763 Campbell at [email protected]. value-added customer training. The ten- hour course incorporates multimedia plat- Laser Marking In Colors forms with hands-on exercises and train- Change of Address? ing to accommodate students with a range Demonstrated In Video of learning styles. The course covers common industrial uses for plasma systems, An online five-minute-long tutorial Moving? differences among the various cutting video demonstrates the company's Make sure delivery of your Welding methods, proper setup and operation, process for laser beam marking aluminum Journal is not interrupted. Contact the proper installation and use of consum- and stainless steel with logos, designs, Membership Department with your ables, how to evaluate cut quality, and how identification numbers and other mark- new address information — (800) 443- to execute a variety of cuts and gouges. ings in gold, black, violet, green, and many 9353, ext. 217; [email protected]. The list price is $449, with special dis- other colors. The process uses a precisely

JULY 2010 CLASSIFIEDS

CAREER OPPORTUNITIES

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JULY 2010 SUPPLEMENT TO THE WELDING JOURNAL, JULY 2010 (W R C Sponsored by the American Welding Society and the Welding Research Council ^—Ji-^ Effects of Mb, V, and W on Microstructure and Abrasion Resistance of Fe-Cr-C Hardfacing Alloys

Various alloying elements were added to a self-shielded flux cored welding wire to determine their influence on the formation of wear-resistant weld metal

BY QINGBAO WANG AND XIAOYAN LI

ABSTRACT (Figs. 1, 2) (Refs. 10, 11), it is known that in order to obtain sufficient wear-resistant The morphology of Nb, V, and W in Fe-Cr-C hardfacing alloy microstructure has been fibers — primary M7C3 carbides — C con- investigated with optical microscope (OP) and scanning electron microscope (SEM). tent should be more than 4.2% and Cr The strengthening mechanism of the three alloying elements in the cladding metal has content more than 10%. o been analyzed. The causes for different hardnesses and abrasion resistances have been High C content will lead to the forma- DC studied. The following is exhibited from the experiment: 1) with addition of around 6% tion of primary chromium carbide, which < Nb, the hardness and wear resistance of the cladding metal increased; 2) with a small ad- will consume the Cr content in the matrix. LU The reduction of Cr content will in turn dition of V and W, the hardness increased and the wear resistance improved more no- (/) ticeably; and 3) with a further slight increase in the content content of V and W, the weaken the matrix's hardenability and cor- hardness of the cladding metal increased in some sort, but had no further significant ef- rosion resistance. To overcome this weak- LU fect on the wear resistance. The optimization of the alloying elements is required to ob- ness, the content of Cr shall be increased. It DC tain good wear resistance and economic efficiency by strengthening matrix and carbides is pointed out that increasing Cr content in simultaneously. the high-chromium white iron can reduce O the eutectic carbon content (Ref. 12). For example, the alloys with Cr concentrations Introduction mine the influence of the alloying ele- of 5,13,17, and 25% have carbon contents ments on the formation of abrasion-resis- of 4.0, 3.7, 3.5, and 3%, respectivley, at the Thanks to their high volume fraction of tant skeletal carbide particles and the eutectic point. In other words, increasing LU hard carbide fibers, Fe-Cr-C hardfacing al- matrix (austenite and its transformation the Cr content and without changing the C loys are used extensively in the mining and product). The abrasive testing result is dis- content will shift the eutectic point to the 5 mineral processing industries where high cussed with the intention to provide a the- left, and more chromium carbides will be wear and abrasion resistance are required. oretical foundation for future formed. Thus, it is not necessary to increase By depositing self-shielding flux cored investigations and applications of the Fe- the C content to get more chromium car- welding wire, cladding metal with high- Cr-C wear-resistant material (Refs. 1-9). bide, and therefore the toughness of the de- chromium content (up to 30%) and car- posited weld metal will not be bon content (up to 6%) can be obtained. Experimental Methods and compromised (Ref. 12). Water cooling during welding will promote Procedures In this experiment, the welding deposit the formation of monocrystalline M7C3 of the Fe-Cr-C self-shielded flux-cored (where M represents the alloying element) Selection of Alloying System welding wire has been designed as 4.7% C carbide rods of irregular hexagonal cross and 23% Cr, which is a common commer- section in a metastable matrix of austen- From the Fe-Cr-C phase diagrams cial embodiment of a primary chromium ite. These M7C3 carbide rods play an im- carbide hardfacing alloy. It can be seen portant role in improving the wear from Fig. 2 that with these chemical com- resistance of the material. Modern Fe-Cr- r positions, it is easy to form sufficient hard C wear-resistant material has been studied KEYWORDS primary M7C3 fiber at high temperature. based on tough austenite matrix with dis- The welding wire was made of 0.3 x 17 persion of hard carbide particles. In this Fe-Cr-C Hardfacing Alloy mm steel strip with extra-low carbon. The investigation, the alloying elements of Nb, Abrasion Resistance diameter of the wire was 3.2 mm and the V, and W were added and varied in a self- Wear-Resistant Carbides weight proportion was 50±1.5%. shielded flux cored welding wire to deter- Alloying Elements With the same contents of C and Cr in Self-Shielded Flux Cored the welding deposit, the microstructures Q. WANG is with MCC Welding Science & Tech- Welding Wire nology Co. Ltd., cindX. LI ('xiaoyan@sasglobal- and mechanical properties of the corp.com);s with SAS Global Corp., Warren, cladding metal were investigated by Mich. adding different amounts of alloying ele-

WELDING JOURNAL Experimental Procedures

Microstructures of the welding deposit were observed with the Neophot 21 microscope. The samples were also examined by using a scanning electron microscope (JSM-6301F). The macrohardness of the welding deposit samples was measured with an H-100 Rockwell hardness machine (1470 kN load). Nine measurements were made on each sample, with the highest and the lowest values omitted, and an average of the remaining seven numbers was calculated and recorded. The microhardness of the welding deposit was measured (on both carbides and matrix) with an HXD-1000 Vickers hardness machine (0.98 N load). Abrasion-resistant tests were performed on a MLS-225 wet sand rubber wheel AR Fig. 1 — Metastable Fe-Cr-C phase diagram for Fig. 2— Fe-rich comer of metastable C-Cr-Fe liq- carbon contents less than 5%. The bold black lines uidus surface (Ref. 11). testing machine, according to the proce- are the monovariant lines separating the primary dure ASTM G105. The specimen size was solidification fields. Conventionally, eutectic-type 57.9 x 25.4 x 11 mm. After the specimen equilibria are indicated by a single arrow and those was cut, it was ground using No. 600 SiC ofperitectic type by a double arrow. The dotted lines paper to remove the rough surface layer _^ represent the limiting solid compositions in equi- then polished so that the testing surface was ^f» librium with the liquid on the corresponding mono- "Jj variant line. There are three four-phase invariant so that the top layer could be examined in parallel to the base surface. The rotating III equilibria (Ref 10): an undiluted condition. Five welding speed of the rubber wheel was 245 rev/min, ^" Liquid + a + .M^Cg + MyCj. Liquid + a + y beads were put on each layer and the over- its diameter was 178 mm, and the hardness m + MyCj; Liquid +y + MjC3 '+ M3C. lapping width was 30% of the welding was 60 HA (Shore hardness). Wet sand was bead. Water cooling was applied during made of 1-kg water and 1.5-kg abrasion the welding process and the interpass tem- Si02 round sand (50~70 mesh). The ap- ^ ments of Nb, V, and W. perature was controlled below 200oC. The plied load was 10 kg. The total revolution ^^ It is known that additional alloying of detailed welding parameters are shown in of the rubber wheel was 1000. Before and JJ high-chromium cast irons with carbide- Table 1. Chemical compositions of the after each test, the specimen was ultrason- ^n forming elements (Nb, V, Mo, W, etc.) welding deposit were analyzed, as shown ically cleaned in acetone, blown dry with /y% significantly affects the mechanical prop- in Table 2. Sample 1 is a Fe-Cr-C alloy warm air, and then weighed to determine —I erties, chemical compositions, and disper- without adding any other alloying ele- the weight loss by using an electronic bal- U' sion of the carbide phases, as well as the ments and is used as the reference sample. ance that has an accuracy of 0.1 mg. The ^^ strength of the matrix (martensite, austen- Sample 2 add 6.12% Nb on the basis of working theory of the testing machine is 30 ite). Based on the previous experiment Sample 1. Sample 3 adds a small quantity shown in Fig. 3. The abrasion testing equip- ^^ and research, in this experiment the Nb of V and W on the basis of Sample 2. Sam- ment is shown in Fig. 4. ^P concentration started with 6%. ple 4 adds a comparatively large quantity The wear resistance of Sample No. 1 is ^^ The welds were deposited in six layers of V and W on the basis of Sample 2. set as 1. Other samples are compared with

Table 1 —Welding Parameters

Welding Welding Welding Stick out Interpass Welding Wire Depositing Current Voltage Speed //mm Temperature Diameter Numbers //A UIW ^/(mm.s"1) trc (O/mm)

480~520A 34-38V 800-850 20-35mm <200oC 3.2 6 Layers mm/min 5 Beads

Table 2 — Chemical Compositions of Experimental Samples (wt-%) Chemical Compositon (%) Samples Cr Nb W Mn+Si

Sample 1 4.74 23.56 0 0 0 <0.2 Sample 2 4.81 22.98 6.12 0 0 <0.2 Sample 3 4.72 23.72 6.03 0.21 0.23 <0.2 Sample 4 4.69 22.57 6.21 0.39 0.42 <0.2

Sample 1 is a Fe-Cr-C alloy without adding any other alloying elements and is used as the reference sample. Sample 2 adds 6.12% Nb on the basis of Sample 1. Sample 3 adds a small quantity of V and W on the basis of Sample 2. Sample 4 adds a comparatively large quantity of V and W on the basis of Sample 2.

JULY2010, VOL. 89 Sample 1 and get a relative wear resistance clei to form austenite. coefficient E (E = weight loss of Sample Since the partition ratio No. 1: weight loss of other sample). The of Cr and C in y-Fe is larger the value of E, the more wear resist- smaller than 1, C and Cr ant is the sample. Five testing specimens will be expelled to the were made from each sample and were surrounding area during tested separately. The highest and the low- the formation of austen- est weight loss numbers were omitted, and ite. Thus, the area be- an average of the remaining three num- tween NbC and bers was calculated and recorded. austenite will have an enrichment of Cr and C. Results and Discussion During the rapid cooling after welding, there Morphology of Nb, V, and W under is no sufficient time for Optical Microscope Cr and C to diffuse, which creates a propi- It is stated by G. Powell (Ref. 8) that in tious condition for the a Fe-Cr-C alloy with hypereutectic com- nucleus formation of positions, the as-solidified microstructure chromium carbide. The is one of long parallel aligned primary car- nucleus formation oc- bides in a eutectic matrix of carbide rods in curs on NbC or the sur- austenite, or short randomly orientated rounding area, and then primary carbides in a eutectic matrix. chromium carbide In this experiment, metallographic forms from the nuclei. specimens were prepared for Samples 1-4. Therefore, niobium car- The specimens were ground, polished, and bide and chromium car- etched by Picral-Nital solution. The spec- bide often cluster imens were examined using Neophot 21 together. microscopy. The microstructures are Figure 5C and D shown in Fig. 5. shows the microstruc- It is shown that all of the four samples ture of Samples 3 and 4. have a typical hypereutectic microstruc- It is noticed that those ture, which consists of hypereutectic (pri- microstructures look mary) M7C3 and matrix. The matrix is similar to that of Sam- composed of mainly austenite and some ple 2, except that Sam- ledeburite transformed from austenite. ples 3 and 4 have some There is a large quantity of monocrys- scattered and fine car- talline M7C3 fibers, which have a hexago- bides present in the ma- nal cross section consistent with the trix due to the fact that pseudo hexagonal crystal structure of V and W were added. M7C3 carbide. The primary M7C3 carbide is the first phase to form on cooling. The The Morphology of Nb, residual liquid then decomposes into V, and W under SEM austenite and more fine M7C3 carbide. Figure 5A is for Sample No. 1. The mi- Figure 6 shows the crostructure is described as above. The SEM-EDS composi- characteristic of this material is hypereu- tional maps of the de- Fig. 4 — Abrasion test equipment (MLS-225 wet sand rubber wheel test tectic microstructure with hard M7C3 pri- posits of Samples 2, 3, machine). mary chromium carbides dispersed in a and 4, in which it is pos- tough austenitic matrix. sible to identify the car- Figure 5B shows that other than the bide types present in the white carbide, there are some light gray microstructures. The It is seen from Fig. 6H that V exists in alloy carbides. Those carbides are formed SEM-EDS (electron dispersive spectro- three forms: 1) some solved in the matrix; clustering with chromium carbide or dis- graph) images show the distribution of the 2) some solved in the primary and eutectic persing separately in the matrix. It is de- elements of Nb, V, and W. carbides; and 3) the others (in a small fined by SEM (Fig. 6B) that those carbides The element Nb is usually agglomer- amount) formed fine carbides with W and are niobium carbides. ated and connected with the chromium Cr. Therefore, V can strengthen the ma- Niobium has a strong affinity for car- carbide particles. At high Nb content (e.g., trix and the carbides, and in the mean- bon and nitrogen, and easily forms nio- 6%), niobium carbide directly precipitates while it can form the primary carbides bium carbide with carbon. In at higher temperature in the melt before directly. hypereutectic high-chrome cast iron, Nb the solidification of the alloy starts. By this There are three formations of W, which exists mainly as niobium carbides. At way the NbC could develop an exact crys- include: 1) dispersion in the matrix; 2) dis- o 1300 C, niobium carbide starts to form, tallographic cubic form, as Fig. 6B shows. persion on the carbides, where it has which is called primary carbide. With the It can be seen from Fig. 6B and F that the strong ability to form primary carbide with formation of NbC, there are zones en- cubic niobium carbides are randomly dis- Nb, which can be seen from Fig. 6F and G; riched with Fe and Cr, which raise the tributed in the structure. Niobium formed and 3) the formation of fine carbides with austenite formation temperature. The Cr cubic niobium carbides directly and V and Cr. Tungsten not only reinforces the and C surrounding NbC work as the nu- strengthened the cladding metal. matrix and carbide, but also forms skele-

WELDING JOURNAL B^*»^ cd^altMH^ r^^ y^Ci^^ ^^^^\

^^ m M ^^ ^ O )iim m P3 k^ 0) fjg. 5 — Microstmctures of four samples and the etchant is Picral+Nital solution. A — Sample No. 1; B — Sample No. 2; C — Sample No. 3; D — Sample No. 4. m > 33 tal primary carbide, which is the main lean around the primary carbides. primary carbide. The hardness of this layer o force to fight abrasion. In Sample 2, the formation of primary is measured by HXD-1000 as HVjSeO. The matrix surrounding the large pri- carbide consumes C and Cr, and during In Sample 4, with the addition of V and mary particles was analyzed by SEM and the fast cooling, there is no sufficient time W, the eutectic point of Fe-C diagram the energy spectrum analysis. It is shown for C and Cr in the austenite to migrate; drifted to the left. The carbon content in from Fig. 6C, D, I, and J that in both Sam- hence, a low-Cr, low, C austenite transfor- the austenite matrix decreased and thus the ples 2 and 4, it is always Fe-rich and Cr- mation zone was formed surrounding the amount of the carbides increased. With the increasing quantity of carbides, the growth of austenite dendrite was hindered, and Table 3 — Energy Spectrum Analysis of Sample 4 therefore, a finer austenite matrix was formed. There existed carbonitride of V Alloying Element (wt-%) and W in the iron liquid between the V ' Cr Fe W austenite dendrites, which worked as the nuclei during the solidification. That is why A Fine primary carbide 21.01 0.53 24.89 51.91 1.67 there formed a substantial amount of fine B Blade-like carbide 14.97 0.12 6.64 76.59 1.86 carbide in the austenite matrix.

Table 4 — Hardness and Relative Wear Resistance of Samples 1-4

No. Weight Loss of 3 Specimens Average Relative Wear Hardness after 1000 Revolutions (mg) Weight Loss (mg) Resistance Ratio E (HRC)

Sample 1 171.3 189.3 178.5 179.7 1 61.2 Sample 2 132.9 118.3 134.0 128.4 1.40 62.8 Sample 3 96.5 110.3 98.6 101.8 1.77 63.6 Sample 4 102.7 99.5 94.5 98.9 1.82 64.1

JULY 2010, VOL 89 • c '

• « \^# / i^^Kv^^^^l

Fig. 6 — SEM-EDS compositional map for Samples 2 and 4. A — Overall image of Sample 2; B — Nb distribution of Sample 2; C — Cr distribution of Sample 2; D — Fe distribution of Sample 2; E — overall image of Sample 4; F — Nb distribution of Sample 4; G— W distribution of Sample 4; H— V distribution of Sample 4; I — Cr distribution of Sample 4; J — Fe distribution of Sample 4.

carbides have plenty of C and Cr, and also imens are caused by the stress relief during accumulate abundant V and W. During the the fast cooling. The fine checking crack, metallurgical reaction, the primary carbides which often runs vertically from the sur- formed with V and W working as the nu- face of the deposit to the substrate, is one clei. The larger blade-like carbides are of the characteristics of the chromium car- mainly composed of Fe, and some Cr, V, bide overlay plate. In the wear and abra- and W solved on the surface. It can be de- sion application, this stress-relief cracking duced from the compositions (Table 3) that is tolerated for the improved wear resist- the blade-like carbides are eutectic ones. ance. Table 4 shows the hardness and relative wear resistance of Sample 1-4. From Table 3 and Fig. 7 (both for the The Effects of Nb, V, and W on Hardness energy spectrum analysis of Sample 4), it and Wear Resistance The Effect of Nb, V, and W on Hardness can be seen that around the large hexagonal primary carbide, there exist two forms Figure 8 shows the surface morphology The basic factors that decide the macro- of carbides: fine primary carbides and of Samples 1, 2, and 3 after the abrasion hardness of Fe-Cr-C hardfacing alloy in- larger blade-like carbides. The isolated fine test. The fine checking cracks on the spec- clude the matrix microstructure and the

WELDING JOURNAL cv—t— "mm*m I- ,1 »H**9l V.. A^' » ^ ftm Him i

CfrC, Ili-XCrl* o„i. «»;# Kr ¥hl,iJOC' *4*)» i *»C IJOCr U»t* hi ^^^^ re • •><• CfH Co* BkM OW/

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Fig 7— SEM image of the matrix around the large primary carbide (Sam- Fig. 9 — Hardness of various carbides and other hard substances (Ref 13). ple 4): (A) fine primary carbides and (B) larger blade-like carbides.

In Sample 2, the ad- hardness requires a combination of forti- dition of around 6% fied carbides and reinforced matrix, as Nb results in the for- stated by Askeland (Ref. 14), "The mation of harder pri- strength of a fiber-reinforced composite mary niobium carbide depends on both the strength of the raw in the cladding metal. fiber and bonding between the fibers and Therefore, the macro- the matrix." hardness of Sample 2 is higher than Sample The Effect of Nb, V, and W on Wear 1. In Sample 2, the Resistance cubic-shaped niobium 33 carbides showed a Comparing the relative wear resistance m very high average in Table 4, it is found that Sample 1 with- 0) Fig. 8—Abrasion surface morphology of Samples 1, 2, and 3 after the abra- hardness value of 2550 out any addition of alloying elements has m sion test. A — Sample 1; B — Sample 2; C — Sample 3. HV, as it is known of the most inferior wear resistance. Sample > pure NbC — Fig. 9. 2 with the addition of 6% Nb has a rela- While the chromium tive wear resistance coefficient of 1.40 33 carbides showed an compared to Sample 1, and the coefficient o volume fraction of hard carbide particles. average hardness of 1410 HV, which means of Sample 3 is 1.77, while Sample 4 with The most important factor that affects the that the chromium carbide is not alloyed higher quantify of V and W has a relative austenite formation and the volume fraction with Nb. The niobium in the melts has been wear resistance coefficient of 1.82. of carbide is the carbon content. bound in the NbC. Sample 2 has a good wear resistance In this experiment, there is little differ- In Samples 3 and 4, fortifying elements because of the formation of hard primary ence in the carbon content for the four V and W were added. Microhardness tests niobium carbide NbC. The coarse M7C3 samples. The matrix microstructures look showed that the added V and W were dis- carbide particles provided a barrier against similar and the volume fractions of the solved in chromium carbide and increased microgouging and microcutting. This ben- carbide are about the same for all samples. the hardness of the M7C3 carbides by eficial effect is reinforced by the NbC par- For general reference, the microhardness solid-solution hardening. Vanadium and ticles, which prevent the detachment of for various carbides and other hard sub- W dispersed in the matrix and carbides, M7C3 carbides due to their finely dis- stances is shown in Fig. 9. thus reinforcing the matrix and eutectic persed distribution in the matrix, as shown In this study, the carbides in the mi- carbide simultaneously. Vanadium and W by Chen and Chang (Ref. 15). The exper- crostructure were big enough to measure also agglomerate and form primary car- imental result shows that the wear resist- the microhardness with a load of 0.98 N. bides. Therefore, the cladding metal with ance of Sample 2 is 1.4 times better than In the Nb-, V-, and W-free alloy Sample 1 addition of V and W was harder than Sam- Sample 1. Sample 3 adds matrix-fortifying (4.74C-23.56Cr), the chromium carbides ple 2. With the increase of V and W, the elements V and W, which not only fortifies had an average hardness of 1410 HV with extent of reinforcement increased. But in the matrix but also the carbide, thus a a standard deviation of 220 HV. In Sample Table 4, it does not show a considerable good combination of hard carbides and 2 (4.81C-22.98Cr-6.12 Nb), the chromium macrohardness increase from Sample 3 to tough matrix is obtained. The experimen- carbides were harder. An average value of Sample 4. The main reason is probably tal result shows that the wear resistance of 1520 HV was found. In Sample 3 (4.72C- that V and W are strong elements in form- Sample 3 is 1.26 times better than Sample 23.72Cr-6.03Nb-0.21V-0.23W), the aver- ing carbides, and consume more carbon, 2. Sample 4 adds slightly more V and W, age microhardness of carbides was 1590 which probably leads to the reduction of which leads to formation of more vana- HV and in Sample 4 (4.69C-22.57Cr- carbon content in the matrix and, there- dium and tungsten carbides. But the for- 6.21Nb-0.39V-0.42W) was 1610 HV. fore, the hardness of the matrix. High mation of these vanadium and tungsten

JULY2010, VOL 89 carbides reduces the carbon content and some extent and the wear resistance in- morphology in high chromium white irons. hardness in the matrix. In this experiment, creases. With a further slight addition of Journal of Materials Science 32, pp. 561-565. adding slightly more V and W did not get W and V, the hardness increases further, 6. Wo, W, and Wu, L. T. 1996. The wear be- a good combination of hard carbides and but there is not much difference in wear havior between hardfacing materials. Metallur- gical Material Transaction, A 27 A, pp. tough matrix, therefore the wear resist- resistance. 3639-3648. ance of Sample 4 did not improve much, 2) In the cladding metal, Nb increases 7. Choteborsky, R. 2008, Abrasive wear of compared to Sample 3. The experimental the hardness of carbides by forming pri- high chromium Fe-Cr-C hardfacing alloys. Res. result shows that the wear resistance of mary carbide, while V and W reinforce Agr.Eng,pp. 192-19?, Sample 4 is 1.02 times of Sample 3. both matrix and carbides, and also form 8. Powell, G. L. F, Brown, I. H., and Nelson, The erosive weight loss of high- primary carbides. G. D. Tough Hypereutectic High Chromium chromium white irons is a combination of 3) In order to obtain good wear resist- White Iron — A Double In-Situ Fibrous Com- the weight loss due to matrix removal and ance, it is required to optimize the alloy- posite. The University of Adelaide, South Aus- carbide removal. Large quantity of car- ing elements and get a good combination tralia. 9. Sun, D., and Wang, W, et al. 2003. Ef- bides shortens the distance between each of hard carbides and tough matrix. fects of alloying elements on microstructure and carbide particle, and reduces the area of erosion resistance of Fe-C-Cr weld surfacing matrix between them. Hence the matrix References layer, Journal of Material and Science Technol- can be protected well. On the other hand, ogy,19{A): 351-354. the matrix can in turn support the primary 1. Svensson, L. E., Gretoft, B., Ulander, B., 10. Durand-Charre, M. 2004. The Mi- and secondary carbides. The key is to ob- and Bhadeshia, H.K.D.H. 1986. Fe-Cr-C hard- crostructure of Steels and Cast Irons, pp. 52-73 tain a good combination of tough matrix facing alloys for high-temperature applications. 11. Thorpe, W R., and Chicco, B. 1985. The and hard carbide particles. In high-chrome Journal of Material Science, Vol. 21, pp. Fe-rich corner of the metastable C-Cr-Fe liq- cast iron, in order to obtain good wear re- 1015-1019. uidus surface. Metallurgical Transactions A, Vol. sistance, it is required to optimize the al- 2. Hao, S. 1992. High Carbon Wear Resist- 16A. ance Casting, Coal Industry Publishing House, 12. Ju, C. 1999. High Chromium Cast Iron loying elements so that both the matrix Beijing, pp. 79-180, pp. 230-232. and Its Application. Metallurgical Industry Pub- and carbide will be reinforced. 3. Atamert, S., and Bhadeshia, H. K. D. lishing House, pp. 10-20 H. 1990. Microstructure and stability of Fe-Cr- 13. Theisen, W 1998. Hartphasen, in Conclusions C hardfacing alloys. Materials Science and Engi- Hartlegierungen und Hartverbundstoffe, Hrsg. neering, Vol. A130, pp. 101-112. Hans Berns. Springer-Verlag Berlin, S. 28. 4. Sharma, T., Maria, S., and Dwiedi, D. K. 14. Askeland, D. R. 1996. The Science and 1) With the addition of around 6% Nb 2005. Abrasive wear behavior of Fe-30Cr-3.6C Engineering of Materials, Third S.I. Edition, in the cladding metal, the hardness in- overlays deposited on mild steel. ISIJ Interna- Chapman and Hall, London, p. 560. creases and the wear resistance increases. tional, 45(9): 1322-1325. 15. Chen, H. X., and Chang, Z. C. 1993. Ef- With the slight addition of W and V in the 5. Powell, G. 1997. The effect of Si on the fect of niobium on wear resistance of 14% Cr cladding metal, the hardness increases to relationship between orientation and carbide with cast iron. Wear 166, pp. 197-201.

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WELDING JOURNAL Hybrid Laser Arc Welding Process Evaluation on DH36 and EH36 Steel

This study characterizes the effects laser power, arc power, and laser-arc separation have on weld macrostructure, microstructure, and welding arc

BY C. ROEPKE, S. LIU, S. KELLY, AND R. MARTUKANITZ

dius, and the cathode spot is fixed to the ABSTRACT point of laser incidence (Refs. 6-9). In the laser plus arc welding category, a high- The effects of laser power, arc power, and laser-arc separation on the power laser, typically greater than 1 kW, is macrostructure, microstructure, and welding arc were characterized in hybrid laser used so that a keyhole is formed and the arc welds on DH36 and EH36 steels. Experiments were done to study a range of arc and laser have similar power levels. arc and laser powers at a constant laser-arc separation and a range of laser pow- Neither power source dominates the welders and laser-arc separation at a constant arc power. High-speed video captured ing process. The laser provides improved images of the welding in process, and arc voltage and current were also measured. penetration, and the arc allows root open- Two distinct weld macrostructure morphologies were observed. The first had a uni- ing bridging ability. In addition, the weld- form fusion zone, and the second had a two- part fusion zone with an upper laser ing speed is increased over arc welding, and arc combined region and a lower laser-only penetration region at the root. and the weld quality is improved over laser m This two-part fusion zone was only observed for partial joint penetration welds, beam welding (Refs. 1-4). This research and process parameter maps were made to define the windows for both mor- work used a high-power laser and while phologies. Complete penetration welds always exhibited a uniform fusion zone. the process falls into the latter category of g Decreasing the laser-arc separation increased the total penetration of the uniform laser plus arc welding, the rest of this z fusion zone welds and reduced the size of the laser-only penetration region in the paper discusses this category of hybrid two-part fusion zone welds. The formation of acicular ferrite was promoted by in- laser arc welding. o creasing the arc power and increasing the laser-arc separation. Laser power did There are many process variables asso- not have a major effect on the weld metal microstructure. Small laser-arc separa- ciated with hybrid laser arc welding, and it tions and low laser powers added a low-frequency large globular/short circuiting is important to understand how they affect m metal transfer mode to the predominately spray arc. Welding with larger laser-arc the welding process. In hybrid laser arc 0) separations and higher lasers powers did not exhibit this low-frequency transfer welding, the arc power controls the weld m but did have a mid frequency small globular free-flight transfer that was not ob- width and root opening bridging ability, > served in the gas metal arc welding (GMAW) only arc. and the laser power controls the penetration (Refs. 10-14). Modeling work (Ref. 15) also verifies these results. The laser- o Introduction for industrial applications and for re- arc separation can also be optimized to in- search (Refs. 1-4). Hybrid laser arc weld- crease the penetration (Refs. 10,11); how- Hybrid laser arc welding (HLAW) is a ing can be divided into the following two ever, laser-arc separation also greatly process that combines conventional arc general categories: laser-stabilized arc influences the stability of the process welding, typically gas metal arc welding welding (Refs. 6-9) and laser plus arc (Refs. 11,16,17). Hybrid laser arcwelding (GMAW) or gas tungsten arc welding welding (Refs. 1^1). Laser-stabilized arc has an increased melting efficiency, as (GTAW), and laser beam welding (LBW) welding uses a low-power laser, less than 1 measured by the weld cross-sectional such that both heat sources are incident on kW and typically around 500 W, such that areas, over the sum of the individual a single weld pool (Refs. 1-4). The process no keyhole is formed. Here the arc domi- process (Ref. 16). Laser focal position can was first developed by Steen and Eboo nates the welding process, although the also influence penetration greatly; it (Ref. 5) using a 2-kW CO2 laser and laser does have some profound effects. should be slightly below the base metal GTAW, and it produced some interesting The arc voltage is lowered and with re- surface such that the laser is focused on results. The laser was found to stabilize duced fluctuation. Melting efficiency is in- the surface of the depressed weld pool the voltage and current of an unstable arc, creased, the arc contracts to a smaller ra- (Refs. 11,14). reduce the arc column resistance, and in- The microstructural development of crease the depth-to-width ratio of the re- hybrid laser arc welds is an important research interest. Steel weld metal mi- sulting welding morphology (Ref. 5). As KEYWORDS laser technology developed, higher-power crostructure depends on the following im- welding lasers were more readily avail- portant parameters: chemical Laser Power able, and the process has gained interest composition, nonmetallic inclusions, so- Arc Power lidification structure, prior austenite grain Laser-Arc Separation size, and the thermal cycle (Ref. 18). C. ROEPKE and S. LIU ([email protected]) are Hybrid Laser Arc Welding These parameters may be significantly dif- with Center for Welding, Joining and Coatings Re- DH36 and EH36 Steels ferent in hybrid laser arc welds over other search, Colorado School of Mines, Golden, Colo. S. KELLY and R. MARTUKANITZ are with Ap- more conventional processes and need to plied Research Laboratory, Pennsylvania State be studied in addition to the resultant weld University, State College, Pa. metal microstructure to ensure the viabil- !HJULY2010, VOL. 89 ity of hybrid laser arc welding as an industrial process. The size distribution of nonmetallic inclusions is very important in |- controlling weld metal microstructure. Acicular ferrite is observed to nucleate on / / inclusions, and a high content of acicular ferrite is associated with inclusions greater 0*fc» than 0.2 jxm, more specifically between 0.4 and 0.6 jxm (Refs. 19-21). These inclu- n sions are typically oxides of manganese, aluminum, and titanium, and are formed w / / Aft Ton* during deoxidation of the weld pool by the <^- 1 alloy additions of the filler material (Refs. 20, 21). Oxygen potential of the weld sys- Y /\ /h Contact TtoM Wort Ouunca tem during welding and solidification has an important effect on the type and size of Wort (•*<» UMf A/c WOWMIOO the inclusions that result. Higher oxygen content and short solidification time both promote smaller inclusions (Refs. 19, 22). Fig. 1 — Schematic representation of the hybrid laser arc welding setup showing the direction of travel and It is well established in low-carbon struc- critical dimensions. tural steel welds that high contents of acicular ferrite generally exhibit high toughness and strength; consequently, acicular ferrite is a preferred weld metal mi- preheat, a predominately acicular ferrite major hybrid variables on the welding crostructure for good mechanical performance (Refs. 18-22). weld metal microstructure can be produced process will be critical to the implementation of hybrid laser arc welding in these There have been several studies focused in hybrid laser arc welds on HY-80 (Ref. industries. on the weldment microstructure and me- 28). Because DH36 and EH36 steels do not have as high hardenability as HY-80, it is ex- chanical properties of hybrid laser arc weld- Research Objectives ing of steel (Refs. 23-33). Hybrid laser arc pected that high contents of acicular ferrite welds on DH36 steel using either CO2 or can form in hybrid laser arc welds of these steels. It is also expected that the weld metal The main objective of this research was Nd:YAG lasers with conventional GMAW to characterize the effects of the following microstructure will not be influenced by the produced a weld metal microstructure high major hybrid laser arc welding parame- change in base material between DH36 and in acicular ferrite. The hybrid welds also had ters: laser power, arc power, and laser-arc better weld metal impact toughness, 53 to EH36 steels. This is because the chemical separation on the macrostructure, mi-1 64 J at -20oC, than a comparison submerged compositions of the two steels are very sim- crostructure, and the welding arc. arc weld (SAW), 49 J at -20oC (Ref. 23). The ilar (they are designated differently because weld metal hardness of hybrid laser arc of different impact toughness require- Experimental Procedures welds on DH36 and A36 steel have been re- ments), and the weld metal is predomi- ported to be acceptable for arc and laser nately influenced by the filler material, The hybrid laser arc welding system welding (Refs. 23, 24). Hybrid laser arc which remains constant for both base mate- consisted of a continuous-wave 14-kW welding can be used to weld a variety of rials. Consequently, DH36 and EH36 steels CO2 laser with an F/# (ratio of raw beam pipeline steels (Ref. 26). With the proper have been used interchangeably in this diameter to focal length) of 5.2 and a fo- filler material that allows for the formation study, and no comparison is made between cused beam diameter of 0.8 mm, and a of nonmetallic inclusions, hybrid welds have the hybrid laser arc welds made on them. constant voltage gas metal arc welding power source. The electrode was 0.045- a predominately acicular ferrite microstruc- This research work will have application to the shipbuilding, pipeline, heavy- in.-(l.l-mm-) diameter ER70S-6 wire, fed ture and acceptable hardness levels. In a equipment, and other heavy construction using a conventional wire feeder and higher-alloy steel like HY-80 that has high industries. Hybrid laser arc welding allows GMAW gun. The shielding gas used was hardenability, it can be more difficult to welding to be done at higher travel speeds, 50%He-45%Ar-5%CO2 (after the work produce acicular ferrite in a hybrid laser arc with greater penetration, reduced distor- of A. Fellman and V. Kujanpaa (Ref. 36)) weld because of the high cooling rates and tion compared to conventional arc weld- and was fed solely through the GMAW high dilution of the filler material associated ing (Refs. 34, 35), and improved root gun. Two different base materials were with hybrid laser arc welding (Ref. 27). opening tolerance over laser beam weld- used, 5-mm-thick ABS Grade DH36 steel However, through control of heat input and ing. Understanding the effects of the for welds made with laser powers of 4 and

Table 1 — Measured Base Material Chemical Composition as Determined by Direct Reading Atomic Spectroscopy (wt-%)

Material Mn Si Al Nb V Ti Cu Cr Ni Mo Fe Carbon Equivalent DH36 0.06 1.39 0.19 0.011 0.004 0.025 O.OIW 0.06 0.01 0.25 0.11 0.14 0.03 bal 0.39 EH36 0.06 1.38 0.25 0.010 0.004 0.024 0.04 0.05 0.02 0.02 0.02 0.02 0.01 bal 0.35

(a) Under minimum specification requirement of 0.02%.

WELDING JOURNAL Fig. 2 — Example macrographs of the two distinct morphologies observed in the partial joint penetration welds. Left — Hybrid weld with a uniform fusion zone. Right — Hybrid weld with a two-part fusion zone consisting of an upper, laser, and arc penetration region and a lower, laser-only penetration region.

Fig. 3 — Micrographs from a partial-penetration hybrid weld with a two-part fusion zone. Left - - Micrograph from the laser and arc penetration region. Right — Micrograph from the laser-only penetration region. o 6 kW, and 10-mm-thick ABS Grade EH36 terial to prevent melt-through at the held constant throughout the experiment steel for welds made with laser powers of higher laser powers. At the time of the ex- as shown — Fig. 1. All the constant pro- 8 and 9 kW (note the steel grade here is periment, only DH36 steel was available in cessing parameters are shown in Table 2. specified in the commercial standard 5 mm thickness and EH36 steel in 10 mm An experimental matrix was developed ASTM A131, Standard Specification for thickness. The base material was cut into to test the following three major hybrid Structural Steel for Ships). The chemical 5 cm x 30 cm coupons, and bead-on-plate laser arc welding variables: laser power, compositions of these steels are given in welds were made. Welding was done with arc power, and laser-arc separation. The Table 1. The reason for selecting the two the laser leading the arc. Contact tip-to- first experimental matrix used a constant thicknesses was the need for a thicker ma- work distance and welding angles were all laser-arc separation of 4.5 mm and tested three levels of arc power, 3.4, 6.3, and 8.5 kW, plus four levels of laser power, 4, 6, 8, Table 2 — HLAW Processing Constants and 9 kW. The three arc parameters were chosen to produce a change in the domi- Welding Position Flat nant metal transfer mode. The 3.4-kW pa- Process Orientation Laser leading arc rameter (20 V and 170 A with 200 in./min Laser Focus At workpiece surface or 85 mm/s wire feed speed (WFS)) pro- Laser Orientation Perpendicular to work duced predominately short circuiting GMAW Polarity DCEP-CW transfer; the 6.3-kW parameter (28 V and Contact Tip-to-Work Distance 0.75 in. 225 A with 250 in./min or 106 mm/s WFS) Laser-Arc Angle 15 deg (from laser beam) was predominately globular transfer; and Shielding Gas 50%He-45 % Ar-5 %C0 2 the 8.5-kW parameter (32 V and 265 A Shielding Gas Flow Rate 150 ft3/h with 300 in./min or 127 mm/s WFS) was Electrode ER70S-6, 0.045 in. diameter predominately spray transfer. The second Travel Speed 30 in./min experimental matrix used a constant arc

JULY2010, VOL 89 90% 5 «* -• •-

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Fig. 4 — Weld metal microstructural content in the two different regions Fig. 5 — Hardness traverses through the two different regions of the two- of the two-part fusion zone partial-joint-penetration welds. part fusion zone partial penetration welds. Dotted lines show the location of the weld interface.

Fig. 6 — Map of the arc power and laser power Fig. 7 — Macrographs showing the change in morphology associated with partial and complete penetration ^^ parameter space for partial-joint-penetration hy- welds. Left — Partial penetration weld with a two-part fusion zone made with 4-kW laser power. Right — Full ^^ brid welding showing the two distinct weld mor- penetration weld with a uniform fusion zone made with 6-kW laser power. phologies. The dotted line shows the boundary between the two morphologies. Previous experimental data are from earlier work by the authors that is reported in Ref 28.

power of 8.5 kW (the spray arc parameter used a Fast Fourier Transform (FFT) to the classification of weld metal mi- as above) and tested four levels of laser output the voltage and current frequency crostructures (Ref. 37). power, 4, 6, 8, and 9 kW, plus four levels of spectra. From these frequency spectra, the laser-arc separation, 2.0, 4.0, 6.0, and 12.0 major voltage and current frequencies Results and Discussion mm. In addition to the two matrices, arc- could be determined. only welds were made at the three arc Transverse samples for macrostructure Macrostructure power levels tested, and laser-only welds and microstructure analysis were sec- were made at the four laser power levels tioned from the center portion of the weld When examining the macrostructure of tested. length. The samples were mounted in the hybrid laser arc welds, it was immedi- During welding, a Lab VIEW based Bakelite, ground down to 600 grit, and ately apparent that there were two distinct data-acquisition system was used to mon- then polished with a diamond suspension types of morphologies — Fig. 2. The first itor arc voltage and current at a 10-kHz down to 1 [xm. The welds were etched with morphology has a uniform fusion zone (the sampling rate. Additionally, a high-speed a 2% Nital solution for 10 s. Macrographs microstructure is the same everywhere in video system was used to capture images of the welds were then taken using a stere- the fusion zone), much like a conventional of the welding arc, laser plume, and weld- omicroscope at lOx. The weld morphology gas metal arc weld but with increased pene- ing pool. The high-speed video camera was observed, and characterizing dimen- tration. The second morphology has a two- was filtered with a shade 11 welding lens, sions were measured. Multiple micro- part fusion zone consisting of an upper, and the capture rate was 600 frames/s with graphs of each of the welds were taken laser and arc penetration region (similar to an exposure time of 8 [xs/frame. The arc throughout the fusion zone using a light a conventional gas metal arc weld) and a voltage and current were analyzed using optical microscope at 200x. The weld mi- lower, laser-only penetration region (simi- an IGOR Pro program that computed the crostructures were observed and charac- lar to a laser beam weld). This second mor- average voltage, current, and power, and terized according to the IIW system for phology has been previously observed by

WELDING JOURNAL Fig. 8 — Macrographs showing the morphology changes due to the laser-arc separation in the partial penetration welds with a two-part fusion zone. From left, the laser-arc separation is 4.5, 6.0, and 12.0 mm. Laser power and arc power are constant for all welds at 8 and 8.5 kW, respectively.

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__ Fig. 9 — Schematic macrograph showing the penetration measurements Fig. 10— Total penetration and the penetration of the two distinct fusion ^J of the laser and arc region, and the laser-only region. zone regions as a function of the laser-arc separation in-partial penetration bead-on-plate welds. Laser power and arc power are constant for all welds at 8 and 8.5 kW, respectively.

Fig. 11 — Macrographs showing the morphology changes due to the laser-arc separation in the welds with a uniform fusion zone. From left, the laser-arc separation is 4.5, 6.0, and 12.0 mm. Laser power and arc power are constant for all welds at 4 and 8.5 kW, respectively.

the authors (Ref. 28) and by several other 4. These differences were also reported by cause of high cooling rates at the root of the researchers (Refs. 29, 30, 33, 38, 39). The other researchers (Refs. 29, 30). It is likely weldment. Real-time X-ray transmission two regions in the second morphology not that this second morphology is the result of imaging of hybrid laser arc welding with only appeared different at low magnifica- incomplete mixing of the filler material tungsten tracers by Naito et al. (Ref. 39) has tion but also at high magnification. The mi- from the gas metal arc welding part of the shown a dual-flow convection pattern in crostructure of the upper, laser, and arc hybrid process to the root of the weldment. welds with a 5-mm laser-arc separation that penetration region is mostly acicular ferrite The lower, laser-only penetration region is would produce this second type of mor- with some grain boundary ferrite whereas basically an autogenous laser beam weld in phology. This dual-flow convection pattern the lower, laser-only penetration region is the base material. In addition, the lower, consists of one flow from the bottom of the mostly ferrite with second phases and only laser-only penetration region may actually keyhole up along its sides and another from a small amount of acicular ferrite — Figs. 3, be solidifying before mixing can occur be- the center of the arc at the surface down and

JULY2010, VOL89 Fig. 12 — Micrographs of the GMAW 8.5-kW arc power, left, and LBW 8-kW laser power, right, comparison welds. away from the arc. This creates a region at tion welds was the same the bottom of the keyhole that flow from the throughout the fusion MM arc never reaches. In general, for hybrid zone. However, it is pos- * •<* laser arc welding, this second morphology sible that there may be 70% would be undesirable because it has a re- some small composi- gion that is unalloyed by the filler material tional changes in the fu- | so% — from the gas metal arc welding part of the sion zone of these welds; process, and the alloying addition from the the fluctuation in weld | 40% gas metal arc welding component is a key metal composition has 1 10% advantage of the hybrid laser arc welding not been measured and S :ox process. Hardness traverses measured will be the subject of fu- 10% across both regions show no major differ- ture work by the authors. 0% (/) ence in weld metal hardness between the Even when a complete CM** •.'. two regions — Fig. 5. This behavior is ex- penetration weld was 1 9mmm pected because DH36 and EH36 steels both achieved by increasing have low hardenability. However, if this the laser power, such that Fig. 13 — Weld metal microstructural content as process. The GMA weld Vj^ morphology were present in a more hard- the weld would now fall was made with 8.5 kW of arc power, and the laser beam weld was made 5^ enable steel, it is likely that the laser-only in the processing window with 8 kWof laser power. ^" penetration region would have a much for the two-part fusion higher hardness than the laser and arc pen- zone morphology as de- etration region, and this would be undesir- fined on the previous power and 8.5 kW of arc power as shown UJ able. Much of the rest of this macrostruc- map, a uniform fusion zone was observed. in the macrographs, decreasing the laser- ture discussion focuses on how to eliminate This is believed to be due to the base metal arc separation decreased the weld width 5 or avoid this laser-only penetration region being sufficiently thin to result in com- and reduced the size of the laser-only pen- that creates the second type of fusion zone plete penetration and partially altering the etration region — Fig. 8. It may be advan- morphology. A process map laser power flow characteristics. This is illustrated in tageous to quantitatively describe the and arc power at a laser-arc separation of Fig. 7. It is likely that the fluid flow in a changes in the size of the two fusion zone 6mm was developrd to show the processing complete penetration weld promotes bet- regions as a function of the processing windows where the two different mor- ter mixing in the fusion zone and conse- conditions. To do this, the penetration of phologies would result — Fig. 6. The figure quently does not have the laser-only pen- the laser and arc region, DLA, the pene- shown includes data from previous work by etration region. Additionally, a complete tration of the laser-only region, DL, and authors (Ref. 28), which help define the penetration weld changes the heat flow the total penetration, DT, are defined, and boundary between the two morphologies. conditions of the weld and, as a conse- these penetrations are plotted — Figs. 9, Low laser powers and high arc powers pro- quence, the cooling rate at the root of the 10. The total penetration remained rela- moted a uniform fusion zone, the first mor- weldment will be much slower than in a tively constant over the range of laser-arc phology. Welds made with a high Iser power partial-penetration weld allowing more separation tested. The penetration of the and low arc power will have a two-part fu- time for mixing to occur to the root of the laser and arc region increased with de- sion zone, the second morphology. Work weld before solidification. When making creasing laser-arc separation, resulting in done by Gao et. al. (Ref. 33) also shows that complete penetration hybrid laser arc a smaller laser-only penetration region. increasing the arc power promotes the uni- welds, the two-part fusion zone morphol- As the spatial separation of the heat form fusion zone. It is important to note ogy with a laser and arc upper penetration sources is reduced, the thermal gradient that this process map was made for partial- region and a lower laser-only penetration behind the laser keyhole is also reduced. penetration welds. region was not observed. Consequently, the solidification rate be- Complete-joint-penetration welds The laser-arc separation also plays a hind the laser keyhole is reduced, allowing were always observed to have a uniform major role in modifying the hybrid laser greater time for weld metal mixing. It is fusion zone, the first morphology. The mi- arc weld morphology. Considering partial- also likely that the fluid flow pattern in the crostructure in these complete penetra- penetration welds made with 8 kW of laser molten weld pool changes with changing

WELDING JOURNAL zFig. 14 — Micrographs showing the effect of laser power. From left, the laser power is 4 and 8 kW. Con- Fig. 15 — Weld metal microstructural content as a stants include arc power, 8.5 kW, and laser-arc separation, 4.5 mm. function of laser power. Arc power and laser-arc separation were constant at 8.5 kW and 4.5 mm, respectively.

Fig. 16 — Micrographs showing the effect of arc power. From left, the arc power is 3.4, 6.3, and 8.5 kW. Constants include laser power, 8.0 kW, and laser-arc separation, 4.0 mm. o on the process map for partial penetration (AF) and primary ferrite (PF). l»«» 1—^«— uniform fusion zone welds. First, the effect of laser power on the -• Laser-arc separation also plays a signifi- microstructure of hybrid laser arc welds in m I 1 1 cant factor in hybrid welds with a uniform the laser and arc region was examined. 0) 1 1 fusion zone. Figure 11 shows macrographs Figure 14 shows representative micro- m 1 1 tx of welds made with 4 kW of laser power graphs of the hybrid laser arc welds made > i • Mi and 8.5 kW of arc power; these parameters with 4 and 8 kW of laser power with con- -. produced welds with a uniform fusion stant arc power, 8.5 kW, and constant zone. Decreasing the laser-arc separation laser-arc separation, 4.5 mm. The welds o 1 •v 1 ! dramatically increased the penetration of had very similar microstructures. The mi- MM 1 IM ISM1 these welds. There is also a corresponding crostructural content of these welds is decrease in width as laser-arc separation is shown in Fig. 15. The hybrid laser arc weld decreased. From these results, it is clear made with 4 kW of laser power was pre- that reducing the laser-arc separation is dominantly acicular ferrite (AF) with a Fig. 17— Weld metal microstructural content as a advantageous because it promotes higher significant amount of primary ferrite (PF) function of arc power. Laser power and laser-arc penetration in the uniform fusion zone and some ferrite with second phases (FS). separation were constant at 8.0 kW and 4.0 mm, welds and reduces the size of the laser- The hybrid laser arc weld made with 8 kW respectively. only region in the two-part fusion zone of laser power was predominantly acicular welds. ferrite (AF) with a significant amount of primary ferrite (PF) and some ferrite with laser-arc separation (Ref. 39), and this Microstructure second phases (FS). The change in laser may also contribute to the reduced frac- power from 4 to 8 kW did not produce any tion of laser-only penetration. While the For microstructural comparison to the major changes in the microstructure of the fraction of laser-only penetration was re- hybrid laser arc welds, representative mi- hybrid laser arc welds. This observation is duced by decreasing the laser-arc separa- crographs from a GMA weld made with likely because the major factor in control- tion, it was not completely eliminated in 8.5-kW arc power and a LBW weld made ling weld metal microstructure is the filler the range of laser-arc separation (4.5-12.0 with 8-kW laser power are provided — material added, and this did not change mm) and plate thickness (10 mm) tested. Fig. 12. The microstructural content of when changing laser power. However, extrapolation of the graph these welds is shown in Fig. 13. The mi- Next, the effect of arc power on the mi- shows that it may be possible to produce crostructure of the GMA weld is predom- crostructure of hybrid laser arc welds was the uniform fusion zone morphology with inantly acicular ferrite (AF) with a small examined. Figure 16 shows representative no laser-only penetration region if the amount of primary ferrite (PF). The mi- micrographs of the hybrid laser arc welds laser-arc separation is less than 2.0 mm. crostructure of the laser beam weld is pre- made with 3.4, 6.3, and 8.5 kW of arc Consequently, laser-arc separation would dominately ferrite with second phases power with constant laser power, 8.0 kW, be a third variable in creating a boundary (FS) and a small amount of acicular ferrite and constant laser-arc separation, 4.0 mm.

JULY2010, VOL 89 Fig. 18 — Micrographs showing the effect of laser-arc separation. From left, the laser arc separation is 4.5, 6.0, and 12.0 mm. Constants include laser power, • kW, and arc power, 8.5 kW.

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*« #* o DC < i S Ml ; Oran I? Ot LU l*.ri Alt WoaratKin (/) LU Fig. 19 — Weld metal microstructural content as a function of laser- Fig. 20 — Selected high-speed video frames showing the differences caused by arc separation. Laser power and arc power were constant at 4.0 and changing the laser-arc separation. Red triangles indicate the position of the laser DC 8.5 kW, respectively. beam. i

The microstructural content of these with second phases and an increase in aci- acicular ferrite (AF) and a small amount welds is shown in Fig. 17. The hybrid laser cular ferrite. It is also important to note of primary ferrite (PF). The hybrid laser LU arc weld made with 3.4 kW of arc power that the filler wire used has been designed arc weld made with 12.0 mm of laser-arc was predominantly ferrite with second to produce a high content of acicular fer- separation was predominantly acicular phases (FS) with some acicular ferrite rite in conventional GMAW. Because ferrite (AF) and a small amount of pri- (AF) and a small amount of primary fer- HLAW has increased penetration over mary ferrite (PF). The change in laser-arc rite (PF). The hybrid laser arc weld made GMAW, there is higher base metal dilu- separation produced significant changes with 6.3 kW of arc power was mostly fer- tion in HLAW. This may require higher in the microstructure of the hybrid laser rite with second phases (FS) with a signif- wire feed rates to be used to counteract arc welds. Increasing the laser-arc separa- icant amount of acicular ferrite (AF) and the increased penetration in HLAW or tion increased the amount of acicular fer- a small amount of primary ferrite (PF). new filler wires to be designed specifically rite in the welds and promoted a mi- The hybrid laser arc weld made with 8.5 for HLAW. crostructure very similar to the GMAW kW of arc power was predominantly acic- Finally, the effect of laser-arc separa- comparison weld. This is likely because in- ular ferrite (AF) and a small amount of tion on the microstructure of hybrid laser creasing the laser-arc separation de- primary ferrite (PF). The change in arc arc welds was examined. Figure 18 shows creased the penetration and consequently power produced significant changes in the representative micrographs of the hybrid decreased the dilution of the welding wire. microstructure of the hybrid laser arc laser arc welds made with 4.5,6.0, and 12.0 welds. Increasing the arc power increased mm of laser-arc separation with constant Welding Arc the amount of acicular ferrite and de- laser power, 4.0 kW, and constant arc creased the amount of ferrite with second power, 8.5 kW The microstructural con- The welding arc was observed with phases. This observation is likely because tent of these welds is shown in Fig. 19. The high-speed video, and the arc current and increasing the arc power increases the hybrid laser arc weld made with 4.5 mm of voltage were monitored to look for total heat input of the process, and the arc laser-arc separation was predominantly changes in the properties of the arc that power is increased by increasing the wire acicular ferrite (AF) with a significant may have been caused by the three major feed speed, which adds additional filler amount of primary ferrite (PF) and some hybrid laser arc welding variables. When metal to the weld pool. Both of these ef- ferrite with second phases (FS). The hy- the arc power was increased in the hybrid fects of increasing the arc power would brid laser arc weld made with 6.0 mm of laser arc welding process the arc current cause a decrease in the amount of ferrite laser-arc separation was predominantly increased, the predominate frequency in

WELDING JOURNAL Fig. 21 — Major arc voltage frequencies and corresponding arc current Fig. 22 — Selected high-speed video frames showing the differences caused by as a function of laser-arc separation. changing the laser power. Red triangles indicate the position of the laser beam.

subsequent violent trans- The arc voltage and current signals cor- fer that sometimes roborated well with the visual observation shorted out the arc. It is of the arc behavior. At the low laser-arc possible that because of separations, 2.0 and 4.5 mm, a new low- -no the close proximity of the frequency (—10 Hz) peak was observed in -NO arc to the laser plasma, the the voltage FFT that was not observed in laser plasma is heating the the GMA weld — Fig. 21. This voltage fre- -in) electrode and causing the quency would correspond to the large m globule formation. When globular/short circuiting transfer that was the laser-arc separation observed visually with the high-speed / -no was increased to 4.5 mm video. When the laser-arc separation was •.••, the arc behavior was very increased to 6.0 and 12.0 mm, this low-fre- - no similar, predominately quency peak was no longer observed; how- • • I I spray transfer with some ever, a new mid-frequency (—70 Hz) peak O low frequency (approxi- was observed. This peak likely corre- <»... flVNl mately ten times a second) sponds to the small globular transfer that m globular formation and vi- was visually observed in the welds at these Fig. 23 — Major arc voltage frequencies and corresponding arc cur- olent transfer. At 4.5 mm, laser-arc separations. In addition to these 0) rent as a function of laser power. the arc plasma and laser voltage frequency changes caused by the m plasma were observed to laser-arc separation, there was also a > separate occasionally; change in the arc current — Fig. 21. In- however, they were most creasing the laser-arc separation in- often joined. Several other creased the arc current. However, it did so o researchers (Refs. 11, 16, in a stepwise function that seemed to cor- the arc voltage FFT spectrum increased 17) have shown that small laser-arc sepa- relate with the observed changes in the (-10 Hz to -70 Hz to -400 Hz and -525 rations destabilize the process and in- voltage frequency and metal transfer Hz), and the metal transfer in the arc creasing the separation stabilizes the mode. The lowest currents, —250 A, were changed from short circuiting to globular process. At 6.0 mm of laser-arc separation, associated with the low voltage frequency to spray. This behavior is no different than the arc began to behave differently. The peak and the large globular/short circuit- the typical response to changes in arc arc and laser plasmas were now very in- ing transfer, while the mid current levels, power in conventional GMAW. Conse- frequently joined, and the arc had a much —265 A, were associated with the mid volt- quently, the discussion focuses only on the more stable spray metal transfer with no age frequency and the small globular effect of laser-arc separation and laser violent globular/short circuiting transfers. transfer. The highest current, 281 A, was power on the welding arc. The arc, however, did not have a pure only observed in the GMA weld that only To examine the effect of laser-arc sep- spray metal transfer as some small metal exhibited high voltage frequencies and aration on the welding arc, welds were globules were observed to form on the pure spray transfer. made using an arc power of 8.5 kW; this electrode tip and transfer in free flight To observe the effect of the laser power parameter produced pure spray transfer through the arc. Very similar arc behavior on the welding arc, welds were made using and a laser power of 4 kW. Figure 20 shows was observed when the laser-arc separa- an arc power of 8.5 kW, which produced selected high-speed video frames high- tion was increased to 12.0 mm. The arc ex- pure spray transfer, and a laser-arc sepa- lighting the differences in the arc caused hibited predominately spray metal trans- ration of 4.5 mm. Figure 22 shows selected by laser-arc separation. At 2 mm of laser- fer with a small amount of small globular high-speed video frames highlighting the arc separation, the arc plasma and laser transfer. At this laser-arc separation, the differences in the arc caused by laser plasma ejected from the keyhole were arc and laser plasmas were observed to be power. The arc behavior of the welds nearly always joined. The arc exhibits completely separate from one another. made with 4 and 6 kW of laser power was mostly spray metal transfer; however, There was, however, still a single weld very similar. The arc and laser plasmas there was a low frequency (approximately pool at this laser-arc separation, and be- were observed to be almost always joined, ten times a second) of large metal globule cause of this the process was still consid- only separating occasionally. The metal formation on the tip of the electrode and ered "hybrid" and not "tandem." transfer was predominantly spray transfer.

JULY2010, VOL 89 but at both of these low laser powers, the arations produced a mid frequency small hybrid- and hydra welding processes for ship- large metal globular formation that vio- globular free flight transfer. building. Welding in the World 45(7/8): 10-15. lently transferred/short circuited was ob- • Low laser powers produced the large 14. Matsuda, J., Utsumi, A., Katsumura, M., served. When the laser power was in- globular/short circuiting transfer in the arc, Hamasaki, M., and Nagata, S. 1988. TIG or MIG arc augmented laser welding of thick mild creased to 8 kW the keyhole was observed while high laser powers produced the mid steel plate. Joining and Materials 1(1): 31-34. to be much larger and more stable, and the frequency small globular free flight transfer. 15. Ribic, B., Rai, R., and DebRoy, T 2008. ejected laser plasma remained more sepa- Numerical simulation of heat transfer and fluid rate from the arc plasma than with the Acknowledgments flow in GTA/laser hybrid welding. Science and welds made with lower laser powers. The Technology of Welding and Joining 13(8): metal transfer was again predominately The authors would like to thank Ed 683-693. spray, but the large globular/short circuit- Good at the Applied Research Laboratory, 16. Gao, M., Zeng, X. Y., and Hu, Q. W ing transfer was not observed, and instead Pennsylvania State University, for his help 2006. Effects of welding parameters on melting a small globular free flight transfer was de- making the welds, and Scott Mitzner at energy of CO2 laser-GMA hybrid welding. Sci- ence and Technology of Welding and Joining tected. CSM-CWJCR for his help with the prelim- 11(5): 517-522. These visual observations of the arc inary metallographic work. C. Roepke and 17. Nakajima, T, Sakurai, S., Miyanagi, N., and metal transfer correlated well with the S. Liu would also like to thank Matt John- and Takano, Y. 2002. Radiation phenomena in arc voltage and current signals. The rela- son and Pat Hochanadel at the Los Alamos the groove in laser-arc combination welding. tionship between metal transfer, voltage National Laboratory for their financial sup- Welding in the World 46(Special): 51-61. frequency, and current was the same as port of the graduate research program at 18. Grong, O., and Matlock, D. K. 1986. Mi- what was observed in the effect of laser- the Colorado School of Mines. crostructural development in mild low-alloy arc separation even though now the steel weld metals. International Metals Review changes were caused by laser power level. References 31(1): 27-48. 19. Liu, S., and Olson, D. L. 1986. The role The effect of laser power on the major arc of inclusions in controlling HSLA steel weld mi- voltage frequencies and arc current is 1. Tusek, J., and Suban, M. 1999. Hybrid welding with arc and laser beam. Science and crostructures. Welding Journal 65(6): 139-s to shown in Fig. 23. The low laser powers, 4.0 149-s. and 6.0 kW, that produced the large glob- Technology of Welding and Joining 4(5): 308-311. 20. Koseki, T, and Thewlis, G. 2005. Inclu- ular/short circuiting transfer had a low- sion assisted microstructure control in C-Mn 2. Dilthey, U., and Wieschemann, A. 2000. frequency (—10 Hz) peak observed in the Prospects by combining and coupling laser and low alloy steel welds. Materials Science and o Technology 21(8): 867-879. voltage FFT, and the lowest current levels, beam and arc welding processes. Welding in the DC —245 A. Other research work (Ref. 40) World 44(3): 37^6. 21. Liao, F C, and Liu, S. 1992. Effect of deoxidation sequence on carbon manganese steel has shown that the introduction of the 3. Bagger, C, and Olsen, F. O. 2005. Review < laser beam reduces the arc current. When of laser hybrid welding. Journal of Laser Appli- weld metal microstructures — Deoxidation se- LU quence has a strong influence on nonmetallic in- the laser power was increased to 8.0 kW, cations 17(1): 2-14. clusions formation and the subsequent weld re- (/) the small globular free flight transfer was 4. Mahrle, A., and Beyer, E. 2006. Hybrid LU laser beam welding — Classification, charac- finement. WeldingJoumall 1(3): 94-s to 103-s. produced, the mid frequency (~70 Hz) 22. Osio, A. S., Liu, S., and Olson, D. L. DC voltage peak replaced the low frequency teristics, and applications. Journal of Laser Ap- plications 18(3): 169-180. 1996. The effect of solidification on the forma- peak, and the current increased to 270 A. tion and growth of inclusions in low carbon steel 5. Steen, W. M., and Eboo, M. 1979. Arc O Again, this current was still less than the augmented laser welding. Metal Construction welds. Materials Science and Engineering a- Structural Materials Properties Microstructure GMAW current, 281 A, that was associ- 11(7): 332-335. ated with only the high frequency voltage 6. Hu, B., and den Ouden, G. 2005. Laser in- and Processing 221(1-2): 122-133. 23. McPherson, N. A., Suarez-Fernandez, peaks and a pure spray transfer. duced stabilisation of the welding arc. Science and N., Moon, D. W., Tan, C. P. H, Lee, C. K, and Technology of Welding and Joining 10(1): 76-81. Baker, T N. 2005. Laser and laser assisted arc 7. Hu, B., and den Ouden, G. 2005. Syner- LU Conclusions welding processes for DH 36 microalloyed steel getic effects of hybrid laser/arc welding. Science ship plate. Science and Technology of Welding and Technology of Welding and Joining 10(4): 5 • Partial-joint-penetration hybrid welds and Joining 10(4): 460-467. 427-431. 24. Jokinen, T, Viherva, T, Riikonen, H, should be made within a processing win- 8. Shinn, B. W., Farson, D. F, and Denney, dow, defined by a maximum laser power for and Kujanpaa, V. 2000. Welding of ship struc- P. E. 2005. Laser stabilisation of arc cathode tural steel A36 using a NdYAG laser and gas- a given arc power and laser-arc separation, spots in titanium welding. Science and Technol- metal arc welding. Journal of Laser Applications for a uniform fusion zone to prevent laser- ogy of Welding and Joining 10(4): 475^181. 12(5): 185-188. only penetration at the root. 9. Stute, U., Kling, R., and Hermsdorf, J. 25. Gao, M., Zeng, X. Y., Hu, Q. W, and • Complete-joint-penetration hybrid 2007. Interaction between electrical arc and Yan, J. 2009. Laser-TIG hybrid welding of ultra- welds always had a uniform fusion zone Nd:YAG laser radiation. CirpAnnals-Manufac- fine grained steel. Journal of Materials Process- macrostructure and microstructure re- turing Technology 56(1): 197-200. ing Technology 209(2): 785-791. 10. Qin, G. L., Lei, Z., and Lin, S. Y. 2007. gardless of the laser power. 26. Moore, P. L, Howse, D. S., and Wallach, Effects of Nd:YAG laser plus pulsed MAG arc • Decreasing the laser-arc separation E. R. 2004. Microstructures and properties of hybrid welding parameters on its weld shape. laser/arc hybrid welds and autogenous laser increased the penetration of the laser and Science and Technology of Welding and Joining welds in pipeline steels. Science and Technology arc region in the two-part fusion zone 12(1): 79-86. of Welding and Joining 9(4): 314-322. welds and increased the total penetration 11. Campana, G., Fortunato, A., Ascari, A., 21. Hyatt, C. V., Magee, K H, Porter, J. F, in the uniform fusion zone welds. Tani, G., and Tomesani, L. 2007. The influence Merchant, V. E., and Matthews, J. R. 2001. • Increasing the arc power and in- of arc transfer mode in hybrid laser-MIG weld- Laser-assisted gas metal arc welding of 25-mm- creasing the laser-arc separation both pro- ing. Journal of Materials frocessing Technology thick HY-80 plate. Welding Journal 80(7): 163-s moted the formation of acicular ferrite in 191(1-3): 111-113. to 172-s. 12. Yao, Y., Wouters, M., Powell, J., Nilsson, the weld metal microstructure. Changes in 28. Roepke, C, and Liu, S. 2009. Hybrid K., and Kaplan, A. F H. 2006. Influence of joint laser arc welding of HY-80 steel. Welding Jour- laser power did not produce a major geometry and fit-up gaps on hybrid laser-metal nal 88(8): 159-s to 167-s. change in the weld metal microstructure. active gas (MAG) welding. Journal of Laser Ap- 29. Gao, M., Zeng, X. Y., Yan, J., and Hu, • Small laser-arc separations introduced plications 18(4): 283-288. Q. W 2008. Microstructure characteristics of a low frequency large globular/short circuit- 13. Wieschemann, A., Keller, H., and laser-MIG hybrid welded mild steel. Applied ing transfer in the arc. Larger laser-arc sep- Dilthey, U. 2001. Development of laser-GMA Surface Science 254(18): 5715-5721.

WELDING JOURNAL 30. Liu, Z., Kutsuna, M., and Xu, G. 2006. 34. Kelly, S. M., Brown, S. W, Tressler, J. E, microscope examination of ferritic steel weld Microstructure and mechanical properties of Martukanitz, R. P., and Ludwig, M. J. 2009. metals. IXJ-123-87 Revision 2, June 1988. CO2 laser-MAG hybrid weld of high strength Using hybrid laser arc welding to reduce distor- 38. El Rayes, M., Walz, C, and Sepold, G. steel. Quarterly Journal of the Japan Welding So- tion in ship panels. Welding Journal 88(3): 2004. The influence of various hybrid welding ciety 24(4): 18-23. 32-36. parameters on bead geometry. Welding Journal 31. Metzbower, E. A., Denney, P. E., Moon, 35. Reutzel, E. W, Kelly, S. M., Sullivan, M. 83(5): 147-s to 153-s. D. W, Feng, C. R., and Lambrakos, S. G. 2003. J., Huang, T. D., Kvidahl, L., and Martukanitz, 39. Naito, Y., Mizutani, M., and Katayama, S. Thermal analysis and microhardness mapping R. P. 2008. Hybrid laser-GMA welding for im- in hybrid laser welds in a structural steel. In proved affordability. Journal of Ship J^oduction 2006. Effect of oxygen in ambient atmosphere on Thermec'2003, Pts 1-5. 24(2): 72-81. penetration characteristics in single yttrium-alu- 32. Webster, S., Kristensen, J. K., and 36. Fellman, A., and Kujanpaa, V. 2006. The minum-gamet laser and hybrid welding. Journal Petring, D. 2008. Joining of thick section steels effect of shielding gas composition on welding of Laser Applications 18(1): 21-27. using hybrid laser welding. Jronmaking & Steel- performance and weld properties in hybrid CO2 40. Travis, D., Dearden, G., Watkins, K G., making 35(7): 496-504. laser-gas metal arc welding of carbon man- Reutzel, E. W, Martukanitz, R. P., and Tressler, 33. Gao, M., Zeng, X. Y., Hu, Q. W, and ganese steel. Journal of Laser Applications J. F. 2004. Sensing for monitoring of the laser- Yan, J. 2008. Weld microstructure and shape of 18(1): 12-20. GMAW hybrid welding process. Proceedings of laser-arc hybrid welding. Science and Technol- 37. Abson, D., Duncan, A, and Pargeter, R. the 23rd International Congress on Applications ogy of Welding and Joining 13(2): 106-113. IIW Doc. No. IX-1533-88. Guide to the light of Lasers & Electro-Optics: 33^10.

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!OJULY2010, VOL. 89 Effect of Continuous Cooling Transformation Variations on Numerical Calculation of Welding-Induced Residual Stresses

Three continuous cooling transformation (CCT) diagrams for S355J2 steel were employed to study the effect of CCT variations on calculated residual stresses

BY J. CARON, C. HEINZE, C. SCHWENK, M. RETHMEIER, S. S. BABU, AND J. LIPPOLD

sion has been found to be more signifi- ABSTRACT cant than that due to the yield strength change (Refs. 7, 10). Ferro et al. (Ref. 8) Continuous cooling transformation (CCT) behavior affects the transient state of isolated the effects of volume change and material properties employed in a numerical welding simulation, having a direct in- transformation plasticity in a numerical fluence on the developing stress state. Three different CCT diagrams for S355J2 steel simulation of laser beam welding of steel were employed to understand the influence of variations in CCT behavior on the nu- plate. The overall effect of phase trans- merical calculation of welding-induced residual stresses. The CCT diagrams were formations was to generate compressive constructed from transformation data contained in the Sysweld software database, longitudinal stresses in the fusion zone o measured dilatometric data from Gleeble experiments, and transformation data cal- and to shift the location of the maximum DC culated from the JMatPro software. The calculated transverse and longitudinal resid- tensile stress in the heat-affected zone < ual stress distributions provided a qualitative correlation only in comparison to ex- (HAZ). In an investigation of the influ- LU perimental measurements, with the largest deviation occurring near the weld ence of thermophysical and thermome- (/) interface. Overall, the results indicate a weak dependency of the calculated residual chanical material properties on the nu- LU stresses due to anticipated CCT variations. The most significant effect on the calcu- merical calculations, thermal expansion lated residual stresses was shown to be related to the proportion of formed marten- was shown to have the most significant in- DC site. It is suggested that CCT data of approximate accuracy is sufficient for reliable fluence; giving a direct proportional vari- calculation of welding-induced residual stresses. ation of the calculated distortions in both O the longitudinal and transverse directions (Ref. 11). In addition to the simula- mote brittle fracture, fatigue failure, and Introduction tion results, experimental development stress corrosion cracking (Ref. 3). of new filler metal compositions has An historical account of research re- During welding, residual stresses are demonstrated that a lower martensitic LU lating to weld residual stresses and dis- developed due to the local plastic defor- transformation temperature reduces tortions is provided by Dong (Ref. 4). mations created by the steep thermal gra- residual stresses by allowing the expan- 5 One of the initial studies to use the finite dient that occurs in the weld zone from lo- sion associated with the martensite trans- element (FE) method to study welding- calized heating and cooling (Ref. 1). Phase formation to compensate for the accu- induced residual stresses dates back to transformation strains, which are created mulated thermal contraction strains Ueda et al. in 1977 (Ref. 5). In recent from differences in crystal structure and (Ref. 12). A review of the metallurgical years, the on-cooling phase transforma- mechanical properties, also contribute to issues and modeling challenges associ- tion behavior has been integrated in FE the evolution of residual stresses during ated with calculation of welding-induced simulations of steel (Refs. 6-10). These welding (Ref. 2). Both the diffusive and residual stresses, with respect to ferritic studies have all shown the strong effect of displacive phase transformation mecha- power plant steels, is given by Francis et the austenite to martensite transforma- nisms are often accompanied by substan- al. (Ref. 13). tion on the final residual stress state. The tial strains, which greatly exceed elastic While the effect of on-cooling phase influence induced by the volume expan- strain values (Ref. 1). Residual tensile transformations and material properties stresses result in unwanted deformations variations have been established, informa- of the welded component, increase the r tion regarding the effect of variations in susceptibility to hydrogen-induced cold KEYWORDS CCT behavior has not yet been considered. cracking, and also combine with tensile Given the relatively wide composition stresses experienced during service to pro- Continuous Cooling ranges specified for certain alloys and the Transformation Diagrams heat-to-heat composition variations that /. CARON, S. S. BABU, andJ. LIPPOLD are with Residual Stresses do occur, significant differences in CCT be- Welding Engineering Program, The Ohio State Gas Metal Arc Welding havior can be expected. In steels it is well University, Columbus, Ohio. C. HEINZE, C. C-Mn Steels known that the martensite start (Ms) tem- SCHWENK, andM. RETHMEIER are with Divi- Welding Simulation perature is a strong function of the carbon sion V5 Safety ofloined Components, Federal In- content, and that the ferrite and bainite stitute for Materials Research and Testing (BAM), Berlin, Germany. transformation kinetics are known to be

WELDING JOURNAL V v-

i • ^wSS

; • 100 pm

Fig. 1 — Microstructure of S355J2 plate material following heat treatment Fig. 2 — Experimental weld schematic with plate dimensions in mm. Dotted line and prior to welding. Etched with 2% Nital. indicates location of residual stress measurements.

sensitive to alloying elements that decrease Furthermore, a detailed knowledge about 1 and 2, respectively. the driving force for austenite decomposi- the important aspects of the CCT behavior The chemical composition of the plate m tion, particularly carbon, manganese, helps to define the quality and the suitabil- material used in the welding experiments nickel, and chromium (Ref. 14). Also con- ity of a CCT diagram with respect to the cal- was determined through spark emission tributing to variability are the different ex- culation of welding-induced residual spectroscopy. The average composition g perimental and computational methods stresses. This information would allow an from three analyses is provided in Table 3. that are used to determine CCT diagrams. estimation of the required accuracy of CCT A tensile test conducted on the base plate z In welding, austenite inhomogeneity often data and is also necessary to benchmark the confirmed the yield strength and ultimate o occurs due to the inability of alloying ele- quality of the numerically calculated resid- tensile strength to be 363 MPa (53 ksi) and ments and precipitates to completely solu- ual stresses when considering phase trans- 488 MPa (71 ksi), respectively. The aver- tionize during the rapid weld thermal cycle. formation effects. age hardness of the as-received material m Thus, CCT diagrams constructed from was determined to be 144 HV10. 0) short-time holds at high temperatures in A stress-relief heat treatment, consist- Experimental Procedure o o m the austenite region are more appropriate ing of heating to 570 C (1058 F) at > for determining HAZ CCT behavior than 50C/min, holding at temperature for 3.5 the conventional CCT procedure of hold- The steel used for the welding experi- hours, and furnace cooling to ambient 33 ing on the order of an hour at a tempera- ments was S355J2 (1.0577), a German temperature, was applied to the plate ma- o ture slightly above the fully austenite (AQ}) standardized plain-carbon fine-grained terial before welding to reduce any preex- temperature (Ref. 15). construction steel with a minimum yield isting residual stresses. Figure 1 shows the L Knowledge of the effect of CCT varia- strength of 355 MPa (51 ksi). The chemi- microstructure of the experimental plate tions on the numerical calculation of resid- cal composition and specified minimum material following the stress-relief heat ual stress would enable an estimation of the mechanical properties for S355J2 plate treatment, which consisted of ferrite and deviations in the calculated results that can material thicknesses < 16 mm (0.63 in.), as pearlite with an average hardness of 138 be expected when using phase transforma- specified in the German DIN EN 10025 HV10, with no noticeable differences in tion data of unknown or reduced accuracy. standard (Ref. 16), are provided in Tables microstructure compared to the as-

Table 1 — Nominal Chemical Composition of Table 2 — Specified Minimum Mechanical Propert les of S355J2 Plate Material according to S355J2 Plate Material according to DIN EN DIN EN 10025-2:2004 10025-2:2004 (values in wt-%) Yield Strength (MPa) Tensile Strength (MPa) % Elongation V-Notch C Si Mn P S Impact Energy (J) s0.20 <0.55 <1.60 <0.035 <0.035 355 470-630 17 27 (at -20oC)

Table 3 - — Measured Chemical Composition of S355J2 Plate Material (values in wt-%)

C Si Mn P S Cr Mo Ni Al 0.14 0.20 0.67 0.00823 0.012 0.033 <0.01 0.0354 0.0354

Nb Ti V W Co B N Cu Fe 0.005 0.0023 0.00393 <0.01 <0.01 0.0003 0.007 0.0221 balance

J JULY 2010, VOL 89 received material. time, costs, and results I The individual plate dimensions for the (Ref. 19). The line of welding experiments were 500 mm (19.7 measurement across in.) length, 100 mm (3.93 in.) width, and 5- the weld region is rep- mm (0.197 in.) thickness containing a 60- resented schematically deg V-groove with joint edges milled. A in Fig. 2. single-pass complete-penetration gas metal arc (GMA) weld was conducted Experimental with G3Sil filler metal wire of 1.2-mm Results (0.05-in.) diameter, in accordance with DIN EN ISO 14341 (Ref. 17), using a Figure 3 shows the shielding gas mixture of 82% Ar and 18% experimental weld COj at a flow rate of 18 L/min (4.76 macrosection with the gal/min), in accordance with DIN EN ISO weld pool area out- 14175 (Ref. 18). Welding conditions con- lined, microstructures sisted of 261 A welding current, 30.4 V av- at the weld interface, erage arc voltage, 8.5 m/min (27.9 ft/min) and the HAZ mi- wire feed rate, and 0.4 m/min (15.7 crostructure from a lo- in./min) travel speed. This resulted in an cation that experienced Fig. 3 —A — Macrosection of experimental weld joint with weld interface approximate net heat input of 1 kJ/mm a peak temperature of highlighted; B — microstructure at weld interface, weld metal to the left, (25.4 kJ/in.). Type-K thermocouple wires 11590C(21180F)andat coarse-grained heat-affected zone (CGHAZ) to the right; C — HAZ mi- o with a diameter of 0.5 mm (0.02 in.) were t8/5 time of 30.0 s, where crostructure from location noted in (A). Etched with 2% Nital. used to acquire the temperature at posi- t8/5 is the cooling time tions on both the top and bottom of the from 800oC to 500oC. welded plate directly adjacent to the weld The experimental ther- joint. The experimental configuration mal cycles as measured on both the top and phase — Fig. 3B. The HAZ microstruc- provided a force-free support of the plate, bottom of the welded plate are provided in ture shown in Fig. 3C has a hardness of 162 permitting free shrinkage during the weld- Fig. 4A. A summary of the individual pa- HV10 and consists of a mixture of grain ing process and subsequent cooling. Addi- rameters for each measured thermal cycle is boundary ferrite, polygonal ferrite, Wid- tionally, a ceramic weld backing was used provided in Table 4. manstatten ferrite with aligned second for all conducted weld experiments. The transverse hardness distribution phase, and ferrite-carbide aggregate. The The residual stresses before and after across the weld region is shown in Fig. 5. minimum hardness values, which were welding were measured using an Xstress The peak hardness of 172 HV10 was below 140 HV10, were found to occur in 3000 Goniometer G3 X-ray diffractome- found to occur in the weld metal, with a the base metal region. ter. A 2-mm (0.08-in.) aperture was used, microstructure consisting of mainly Wid- The average residual stresses of the which provided a suitable balance between manstatten ferrite with aligned second plate material after heat treatment were

Table 4 — Summary of Individual Parameters for the Measured Thermal Cycles

Measurement Location Distance from Weld Centerline (mm) Peak Temperature ("C) t8/5 Cooling Time (s) 8.4 953 32 Top of Plate 8.9 795 36M 9.1 765 39M 3.9 1159 30 Bottom of Plate 4.9 1007 30 6.8 937 30

(a) Extrapolated tgy5 cooling times

WELDING JOURNAL -TZT

• 4-^—i- • • i • •a -it io « a (men)

Fig. 5—Hardness measurements taken along the top and bottom of the experimental weld plate.

J3 m 0) m Fig. 4 — Measured thermal cycles adjacent to the weld joint. A — Top of Fig. 6 — Residual stress measurements of experimental weld plate accord- plate; B — bottom of plate. ing to line of measurement shown in Fig. 2. > o measured to be 21 ± 47 MPa (3.0 ± 6.8 (0.5 in.) from the weld centerline. ating system. The most important simpli- ksi) in the longitudinal direction and 11 ± fications and assumptions of the simula- 45 MPa (1.6 ± 6.5 ksi) in the transverse di- Numerical Simulation Procedure tion are as follows: rection, obtained from 15 measurements. •Temperature-dependent, homoge- A complete, self-consistent welding sim- Measurements of both the longitudinal neous, and isotropic material proper- and transverse residual stresses after ulation that includes all relevant physical aspects is not yet available. Many cou- ties with consideration of phase trans- welding are given in Fig. 6. While a quali- plings are still unknown or not described formations. tative trend in residual stress is realized, o mathematically, and incorporation of all • A solidus temperature of 1440 C the relatively high error of measurement 0 aspects would result in a very complicated (2624 F) for validation of the weld joint of each of the points and the differences in model that is not realistically solvable. geometry. the measured values between opposite Furthermore, the available computational • No consideration of preceding process points equidistant from the weld center- abilities would be limiting for such a com- steps; the specimen is assumed to be line are noted. The maximum longitudinal plex and demanding task. However, not all geometrically ideal and totally stress residual stress of 333 ± 109 MPa (48.3 ± aspects need to be known with absolute free, and the weld reinforcement on the 15.8 ksi) was measured at a distance of certainty for reliable calculation and clar- top and bottom side are considered. 12.5 mm (0.5 in.) from the weld centerline. ification of individual effects (Refs. 20, • Phenomenological temperature field At an increasing distance from the weld, 21). Welding FE simulations have the abil- calibration using a combination of a the longitudinal residual stresses decrease ity to separate the influence of the various double-elliptical Goldak (Ref. 22) and a monotonically down to a stress-free range. metallurgical parameters and their effect 3D-conical Gauss heat source with The transverse residual stress is compres- on the calculated results. time-independent volumetric heat flux sive in all locations and is mainly constant All numerical simulation calculations density and no consideration of weld toward the outer plate region with a mini- in this study were performed with the com- pool convection. mum stress of -176 ± 64 MPa ( -25.5 ± mercial FE software "Sysweld" Version • Unified heat transfer on all outer surfaces 9.3 ksi) occurring at a distance of 12.5 mm 2008 on a standard PC with a Linux oper- with temperature-dependent radiative

JULY2010, VOL 89 Wi ' ' "U' '— u, T«nt III Fig. 7—Force-free support of the full model for the mechanical calculation. Approximately 90,000 nodes and 94,000 elements.

TOT • 1 i- \ 0 am B M MO cC \ - • i 4.:c 1 ;.:c DC 99 < 200 LU too (/) 0 • LU •• 1 1«0 1*1 1*2 i«3 DC c fmit O Fig. 8 — CCT diagrams. A — Sysweld metallurgical database; B — Gleeble dilatometry experiments; C — JMatPro TTT/CCT calculations.

losses according to Stefan-Boltzmann, a (0.015 in.) in the Z-X plane and 3 mm Thermal Analysis constant emission coefficient of E = 0.8, (0.12 in.) in the welding direction. The full constant convective losses of 4 W/mm2 model used for both the thermal and me- For the thermal analysis, the experi- (1.27 x 106 Btu/h-ft2), and an ambient chanical simulation consisted of approxi- mentally determined data were used to temperature of 20oC (680F). mately 90,000 nodes and 94,000 elements calibrate the heat source of the simulation. • Idealized clamping of the specimen with a linear basis function. Figure 7 ex- Two aspects were considered in the tem- using elastic constraints of 103 N/mm hibits the FE model geometry used in the perature field adjustment. First, the cross- (5715 Ibf/in.) for a force-free support. thermal welding simulation and the posi- section geometry of the simulated weld tion and the directions of the locked de- pool was correlated with both the size and Finite Element Model grees of freedom for the force-free sup- shape of the experimental macrosection of port. The influence of the mesh density on the weld joint. Second, the corresponding The FE model of the flat plates was the stiffness of the model was checked in temperature cycles in the HAZ were cor- meshed as a 3D model corresponding to advance. Consequently, in order to obtain related with the experimental measure- the experimentally determined tempera- an improved bending behavior of the ments, with emphasis given to peak tem- ture gradients. The minimum element mesh, an increase in the element size fur- perature and cooling time. Each of the length in the weld joint area was 0.37 mm ther from the weld was not applied. simulations was performed with an identi-

Table 5 — Characteristic Phase Transformation Parameters for Each CCT Diagram

CCT Diagram Phase Transformation Temperatures ("C) Martensite Temp. Range ("C) KM Coefficient Ferrite/Pearlite Bainite Martensite Martensite Start*") Start*") Start*') Finish Sysweld 730 630 420 98 322 0.01428 Gleeble 800 672 508 346 162 0.02843 JMatPro 847/714 634 451 237 214 0.02154

(a) Represents the highest temperature at which the phase is permitted to form.

WELDING JOURNAL Fig. 9 —A — Validation of the calculated temperature field by thermocouple measurements at top plate position; B — comparison of calculated weld pool outline and experimental macrosections observed at noted locations

physical and thermomechanical properties. The thermophysical and thermomechanical data in the Sysweld database were ac- quired at various temperatures by previous researchers (Ref. 23). For each of the simulations, an Acl temperature of 12TC 0 0 (1341 F) and an AC3 temperature of 867 C (15930F) were employed, as stated in the Sysweld material database for S355J2. The residual stresses in the weld metal were not considered in the analysis due to measurement uncertainties, the direct energy input in the respective elements, and the negli- gence of heat convection in the weld pool. J3 m Fig. 10 — Calculated phase fraction ofbainite at plate midsection for the Sysweld CCT data. Metallurgical Model 0) The general phase transformation m cal calibrated temperature field. previously calculated temperatures in the model incorporated in the Sysweld soft- > model. It is noted that this one-way cou- ware is derived from the Leblond model Mechanical Analysis pling, also referred to as "weak coupling," (Ref. 24) and generalized to account for o does not account for the effect of stress on Johnson-Mehl-Avrami kinetics (Refs. Available in the Sysweld software is the phase transformation behavior. Further- 25-28). The semi-empirical model allows ability to integrate the effect of metallur- more, there is no interaction between the for direct introduction of CCT and TTT gical phase transformations in welding latent heat generated by solid-state phase data and is represented by the following simulations. A thermal-metallurgical cal- transformations and the calculated tem- general equation for transformation of culation is first completed using the ther- perature field. phase i to phase j: mal properties of the material, the calcu- To perform accurate and detailed FE sim- dP. , w JP. {T\-P\ lated temperature field derived and ulations, the thermal and mechanical prop- -J- = n\T]F\t\ validated from the welding experiments, erties of the material must be known at high dt and the CCT behavior formulized mathe- temperatures. One of the advantages in se- matically. The thermal-metallurgicalcal- lecting the S355J2 alloy was the availability culation data are then used as an input to of complete material properties in the the mechanical calculation, which deter- Sysweld database, including metallurgical mines stresses and strains according to the phase transformation temperatures, metal- (1) transient and spatial distribution of the lurgical model parameters, and thermo-

Table 6 — Calculated Phase Percentages and Vickers Hardness Values for Each CCT Diagram, Referring to a Node with a Peak Temperature of o 1300 C and t8/5 = 28 s

CCT Diagram Phase, wt-% Calculated Vickers Hardness*1' rrite Bainite Martensite Sysweld 0.2 96 3.4 207 Gleeble 6.7 91 2.3 202 JMatPro 5.4 45.5 49 281

(a) Equations provided in Ref. 40.

JULY2010, VOL 89 tlwi,«MrngninMCCT CCT ccr

Fig. 11 — Calculated residual stresses as a function of CCT behavior. A — Transverse; B — longitudinal.

where equation (Ref. 29): transformation parameters were adjusted. = Pj,eq equilibrium fraction of phase j ob- (3) tained after an infinite time at tempera- Sysweld Database ture T; where o t = characteristic time constant for the re- P = proportion of martensite; The CCT information available in the action at temperature T; T = temperature; Sysweld database for S355J2 was derived DC from an experimentally determined weld- n = variable illustrating the reaction rate Ms = martensite start temperature; < at temperature T; and KM = Koistinen-Marburger coefficient ing-related CCT diagram (Ref. 30). The LU F = parameter representing cooling rate CCT diagram was determined by heating related to martensitic reaction rate. o (/) dependence. samples to a peak temperature of 1350 C The Ms and Mf temperatures are con- 0 o LU When temperature varies in time, (2462 F) and cooling linearly to 850 C sidered to be 0.01 and 0.99 phase fraction 0 Equation 1 expresses that P: exponentially transformed, respectively. (1562 F) before applying different cooling 0C rates to ambient temperature. The com- approaches P; eq with time constant equal Four phases are given consideration in to x. The metallurgical parameters x and n the model: austenite, ferrite-pearlite, bai- position stated in the Sysweld metallurgi- O are modeled as piecewise linear functions. nite, and martensite. The finish tempera- cal file is the nominal composition for For incorporation of experimentally de- ture of the phase transforming at higher S355J2 as given in the DIN EN 10025-2 termined CCT data, n is given a nominal temperature coincides with the start tem- standard and presented in Table 1 previ- value of 1 in the transformation tempera- perature of the phase transforming at a ously. The CCT diagram implemented in ture range and Equation 1 simplifies to lower temperature. the Sysweld metallurgical file is based on LU the chemical composition given in Ref. 30 dP l_ Metallurgical Model Inputs for the S355J2 CCT diagram. It is noted 5 ••F\T (2) that there is no direct composition adjust- dt x\T Rather than performing an arbitrary ment available in the Sysweld software to The parameters x and F are then man- adjustment of CCT behavior, three justifi- account for differences in CCT behavior ually adjusted to align the predicted phase able data sets were used as input to the nu- due to compositional differences. fraction values with those determined merical calculation: data available in the from the experimental CCT data. For in- Sysweld database, experimental data ac- Gleeble Dilatometry Experiments troduction of TTT data, parameters x and quired through Gleeble dilatometry tests, n are extracted for various temperatures and TTT/CCT predictions calculated A set of dilatometry experiments were and incorporated directly into the metal- from the JMatPro software. The thermo- conducted for S355J2 using a Gleeble lurgical model. physical and thermomechanical proper- 3800 thermal-mechanical simulator. A The martensitic transformation is ties were identical for the three simula- dilatometer was used to extract dilatation modeled using the Koistinen-Marburger tions; only the metallurgical phase vs. temperature data for several cooling rates. Solid cylindrical samples of diameter 5 mm (0.2 in.) and length 100 mm (3.9 Table 7 — Residual Stress Values at Ambient Temperature for Each CCT Diagram, Referring to a in.) were machined from the experimental 0 Node with a Peak Temperature of 1300 C and t8/5 = 28 s S355J2 base plate material. Samples were heated to a peak temperature of 1300oC CCT Diagram Transverse Longitudinal (23720F) at 100oC/s (180oF/s) and held at (MPa) (MPa) the peak temperature for 1 s before being Sysweld -175 434 cooled to 950oC (17420F) at a rate of Gleeble -224 436 250C/s (450F/s). The peak temperature of JMatPro -130 511 1300oC (23720F) was selected in order to allow for austenite grain growth, promoting a fully martensitic phase transforma-

WELDING JOURNAL (mm) i-rim i

Fig. 12 — Best agreement between experimental and calculated residual stresses. A — Transverse; B — longitudinal.

tion to occur at the fastest cooling rates (23720F) and an austenite grain size of 50 determine the Sysweld CCT diagram by achievable. Cooling to 950oC (17420F) was [im (0.002 in.), which was selected as an ap- previous researchers (Ref. 30). necessary in order to perform a helium gas proximate value for the CGHAZ region For the fastest cooling rates > 100oC/s quench without destroying the sample. (Ref. 39). The specific effect of peak tem- (180oF/s), all three CCT data sets predict m The samples were quenched from 950oC perature and austenite grain size is consid- a fully martensitic transformation. Bai- (17420F) at various linear cooling rates. ered for evaluation in subsequent research. nite is predicted to begin forming at cool- o o g The range of tg/5 times achieved was Consistent with the numerical determina- ing rates below 100 C/s (180 F/s), with 2.1-23.8 s, with the fastest cooling rates re- tion of metallurgical parameters outlined in the nose of the bainite curve similarly lo- z peated to achieve an average value of Sysweld, parameters T and n were deter- cated in each diagram. However, the bai- o transformation temperatures. The CCT mined from the numerical data and directly nite transformation kinetics and pre- determination was made in direct refer- incorporated in the Sysweld metallurgical dicted bainite phase fraction values differ ence to the dilatation data, microstruc- model. Since the predicted phase fractions greatly for the three diagrams. For a cool- m tural evidence, hardness measurements, were not directly available from the JMat- ing rate of 60oC/s (108oF/s), the Sysweld 0) and to published CCT data for S355J2 Pro data, Johnson-Mehl-Avrami calcula- database predicts the formation of 47% m (Refs. 30, 31). Following the testing, the tions consistent with the Sysweld metallur- bainite, while the Gleeble and JMatPro dilatation data was analyzed using a linear gical model were performed for individual data predict only 2 and 6% bainite, re- > least squares fitting routine to determine cooling rates to obtain the phase fractions. spectively. For a cooling rate of 10oC/s 33 the transformation temperatures and The calculation employed an additivity (180F/s), there is good agreement in the o phase fractions. The phase fraction values principle whereby continuous cooling rates predicted phase fractions between the determined from the dilatation data for were divided into a series of discrete Sysweld (89% bainite, 8% martensite) individual cooling rates were then used to isothermal steps, with the inclusion of a and Gleeble (9% ferrite, 85% bainite, 3% calibrate the metallurgical model parame- Scheil incubation period (Ref. 40). The cal- martensite) data, with the JMatPro data ters in the Sysweld software. culated phase fraction values for individual predicting significantly more martensite cooling rates were then used to calibrate the (5% ferrite, 29% bainite, 63% marten- JMatPro TTT/CCT Calculations metallurgical model parameters. site). Whereas ferrite-pearlite is predicted to begin forming at cooling rates in JMatPro is a commercially available Summary of CCT Diagrams the 30o-60oC/s (54o-108oF/s) range for software designed to calculate the proper- the Gleeble and JMatPro data, the for- ties and behavior of multicomponent alloys The three CCT diagrams generated mation of ferrite-pearlite is suppressed to (Ref. 32). One feature of JMatPro is the cal- from the mathematically formulized metal- cooling rates below 10oC/s (180F/s) for culation of TTT and CCT diagrams of lurgical data are presented in Fig. 8. From the Sysweld data. It is felt that the overall steels, Al alloys, Ni-based superalloys, and an analysis of the three CCT diagrams, vari- variability of the CCT diagrams investi- Ti alloys. The predicted TIT diagrams for ations are evident in the phase transforma- gated is sufficient to reveal the effect of steels are derived from the chemical com- tion temperatures, the location of the phase anticipated CCT variations on the calcu- position, austenitization temperature, and transformation regions, and the predicted lated residual stresses. austenite grain size (Refs. 33, 34). The in- phase fractions for individual cooling rates. corporated phase transformation model is The characteristic phase transformation pa- Numerical Simulation Results based on the model of Kirkaldy (Ref. 35) rameters for the three diagrams are pre- and validated with experimentally deter- sented in Table 5. The higher Ms tempera- Validation of the numerical simulation mined TTT and CCT diagrams (Refs. tures of the Gleeble and JMatPro data may with experimental data is a necessary re- 36-38). For the TTT calculation, inputs be attributed to the lower level of carbon quirement to ensure the quality of the cal- were the composition of S355J2 experi- (0.14 wt-%) in the experimental steel com- culated results. Figure 9A represents the mental plate material, as provided in Table pared to the carbon concentration (0.18 wt- comparison of a measured and calculated 3, an austenitization temperature of 1300oC %) of the S355J2 material that was used to thermal cycle, with the macrosection and

JULY2010, VOL 89 temperature field also shown. The peak largest compressive stresses exceeding higher yield strength associated with a temperatures of the simulation thermal -250 MPa (-36 ksi). The deviation be- higher proportion of martensite would cycles were interpolated to exactly match tween the Sysweld and Gleeble results are contribute to increasing the maximum po- the experimental peak temperatures. As a less than 20 MPa (3 ksi), except for the val- tential residual stress. result, there is some deviation in the exact ues directly adjacent to the weld interface Notwithstanding the noted differences distances from the weld centerline be- where larger deviations occur. The calcu- between the experimental and calculated tween experiment and simulation; how- lations based on the JMatPro CCT data residual stress values, a determination of ever, this deviation is in the range of the result in the highest longitudinal residual the effect of CCT variations on the calcu- temperature measurement uncertainty. stresses, reaching a peak above 500 MPa lated residual stresses is the main point of The experimental t8/5 cooling time was ap- (73 ksi) near the weld interface. At dis- investigation. As shown in Fig. 11, the cal- proximately 36 s for a peak temperature of tances of 10-30 mm from the weld center- culated residual stresses exhibit a similar 7950C (14630F). In comparison, the calcu- line, a plateau of approximately 300-350 qualitative distribution for each of the three lated thermal cycle for a peak temperature MPa (44-51 ksi) is noted, followed by a CCT diagrams investigated. The largest de- 0 0 of 795 C (1463 F) provided a t8/5 time of monotonic decrease to a stress-free level. viation between the three cases was found 32 s. The difference of 4 s represents a Table 7 provides a summary of the calcu- to occur in the HAZ region nearest to the 12.5% deviation. Regarding the assessed lated residual stress values for a node ad- weld interface. Referring to Table 7, the CCT diagrams, no significant microstruc- jacent to the weld interface. stress values calculated for a node nearest tural differences are expected for this de- to the weld interface vary from -224 to -130 viation. Additionally, Fig. 9B shows the Discussion MPa (-32 to -19 ksi) in the transverse di- calculated weld pool outline in compari- rection and 434 to 511 MPa (63 to 74 ksi) in son to experimental macrosections of the Comparing the experimental measure- the longitudinal direction. This represents a weld pool shape observed at 35-, 150-, and ments and calculated residual stresses, a relatively small deviation between the three 265-mm (1.4-, 5.9-, and 10.4-in.) distances qualitative correlation only was realized in cases, and suggests that only minimal losses from the beginning of the weld joint. The both the transverse and longitudinal di- in accuracy are to be expected for the level deviation between the average area of the rections, with the largest deviation occur- of CCT variations investigated in this study. experimental weld pool shape, repre- ring in the HAZ region nearest to the weld A microstructural comparison shows the sented by the area surrounded by the weld interface. The JMatPro CCT exhibited the most significant effect on the calculated interface, and the calculated weld pool best agreement with the measured trans- residual stresses to be related to the pro- o outline, represented by the area exceeding verse residual stress distribution — Fig. portion of formed martensite. The small de- DC the solidus temperature of 1440oC 12A. Considering the longitudinal resid- viation between the Sysweld and Gleeble (26240F), is approximately 9%. This devi- ual stresses, the Gleeble CCT provided stress distributions correlates with the < ation is within the range of deviation of the the best agreement with the experimental mcrostructural similarity between the two LU experimental weld pool macrosection values — Fig. 12B. The discrepancy in cases (Table 6), where less than 5% marten- (/) measurements. The validation of the nu- stress values may be attributed to the un- site is predicted to form in each case. For the LU merically calculated temperature field certainty associated with the residual JMatPro CCT case, 49% martensite is pre- DC represents both a good qualitative and stress measurements as noted previously, dicted to form in the microstructure, which quantitative correspondence between the simplifying assumptions of the numerical supports the larger deviation in stress distri- O experimental and simulation results. Fur- simulation, and significant differences be- bution in comparison to those calculated thermore, negligible differences were tween the phase percentages of the exper- with the Sysweld and Gleeble CCT data. found for both the maximum temperature imental microstructures and those pre- The higher martensite proportion for the and temperature gradient of the thermal dicted by the CCT data, as discussed in the JMatPro CCT was shown to decrease the cycles. Hence, the temperature field pro- following paragraph. compressive transverse stresses and in- vided ensured input data for the subse- Referring to Table 6, it can be seen that crease the tensile longitudinal stresses LU quent calculation of residual stresses.. the calculated Vickers hardness values are throughout the HAZ region. Specific in- Table 6 shows the calculated phase per- higher than the experimental measure- vestigation regarding the influence of the 5 centages and Vickers hardness values ments as shown in Fig. 5. The Sysweld and martensite transformation on the calcu- after complete cooling to ambient tem- Gleeble CCT resulted in calculated hard- lated residual stresses is planned for fu- perature for a HAZ node nearest to the ness values slightly above 200 HV, while ture work. weld interface experiencing a peak tem- the calculated hardness of the JMatPro perature of approximately 1300oC CCT was found to be 281 HV. The average Conclusions (23720F). The calculated hardness values measured hardness of the experimental were obtained from equations provided in microstructures in the weld metal and 1. A qualitative correlation only was re- Ref. 41. The phase percentages listed are CGHAZ regions was found to be 166 alized between the experimental residual valid for the weld metal and a major por- HV10. Using the equations in Ref. 41 as a stress measurements and the calculated tion of the HAZ, as shown in Fig. 10. This guide, the experimental microstructure residual stresses in both the transverse and kind of qualitative distribution applies for with this hardness value is estimated to longitudinal directions. The discrepancy all three investigated cases because of the consist of approximately 50% ferrite and in stress values is attributed to residual identical temperature field that was 50% bainite, assuming a negligible stress measurement uncertainty, simplify- employed. amount of martensite. Overall, the lower ing assumptions of the numerical simula- Figure 11 exhibits the calculated trans- hardness of the experimental microstruc- tion, and significant differences between verse and longitudinal residual stress dis- ture can be attributed to a higher propor- the phase percentages of the experimental tributions for each of the three CCT dia- tion of ferrite, as evidenced in Fig. 3B and microstructures and those predicted by grams considered in the numerical C. Due to its lower yield strength, a higher the CCT data. simulation. For all three cases, the trans- proportion of ferrite in the experimental 2. For the S355J2 steel investigated and verse residual stresses reach a maximum microstructure would contribute to lower- the employed numerical simulation ap- compressive stress at a distance of 10 mm ing the longitudinal residual stresses proach, there was shown to be an overall (0.39 in.) from the weld centerline, with measured near the weld interface in com- weak dependency of the calculated resid- the Gleeble CCT data resulting in the parison to the calculated stress values. The ual stresses due to anticipated variations

WELDING JOURNAL in CCT behavior. The maximum deviation 7. Taljat, B., Radhakrishnan, B., and 15B(2): 299-305. in the calculated stresses for the three Zacharia, T 1998. Numerical analysis of GTA 23. VoB, O. 2001. Investigation of factors' CCT diagrams investigated was -224 to welding process with emphasis on post-solidifi- significance on numerical simulation of welds. -130 MPa (-32.5 to -19 ksi) in the trans- cation phase transformation effects on residual PhD thesis. Technical University, Braun- stresses. Materials Science and Engineering A, schweig. Shaker. verse direction and 434 to 511 MPa (-63 to pp. 45-54. 24. Leblond, J. B., and Devaux, J. 1984. A -74 ksi) in the longitudinal direction. 8. Ferro, P., Porzner, H., Tiziani, A., and new kinetic model for anisothermal metallurgi- These results suggest that CCT data of ap- Bonollo, E 2006. The influence of phase trans- cal transformations in steels including effect of proximate accuracy, in combination with formations on residual stresses induced by the austenite grain size. Acta Metallurgica 32(1): detailed material property data, is suffi- welding process - 3D and 2D numerical mod- 137-146. cient for reliable calculation of welding- els. Modelling and Simulation in Materials Sci- 25. Johnson, W A., and Mehl, R. F 1939. induced residual stresses. ence and Engineering 14: 117-136. Reaction kinetics in process of nucleation and 3. The most significant effect of CCT 9. Mochizuki, M., and Toyoda, M. 2007. growth. Transactions AIME 135: 416^158. variations on the calculated residual stress Strategy of considering microstructure effect 26. Avrami, M. 1939. Kinetics of phase on weld residual stress analysis. Journal of Pres- change I: General theory. Journal of Chemical distributions was related to the proportion sure Vessel Technology 129: 619-629. Physics 7: 103-112. of formed martensite. A higher martensite 10. Dean, D., and Hidekazu, M. 2006. Pre- 27. Avrami, M. 1940. Kinetics of phase proportion was shown to decrease the diction of welding residual stress in multi-pass change II: Transformation-time relations for compressive transverse stresses and in- butt-welded modified 9CR-1MO steel pipe random distribution of nuclei. Journal of Chem- crease the tensile longitudinal stresses considering phase transformation effects. Com- ical Physics 8: 212-224. throughout the HAZ region. putational Materials Science 37: 209-219. 28. Avrami, M. 1941. Kinetics of phase 11. Schwenk, C, Rethmeier, M., Dilger, K., change III: Granulation, phase change, and mi- Acknowledgments and Michailov, V. 2007. Sensitivity analysis of crostructure. Journal of Chemical Physics 9: welding simulation depending on material prop- 177-184. The authors gratefully acknowledge erties value variation. Mathematical Modelling of 29. Koistinen, D. P., and Marburger, R. E. the financial support for this research Weld Phenomena 8, eds. H. K. D. H. Bhadeshia, 1959. A general equation prescribing the extent from the German Federal Ministry of E. Kozeschnik, and H. Cerjak, pp. 1107-1128. of the austenite-martensite transformation in Verlag der Technischen Universitat Graz. pure iron-carbon alloys and plain carbon steels. Economics and Technology (BMWi) 12. Payares-Asprino, M. C, Katsumoto, H., Acta Metallurgica pp. 59-60. within the framework program of the "In- and Liu, S. 2008. Effect of martensite start and 30. Seyffarth, P., Meyer, B., and Scharff, A. novation with Norms and Standards finish temperature on residual stress develop- 1992. Compendium of Welding ZTU Photo- m (INS)" coordinated and conducted by the ment in structural steel welds. Welding Journal graphs. Deutscher Verlag fiir SchweiBtechnik German Institute for Standardization (87)11: 278-s to 289-s. DVS-Verlag GmbH. g (DIN). The respective INS-project, 13. 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