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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING AND ALLIED PROCESSES, INCLUDING JOINING, BRAZING, SOLDERING, CUTTING, AND THERMAL SPRAYING The Driving Force in LOtifte Welding tivi

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Circle No. 41 on Reader Info-Card SEE YOUR PROCESSED IMAGE ON-SITE IN LESS THAN A MINUTE. KODAK INDUSTREX Digital Systems for Non-Destructive Testing offer portable solutions that let you see if you've got what you need before you leave- saving you time, money, and effort. Plus, our legendary global service and support means you're covered anywhere the job takes you. Visit www.kodak.com/go/ndtproducts to see the full line of INDUSTREX Digital Systems. For a personal demonstration, call 877.909.4280, or e-mail us at [email protected].

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Circle No. 33 on Reader Info-Card THE EXTREME LIGHTWEIGHT WELDING HELMET BY JROCSON

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Circle No. 30 on Reader Info-Card WE VE LOST WEIGHT. HHVE YOU

FOR MORE INFORMATION, VISIT WWW.JRCK50NPR0DUCT5.COM/HRL0 X CONTENTSAugust 2006 • Volume 85 • Number 8 AWS Web site http://www.aws.org Features Departments Single-Sided Resistance Spot Welding for Auto Body Assembly Washington Watchword 4 Hyundai Motor Co. explores use of single-sided resistance Press Time News 6 spot welding for difficult-to-access parts Y. Cho et al. Editorial 8 News of the Industry 12 Resistance Spot Welding of Coated High- Strength Dual-Phase Steels Aluminum Q&A 16 Advanced high-strength steels offer automobiles the Brazing Q&A 18 advantages of higher strength and greater fuel efficiency M. D. Tumuluru Technology 20 New Products 22 Reducing Exposure to Hexavalent Chromium in Welding Fumes Navy Joining Center 53 Methods are given to help manufacturers comply with Coming Events 54 OSHA's new standard for lower exposure to hexavalent chromium Welding Workbook 58 S. R. Fiore Society News 59 Tech Topics 64 What You Need to Know About Remote Laser Welding Guide to A WS Services 78 A look at how remote laser beam welding differs from GTAW Best Practices 80 conventional laser welding and how it can be used for a variety of manufacturing applications New Literature 84 K. Klingbeil Personnel 86 Simulation Software Helps Automakers Classifieds 89 Simulation software considers the metallurgical, electrical, Advertiser Index 92 mechanical, and thermal processes involved with resistance welding and calculates their effects N. Scotchmer

Aluminum GTAW Basics These tips can help you produce better aluminum gas tungsten arc welds M. Sammons

Welding Research Supplement 163-s Evaluation of Chemical Composition Limits of GMA Welding Electrode Specifications for HSLA-100 Steel An algorithm was used to evaluate chemical composition limits of selected GMAW electrode specifications for Welding Journal (ISSN 0043-2296) is published potential application to welding HSLA-100 steel monthly by the American Welding Society for K. Sampath and R. Varadan $120.00 per year in the United States and posses sions, $160 per year in foreign countries: $7.50 per single issue lor AWS members and $10.00 per sin 174-s Using a Hybrid Laser Plus GMAW Process for gle issue for nonmembers. American Welding So Controlling the Bead Humping Defect ciety is located at 550 NW LeJeune Rd„ Miami, FL A defocused laser beam applied in front of a GMAW 33126-5671: telephone (305) 443-9353. Periodi cals postage paid in Miami, Fla., and additional mail pool helped suppress formation of bead humping defects ing offices. POSTMASTER: Send address changes H. W. Choi et al. to Welding Journal. 550 NW LeJeune Rd„ Miami, FL 33126-5671. 180-s End Point Detection of Fillet Weld Using Readers of Welding Joura/may make copies of ar Mechanized Rotating Arc Sensor in GMAW ticles for personal, archival, educational or research A geometrical sensing model was developed to detect purposes, and which are not for sale or resale. Per the end points of joints in GMA fillet welds mission is granted to quote from articles, provided customary acknowledgment of authors and W.-S. Yoo et al. sources is made. Starred (*) items excluded from copyright.

WELDING JOURNAL WASHINGTON BY HUGH K. WEBSTER WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE

H-1B Visas Max Out; Program Problems Reported The Pipeline and Hazardous The annual cap on H-1B visas for highly skilled foreign work Materials Safety Administration is ers for fiscal year 2007 was reached as of June 1. This means that the earliest start date for which an employer can seek an H-1B updating its pipeline safety regulations visa for a foreign worker is October 1, 2007, the start of the next by adopting 38 revised industry techni fiscal year, though employers could file petitions for those visas as early as April 1. This is the second year in a row that the H- cal standards, thereby allowing 1B cap has been reached before the start of the fiscal year. pipeline operators to use current tech The H-1B temporary visa program allows employers to bring highly skilled foreign workers into the United States to fill jobs nologies, materials, and practices. requiring specialized expertise. Changes of employment for cur rent H-1B workers or extensions of their visa terms are not sub ject to the annual cap, nor are such visas for those who would be employed at universities or at nonprofit or governmental research cent report on U.S. economic competitiveness by the National organizations. Academy of Sciences and is consistent with the Administration's American Competitiveness Initiative. It also represents one of In a related development, the General Accounting Office has the few significant legislative efforts with widespread bipartisan issued a report that expresses concern over a lack of government support. oversight of the H-1B program and alleges widespread failure of employers to strictly abide by the restrictions of H-1B visas, in cluding payment of a market wage to H-IB workers. The report, "H-1B Visa Program: More Oversight by Labor Can Improve New Mine Safety Provisions Signed into Law Compliance with Program Requirements," is available at www.gao.gov. The Mine Improvement and New Emergence Response Act has become law. It will increase penalties, promote safety re search, and improve emergency response. The higher civil and criminal penalties for mine owners are expected to become ef Use of Nonconsensus Standards by fective by the end of 2006. Department of Labor Addressed

Legislation has been introduced in the U.S. House of Repre sentatives that would prohibit the use of nonconsensus standards Government Pipeline Standards Updated by the Department of Labor, including the Occupational Safety For the first time since 2004, the Pipeline and Hazardous Ma and Health Administration (OSHA) and the Mine Safety terials Safety Administration within the Department of Trans Administration. portation is updating its pipeline safety regulations by adopting The bill is sponsored by Rep. Norwood, chairman of the House 38 revised industry technical standards, thereby allowing pipeline Education and Workforce Subcommittee on Workforce Protec operators to use current technologies, materials, and practices. tion, and would prohibit adoption or incorporation by reference The technical standards adopted address areas such as purging of a nonconsensus standard in any rule, regulation, guideline, or pipelines and handling flammable and combustible liquids. standard, and would prohibit OSHA from approving standards in states with their own occupational safety and health programs The final rule incorporating these standards took effect July 10. unless the standards are reached by consensus. This legislation would impact, in particular, Threshold Limit Values (TLVs) established by the American Conference of Gov Free Trade Agreement Progress ernmental Industrial Hygienists (ACGIH). ACGIH has been crit in Central America icized for refusing to use an open, consensus-based process for setting TLVs. Honduras and Nicaragua have now implemented the Domini OSHA Administrator Edwin G. Foulke Jr. has publicly stated can Republic-Central America Free Trade Agreement (DR- that OSHA is working to address concerns regarding the use of CAFTA), joining El Salvador. Guatemala and the Dominican nonconsensus standards, but has not pledged to stop their use Republic are implementing inspection procedures before they altogether. can join, and Costa Rica has not yet signed. DR-CAFTA is the largest free trade agreement in more than Competitiveness Bills Progress a decade. It is expected to eliminate 80% of tariffs on U.S. goods exported to the region immediately and phase out the remaining Three bills designed to advance U.S. economic competitive 20% over the next several years. ness by strengthening math and science education and research programs have been unanimously approved by the House Sci ence Committee — The Science and Mathematics Education for Competitiveness Act (H.R. 5358), The Early Career Research Act (H.R. 5356), and The Research for Competitiveness Act Contact the A WS Washington Government Affairs Office at (H.R. 5357). 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail This legislation reflects recommendations contained in a re- [email protected]; FAX (202) 835-0243.

AUGUST 2006 They trusted ESAB to provide the technology to create alternative energy solutions. You can trust us for the innovative technology to meet your welding and cutting needs."

Circle No. 27 on Reader Info-Card WELDING I CUTTING I FILLER METALS PRESS TIME NEWS WELPAM? Nominations Sought for Image of Welding Awards Publisher Andrew Cullison Editorial The American Welding Society, Miami, Fla., is accepting nominations for its Fourth Editor/Editorial Director Andrew Cullison Annual Image of Welding Awards. The awards recognize individuals and organizations Senior Editor Mary Ruth Johnsen that have shown exemplary dedication to promoting the image of welding in their com Associate Editor Howard M. Woodward munities. Awards will be presented in seven categories: Individual; AWS Section; Large Assistant Editor Kristin Campbell Business (200 or more employees); Small Business (less than 200 employees); Distribu Peer Review Coordinator Erin Adams tor (welding products); Educator; and Educational Facility. To nominate an individual or organization for an award, e-mail a description of the Publisher Emeritus Jeff Weber nominee's qualifications to Adrienne Zalkind, [email protected], or mail your nomina tion to AWS Image of Welding Awards, 550 NW LeJeune Rd., Miami, FL 33126. In Graphics and Production clude your name, address, phone number, and e-mail address. Managing Editor Zaida Chavez The deadline for submitting a nomination is September 1, 2006. Senior Production Coordinator Brenda Flores The winners will be selected by members of the Welding Equipment Manufacturers Committee (WEMCO), an AWS standing committee comprised of executives from the Advertising welding industry. National Sales Director Rob Saltzstein The Image of Welding Awards presentation ceremony will be held during the FABTEC Advertising Sales Representative Lea Garrigan Badwy International & AWS Welding Show, scheduled for Oct. 31-Nov. 2, 2006, Georgia World Advertising Production Frank Wilson Congress Center, Atlanta, Ga. Subscriptions Leidy Brigman NASA Announces Crew Launch Vehicle [email protected] Program Support Contract American Welding Society NASA has recently selected MTS Systems Corp., Eden Prairie, Minn., to support the 550 NW LeJeune Rd„ Miami, FL33126 agency's Crew Launch Vehicle Program. (305) 443-9353 or (800) 443-9353 The contract includes engineering design, fabrication, delivery, installation, and ac ceptance testing of a robotic friction stir welding system, a 6-axis machine for friction Publications, Expositions, Marketing Committee stir welding using conventional fixed, auto-adjustable, and self-reacting pin-tool tech R. D. Smith, Chair nology intended for use as a manufacturing development tool for the agency's Crew The Lincoln Electric Co. D. L. Doench. Vice Chair Launch Vehicle Program. Hobart Brothers Co. The process may potentially be used as a production welding tool in the manufacture J. D. Weber. Secretary and assembly of large-scale launch vehicle components. Contract options are also in American Welding Society cluded for a panel welding machine, joint tracker, platform, and a second robotic fric R. L. Arn. WELDtech International tion stir welding system. T. A. Barry, Miller Electric Mfg. Co. The maximum value of the firm, fixed price contract is approximately $9 million; the R. Durda, The Nordam Group maximum period of performance is 25 months. J. R. Franklin, Sellstrom Mfg. Co. J. Horvath, Thermadyne Industries U.S. Steel Fairfield Works Opens New Maintenance R. G. Pali, I P. Nissen Co. J. F. Saenger Jr., Consultant Training Center S. Smith, Weld-Aid Products Fairfield Works of United States Steel Corp., Fairfield, Ala., held a ribbon-cutting H. Castner. Ex Off., Edison Welding Institute ceremony on June 20 to celebrate the opening of a new Maintenance Training Center. F. Luening, Ex Off., Bolder Thyssen Welding USA The center occupies 11,000 square feet in the Flintridge Building, which was remodeled D. C. Klingman, Ex Off., The Lincoln Electric Co. D. J. Kotecki, Ex Off., The Lincoln Electric Co. to accommodate classrooms and labs and to expand an existing in-plant welding lab. . G. Kvidahl, Ex Off., Northrup Grumman Ship Systems For the Maintenance Technician program, sixty-three courses and associated hands- . E. Lawson, Ex Off., ESAB Welding & Cutting Products on exercises were developed. To successfully complete the program, students will be re E. D. Levert Sr, Ex Off, Lockheed Martin quired to demonstrate proficiency in 30 mechanical modules or 33 electrical modules. E. C. Lipphardt, Ex Off., Consultant Classes began on June 5. They are being taught by current Fairfield Works employ S. Liu, Ex Off., Colorado School of Mines ees who have undergone an extensive three-tiered Train the Trainer program, consisting R. W. Shook. Ex Off, American Welding Society of observing training activities at U.S. Steel's Gary Works in Indiana, a three-day train D. R. Wilson. Ex Off., Wilson Industries ing seminar conducted at Fairfield Works, and several months of close observation and coaching by a training consultant. Applied Manufacturing Technologies Acquires Tur-Tech Applied Manufacturing Technologies (AMT), Inc., Orion, Mich., a supplier of fac Copyright © 2006 by American Welding Society in bolh printed and elec tronic formats. The Society is not responsible for any statement made or tory automation design, engineering, and process consulting services, has completed its opinion expressed herein. Data and information developed by the authors acquisition of Tur-Tech (TTI), Inc., a Troy, Mich., based design and engineering house. of specific articles are for informational purposes only and are not in tended for use without independent, substantiating investigation on the The acquisition will expand the company's overall mechanical design capabilities, part of potential users. particularly in the area of automotive body shop weld systems and tooling design. William Turley, Tur-Tech's founder and president, will continue in a consulting role for AMT. The company has assumed the TTI business, assets, and employees effective June 5, BPA 2005. The business operates as part of AMT's Design Group, located in the company's headquarters in Orion, Mich.

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Officers Build Your Welding Legacy President Damian J. Kotecki The Lincoln Electric Co.

Vice President Gerald D. Uttrachi As chair of the Education Scholarship Committee for several years, I have witnessed WA Technology, LLC the generosity of AWS members. You contribute funds through personal and corporate Vice President Gene E. Lawson endowments to the National Scholarships, you make personal donations and endow ESAB Welding & Cutting Products ments to Section scholarships, and you purchase raffle tickets and bid on silent auction items at the FABTECH International & AWS Welding Show. You also donate personal Vice President Victor Y. Matthews and business items for these fund-raising events. For all that you have contributed — The Lincoln Electric Co. thanks! Treasurer Earl C. Lipphardt The benefits of your contributions are highlighted in the stories about national schol Consultant arship recipients featured in the Welding Journal, or in the appreciation letters local Sec tions receive from students who truly value the funds provided to further their welding Executive Director Ray W. Shook educations. The best reward is to see students leverage their welding education into re American Welding Society warding jobs with a great future. A recent graduate from Utah State University shared his excitement in finding a welding engineering job in Indiana and thanked the Utah Section and District 20 for their scholarship assistance. Directors But, there are far more scholarship applicants than funds. To address this gap, the T. R. Alberts (Dist. 4), New River Community College AWS Foundation is moving forward with its capital campaign, Welding for the Strength of B. P. Albrecht (At Large), Miller Electric Mfg. Co. America, with programs that provide you with opportunities to contribute to the future of welding. For a national scholarship endowment of $100,000 you will generate an an O.Al-Erhayem (At Large), JOM nual National Scholarship of $5000 or two $2500 scholarships. Through the generosity A. J. Badeaux Sr. (Dist. 3), Charles Cty. Career & Tech. Center of personal and corporate donors, we currently have 20 National Scholarships as well as K. S. Baucher (Dist. 22), Techmcon Engineering Services, Inc. a unique National Scholarship for the winner of the SkillsUSA welding competition. Section Scholarship endowments of $50,000 generate an annual Section Scholarship of J. C. Bruskotter (Dist. 9), Bmskotter Consulting Services $2500. Currently, we have two such endowments. C. F. Burg (Dist. 16), Ames Laboratory IPRT Our District Named Scholarship program is the newest endowment opportunity. It N. M. Carlson (Dist. 20). Idaho National Laboratory has a regional focus with three levels of giving. The gold level involves an endowment of H. R. Castner (At Large), Edison Welding Institute $25,000 to generate an annual $1250 scholarship; the silver level generates an annual $750 scholarship for an endowment of $15,000; the bronze level gift of $10,000 provides N. A. Chapman (Dist. 6), Entergy Nuclear Northeast an annual gift of a $500 scholarship. You can tailor your scholarship offering to address S. C. Chappie (At Large), Consultant areas of welding education and regional student needs of deep interest to you. For ex N. C. Cole (At Large), NCC Engineering ample, your scholarship can focus on schools offering welding certificate, associate, or J. D. Compton (Dist. 21). College of the Canyons bachelor's degree programs, on assisting your region's welders to complete national welding certification programs, or on providing financial assistance to students with L. P. Connor (Dist. 5), Consultant unique educational needs. You and the AWS Foundation will build a scholarship around J. E. Greer (Past President), Moraine Valley C. C. the legacy you want to establish to benefit the workforce and economy where you live. M. V. Harris (Dist. 15), Reynolds Welding Supply With your assistance, we can impact welding education opportunities at the national, R. A. Harris (Dist. 10), Penton Publishing Co. Section, and regional levels, and increase our level of scholarship support for the stu dents who will benefit each year from your welding W. E. Honey (Dist. 8), Anchor Research Corp. __^_,____^^^__ legacy. Please contact the AWS Foundation at D. C. Howard (Dist. 7), Ornament Technologies Corp. *"- JP ^Htal (800/305)443-9353, ext. 212, to explore ways you can J. L. Hunter (Dist. 13), Mitsubishi Motor Mfg. of America, Inc. -•*•* JEA^^B build your unique welding legacy. J. L. Mendoza (Dist. 18), City Public Service S. P. Moran (Dist. 12), Miller Electric Mfg. Co. T. M. Mustaleski (Past President), Consultant R. L. Norris (Dist. 1), Merriam Graves Corp. T. C. Parker (Dist. 14), Miller Electric Mfg. Co. 0. ?. Reich (Dist. 17), Texas Stale Technical College at Waco W. A. Rice (At Large), OKI Bering Inc. Nancy M. Carlson Chair, A WS Education Scholarship Committee E. Siradakis (Dist. 11), Airgas Great Lakes K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv. P. F. Zammit (Dist, 19), Brooklyn Iron Works, Inc.

AUGUST 2006 1 l«*# ^^'ttJL '' ICC k,,,.,: 0 *tr* .your operation by f B attending the trade

• s,r>^ '< show with everything you need to boost * T productivity and achieve maximum performance.

Nothing compares to seeing technology in action. With nearly 2,000 pieces of equipment powered up on the show floor, the FABTECH International & AWS 0 i Welding Show provides the ultimate "hands-on" experience. It's the best place to evaluate new products, problem-solve, network with peers, and upgrade job skills.

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Circle No. 13 on Reader Info-Card \:

October 31 - November 2, 2006 • Georgia World Congress Center • Atlanta, GA USA Don't be left up in the air. Ground yourself in knowledge of the latest research findings and practical applications of welding in aircraft and aerospace environments. Join an outstanding team Z^^ : '§„ of experts from academia and industry to explore the state of the art in aircraft and space technology. This conference is a compelling opportunity forairframe designers, suppliers, researchers, educators, and administrators involved in aircraft procurement and construction. September 19-20,2006 Dayton, Ohio American Welding Society Welding is gaining importance in the military, commercial, and general aircraft industries. Three technologies in particular are leading the way: friction stir welding, the fiber laser, and additive manufacture. At this major AWS conference in Dayton, attendees will learn the latest about welding processes that are beginning to compete with rivets as the primary means of joining aluminum in fuselage and wing structures, and about the many welding processes being used to build engine parts and other high- performance components "from the ground up."

An Update on the How the Effects of Alternating Welding of Superalloys for Eclipse 500 Aircraft Shielding Gases in Arc Welding Aerospace Applications Brent Christner, Manager, M&P Improve Weld Quality and Donald J. Tillack, Tillack Engineering, Eclipse Aviation Productivity Metallurgical Consulting, Inc. Young H. Chang, Vice President, Bushitol Additive Manufacturing for Corp. The Welding and Aerospace Applications Additive Manufacturing Mary E. Kinsella, PhD, Senior Materials Friction Stir Welding and Research Capabilities of Research Engineer, Materials and Processing at the National Canada's Institute for Manufacturing Directorate, Air Force Institute for Aviation Research Aerospace Research Research Laboratory Dr. Dwight Burford, Senior Research Dr. Mohammad Jahazi, Manager, Scientist, Director, Advanced Joining Operations, Forming and Joining of Additive Manufacture and Lab, National Institute for Aviation Metallic Products, Institute for Welding Developments at Research, Wichita State University Aerospace Research Southern Methodist University Dr. Radovan Kovacevic, Director, Fiber Laser Welding Advanced Fusion Based Research Center for Advanced Dr. Harald Kohn, Head of Dept. Industrial Joining Processes Manufacturing, Southern Methodist Applications, BIAS Bremer Institut fur Israel Stol, Senior Manufacturing University angewandte Strahltechnik GmbH Specialist, Joining and Assembly, Aluminum Company of America; Dr. Ultrasonic Welding of The LENS System for Additive Richard P. Martukanitz, Applied Aluminum and Other Manufacture Research Laboratory, Pennsylvania Aerospace Alloys Robert P. Mudge, President, RPM & State University; and Kyle L.Williams, Karl Graff, Senior Engineer, Edison Associates, Inc. Senior Welding Technologist, Aluminum Welding Institute Hybrid Laser+GMA Welding Company of America Friction Stir Spot Welding of Titanium Electron Beam Welding on the William J. Arbegast, Director, Advanced Paul Denney, Technology Leader for F-22 Fighter Plane Materials Processing and Joining Lasers, Edison Welding Institute James K. McClaflin, Welded Side of Laboratory, South Dakota School of Body Project Manager, Boeing Mines and Technology Strategic Planning for Successful New Manufacturing Integrated Defense Systems Free Form Deposition of Technology Implementation Ti 6AI-4V Dave Reynolds, Consultant Dr. Kevin T. Slattery, Senior Principal Engineer, Boeing Phantom Works

AWS Welding in Aircraft and Aerospace Conference Dayton, Ohio • September 19-20,2006 To register or to receive a descriptive brochure, American Welding Society call (800) 443-9353 ext. 224, (outside North America, call 305-443-9353), or visit Founded In 1919 to advance the science, technology and application of welding and allied processes Including www.aws.org/conferences joining, brazing, soldering, cutting and thermal spraying. Circle No. 7 on Reader Info-Card NEWS OF THE INDUSTRY ASU Now Offering Technical Certificate in Welding

A technical certificate in welding is now offered at Arkansas State University-Searcy, a technical campus of ASU-Beebe. This program will be offered through ASU- Searcy's Area Career Center on the Bald Knob Public School campus. Starting this month, classes will meet Mon day through Thursday from 1 to 7 p.m. The certificate in welding can be earned in one year, with the option to earn an associate's degree in an additional year. All types of welding are covered in this program, including shielded metal arc weld ing, gas metal arc welding, gas tungsten arc At Arkansas State University-Searcy, a tech welding, and metal fabrication. nical campus of ASU-Beebe, a technical cer In addition, this program is available to tificate in welding will be offered beginning part-time students. Individual classes may be this month. Pictured on the above is student taken, as well as classes for continuing edu Mary Turner performing gas tungsten arc cation credits. welding. On the right is student Donald For more information or to enroll, contact Thomason performing shielded metal arc the Office of Student Services at (501) 207- welding on pipe. 4014.

Thermal Dynamics' Plasma Demo Trucks Resultslblog. Short for Weblog, blog is an on-line diary where au Dispatched throughout the United States thors can share their ideas, opinions, and other information. The company is inviting people who work in the manufactur ing, fabrication, or construction welding industries to share their views on issues affecting their businesses, or on the welding in dustry in general.

Wire Harness Manufacturer Cuts Splicing r Time Using Ultrasonic Technology

Thermal Dynamics, St. Louis, Mo., has recently introduced its Plasma Demonstration Truck Program. Six custom-designed and -equipped trucks have been dispatched throughout the United States to demonstrate the technology available in manual plasma arc cut ting machines. A factory-trained plasma demonstration specialist will accompany each truck to all trade shows and distributor visits. In addition, the trucks are equipped with a custom-designed fuse panel, hand-made cutting table, a Magnum 35-kVdiesel generator, an air compressor, and the full family of the company's CUTMAS- TER ISeries manual plasma cutting systems.

Miller Weblog Encourages Viewers to Sound Off on Welding Industry Issues Since the SpliceRite'" wire splicers have been installed at J&M Prod ucts, its director of manufacturing reports the company has cut splic Miller Electric Mfg. Co., Appleton, Wis., has created a cor ing time by 60%. The product uses high energy transfer throughout porate welding blog called Viewpoints at www.MillerlVelds.com/ the weld cycle.

AUGUST 2006 Sonobond Ultrasonics, West Chester, Pa., recently announced its ultrasonic splicing technology has reduced production time for a manufacturer of automotive wire harnesses. This is based

• • on information received from Curt Reynolds, director of manu The Ultrasonic facturing at J&M Products in San Fernando, Calif. Reynolds re Robotic Torch ports that the company has cut splicing time by 60% since in UltraCleaner cleaning station is stalling the Splice Rite™' wire splicers. I the first non- The company's research showed that this ultrasonic technol he Spatter Solution mechanical cleaner ogy quickly splices wire bundles and eliminates the need to crimp, that will automatically clip, solder, or dip in order to make strong, high-quality wire remove spatter from connections. any robotic GMAW1 torch FreightCar America Lands Coal Car Order from Norfolk Southern

Norfolk Southern Railway Co. has committed to purchase 1600 coal cars from FreightCar America, Inc., Chicago, 111. The order is comprised of 400 AutoFlood 111™ aluminum bottom discharge coal cars and 1200 hybrid stainless steel/aluminum coal gondola cars. The company will begin delivery in the first quarter of 2007 s Cleans, Cools and Coats to extend from its Roanoke, Va., railcar production facility, and plans to consumable life complete the order in calendar 2007. / Simple installation and programming The hybrid stainless steel/aluminum car is a new design de veloped and prototyped by the company in conjunction with Nor s Cleans all types and sizes of nozzles folk Southern to address the transportation requirements of east / Limit switch or robot I/O activated ern coal. S Non-contact, no consumable damage Hall of Fame Racing Partners with •f No moving parts to replace Lincoln Electric IWE - International Wire Exchange Ph. (248) 519-5068 'E-Mail: [email protected] Hall of Fame Racing has teamed with Joe Gibbs Racing and Web: www. iwexchange. com/ultracleaner The Lincoln Electric Co. to fabricate and field NASCAR Nextel Circle No. 35 on Reader Info-Card

OUR GRADUATES ARE IN 6REAT DEMAND. Of the few schools that offer underwater welding certification, the College of Oceaneering'sprogram is one of the most comprehensive available anywhere. As a College of Oceaneering certified WeldTech™ your skills and expertise put you in high demand from underwater construction companies the world over. EARN AN ASSOCIATE OF SCIENCE DEGREE IN MARINE TECHNOLOGY. You can decide how far you want to go in your career. Our training qualifies you for a fully-accredited degree. SEE IF YOU QUALIFY. There are age, academic and personal requirements, including stamina, perseverance and a commitment to succeed. Call us or log on to see if you qualify. Then dive in.

COLLEGE OF OCEANEERING A Division of National Polytechnic College of Engineering and Oceaneering FOR MORE INFO FB0O432HWE WWW.NATP0LY.EDU An affiliate of the National University System

Circle No. 18 on Reader Info-Card WELDING JOURNAL Tower Tech Systems Begins Production on Large Wind Energy Support Structures

Tower Tech Holdings, Inc., Manitowoc, Wis., recently an nounced its wholly owned subsidiary, Tower Tech Systems, Inc., has begun production on an increased order of 34 large Wind Tower Support Structures for Gamesa Eolica, a large supplier of wind power systems. The letter of intent, executed in May, confirmed Gamesa Eolica's purchase of 22 towers from the company. Tower Tech has begun manufacturing those, plus an additional 12 towers added during negotiations. The four-section towers are 257.4 ft tall when erected. Also, each has a combined calculated weight of 373,978 lb. Twenty-two towers, and the wind systems that they will support, The NASCAR No. 96 DLP HDTV® Chevrolet crew relies on will be deployed as the first phase of the GSG wind energy farm Lincoln welding machines for its fabrication needs. near Sublette, 111. The multiphase, utility-scale wind project, under current development, will place wind turbines on 60 different wind Cup racing cars. farms around Sublette, West Brooklyn, Mendota, and Southern Hall of Fame Racing Managing Partner Bill Saunders and Lee Counties in Illinois. The agreement calls for the additional 12 Partners Roger Staubach and Troy Aikman, former Dallas Cow towers to be deployed at a wind energy farm in Texas. boys quarterbacks, selected Terry Labonte and Tony Raines to be their codrivers in the 2006 NASCAR Nextel Cup Series. Steel Takes Win in Alternative Design Bid Labonte, a two-time Cup Series champion and 22-time Nextel Cup winner, will drive the No. 96 DLP HDTV® car in seven for Replacing Liberty Memorial Bridge races, while Raines, the 1996 champion of the American Speed Association and 1999 NASCAR Busch Series Rookie of the Year, In recent bids for construction to replace the Liberty Memo will drive the No. 96 DLP HDTV® car in 29 races. rial Bridge over the Missouri River, connecting Bismarck with Saunders moved to Charlotte, N.C., to supervise a 40-person Mandan, N.Dak., a steel box girder design won over segmental staff that is housed in a building formerly belonging to Joe Gibbs concrete. The winning bid by Lunda Construction of Black River Racing. Gibbs will supply cars, engines, and technological knowl Falls, Wis., came in at $47.27 million. edge to the single-car startup entering an arena where multicar teams dominate. — continued on page 19

MANUFACTURERS OF CORED WELDING WIRE AND STICK ELECTRODES We have been told that we are the best-kept secret in the welding industry. In an effort to correct this situation we advise that: WE MAKE Stainless Cast Iron Cobalt AISI Nickel 410NiMoFC 33% Ni 1 4130 ENiCrFe-2 502 FC 55% Ni 6 4140 ENiCrFe-3 505 FC 99% Ni 12 4340 ENiCrCoMo-1 E2553 FC 21 ERNiCrMo-3 E2209 FC 2101 ERNiCr-3 E630 FC 904L FC THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE INFORMATION CALL: COR-MET, INC. • 12500 EAST GRAND RIVER • BRIGHTON, Ml 48116 PH: 800-848-2719 FAX: 810-227-9266 www.cor-met.com Circle No. 20 on Reader Info-Card

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ESAB Welding and Cutting Products has been a leader in the welding and cutting 52^ industry for more than 100 years and is one t of the world's largest manufacturers of *=*?** welding and cutting equipment and welding filler metals. To demonstrate die confidence ESAB has in its welding and cutting products, the company backs tiiesc products with an AlcoTec Wire Corporation - a subsidiary of ESAB"1 Welding and Cutting Products - is the exclusive 100% Satisfaction Guarantee. world's largest producer of aluminum welding wire and the only single source for all the Service and support starts from die moment the order is confirmed, with an expanded aluminum alloys currently registered for aluminum welding applications. Our state-of- service organization to ensure that customers the-art drawing and spooling equipment, combined with proprietary processes, ensure are completely satisfied widi tiieir ESAB the best dimensional, mechanical and metallurgical control in the industry. The result is product. Spare and consumable parts are wire with precise diameter, cast, helix, and sliding friction controls for exceptional manfactured according to ESAB's quality feedability and lot-to-lot consistency. For your next aluminum welding job, ask for plan. Product and process training" for end AlcoTec by name. users is offered as part of a total ESAB package. The 100% Satisfaction Guarantee 1.800.228.0750 www.alcotec.com AlcoTec is evidence of ESAB's commitment to total customer satisfaction and support. Talk ^^•^^ Your Partner in to your local ESAB representative or call ESAB Welding & Cutting Great things happen when you put us to work. ^f^f^f^V Since i'J04 800-ESAB-123 for more information.

Circle No. 26 on Reader Info-Card ALUMINUM Q&A BY TONY ANDERSON

Q: When I weld aluminum plate Yn to 'A through a very wide range of temperatures, The samples may not have been prepared in. for truck bodies, it loses its stiffness. practicality of physically heating and cool correctly prior to bending, or maybe they The same thing happens when making ing the entire component, and the cost in were bent over the incorrect radius. Ex panels for car bodies. If I heat the panel volved with this elaborate procedure. amination of the failed samples is neces to about 400° or 500°F and let it cool, it sary to verify that they were prepared in becomes very flexible and I can form the Q: I have a customer who is having prob accordance with the relevant specifica plate very easily. How can I put the stiff lems passing guided bend tests on 5083 tion. The test procedure should be evalu ness back into the plate after I am done base material. What filler metal should ated to determine its correctness. forming it? he be using, and why are the bend tests 3. Which testing method was used? failing? The wraparound guided bend test is the A: Aluminum alloys are normally pur preferred method of testing aluminum chased in a specific temper. In the case of A: Base material 5083 can be welded suc weldments because of the significant vari the non-heat-treatable alloys, this is the cessfully with 5356, 5183, and/or 5556. All ations in the as-welded mechanical prop -H temper, which relates to the strain- three of these filler metals may be suit erties of some aluminum alloys. The hardened condition of the material. In the able for welding this base material; how plunger test method is not recommended case of the heat-treatable alloys, this is the ever, choosing one of these filler metals for higher-strength aluminum alloys like -T temper, which reflects the thermal is dependent upon the application and those that you are testing. treatment that the material has been sub service requirements of the component 4. The use of an inappropriate filler jected to during manufacturing. Both of being welded. metal, such as a 4xxx series used on this these temper methods are used to impart The 5083 base material can be used in base material, could result in a weld with strength to the base material. The a number of applications including ship low ductility and, therefore, susceptibility strengthening characteristics of the -H building, cryogenic tanks, military vehi to failure.• and -T Tempers can be significantly af cles, and structural fabrications. From a fected by heating of the base material. design standpoint, considering fillet After arc welding, for instance, a re welds, the typical transverse shear duction in strength is seen as well as an strength values of these three filler met increase in ductility within a localized area als are 26, 28, and 30 ksi for 5356, 5183, TONY ANDERSON is corporate technical adjacent to the weld. This area has been and 5556, respectively. heated, during the welding operation, to Considering groove weld transverse training manager for ESAB North America and a sufficient temperature for an adequate tensile strength, the 5356 filler metal is coordinates specialized training in aluminum amount of time to anneal or partially an normally used only on 5083 base material welding technology for AlcoTec Wire Corpora neal the base material. The same effect when there is no requirement for groove occurs when heating an entire panel. The weld welding procedure qualifications. tion. He is a Senior Member of the TWl and a heating operation starts to remove some The 5356 filler metal may not consistently Registered Chartered Engineer. He is chairman of the strengthening that was introduced achieve the minimum tensile strength re by the tempering operations, and lowers quirements of the code [40 ksi(275 MPa)] of the Aluminum Association Technical Advi the tensile strength and increases the ma for groove weld transverse tensile testing sory Committee for Welding and holds numer terial's ductility (formability). The higher of the 5083 base material. ous positions including chairman, vice chair the temperature and the longer the time The 5183 filler, developed specifically man, and member of various A WS technical at temperature, the more pronounced the for welding the 5083 base material, will effect on the material. meet the mechanical property require committees. Questions may be sent to Mr. An Unfortunately, there is not a practical ments for the groove weld procedure derson clo Welding Journal, 550 NW LeJeune way to reintroduce stiffness into the base qualification. Rd., Miami, FL 33126, or via e-mail at tander- material of a fabricated part after it has The 5556 base alloy has slightly higher been reduced by heating. In theory, mechanical properties over the 5183 and [email protected]. strengthening the affected material by can be used to weld the slightly higher- strain hardening or heat treatment could strength 5456 base material, but will also be done; however, because of the proce meet the minimum tensile requirements dures required to perform these opera for the 5083 base material. The 5083 base tions, it is not usually an appropriate op material should not be welded with a 4043 tion. Strain hardening is achieved through or a 4047 filler metal. It not recommended Dear Readers: controlled physical deformation of the that any 5xxx series base material with base material, which generally involves a more than 2.5% magnesium be welded The Welding Journal encourages reduction in the cross-sectional area. Heat with a 4xxx series filler metal. an exchange of ideas through treatment to improve mechanical proper Failing a guided bend test can be due letters to the editor. Please send ties generally involves heating to a very to a number of reasons, as listed below. your letters to the Welding Journal high temperature, followed by quenching 1. The most obvious reason is that Dept., 550 NW LeJeune Rd., in water, and then controlled reheating there is some form of discontinuity in the Miami, FL 33126. You can also for a period of time. weld, which has caused the break (usually Postweld heat treatment of aluminum incomplete fusion). To determine the reach us by FAX at (305) 443-7404 alloys is used in some specialized applica presence of any significant discontinuities or by sending an e-mail to Kristin tions; however, there are a number of major that may have caused the failure, the failed Campbell at [email protected]. considerations such as distortion of the fab sample needs to be inspected. ricated part as it is heated and cooled 2. Was the test conducted correctly?

AUGUST 2006 AWS Welding New Materials for the Automotive Industry Conference Atlanta • October 31,2006 The emphasis of this conference will be on the new advanced high-strength steels (AHSS) which are becoming quite popular in the automotive industry. A speaker from Dofasco will discuss some of the dual-phase steels, while an engineer from Mittal Steel will talk about other grades, including the martensitic steels. The weldability of all of these grades will be the main issue of the conference. Experts will cover such processes as resistance welding, gas metal arc welding, laser welding, hybrid welding, and spot friction welding. A speaker from Israel will discuss his company's patented magnetic pulse welding process.

9:00 AM-9:40 AM 11:15 AM-11:55 AM 2:10 PM-2:50 PM Welding Dual-Phase Steels for Automotive Applications Magnetic Pulse Welding Solutions for the Automotive High Strength Steels Mandate the Use of Ultrasonic Elliot Biro, Senior Research Specialist, Dofasco, Industry Inspection for Resistance Spot Welds Research and Development, Hamilton, Canada Yoav Tomer, Director, Product Marketing, Pulsar Ltd., Robby Hawkins. Marketing and Sales Manager, Spot This presentation will consist of what dual-phase steels Yavne, Israel Weld Applications, IRT ScanMaster Systems, Greenville, are. It will include the variants in dual-phase Magnetic pulse welding is becoming one of the preferred SC microstructures and the changes that occur when solutions for joining similar and dissimilar metal Historically die hammer and chisel were die tools of heating the materials during welding. The talk will then combinations of aluminum, copper, steel and stainless choice for quickly checking resistance spot welds during present results from various welding experiments steel. It is only an issue of fast return on investment the final assembly of vehicles. Over the last several years showing how best to weld these materials using (R0I). It is mainly an issue of a stable and reliable automakers have continued to expand the use of high resistance spot welding, gas metal arc welding and laser process which provides high production rate with strength steels in the manufacturing of cars and trucks. beam welding. minimal scrap and rework. More than that, in many High strength steels, with their superior strengtli over cases, such as in welding of dissimilar metals or in conventional steels, make it virtually impossible to verify 9:40 AM -10:20 AM applications which require very high strengdi with the spot welding process using a hammer and chisel Spot Friction Welding in Automotive Body Construction minimal wall thickness (CO2 air conditioning systems, without scrapping the component being inspected. This Tsung-Yu Pan, Senior Technical Specialist, Ford Motor for example), magnetic pulse welding (MP-Weld) is the presentation will focus on the growing implementation Company, Ford Research and Advanced Engineering. only solution that works. Typical MP-Weld applications of ultrasonic inspection in production in order to Dearborn, MI are automotive air conditioning components, aluminum efficiently inspect spot welds created using high strength Spot friction welding (SFW), a novel variation of the fuel filters, cables, and body parts. steels. linear friction stir welding (FSW) process, is a low- temperature solid state welding process producing 12:00 PM- 1:30PM Lunch 3:05 PM-3:45 PM coalescence of metals through heat generated from a Laser Welding of Zinc-Coated Advanced High Strength spinning tool. It offers cost advantage, energy saving, and 1:30 PM-2:10 PM Steels is better vs. resistance spot welding (RSW) and self- Fiber Lasers and Applications for the Automotive Industry Y. Norman Zhou, Canada Research Chair in piercing riveting (SPR) for aluminum lap joining. Eric Stiles, Laser Division Manager, Fraunhofer USA, Microjoining and Associate Professor and Director, Center for Coatings and Ixiser Applications, Plymouth, Centre for Advanced Materials pining, Dept. ofMech. 10:35 AM-11:15 AM Ml Eng., University of Waterloo, Waterloo, Canada Weldability and Joint Design of AHSS for Automotive High power fiber lasers offer large improvements over This presentation will provide an overview of die research Applications conventional lamp pumped Nd:YAG laser technology in activities on laser welding of advanced high strength Min Kuo, Ph.D., Platform Manager, Product terms of beam quality, electrical efficiency and power steels at the University of Waterloo. This research is part Applications, Mittal Steel, USA Research & scalability. Better beam quality makes the fiber laser of the effort to improve vehicle fuel efficiency by reducing Development Center, Soulhfield, MI interesting for applications such as remote welding, deep the body weight. This talk will focus on die weldability of This presentation will include current and future trend of penetration welding, and high speed welding or cutting, various zinc-coated dual-phase and TRIP steels and also AHSS applications. Brief introduction of weldability with where previously only C(>2 lasers were considered. This the formability of welded joints. grade lower than 900 MPa products. Discussion presentation gives an overview of the technology and new Weldability of Martensitic grade and their automotive application developments for the automotive industry. 3:45PM-4:15PM Question and Answer Session applications. Welding processes include RSW (Resistance Spot Welding), GMAW (Gas Metal Arc Welding) and LBW (Laser Beam Welding). AHSS Joint Design Concept will be discussed.

To register, call (800) 443-9353 ext. 224, (outside North America, call American Welding Society 305-443-9353), or visit www.aws.org/conferences Founded in 1919 to advance the science, technology and application of welding and allied joining and cutting processes, including brazing, soldering and thermal spraying.

Circle No. 8 on Reader Info-Card BRAZING Q&A BY ROBERT L PEASLEE Q: We have a new continuous furnace, erator is around -50°F (-46°C). The fur copper occurs because copper is a very and use an atmosphere supplied by an nace is a three-zone furnace with the first good catalyst, and below 300°F (149°C), it endothermic generator. We are brazing preheat running at 1250°F (675°C). The decomposes the organic materials that are 1008 carbon steel tube and fitting joints. second preheat is at 1930°F (1052°C), and used as binders for the copper paste. If Copper paste is applied to the top of the the high-heat zone runs around 2030T there is sufficient oxygen in the furnace, tube, with the part lying horizontal on the (1109°C). We do not have this problem which can come from moisture in the air belt. After brazing, at the point where the when we use our smaller, older furnaces, coming in from the ends of the furnace, and copper was applied, there is a black de and we get a good braze joint all the way with the parts, the carbon will burn off and posit that sometimes has small beads of up to the top. Why can't we get equally leave as CO, thus cleaning up the surface copper on top. The rest of the joint has suitable parts from this furnace? of the iron and the copper before it reaches good flow and has a sufficient fillet of cop the melting temperature of the copper. per. Our dew point coming from the gen- A: The black residue and beading up of the The usual way of eliminating the car bon is to increase the dew point of the at mosphere in the furnace high enough to burn off the carbon. Variations can be seen, as different types of parts being Impress my Maybe save brought through the furnace can bring in my employer more air and moisture. The larger the friends... door opening, the more air and moisture will come in. The tubing parts will carry air in the hollow tube area. Change in belt speed can also be a factor. The more belt surface going through the furnace, the more moisture and oxygen you are bring ing in. The dew point, or humidity, in the atmosphere from day to day and from sea son to season can also cause variations. The more moisture in the atmosphere, the more moisture will be brought in on the parts and the belt; and conversely when the atmosphere is drier, less mois ture will be brought in. Many of the new furnaces are built with nitrogen curtains in the front and ceramic curtains in the back, which means that the atmosphere in the furnace will be drier than normal. It is quite likely that there is more mois ture in the older furnaces, and it might be desirable to check the dew point in the center of the high-temperature zone of the furnace. This can be done by loading a small tube, % in. in diameter or less, back in the furnace from the front door, and using a pump to bring the atmosphere out Consider the AWS Certifie into the dew point instrument and then into the pump. You would want to do the Welding Supervisor Program. same to the new furnace and find out what the dew point is in both furnaces. This Now there's an AWS certification for welders, foremen and might be a good indicator of the dew point managers who want to lead their company's welding team to required in the new furnace at the hot new heights of productivity and quality. A five-day prep zone of the furnace. course focuses on knowledge of the science and economics 1. As a first step, it may be desirable of high-throughput welding. As an AWS Certified Welding to increase the dew point in the new fur nace to about 50°F (9.9°C) or higher to Supervisor, you can make a difference in making your see whether this solves the problem. company more profitable and competitive! 2. If the problem still exists, the next step would be to take a copper wire that For more information on the AWS Certified Welding Supervisor has a sufficient quantity of copper, form program, visit our website at www.aws.org/certification/cws a ring just over half of the diameter of the or call 1-800-443-9353 ext 470 (outside the U.S. call 305-443- tubing, and snap it on the top side of the 9353). See a schedule of certification seminars coming to your tubing. If the problem is with the paste area in the 'Coming Events' pages of this Welding Journal. material, then parts with the wire should come out bright and shiny, while parts run at the same time with the copper paste \ American Welding Society may still come out with some discoloration at the top, or have a carbon residue.

AUGUST 2006 Circle No. 5 on Reader Info-Card 3. If the parts with the copper wire are NEWS OF THE INDUSTRY bright and shiny and the parts run with the — continued from page 14 copper paste are discolored black at the point of application of the paste, the partial The steel option con pressure of oxygen in the furnace (dew sists of four lines of con point) is not high enough, or there may be tinuous trapezoidal steel additives in the paste that are causing a box girders having a ver problem. tical depth of 8 ft and 4. Tests should be done with a full run spaced 21 ft 10 in. be of parts in the furnace, as testing with one tween centerlines. The or two parts is not going to be indicative bottom flange width of of the partial pressure of oxygen that will each girder is 85 in., be present when the furnace is fully loaded. Above is an artist's rendering of how the Liberty Memorial while the top flanges are 5. Checking the dew point in the hot Bridge will look after it is constructed. The bridge has a hybrid 18 in. wide. The bridge zone during a production run on both fur design because the top flanges over the piers consist of high- has a hybrid design with naces would be desirable. performance steel, and the remainder is Grade 50. Work will the top flanges over the 6. Another way of increasing the par begin this summer. piers consisting of high- tial pressure of oxygen in the furnace is to performance steel (HPS reduce the flow of atmosphere in the hot 70WT2), and the re zone of the furnace. mainder being Grade 50. As I am sure everyone knows, I am a The bridge will have four center spans of 285 ft and two end spans of 230 ft. Addi great believer in footprints. The black tionally, the project includes a 3-span, 251 -ft approach on the east side, and a 5-span, residue that forms where the filler metal 460-ft approach on the west side. was applied is one of the footprints that The bridge deck will provide 34 ft of clear width for traffic lanes in both the east- tells us that the moisture content (partial bound and westbound direction, separated by a 3-ft median. A 10-ft pedestrian walk pressure of oxygen) is not high enough to way runs along the south side of the bridge. Pedestrian walkout areas over the five oxidize the carbon and remove it from the piers will each represent one branch of the military. surface, leaving the part clean and shiny.^ Industrial Steel Construction (ISC), Hodgkins, 111., will fabricate and paint the steel girders. Tensor Engineering is developing the shop drawings. ISC anticipates that fab ROBERT L. PEASLEE is vice president emeri rication will start in September, and shipments will begin in March 2007. tus, Wall Colmonoy Corp., Madison Heights, Work will begin on the new bridge project this summer. The North Dakota Depart Mich. Readers may send questions to Mr. ment of Transportation expects traffic to be transferred to the new structure in late Peaslee c/o Welding Journal, 550 NW LeJeunc 2007. The original bridge, which was built in 1922 and stands just north of the new Rd., Miami, FL 33126 or via e-mail to bridge site, will be demolished. [email protected].

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Circle No. 23 on Reader Info-Card WELDING JOURNAL TECHNOLOGY

Advanced Welding Technology Helps Electric Boat Win Manufacturing Award In December 2000, the folks at Gen eral Dynamics Electric Boat, the primary builder of submarines for the U.S. Navy, were challenged to cut the time it took to join hull sections from their average of twelve weeks to four. With the comple tion of the USS Hawaii (SSN-776) this year, the workers met the challenge and were rewarded with General Dynamics' Manufacturing Excellence Award in May *$ for their efforts. "The tradesmen applying their knowl edge, experience, and skills is what made Fig. 1 — Welders Charles Dubicki (fore Fig. 2 — The company's prototype "burn this happen," said Bob Burkle, general ground) and Nestor Hernandez using the box," which controls smoke, noise, sparks, foreman, Steel Trades, and operations computerized plasma gouging machines. and slag in the work area, allows nearby lead for the automated welding process workers to perform their duties while the improvement program. "I can't empha cutting work continues. size enough the cooperation and help of • Power Wave 455/R welding power sup our tradesmen." ply, Power Feed 10 robotic wire drive unit, This is the third year General Dynam and Wave Designer 2000 software from The doors, and we're using it outdoors," ex ics has offered the award. At each busi Lincoln Electric Co., Cleveland, Ohio. plained Chris Barrett, engineering proj ness unit, departments are encouraged to Lee O'Connell, engineering specialist, ect manager. submit for internal review a three- to five- Welding Engineering, said the company They found that the computer- page paper on their process improve now has ten of the systems in operation. controlled equipment overheated in the ments. At Electric Boat, Vice President A major change added after the initial summer, the lines that cool the camera for Quality Robert Scheel selects one equipment purchase was a switch to froze in the winter, and the winds affected entry and forwards it to Vice President for plasma arc cutting, using a Hypertherm® the shielding gas. They had always used a Operations Richard Geschrei, who sits on 200 plasma arc cutting power source and staging area to protect the welding oper the General Dynamics Manufacturing cutting torches from Hypertherm, Inc., ations, Burkle explained, but found they Council, the group that nominates the Hanover, N.H. With that move, they need to make it more airtight for the new programs for the award. Four papers were found they needed travel carriages capa equipment. They also added steam heat, reviewed at Electric Boat this year, with ble of carrying higher payloads. Electric improved the electrical service, and made the automated welding process improve Boat started out with a 150-lb payload sys other improvements. For the Hawaii, the ment program the one selected. The win tem and now is up to a 350-lb payload. rejection rate was under 2%; currently it ning teams attend an annual symposium They also utilize trailing tractors with a is below 1%. in Tampa, Fla., where they present the re harness that carries the coolant, cables, "The defects on the Virginia were re sults of their project and receive a trophy and other gear. lated to fitup," explained AI Smith, weld from Chairman Nicholas D. Chabraja. Electric Boat first used the equipment ing work leader and the technical lead for Key to the project was new equipment on an axis-horizontal hull butt for SSN-23, the program. "We needed precise cuts to the company invested in to weld circum a Seawolf class submarine. It got extensive have consistent root gaps all around, so ferential pressure hull butt joints and sim use on the Virginia class sub USS Virginia we switched from flame to plasma cutting. ilar applications. The initial equipment (SSN-774), but the Hawaii was the first Now we use a robot with the plasma cut purchased included the following: submarine for which the equipment was ter to get very precise cuts." • Laser vision system and WinUser and used for the entire hull. The Virginia The company now uses plasma arc ADAPT software from Servo Robot, Inc., proved to be a real learning experience for technology for both cutting and gouging St. Bruno, Quebec, Canada. The system the company. The 7.4% reject rate was — Fig. 1, In addition, workers developed features a CAMIBOX compact control much higher than the 2% the company had a "burn box" that travels with the cutting unit and M-Spot 280 laser camera. experienced with its aging mechanized torch to capture fume, slag, and sparks — • SE-NAVI/Pc robot control unit and pulsed gas metal arc welding equipment. Fig. 2. "Before, people had to be away servo-controlled three-axis travel carriage With the Virginia, the company learned the from the cutting operation," Burkle ex and idle carriage supplied by Sumikin Weld changes it needed to make with regard to plained. "With this, we had people com ing Industries, Ltd., of Japan. The portable, equipment and to its facilities. ing in and out all the time, and they barely multipass welding robot includes a standard The company's eight-story-tall hull knew cutting was going on. PC-based controller with welding, crater erection facility sits next to the water in "We had the challenge. We didn't get fill, and weaving parameter database; re Groton, Conn. Open on three sides, it pro it right overnight, but with 776, Hawaii, mote-operator teach pendant; three-axis tects the workers and equipment from we did exactly what we said we'd do." travel carriage and robot movement; wire precipitation, but not from the summer Burkle added, "However, we're never feeder; and Tweco® water-cooled robotic heat, winter freezes, or wind. "Across all done with improvement." — Mary Ruth welding gun. of industry, this equipment is used in- Johnsen, senior editor*

M AUGUST 2006 TMs month's AWS Foundation spotlights: Spotlight on a scholar

"My name is Jerica much in my academic efforts. I greatly Cadman, a student of look forward to the remaining years I Materials Joining have to pursue my undergraduate Engineering at LeTourneau degree and even more so to my future University. What a blessing it in the materials joining field. This special is to have received the Don and honor has increased my anticipation even Shirley Hastings Scholarship! Reward and more. Thank you to those who support and recognition such as this encourage me so who are the American Welding Society!"

Spotlight on a scholarship The Donald and Shirley Hastings minimum four-year bachelors Scholarship is provided from personal degree in welding contributions from the Hastings family to engineering or welding the AWS Foundation to promote higher engineering technology; education in welding. The Donald and however, priority is Shirley Hastings Scholarship is awarded to given to welding a college undergraduate student pursuing a engineering students.

The American Welding Society Foundation has helped thousands of students who otherwise would be unable to afford a welding education. We are proud of the fact that we help hundreds of welding students annually by providing them with funding towards their education. In fact, we are the only industry foundation set up specifically to further welding education and, in so doing, create the careers that sustain and grow our industry. These funds are from your generous contributions. If you don't contribute, we will not be able to expand our work and our students' educations. And there is so much work to be done. Please make a scholarship contribution, or set up your own Section, District Named, or National Named Scholarship. Contact the AWS Foundation at 1-800-443-9353, ext. 212.

Jm^ Foundation, Inc. Welding for the Strength of America Ny Building Welding's Future through Education The Campaign for the American Welding Society

Circle No. 9 on Reader Info-Card NEW PRODUCTS FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD. GTAW Machine Offers Wide Welding Amperage Range The Precision TIG® 225 features both AC and DC output, increased welding output, and auxiliary power. Its wide operating range al lows for flexibility with as low as 5 A on both AC and DC for thin materials, and up to a maximum of 230 A for heavier GTAW and SMAW applications. The machine is useful for automotive welding as well. Micro-Start™ II technology delivers stable arc starting, even at the lowest amperages for AC and DC weld ing. This technology also delivers enhanced arc stability throughout the welding cycle. AC Auto-Balance™ Control with manual over ride optimizes the ratio of cleaning action vs. penetration. The pulse control features a light that flashes at the same frequency as the arc's pulse rate. The UltraFlex™ torch cable helps to reduce user fatigue, while the easy-to-use control panel features large knobs for adjust ment. The digital meter and indicator lights make setup simple.

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Circle No. 40 on Reader Info-Card WELDING JOURNAL Single-Sided Resistance Spot Welding for Auto Body Assembly

BY YONGJOON CHO, INSUNG CHANG, AND HEUIBOM LEE Single-side access holds promise for applications that normally are difficult to resistance spot weld such as hydroformed and closed-section parts

esistance spot welding (RSW) has This article focuses on developing a been widely employed in sheet new RSW technology and its potential for Rmetal fabrication for several improving the traditional RSW issues. A decades. The automotive industry, for ex new welding system was designed that ample, prefers RSW because it is a simple could make a weld using single-sided ac and cost-effective joining method. Resis cess with low electrode force. Using the tance spot welding is performed on thou system, spot welds were made using only sands of spots for every passenger vehicle; single-sided access with or without a back therefore, each welded spot has its own ing plate. Various tests were completed to importance not only with regard to qual understand the characteristics of the sys ity but also for production manufacturing. tem. Weldability lobe curves were also de Because of the nature of a conventional termined in terms of welding time and cur RSW machine, sheet metals have to be in rent along with electrode force. Finally, serted between upper and lower elec this technique was applied to a number of trodes. However, this introduces various automotive assembly cases and the results limitations for RSW of an automotive were discussed. body assembly: 1) In order to make a weld on the auto- Experimental Setup body floor, a large C-type gun is needed to access the weld spots. Sometimes the The experimental procedure was di mouth size of the gun is larger than 1 m vided into two stages: lab-oriented speci resulting in it being hard to teach and men tests and field-oriented automotive maintain. parts tests. Lab-oriented tests were done 2) Many welding spots are located in by tensile-shear coupon — Fig. 1. In order closed-section parts that an ordinary RSW to investigate the effect of a backing plate gun cannot access. In those cases, arc or on weld quality, copper backing plates laser beam welding techniques can be al (electrodes) were used with and without ternatives to RSW; however, both holes. Figure 1A depicts the size and processes have their own weak points. Arc arrangement of the coupons. Figure IB welding has thermal deformation and shows an experimental setup for single- quality control issues. While laser beam sided spot welding with a backing plate. A YONGJOON CHO (yongjoon@hyundai- welding has unique advantages, it is very holed (30-mm) backing plate was used to motor.com;, INSUNG CHANG, and expensive. simulate single-sided spot welding with HEUIBOM LEE are with Hyundai Motor 3) New joining methods are needed for out a backing plate — Fig. 1C. Co., Gyeonggi-Do, Korea. newly developed sheet metal forming Field-oriented tests were made using technology. Hydroformed parts are usu real automotive parts and a robot system. Based on a paper presented at the A WS De ally difficult to join with conventional Welding was performed on a specially de troit Section's Sheet Metal Welding Confer RSW due to the high electrode force and signed single-sided welding machine. ence XII, May 10-12, 2006, Livonia, Mich. their geometry. Thanks to the high-grade transformer and

AUGUST 2006 100 Welding robot ^. 3 : o • Single-sided gun (a)

^ Electrode

QO00O cccco a d T f^l Back plate (b)

Welding machine Robot controller \ a J J: Fig. 2 — Configuration of the single-sided RSW system.

(O Time (sec) Fig. 1— Experimental setup for tensile- shear test coupon. A — Size of coupons 0.33 - -X- I (mm); B — single-sided RSWwith backing I plate; and C — single-sided RSW without I backing plate. 0.25 - -x-

0.17 X: No-weld •: Good A : Undei size 0.08 - fine inverter control of the machine, it is A: Expulsion possible to extend the secondary cable up to 20 m. A robot system with a 200-kg max imum load capacity was used to maintain —I— + -f- proper reaction force of the single-sided 2.4 3.0 3.6 4.2 4.8 5.4 welding gun. Schematic configuration of Current (kA) the system is shown in Fig. 2. Secondary 0.6kA cables were connected with a single-sided welding gun and ground plates. The robot Fig. 3 — Typical single-sided RSW weldability lobe curve. controller integrated and managed all the actions of the welding and communication. Large Panel with Members formed parts. The most challenging issues Results and Discussion and Brackets with regard to using hydroformed parts in the body-in-white are joining them with The results reported in this section de In order to make a weld with members other structures, such as panels, rein scribe the characteristics of the single- and brackets on the large panel, such as forcements, brackets, etc., due to their sided RSW machine and its application the center floor of the auto body, a large closed-section geometry. While arc or examples. Various types of closed-section C-type gun is needed to access in the mid laser welding can be a solution, the sin spots were tested and showed good re dle of the panel. Since complicated jig fix gle-sided RSW technique can be another sults. A few limitations and challenges of tures and clamping devices are located un great solution. Once brackets or flanges the system are also discussed. derneath the panel, it is very hard to teach are welded onto hydroformed parts (Fig. the robot the right position with proper 5), those parts are easily assembled with conventional RSW. Weldability Lobe Curve cycle time — Fig. 4A. Once the single- sided RSW system is adopted for this ap Welding was performed on various plication, fixture and clamping units can Preassembled Parts combinations of automotive sheet metals be dramatically reduced — Fig. 4B. (0.7- to 1.6-mm thickness, coated, un- Thanks to the easy access to the weld Usually, large parts are assembled at coated, advanced high-strength steel, with spots, cycle time also can be decreased. original equipment manufacturers or without a backing plate, etc.). The typ (OEMs). This means the OEMs need ical weldability lobe curve of single-sided large facilities with complicated manufac RSW is shown in Fig. 3. The experimen Hydroformed Parts turing processes. Once parts are provided tal setup of Fig. IB was used with coated Hydroformed auto parts are getting as a preassembled unit, lean assembly line steel [0.8t (upper sheet) + 1.4t (lower used more widely due to their flexible manufacturing can be achieved with a sheet)]. Because of the low electrode force geometry and high stiffness. A recent ap minimum number of production cells. As (500 N), acceptable welds were obtained plication is reported in which body mem shown in Fig. 6, package tray panels are at a relatively low current range. bers and pillars are replaced with hydro- assembled with three stages. In this case,

WELDING JOURNAL Large C-type gun —t-V Bracket or flange Center floor

Hydro-formed member

Jig and clamping units (a) Fig. 5 — Single-sided RSW of hydroformed parts.

considered to guarantee a good-quality Small one-sided gun weld. First, the thickness of the upper sheet should be no more than 1.4 mm. A weld can be made with thicker sheet; how ever, due to the low electrode force, it is very hard to set up a point contact between sheets where proper current density is needed for molten nugget. Second, lower sheets have to have a certain amount of stiffness to support the single-sided elec trode force. Therefore, geometry and thickness of the lower sheets are very im Copper back plates portant. Basically, two-sheet welding is recommended unless the geometric struc ture of the third or forth sheet is strong (b) enough to maintain electrode force. Fig. 4 — Single-sided RSW of a large panel. A — Large C-type gun with jig and clamping units; and B — single-sided gun with backing plates. Conclusions An automated single-sided RSW sys the package tray side panel has to be been tested; the benefits are also listed. tem was introduced and various applica welded in the first stage and then the side • Closed section parts: alternatives for tions to automotive body assembly are dis outer panel is assembled, resulting in body conventional single-sided welding cussed in this research. The weldability side complete. After that, this complete processes. lobe curve shows that operating points can is built together with a package tray at a • Jig-less clamping units for laser beam be found at a relatively low welding cur later assembly station. However, if the welding: easy-to-control gaps for rent range due to the low electrode force. package tray assembly is preassembled coated steel. Because only single-side access is neces (Fig. 7), the manufacturing process can • Flexible configuration of production sary to make a good weld, great potential be reduced to two stages; body side com line: no more limitations on closed sec advantages can be found in the joining of plete stage and its joining stage with pack tion. large panels. The single-sided system can age tray assembly. In order to assemble • Indentation-free welds (backing plate also be used for applications that are dif package tray panels on the body side com side): good appearance with low elec ficult to spot weld, such as hydroformed plete, a single-sided welding technique is trode force. or closed-section parts. Due to the simple needed. While arc or laser beam welding • Mismatched parts: relatively robust for system configuration and easy-access ca may not be a perfect solution due to the gap/mismatch issues. pability, productivity can be increased by gap issue of the end of the panel edge, sin There are many advantages of using improving cycle time and reducing main gle-sided RSW has sufficient electrode the single-sided RSW system. It offers a tenance efforts. Although some limita force to control the gap. simple system configuration and easy- tions exist, this technique can be a great access capability. Other advantages in alternative to conventional single-sided sheet metal joining processes. • Other Applications clude the need for smaller facilities, shorter cycle times, easy maintainance, ef Since the single-sided RSW system was fortless robot teaching, etc. References developed to make closed-section welds, various other applications have been pre Limitations and Challenges 1. Dickinson, D. W, Franklin, J. E., and sented. Low electrode force and long sec Stanya, A. 1980. Characterization of spot ondary cables make the system feasible at Even though single-sided access of spot welding behavior by dynamic electrical pa an automated body line with proper cycle welding gun gives us a great advantage, a rameter monitoring. Welding Journal time. The following applications have few limitations and challenges have to be 59(6): 170-s to 176-s.

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Wheel house inner Package tray side f\ This is a highly specialized program offered at CDA and is designed for persons who want to become a commercial diver and who are serious /I ssA Sss\ ~~ about obtaining y i high quality \Y \ i Manual Metal Arc (MMA) 4^Ck . A If welding skills, •*• both above &

Side outer panel below water. j The course ivnrffiJEIJn W follows the guidelines under the European Welding Federation (EWF) with qualifications being awarded in accordance with BSEN ISO 15618-1 and/or AWS D3.6-99M.

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Side panel assembly Package tray assembly Single-sided RSW

Fig. 7— Proposed way to build preassembled package tray panels.

2. Thornton, P. H., Krause, A. R., and 82(8):195-sto201-s. Davies, R. G. 1996. Contact resistances in 5. Gould, J. E., and Peterson, W. A. spot welding. Welding JournaX 75(12): 402-s 1989. A detailed examination of weldabil- to412-s. ity lobes for a range of zinc-coated steels, 3. Han, A., Indacochea, J. E., Chen, C. SAE Technical Paper No. 880279. H., and Bhat, S. 1993. Weld nugget devel 6. C1.1M/C1.1-2000, Recommended opment and integrity in resistance spot weld Practice for Resistance Welding. Miami, ing of high-strength cold-rolled sheet steels. Fla.: American Welding Society. Welding Journal 72(5): 209-s to 265-s. 7. Hyundai Motors Co. 1990. Specifi 4. Cho, Y., and Rhee, S. 2003. Experi cations of material standard and proce mental study of nugget formation in re dures for determining the weldability of sistance spot welding. Welding Journal auto steel. Circle No. 19 on Reader Info-Card

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Mild Steel AM&S Mild Steel AHSS 10% 12% 41% 50%

HSS HSS 47% 40%

1995 2005 2015

Fig. 1 — The pie charts show the evolution of automotive body structure in the usage of ad vanced high-strength steels. Courtesy ofJ. Shaw, United States Steel Corp., Automotive Center, Troy, Mich.

New car models will Automotive companies are constantly 590 MPa dual-phase steel found several seeking ways to improve the fuel efficiency applications in 2004 and 2005 model year of their vehicles and to build vehicles from automotive bodies. be safer, lighter, and materials that offer improved occupant Dual-phase steels are considered ad safety. vanced high-strength steels (AHSS) to dis Any material intended for automotive tinguish them from the conventional high- more fuel efficient as use must be easily formable, weldable, strength steels (HSS). The HSS types coatable (for corrosion protection), and include high-strength low-alloy steels and repairable. carbon-manganese steels of tensile advanced high- One such class of materials that shows strengths up to 440 MPa. While AHSS was promise of fulfilling all these needs is dual- not used at all up to 2001, the AHSS con phase steel. As a result, dual-phase steels tent in 2005 models is about 12% — Fig. 1. strength steels are with a minimum tensile strength of 590 MPa have found their way into several Use of AHSS to Grow 2004 and 2005 model vehicles (Refs. 1, 2). introduced into With the use of 590 MPa dual-phase Based on the expressed objectives of steel in automotive bodies, the automo various automotive companies to build tive companies realized that dual-phase more fuel-efficient and safer cars, and the steels have excellent formability without trends in steel usage to meet the increas production sacrificing strength (Ref. 3). This combi ingly stringent government requirements, nation of high ductility (hence formabil it is anticipated that AHSS usage in auto ity) and high strength can allow thinner motive bodies will climb to 50% by 2015 steels to be used in automotive bodies, (Ref. 4). thus providing improved fuel economy Although the technology of dual-phase for vehicles. Further, the high energy-ab steels is not new, and 590 MPa dual-phase sorption capability that dual-phase steels steel has been available since 1979 (Ref. possess can offer improved occupant pro 3), their uses in automotive applications tection. Therefore, it is no surprise that prior to 2000 was virtually nonexistent.

BY MURALI D. TUMULURU MURALI D. TUMULURU ([email protected]) is with the Research and Technology Center, United States Steel Corp., Munhall, Pa. Based on a paper presented at the AWS Detroit Section's Sheet Metal Welding Conference XII, Livonia, Mich., May 9-12, 2006.

WELDING JOURNAL 45 [590 MP^nQHHMH, I

_35 • *£"Hr5 ":%• * A * r/S*

30 o Si 2 25 o

15 200 400 600 800 1000 1200 Ultimate Tensile Strength (MPa|

Fig. 2 — A plot showing the relationship between strength and elongation for various sheet steel grades used in automotive applications. TRIP is transformation-induced plasticity steel.

The increased demand to improve Corpo •To achieve higher strength, more rate Average Fuel Economy (CAFE) stan martensite is required in the steel. There dards and the tightening of roof crush- fore, as the strength of the steel increases, strength requirements to better protect the amount of martensite in the steel in occupants in roll-over situations, sparked creases (Fig. 3). a renewed interest for the automotive •Dual-phase steels possess high strength companies to look at dual-phase steels to with high elongation when compared to enable them to meet these increasingly conventional HSS. rigorous standards. It can be seen from •Dual-phase steels do not exhibit yield Fig. 1 that the present use for AHSS in au point elongation. Yield point elongation tomotive bodies is limited to dual-phase or discontinuous yielding causes Luder steels with a minimum tensile strength of bands (or stretcher strains) and surface 590 MPa. With the development and com appearance problems. Fig. 3 — Photomicrographs of the as- mercialization of dual-phase steels with •Dual-phase steels possess high strain received base metal microstructures for the minimum tensile strengths of 780 and 980 hardening (high n-value), which indicates three dual-phase steel grades. The white is MPa, many automotive companies are ag excellent formability. lands are martensite distributed in soft fer gressively targeting the use of these two •They have a low plastic strain ratio value rite phase (gray areas). steel grades into the models to be rm. It is the ratio of the width strain to the launched in 2007 and later (Refs. 5, 6). thickness strain. Low rm indicates poor For steels, as their strength increases, deep drawability. This means dual-phase Resistance spot welding behavior of the ductility (as measured by elongation) steels are not good candidates for applica coated 590 MPa dual-phase steel has pre drops. However, from Fig. 2 it is apparent tions that require deep drawability. viously been the focus of research (Refs. that even at strength levels of 780 MPa, •They are bake hardenable (strain aging 7-9). This understanding led to the suc dual-phase steels possess elongation val at elevated temperature). Bake hardening cessful implementation of 590 MPa dual- ues as high as 25% and 980 MPa grade fea provides an increase in strength after the phase steel into automotive production. tures elongation values as high as 18%. paint bake cycle that welded automotive With the availability of 780 and 980 MPa This combination of high strength and bodies undergo. steels, there is a need to understand the high ductility comes from the unique mi- resistance spot welding behavior of these crostructure and characteristics that this Spot Welding Concerns steels. Therefore, resistance spot welding grade possesses. studies were undertaken to examine the Resistance spot welding is the main welding behavior of 590, 780, and 980 Features of Dual-Phase Steels method of joining used in the automotive MPa dual-phase steels. Another purpose industry with each vehicle containing sev of the study was to determine whether Some of the characteristics that make eral thousand welds. To be able to suc these higher-strength grades could be dual-phase steels attractive for automo cessfully use these steels, it is important to welded with simple, easy-to-use welding tive applications include the following: characterize and understand the spot parameters. •They achieve strengthening through a welding behavior of dual-phase steels. phase transformation, namely the trans For body-in-white applications, to pro Materials and Procedure formation of austenite to martensite. vide corrosion protection, dual-phase •Depending on the strength level, they steels are used with either galvannealed Commercially processed coils were contain 10% to 40% martensite in a soft (zinc-iron alloy) or galvanized (pure zinc) used in this study. Examples of tensile ferrite matrix. coating. properties of 590, 780, and 980 MPa dual-

AUGUST2006 phase steels are provided in Table 1. The Table 1 — Tensile Properties of Dual-Phase Steels tensile properties of draw-quality special- killed (DQSK) steel are provided for com Steel Grade Yield Strength, MPa Ultimate Tensile Strength, MPa Total Elongation parison. The DQSK steels are low- 590* 370 620 25% strength steels that are used in automotive 780 465 835 17% bodies —Fig. 1. Typical alloying elements, 980 600 1040 14% their ranges, and the reasons for adding DQSK* 170 300 45% them in dual-phase steels are shown in Table 2. All steel coils were produced •Provided tor comparison. through intcrcritical annealing of cold rolled sheets (Fig. 4) and hot-dip coated. The nominal coating weights for all the 2 coils used were 45/45 g/m (i.e., same coat Table 2 — Hot-Dip Coated Dual-Phase Steel Composition Ranges ing weight on both surfaces of the coils). These coating weights are typical of cur Alloying Element Influence and Reason For Adding rent commercial automotive use. The (Wt-%) steel sheet thickness for all three grades C 1. Ferrite stabilizer was 1.6 mm. To examine the effects of (0.06-0.15) 2. Strengthens martensite welding current and button size on the 3. Determines the phase distribution weld tensile strength in 780 MPa grade Mn 1. Ferrite stabilizer sheets from 2.0-mm-thick coil were also (1.5-2.5) 2. Solid solution strengthener of ferrite used. All welding was performed using a 3. Retards ferrite formation Taylor Winfield pedestal-type welding ma chine equipped with an AC power source. Cr, Mo 1. Austenitc stabilizer Resistance Welding Manufacturers Asso (each up to 0.40) 2. Retards pearlite and bainite formation ciation Class 2 (copper-chromium) elec trodes were used to make test welds. Both V 1. Austenite stabilizer truncated cone electrode tips with 45-deg (up to 0.060) 2. Precipitation strengthener 3. Refines microstructure included angle- and ball-nosed tips were used. The welding machine details and pa Nb 1. Austenite stabilizer rameters used in this study are shown in (up to 0.04) 2. Reduces Ms temperature Table 3. 3. Refines microstructure

Characterizing Welding Behavior of Steels

To characterize the welding behavior of Table 3 — Welding Machine Details and Conditions the steels, useful current ranges and static weld tensile tests were performed. The Manufacturer Taylor Winfield Corp. useful current range is the difference be Type Pedestal Type tween the welding current required to pro Transformer 100 kVA duce a minimum button size (Imjn) and the Controller TrueAmp IV current that causes expulsion of weld Electrode Face Diameter 7-mm truncated tip for 1.6-mm and 8-mm dome-shaped tip for 2-mm 780 MPa steel metal (Imax). In this study, the minimum button size was defined as 4(t)^, where t is Electrode Force 4.2 kN for 590 and 5.3 kN for 780 and 980 MPa steels the nominal sheet thickness. The use of Squeeze Time 30 cycles 4(iy2 as the minimum button diameter, Weld Time 18 cycles for 1.6-mm and 23 cycles for 2-mm sheets Hold Time 10 cycles where t is the nominal sheet thickness, is Preheating None generally used in the automotive and steel Posthcating None industries. The procedure to determine current range is described in detail in Ref. 10. Peel test coupons measuring 140 x 50 mm were used in the current range determination lowest welding current that produced the coupons used were 150 mm long x 50 mm — Fig. 5. The coupons were overlapped by minimum acceptable button size. Then, wide — Fig. 6. Two coupons were placed 25 mm and a shunt or anchor weld was the current was gradually increased until at 90 deg to each other and a spot weld was made on one side of each coupon pair. On weld metal expulsion resulted. made at the center of the overlapped area. the other side, 35 mm from the edge, test Prior to making the weld test samples, the welds were made. The test welds were Determining Weld Quality electrode tips were stabilized as described peeled open and the button sizes were in Ref. 10 by making 250 welds on flat pan measured using calipers. The current Weld shear-tension and cross-tension els. Per Ref. 10, all shear and cross-tension range is useful because it provides a range strengths were determined to assess the test samples were prepared with a speci of welding currents over which welds with load-bearing ability of the welds. For fied weld size of 6.7 mm, which was slightly buttons of acceptable size can be pro shear-tension strength determination. higher than 90% of the electrode face di duced. Prior to determining the current 140- x 60-mm samples were sheared and a ameter. Weld sizes were verified prior to range, the electrode tips were conditioned single spot weld was made at the center of the tensile tests on each grade. Weld sizes by making 250 welds. Current ranges were an overlapped area that measured 45 mm measured after the tensile tests agreed then determined by first determining the — Fig. 6. For cross-tension tests, the test well with the specified weld size. Tensile

WELDING JOURNAL PRODUCTION ROUTE FOR DUAL-PHASE STEELS Anchor Weld Test Weld

Overlap 50 mm

•* P-

o YY 50 mm

— 1 140 mm H Fig. 5 — Sketch showing the dimensions of a peel test coupon used to determine welding current ranges.

B Time

Fig. 4 — Sketch of a continuous cooling diagram showing the A production route typically used for the production of dual-phase steels. 50 mm

A \ 45 mm 50 mm Weld

0 60 mm 150 mm

140 mm

:>-*•. r"^ ^" -• fc

Weld

^^ ^\

F(g. 6 — Sketches showing the dimensions of shear-tension and cross-tension test coupons. The airows in the sketches show the direction of the application of tensile stress during the test. A — Shear-tension test coupons; B — cross-tension test coupon.

tests were carried out per the procedure ture, the entire weld fails through the plane Results and Discussion outlined in Rcf. 10. Additional details on of the weld. In partial interfacial fracture, the testing methodology can be found in part of the weld nugget fails through the Figure 7 shows a plot between welding this reference. plane of the weld and some portion of the current and the button sizes for all three Fracture appearance of the welds was weld pulls out as a partial button. grades of dual-phase steels. A welding determined on all weld tensile test samples Weld and heat-affected zone microstruc- force of 4.2 kN was used for 590 MPa steel after the tests. Weld tensile test fractures tures were examined to check for any im while 5.3 kN was used for the 780 and 980 were classified as full button pullout, in- perfections such as pores and cracks and to MPa steels. Figure 7 shows that a current terfacial fracture, or partial interfacial provide an understanding of the tensile range of 2.2 kA was obtained for the 590 fracture. In full button pullout fracture properties of the weld. Weld microhardness and 780 grades, and 2.5 kA for the 980 mode, the entire weld nugget pulls out profiles were determined by making hard MPa grade. These current ranges are con from the sheets by fracture occurring out ness measurements at 0.4 mm spacing along sidered broad and show that there is a side of the weld area. In interfacial frac a diagonal in a weld cross section. wide current range to successfully weld

AUGUST 2006 Welding Current Ranges for 1.6 mm HDGA Dual Phase Steels I""-- • i i ' i • I ' • 1 ! • 590MPa-4.2kN-Bu«on Size, mm • 780MPa-5 3kN-Button Size, mm » 980MPa-5 3kN-Burton Size, mm A - I *•* E Min. Button Diameter _••••' E6 ••!••! i*.W i

E 5 i ra §5 i— i.. t'.t 4—u—h-— — 5 c 4 : 2.5 kAmps oO Expulsion o m 3 2.2 kAmps 1

*<' • • •• I • l£ L. < 8 9 9 9.5 10 Welding Current, kAmps Welding Current, kAmps

Fig. 7— Welding current range plot for the three dual-phase steels Fig. 8— Welding current range plot for 1.6-mm 980 MPa dual-phase studied. steel shown to indicate the fracture appearance in peel tests. Open circles in the plot refer to inter)ucial fractures in the test samples.

780 MPa Grade 2 mm- Welding Current vs. Weld Strength 1.6 mm HDGA 980DP Weld Strength vs Button Size 50 • Weld Shear-Tension Strength, kN • Weld Cross-Tension Strength. kN i i ! • i-H" S 30 - """I- c i ' • en

Fig. 9 — Weld shear- and cross-tension plots as a function of but Fig. 10 — Weld shear- and cross-tension plots as a function of ton diameter for 780 MPa dual-phase steel. welding current for 980 MPa dual-phase steel. these dual-phase steels. From Fig. 7 it is welding. The second observation is that as beyond the minimum button size. The rea interesting to note that at any given weld the weld button size increased beyond the sons for the significant difference between ing current, the button sizes were clearly minimum button size, the welds showed a the shear-tension and cross-tension the smallest for the 980 MPa grade com full button pull out fracture mode upon strengths at larger button sizes may have pared to the 590 and 780 MPa grades. Al peeling the coupons. to do with the type of stress the welds are though not as distinct as those of 980 MPa Figure 9 shows the relationship be subjected to in the shear- and cross- grade, in general, it appeared that the tween the button diameter and the weld tension tests. weld sizes were slightly smaller for 780 strength of the 780 MPa steel. It can be Chao showed that in shear-tension compared to 590 MPa grade. One possible seen that as the button diameter is in testing, even though the weld is subjected reason for smaller weld sizes seen at any creased, both the shear-tension and cross- to a shear load, due to the rotation of the given welding current as the base material tension strengths went up. This is because sample the weld is aligned with the load strength goes up may have to do with the larger welds have higher load-bearing ing axis. As a result, the weld experiences weld nugget growth. However, this needs ability. Figure 10 also shows the same ef a tensile load and undergoes a tensile further studies. fect of weld size on weld strength for the overload failure (Ref. 11). Therefore, the Figure 8 shows the current range plot 980 MPa steel. In the results shown in Figs. weld shear-tension strength depends upon from a second test done on 980 MPa steel 8-10, tests were terminated when weld the tensile strength of the base material. In to examine the fracture appearance of metal expulsion was experienced. In Fig. the case of a cross-tension test, the weld welds in the peel samples used. Two ob 10 for example, 8.2 mm was the largest specimen is subjected to bending loads servations can be made from Fig. 8. The button size that could be achieved without and is sheared off when overload occurs. first one is that, as the welding current was expulsion. Therefore, in a cross-tension test the frac increased, the weld size also increased. An interesting observation that can be ture mechanism is by shear even though This is no surprise because increasing the made from Fig. 9 is that as the button di on a macroscopic scale the loading mode welding current increases the heat gener ameter increased, the increase in the is tensile. Shear failure is dependent on ation at the sheet interface. In resistance shear-tension strength was much more the shear strength of the base material. spot welding, heat generation is provided rapid than that of the cross-tension The shear strength of steel is about 50% to by I2Rt, where I is the welding current, R strength. In fact, there was no increase in 60% of its tensile strength. Therefore, is the total resistance, and t is the time of the cross-tension strength at button sizes weld cross-tension strength tends to be

WELDING JOURNAL Weld Hardness Plots in Dual Phase Steels

> X

10 15 20 Indentations

Fig. 11 —A plot of hardness distribution across the weld, the heat-affected zone, and base metals for 590, 780, and 980 MPa steels. The bottom photograph shows the location of hardness indentations.

much lower than its shear-tension lower hardness compared to welds in 780 strength. and 980 MPa steels. However, the mi- Figure 11 shows the microhardness dis crostructural constituents in all three tribution for welds in all three strength lev grades were similar. els. While hardness of the base material For simplicity, weld fractures were increases as its strength increases, the classified in this study either as full button weld hardness distribution in 780 and 980 pullout or interfacial fractures. Other Fig. 12 — Weld and heat-affected zone mi- MPa steels is similar, and the average types of fractures that are seen sometimes crostructures in dual-phase steels. Both the hardness for both the steels is around 415 in high-strength steels include partial in weld and the near heat-affected zones VHN. The average hardness for the 590 terfacial and partial thickness fractures. showed martensite. The heat-affected zone MPa steel is around 380 VHN, which is Work at United States Steel Corp. has area consisting of martensite was quite wide. only slightly lower than those of the 780 shown a dependence of fracture mode on The far heat-affected zone, which was nar and 980 MPa steels. The reason for the sheet thickness, weld size, and steel tensile row, showed areas offerrite and tempered similarity in weld hardness between the strength. Weld tensile tests in this study martensite. 780 and 980 MPa steels is due to the pres showed that full-button pull out fracture ence of untempered martensite in the mode was seen in 980 MPa grade when the weld and the heat-affected zones — Fig. weld size is large. However, even when in 2. Similar welding behavior can be ex 12. Even at 500°C, cooling rates of terfacial fractures were seen, the load- pected with all three DP steels studied. 1000°C/s were estimated in a 2-mm steel bearing ability of the welds was still high. All three DP steels showed wide welding resistance spot weld (Ref. 12). Recent cal Therefore, fracture mode alone is not a current ranges to achieve acceptable weld culations showed that for 2-mm-thick good indicator of weld integrity and per sizes. steel, the overall cooling rate from melting formance. 3. Fracture appearance alone should to ambient was about 2000°C/s (Ref. 13). not be used to judge weld quality in dual- Calculations showed that the cooling rate Conclusions phase steels. required to form martensite in these steels The material in this paper is intended is about 250°C/s (Ref. 14). Due to the ex Based on the resistance spot weld eval for general information only. Any use of tremely rapid cooling that resistance spot uations done on 590, 780, and 980 MPa this material in relation to any specific ap welds undergo, it is not surprising to see dual-phase steels, the following conclu plication should be based on independent untempered martensite in the welds. The sions can be drawn: examination and verification of its unre hardness of martensite is controlled by the 1. Welds with no imperfections were stricted availability for such use, and a de carbon content present. Both 780 and 980 obtained in all three of the steel grades termination of suitability for the applica MPa steels contain similar levels of car studied, which suggested that dual-phase tion by professionally qualified personnel. bon. Due to a lower carbon content re steels possess good weldability and could No license under any United States Steel quired to achieve the required strength be welded with simple, easy-to-use weld Corporation patents or other proprietary level in 590 MPa steel, the weld showed ing parameters. interest is implied by the publication of

AUGUST 2006 this paper. Those making use of or relying Proc. lnt'l Sheet Metal Welding Conference upon the material assume all risks and li VIII, Paper 5-6, Troy, Mich. Want to be a ability arising from such use or reliance. 13. Gould, J. E., Khurana, S. P., and Li, Welding Journal T Prediction of microstructures when Advertiser? welding automotive advanced high- References strength steels. 2006. Welding Journal For information, contact 85(5): 111-s to 116-s. Rob Saltzstein at 1. Horvath, C. D. 2004. The future rev 14. Grong, 0.1997. Metallurgical Mod (800) 443-9353, ext. 243, olution in automotive high strength steel eling of Welding. The Institute of Materi or via e-mail at usage. Paper presented at Great Designs als, London, U.K. [email protected]. in Steel, American Iron and Steel Insti tute, Southfield, Mich. 2. Rocheleau, G., Robin, J., Gordon, C, and Bhatnagar, R. 2004. Advanced high strength steel outer panels in the Ford Mustang. Paper presented at Great Designs in Steel, American Iron and Steel Institute, Southfield, Mich. 3. Repas, P. E. 1979. Metallurgy, pro duction, technology, and properties of dual-phase sheet steels. SAE paper, Series 790008, presented at the SAE Congress, JU Society of Automotive Engineers, Inc., Warrendale, Pa. 4. Shaw, J. Private communication. United States Steel Corp., Automotive Center, Troy, Mich. 5. Mehrkens, M. 2004. Advanced high strength steel technology in Porche Cayanne. Paper presented at Great De signs in Steel, American Iron and Steel In stitute, Southfield, Mich. 6. Pfestorf, M. 2006. BMW — Func tional properties of the advanced high strength steels in the body-in-white. Paper presented at Great Designs in Steel, American Iron and Steel Institute, South- field, Mich. 7. Pakalnins, E., and Morrisette, T. 2004. Comparative resistance spot weld characterization of 600 MPa dual-phase steels using DOE analysis. Proc. lnt'lSheet Metal Welding Conference XI, Livonia, Mich. 8. Biro, E., and Lee, A. 2002. Welded properties of various DP600 steel chemistries. Proc. Sheet Metal Welding TOUGH GUIfl.CE. Conference X, Livonia, Mich. 9. Takahashi, I., Kato, T, Hashimoto, ROBOTIC TORCH H., and Shinozaki, M. 1981. Properties of Do you want your front-end consumables to rue co..,., hot rolled high-strength steel sheets for and last longer? Just add I.C.E. - our innovative automotive use. Kawasaki Steel Technical cooling system that circulates water to the nozzle of Report No. 2. our TOUGH GUN Air-Cooled Robotic Torch. 10. AWS/SAE D8.9M, Recommended The TOUGH GUN I.C.E. (Integrated Cooling Enhancer) Practices for Test Methods for Evaluating Robotic Torch combines all of the cooling benefits the Resistance Welding Behavior of Auto of a traditional water-cooled torch with the durability motive Sheet Steel Materials. 2002. Miami, of an air-cooled torch. Fla.: American Welding Society. Longer consumable life. Maintenance friendly. Increased safety. 11. Chao, Y. J. 2003. Ultimate strength That's the advantage of adding I.C.E.! and failure mechanism of resistance spot Contact Tregasklss today at 1-800-787-6966 weld subjected to tensile, shear or com or visit us online at www.tregaskiss.com. bined tensile/shear loads. ASME Journal of Engineering Materials and Technology, Vol. 125, pp. 125-132. 12. Li, M. V, Dong, P., and Kimchi, M. 1998. Analysis of microstructure evolution and residual stress development in resist ance spot welds of high-strength steels. Circle No. 43 on Reader Info-Card

WELDING JOURNAL Reducing Exposure to Hexavalent Chromium in Weldina Fumes

'.ally, the exhaust nozzle should be positioned close to and above the arc at an angle of approximately 45 deg.

In October 2004, the Occupational cover general industry (29 CFR BY SUSAN R.FIORE Safety and Health Administration 1910.1026), shipyards (29 CFR 1915.1026), (OSHA) announced a proposal to amend and construction (29 CFR 1926.1126). Al the 8-hour time-weighted average permis though the proposed standards for the sible exposure limit (PEL) for hexavalent three industry sectors differed in some of Ways to comply with chromium (Cr(VI)), and for all Cr(VI) the detail (e.g., provisions for exposure de compounds. On February 28,2006, OSHA termination) in the final standards, the re issued its final rule. The new standard low quirements are very similar. ers the PEL from 52 to 5 micrograms (u_g) The decision to lower the exposure the new OSHA of hexavalent chromium per cubic meter limit was based on a finding that employ of air as an 8-hour time-weighted average ees exposed to Cr(VI) face an increased (TWA). The new action level has been set risk of significant health effects. The standard for lower at 2.5 |ig/m3 of air. Although lower limits health effects cited by OSHA that are as were considered by OSHA, it was deter sociated with Cr(VI) include lung cancer, mined that a PEL of 5 |ig/m3 is the lowest asthma, nasal septum ulcerations and per exposure to level that is technologically and economi forations, skin ulcerations ("chrome cally feasible for industries impacted by holes"), and allergic and irritant contact this standard. dermatitis. One group cited by OSHA as hexavalent chromium being at risk is workers who are involved Reasoning behind the with welding of stainless steels. OSHA Lower Exposure Limits stated, "In general, the studies found an are detailed excess number of lung cancer deaths There are three separate standards that among stainless steel welders. However,

SUSAN R. FIORE is with Edison Welding Institute, Columbus, Ohio.

AUGUST 2006 ER316L, Ar-5%C02

FCAW- > 500 IPM GMAW - Ar/COz • 400 IPM o> 0.6 Steady ^^ Current • 300 IPM MAW „,.,.. GMAW- Pulsed Current

I GTAW SAW 20 22 24 26 28 30 32 34 36 Arc Voltage (V)

Fig. 1 — Approximate fume generation rates for various welding Fig. 2 — Effect of voltage on fume generation rate for ER316 L processes. (GMAW).

few of the studies found clear trends with posure for each employee exposed to more days per year. Respirators can also Cr(VI) exposure duration or cumulative Cr(VI). Exposure testing should be done be used in those cases where engineering Cr(VI). In most studies, the reported ex by taking a sufficient number of personal controls are not feasible, or in those cases cess lung cancer mortality among stain breathing zone samples to characterize full in which they have been implemented but less steel welders was no greater than mild shift exposure on each shift for each job are not sufficient to reduce exposures to steel welders, even though Cr(VI) expo classification, in each work area. Repre below the PEL. sure is much greater during stainless steel sentative sampling can be done instead of welding. This weak association between sampling all employees in order to meet lung cancer and indices of exposure lim this requirement. However, if representa The Nature of Cr(VI) in its the evidence provided by these stud tive sampling is performed, the employer Welding Fume ies. Other limitations include the coexpo- must sample the employee(s) expected to sures to other potential lung carcinogens, have the highest Cr(VI) exposure. Chromium is found in stainless steel and such as nickel, asbestos, and cigarette As an alternative, the employer can de many low-alloy base materials, electrodes, smoke, as well as possible healthy worker termine the 8-h TWA exposure for each and filler metals. It is also found in some effects and exposure misclassification in employee based on any combination of air hardsurfacing electrodes, tool steels, and some studies, which may obscure a rela monitoring data, historical monitoring some nickel-based alloys. The chromium tionship between Cr(VI) and lung cancer data, or objective data that is sufficient to that is present in electrodes, welding wires, risk." And "Nevertheless, these studies accurately characterize employee expo and base materials is in the form of metal add some further support to the much sure to Cr(VI). lic chromium and chromium alloys. It is stronger link between Cr(VI) and lung If the initial monitoring shows that em generally not in the form of chromium oxide cancer found in soluble chromate produc ployee exposures are below the action or other compounds of hexavalent tion workers, chromate pigment produc level (2.5 M.g/m3), the employer may dis chromium. During welding, the intense tion workers, and chrome platers." continue monitoring for those employees heat of the electric arc vaporizes a fraction who are represented by that monitoring. of the chromium and other metals in the Timeline of the Ruling If, on the other hand, exposures are found electrode and weld pool. Any metal vapor to exceed the action level, the employer that escapes the arc area condenses as it The final rule took effect on May 30, must perform monitoring at a minimum cools and oxidizes into weld fume. 2006, which was 90 days after the date of of every 6 months. If the initial monitor Welding fume is a complex mixture of publication in the Federal Register, Feb ing shows that employee exposures are metal oxides. Fumes from some processes ruary 28, 2006. Employers have until No above the PEL, then the employer must may also include fluorides. The predomi vember 27, 2006, 180 days from the effec perform periodic monitoring at a mini nant ingredient in mild, low alloy, and tive date, to comply with the rule (1 year mum frequency of every 3 months. It is stainless steel welding fume is iron oxide. for employers with fewer than 20 employ important to note that there is a specific Oxides of manganese and silicon are also ees). The deadline for implementing en prohibition in the standard against rotat typically present. Fume from stainless gineering controls is 4 years after the ef ing employees to different jobs in order steel and some low-alloy steel welding will fective date, or May 31, 2010. Complete to comply with the standard. also contain chromium and, in many cases, details of the standard can be found at In order to comply with the standard, nickel. Chromium is typically not inten www.osha.gov. The following section pro employers must implement engineering tionally added to mild steels or mild steel vides some highlights. controls to protect those workers whose welding consumables, but because of the exposures exceed the PEL. Respirators nature of steel making and the use of scrap may be used as an interim measure while metal, it is not unusual to find low levels. Requirements of the New engineering controls are being imple Even though only trace amounts may be Standard mented or in the case where the employer present in the steel or the welding con can demonstrate that a process or task sumable, with very low allowable limit ma The first step in complying with the does not result in any employee being ex terials such as Cr(VI), it may be possible standard is to determine the 8-h TWA ex posed to Cr(VI) above the PEL for 30 or to exceed the PEL when welding mild

WELDING JOURNAL High Volume Low Vacuum Extractor with Flange High Vacuum Low Volume Extractor with Flange

Boundary at or near 100 8- ID 7 - S' • • V • • 6 - • • Boun200 ft/min 2 - 3 . • • • • • Flange 200-100 ft mill Flange Hose 2 - 1 - . 1 1-4-

-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 -6-5-4-3-2-10123456789 10 Distance (inches)

Fig. 3 —Air velocity as a function of distance from the exhaust noz- Fig. 4 — Air velocity as a function of distance from the exhaust noz zle for a typical high-volume low-vacuum fume extractor. zle for a typical high-vacuum low-volume fume extractor.

steels, particularly under conditions of Preliminary Testing that the fume collected for exposure test poor local exhaust. In most mild steel ing be taken from inside the welding hel welding, however, it is likely that the ex As discussed earlier, the first step that met or as close to the welder's breathing posure limits for fume constituents other must be taken is to determine if either the zone as possible. than Cr(VI) will be exceeded before the PEL or the action level are being ex If it is determined that the PEL is being limit for Cr(VI) is reached. ceeded. This can only be done by per exceeded, the solution may range from The majority of the chromium found forming some baseline analysis of the ex relatively simple process or procedure in welding fume is typically in the form of isting situation. A certified industrial hy- changes, to improvements in exhaust/ Cr203 and complex compounds of the gienist (CIH) can perform exposure test ventilation, to changes in personnel pro trivalent form of chromium (Cr(III)). ing of workers to determine baseline con tective equipment. The following sections Cr(III) is an essential nutrient in the ditions. The CIH must test for the fume outline some of the possibilities. human body and has only a limited toxic constituents in addition to traditional total 3 effect (the PEL for Cr(III) is 500 ug/m ). fume measurements. Testing for Cr(VI) Welding Process and Some of the chromium in the fume is requires extraction of the Cr(VI) from the found in complex metal oxides in its hexa- fume sample, and must be done separately Procedure Changes valent form (Cr(VI)), which is also the from testing for other fume constituents. form found in Cr03. Pure Cr03 is ex The employer can either test all employ Different welding processes generate tremely unstable and is not found in weld ees within each job classification, or he different amounts of welding fume. ing fume. However, in the case of weld can perform representative sampling. If Processes such as gas tungsten arc weld ing fume, other metal oxides are present, representative sampling is performed, the ing (GTAW) and submerged arc welding and the presence of these metal oxides, employees selected for sampling should (SAW) are inherently low in fume gener especially alkali metals, tends to stabilize be those expected to have the highest ation. Gas metal arc welding (GMAW) Cr(VI) (Refs. 1, 2). Cr(VI) exposures. OSHA recommends also tends to be a relatively low-fuming using either the National Institute of Oc process. Shielded metal arc (SMAW) and cupational Safety and Health (NIOSH) flux cored arc welding (FCAW) tend to Minimizing Cr(VI) Exposure Method 7605 (Ref. 3) or OSHA Method produce more fume, especially when the from Welding ID-215 (Ref. 4) for the analysis. amount of fume generated per unit length The ID-215 method was developed of weld is considered. Alkali metals, such Welder exposure to Cr(VI) depends when OSHA was originally considering as sodium and potassium, stabilize Cr(VI) on many things. Some of the critical con lowering the exposure limit, and PELs as (Refs. 1, 2), and are often present in siderations include the quantity and dis low as 0.1 u.g/m3 were being considered. SMAW electrode coatings and may be tribution of ventilation (both natural and Other NIOSH methods (Method 7600 present in FCAW flux. As a consequence, forced), the work habits and training of and 7604) can also be used, but their de Cr(VI) levels tend to be higher with SMA the welder, the size of the room in which tection limits are higher than NIOSH 7605 and FCA welding. Figure 1 shows the rel the welding is being performed, and the and OSHA ID-215. ative amounts of total fume generated for material being welded. Regardless of which method is used, it several different welding processes (Ref. There are a number of actions that may should be clearly communicated to the 5). Because some of the processes repre be taken in order to reduce exposure to testing laboratory that exposure levels sent lower deposition rates, the total Cr( VI) in the welding environment (work down to 2.5 ug/m3 (i.e., the action level) amount of fume generated to complete a place). The overall effectiveness of these must be reported. weld should also be considered. measures will depend on the material Ideally, exposure testing should be Unfortunately, not all processes can be being welded as well as the other factors done over an 8-h period. If a shorter time used in all situations. SAW is limited to listed above. Implementation of some of period is chosen, it should be representa the flat and horizontal positions. GTAW these measures may not be practical, and tive of the work pattern for the entire 8-h tends to be very low in deposition rate and in some cases, may not even be possible. shift. The AWS and OSHA recommend may not be the best choice for production

• AUGUST 2006 To exhauster Goscrd etectrtxie wire feed

Fig. 6 —Air-purifying respirator.

Fig. 5 — Schematic diagram of different types of fume-extraction welding guns. welding. A large percentage of repair creases, the fume generation rate will typ vacuum systems use large-diameter ducts welding is done using SMAW due to its ically decrease to a point, and then in or hoses that provide for larger capture low cost, portability, and ease of use. crease with increasing voltage. This be distances. Most bulk systems are high- havior, which is related to arc stability, is volume low-vacuum systems. High- Other Ways to Reduce shown graphically in Fig. 2 (Ref. 5). vacuum low-volume systems tend to be Finally, a number of studies have more portable and less expensive to im Exposure shown that GMAW with pulse transfer plement than the high-volume systems. produces less fume than GMAW with They use smaller hoses, and as a conse Even if it is not possible or practical to spray transfer (Ref. 6). The type of pulse quence, the capture distance is generally change to a different welding process in power (inverter vs. conventional) appears smaller. Table 1 shows typical capture dis order to reduce exposure to hexavalent to play a role in the level of fume reduc tances for various systems and air flow chromium, it may be possible to modify tion, and the process may need to be fine- rates (Ref. 5). the process to reduce exposure. Argon- tuned to achieve the lowest possible lev Figures 3 and 4 show the air velocity rich shielding gases produce less fume els. Some researchers have shown (Refs. as a function of distance from the exhaust than 100% C02 and shielding gases that 7, 8) that the percentage of hexavalent nozzle for typical high-volume low- are high in helium. For GMAW and chromium in the fume may increase some vacuum and high-vacuum low-volume sys FCAW, replacing straight C02 with shield what with pulsed vs. spray transfer. How tems, respectively (Ref. 5). The rule of ing gas mixtures containing a minimum of ever, because the total amount of fume thumb is in order for LEV to be effective, 75% argon along with C02 and/or oxygen generated is reduced, the overall poten it must achieve a minimum air velocity of will result in a significant reduction in tial exposure to hexavalent chromium will about 100 ft/min at the point of fume cap fume generation rate. also be reduced. ture. Clearly, it is critical that the nozzle The oxidation potential of the arc at be repositioned regularly during the mosphere will affect both the amount and Engineering Controls course of welding. Adding a flange to the the composition of the welding fume. In nozzle increases the capture distance, general, as the arc atmosphere becomes If changing the welding process is not which increases the length of weld that more oxidizing, the total amount of fume possible, or if the changes do not reduce can be made before it becomes necessary generated will increase. Elements such as worker exposure levels to below the PEL, to reposition the exhaust nozzle. manganese and silicon, which have a high it will be necessary to introduce changes oxidation potential, will increase prefer to improve the ventilation in the worker's Fume Extracting Guns entially to those with lower oxidation breathing zone and the surrounding area. potentials. It should be noted that while Local exhaust ventilation (LEV) is a sys One solution to the problems associ argon-rich shielding gases produce less tem of capturing the welding fume before ated with frequent exhaust hose reposi fume than C02, the fume itself may it reaches the operator. The effectiveness tioning is the use of fume-extraction weld be somewhat higher in hexavalent of the LEV is highly dependent upon its ing guns. The typical fume-extraction chromium. However, because the total proximity to the source of the fumes, i.e., welding gun has small exhaust holes or amount of fume generated will be signifi its position relative to the welding arc (see vents around the circumference of the cantly less, the potential exposure to hexa lead photo). gun. They have the advantage that the ex valent chromium should be reduced. tractor is always positioned very close to It may also be possible to reduce the Using Ventilating Systems the arc. Fume-extraction guns are most amount of fume generated for a given effective when welding in the flat or hori process by adjusting the welding parame The two most common types of venti zontal position. It should be noted that ters. In general, reducing the current and lation systems arc high-volume low- because fume-extraction guns tend to be voltage will lead to a decrease in fume gen vacuum systems, and high-vacuum low- heavier and may have stiffer hoses than eration rate. For GMAW, as voltage in volume systems. High-volume low- traditional welding guns, an evaluation for

WELDING JOURNAL Table 1— Typical Air Flow Rates and Capture Distances for LEV Equip ment also offers a number of resources, includ ing guidelines on selection and use of res Air Flow (Q) ft3/min Duct or Hose Capture Distance (in.) Weld Length Before pirators, available at www.cdc.gov/niosh.• Diameter (in.) Repositioning (in.) References High vacuum, Low volume 50 1M-2 2-3 4-6 for duct 1. Kimura, S., Kobayashi, M., Godai, 8-12 with flange T, and Minato, S. 1979. Investigations on 88 l'A-2 2-3 4-6 for duct chromium in stainless steel welding fumes. 8-12 with flange Welding Journal 58(7):195-s to 204-s. 110 2 3 4-6 for duct 2. Khoroshavin, L. B., Deryabin, V. A., 8-12 with flange Perepelitsyn, V. A., and Lapteva, T. N. 160 3 5-6 9-12 1993. Hexavalent chromium in refracto High volume, Low vacuum ries. Refractories 34(9/10) 457-462. 500-600 4-6 6-9 12-18 3. Details of the methods are available 800-1000 6-8 9-12 18-24 from the National Institute for Occupa tional Safety and Health, www. cdc.gov/niosh/nmam. 4. Details of the method are available ergonomic stresses should be performed. respirators are indeed needed, they should from the U.S. Department of Labor, Oc Welding gun weight-assists (bungee cords, be NIOSH-approved and in compliance cupational Safety and Health Administra counterweights, etc.) may be needed. Sev with 42CFR part 84. The two types of res tion, www.osha.gov/dts/sltc/methods/inor- eral types of fume-extraction welding guns pirators are air-purifying respirators and ganiclid215lid215.html. are shown schematically in Fig. 5. Fume- atmosphere-supplying respirators. Air- 5. Reduction of worker exposure and extraction welding guns are particularly purifying respirators are either particulate environmental release of welding emis well-suited for use with self-shielded respirators, gas and vapor respirators, or sions. NSRP report, EWI, 2003. FCAW. When using fume-extraction combination respirators. They utilize fil 6. Dipietro, D., and Young, J. 1996. welding guns with GMAW or gas-shielded ter cartridges to remove particulate and/or Pulsed GMAW [GMA welding] helps FCAW, care must be taken to ensure that gases from the air before it is inhaled by John Deere meet fume requirements. the air-velocity is not so high that it im the user. Figure 6 shows an example of an Welding Journal 75(10): 57-58. pairs the coverage of the gas-shielding. air-purifying respirator. 7. Bosworth, M, and Gordon, T 1999. In some situations, it may be possible Atmosphere-supplying respirators The influence of power source character to isolate the welding process to reduce may be air-supplied respirators, self- istics on Cr(VI) in fume generated during worker exposures. Welding can be done contained breathing apparatus, or combi GMAW of stainless steel. Australasian in a "room-within-a-room" or similar iso nation respirators. Air-supplied respira Welding Journal 44: 48-51, 3rd Quarter. lated chamber. This generally requires tors typically have a hose that is connected 8. Brooks, G., Mahboubi, F, French, I. that welding be done robotically or oth to an external air supply, whereas self- E. and Tyagi, V. K. 1997. The influence of erwise fully automated. Welding can also contained breathing apparatus has air the consumable and power supply type on be done in a glove box, but this is only fea tanks that are integrated into the system. welding fume characteristics. Australasian sible for relatively small assemblies. Combination respirators have an auxiliary Welding Journal 42: 38^13, 2nd Quarter. self-contained air supply that can be used 9. ANSI Z49.1, Safety in Welding, Cut When LEV Is Not Enough if the primary supply fails. Some manu ting, and Allied Processes. Available for facturers also make systems in which the free download from AWS, www.aws.org. In some cases, process changes and en air-supply hose is integrated into the weld gineering controls will not be sufficient to ing helmet. Additional References from AWS reduce the hexavalent chromium expo sure to below the PEL. In those situations, Summary • AWS Fl.l, Method for Sampling Air it becomes necessary to introduce respi borne Particulates Generated by Weld rators. Respirators should not be used in A number of steps can be taken to re ing and Allied Processes. place of implementing engineering con duce exposure to hexavalent chromium • AWS F1.2, Laboratory Method for Mea trols. Rather, they should be used in those from welding processes in the workplace. suring Fume Generation Rates and Total situations where engineering controls First, fume production should be consid Fume Emission of Welding and Allied have been implemented and exposure ered in the choice of the welding process. Processes. testing has indicated that they are not ad Shielding gases and welding parameters • AWS F3.2, Ventilation Guide for Weld equate, or as an interim measure while en should also be selected to minimize fume Fume. gineering controls are being imple production. The local exhaust ventilation • AWS Safety and Health Fact Sheet Nos. mented. Respirators can also be used as should be examined to determine if it is 1 and 4. an assurance/back-up to maintain expo adequate and where improvements may sure below the PEL. Special ventilation, be made. air monitoring, and, in some cases, respi Finally, if process modifications and rators should always be used for welding engineering controls are not adequate to Change of Address? in confined spaces. See ANSI Z49.1, reduce exposures to hexavalent chromium Moving? Safety in Welding, Cutting, and Allied or other contaminants to below the PEL, Processes (Ref. 9) for guidelines on weld respirators should be employed. OSHA Make sure delivery of your Welding Jour ing in confined spaces. offers a number of publications and on nal is not interrupted. Contact the Mem bership Department with your new ad In order to determine whether respira line tools for evaluating hazardous con dress information — (800) 443-9353, ext. tors are needed, exposure testing should taminants in the work environment. These 217; [email protected]. again be performed. If it is determined that are available at www.osha.gov. NIOSH

AUGUST 2006 (There's more to D1 than D1.1)

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Structural I welding Code- Reinforcing Steel

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Structural Structural The power of D1: Working under ANSI procedures, the Welding Code- I welding Code- Seismic Titanium contributors and reviewers of AWS D1 codes have built upon the Supplement work of hundreds of prior experts who, since the first D1 code in 1928, have continuously labored to represent proven practices. The result is a resource that provides a consensus of the finest minds in the industry on the most reliable approaches to achieving a successful final outcome. That's why D1 code books have been mandated by local, state, and overseas codes, approved by ANSI, adopted by the Defense Department, <&mfc preferred by NASA, and required by contracts for countless industrial and construction applications.

NEW! AWS D1.8/D1.8M-.2005 Structural Welding AVAILABLE SOON! AWS D1.9/01.9M.2006 Code—Seismic Supplement complements AISC Structural Welding Code—Titanium covers Order today. Call 888-WELDING (935-3464). Seismic Provisions to help ensure that welded requirements for design, welding, and inspection Outside North America, call 305-824-1177. joints designed to undergo significant repetitive of any type of titanium structure. Includes Or order online at www.aws.org/standards inelastic strains as a result of earthquakes have qualification requirements for weld procedures adequate strength, notch toughness, and integrity and personnel. to perform as intended. Circle No.14 on Reader Info-Card A American Welding Society Whni: Yoi I I\ ^ A 0

A look at how remote laser welding works and how it can be applied to your manufacturing process

BY KEVIN KLINGBEIL

Remote laser welding is quickly be into a more complex system with the scan coming an accepted method for laser head mounted on a robot as shown in Fig. beam welding. This method differs from 3. This system is more complex in pro conventional laser welding in that the gramming and can be less accurate. There beam is steered to the work surface using Y-MIRROR can be inaccuracies of the scan head, and small lightweight mirrors instead of a con also inaccuracies in the robot. These can ventional focusing head, and either mov be reduced by adding a vision system to ing the part or positioning the focusing X-MIRROR match the weld program to the actual po head with a robot. Much faster position LENS sition. The advantage to such a system is ing speeds can be realized utilizing remote that line-of-sight issues can be overcome welding technology. Positioning speeds of by changing the position of the scan head. up to 20 m/s (800 in./s) can be achieved Whether the system is simple or com with today's technology. LASERSOURCE plex, if the full extent of the working field There are a few design considerations is used, the beam will impinge on the work that welding engineers need to be aware surface at different angles depending on of for proper design of parts and assem where within the field the weld is located. blies that are going to be remote laser Fig. I — Elements of a scan head. The laser beam is always directed from a welded. An informed engineer can design point in the center of the field. At the cen assemblies and parts so that manufactur ter of the field the laser beam will impinge ing can fully use the benefits of remote beam along the y-axis. This configuration normal to the work surface. The incident laser welding. One consideration is how is shown in Fig. 1. This allows for com angle will increase as the beam is directed the focused laser beam is positioned onto plete access to the entire work surface toward the outer edges of the working the work surface. Second is how the weld without having to move the work surface field. The maximum angle that the beam profile changes as the beam is positioned or the scan head. The only moving parts makes with the normal to the work sur around the work surface. A third consid are the two lightweight mirrors and the face is approximately 20 deg. eration is the type or shape of the laser first lens. The scan head is designed so that the weld required to get the most strength The scan head can be integrated into first lens is moved along the optical axes with the least number of welds. very simple or complex systems. A simple to keep focus throughout the work sur system would have the scan head and laser face. The focusing lens can also be moved Process Description stationary as shown in Fig. 2. This system to form a 3-D work volume, as shown in may have some limitations with line of Fig. 4. Depending on the specific optical The key technology behind remote sight for certain part designs. Because the setup, the height of the work volume and laser welding is using a scan head to rap laser beam is directed from a central lo the maximum length and width can vary. idly position and focus the laser beam on cation, all joints need to have a line of sight Note that the work volume is pyramid the work surface. Figure 1 shows elements from this point. The advantages of such a shaped and the incident angle of the laser of a scan head where the beam is first sent system are accuracy, ease of program beam to any planar surface varies from 0 through a set of lenses where the first lens ming, and lower equipment cost. Position to 20 deg. is moved along the optical axis to change ing accuracies of ± 0.15 mm (± 0.006 in.) the focal position of the laser beam. can be achieved for large work volumes. Part Design The beam is then steered with two mir Programming is fairly simple with a nor rors. One mirror steers the beam along mal x-y-z coordinate system. As stated earlier, the beam is directed the x-axis; the other mirror steers the The scan head can also be integrated from the center of the field. When a part

KEVIN KLINGBEIL ([email protected]) is with LasX Industries, Inc.

Based on a paper presented at the A WS Detroit Section's Sheet Metal Welding Conference XII, Livonia, Mich., May 9-12, 2006.

AUGUST 2006 is presented to the remote laser welding system, there needs to be a line of sight to all welding areas. For instance, if the joint is located below an edge that cannot be seen from the center of the field, it would be necessary to move the part so that line of sight is reestablished. The number of times that the part has to be moved should be minimized since repositioning the laser beam is much faster than repositioning the part. If a part is redesigned as shown in Fig. 5, the manufacturer can take more advan tage of the benefits offered by remote laser welding. Tooling design is usually much easier for stationary parts, and process repeatability is usually much higher the less the part has to be moved. Every time the part is moved, you increase the number of opportunities for error. Joint design should also be determined by where within the work volume it is lo cated. If the joint is located near the outer edge of the work volume, the designer should take into consideration that the beam will have an incident angle with the work surface of approximately 20 deg. For a lap joint, the lap joint could be bent at 20 deg from coplanar so that the beam will intersect normal to the joint. If possible, laser welding should be done normal to the work surface. The rea son for this is that the weld profile will take on the same angle that the laser beam has with the normal to the work surface, as shown in Fig. 6. What this essentially Fig. 2 — Scan head and laser. means is that in order to achieve the same penetration, either higher powers or slower weld speeds will be necessary for welding at an angle as compared to weld ing normal to the joint. This can be an issue for butt joints that require deeper penetration. Laser beam welding is known for pro ducing narrow welds with low heat input, and a wide weld may be necessary to fully fuse the butt joint. This would cause higher heat input into the part and poten tially more distortion and stress. The butt joint can be designed to accommodate the angle of incidence as shown in Fig. 7. The butt joint could then be fused with the typ ical narrow, low-heat-input laser weld.

Process Development Fig. 3 — Scan head mounted on a robot. Fig. 4 — Focusing lens. There is a great deal of flexibility in the remote laser welding process. Because of this flexibility, process development related to the cross-sectional area of the of the fusion zone that is needed to should be done for each family of parts fusion zone between the parts to be achieve the strength required for the part. that is going to be manufactured. There joined. With remote welding there are Testing can be done to determine the best are several items that should be investi many options for the programmed tra design for the particular part being gated before finalizing the process. The verse of the weld. A few different possi welded. programmed weld traverse, weld penetra ble designs are shown in Fig. 8. For cer For certain applications, not only does tion, weld sequence, and number of welds tain applications a simple spot weld may the cross-sectional area of the fusion zone will affect the final part strength and fa suffice; other applications may require a affect the strength of the weld, but also tigue life. sinusoidal or spiral weld in order to the penetration. Certain metals, such as The strength of a laser weld is directly achieve the required cross-sectional area medium-carbon steels, do not weld read-

WELDING JOURNAL Fig. 5 — Parts de sign. A — With the lap joint located this far below the top edge, it would be necessary to have the joint near the center of the field for line of sight; B — re designing the part so that the joint is lo cated higher on the part can put the lap joint within the line of sight of the remote laser welding system.

Fig. 6— Weld profiles.

Fig. 8 — Possible weld designs.

laser welding was able to complete six spot welds in slightly less than 0.3 s. Reposition ing of the laser beam is an insignificant por tion of the cycle time. An added advantage to using remote laser welding is that the Fig. 7 — Butt joints. A — With the butt joint straight cut, it would be necessary to create a parts can be processed while in motion. wide weld to fuse the entire joint; B — redesigning the part so that the joint accommodates Remote laser welding also has the typ the angle of incidence allows the manufacturer to use the typical narrow laser weld. ical advantages that are associated with laser beam welding. Some of these are that ily without cracking. For instance, if a low- blies and subassemblies could benefit it is a noncontact process, it does not re carbon steel is being lap welded to a from this process. Applications where a quire a filler material, it is a low-heat- medium-carbon steel, decreasing the pen long reach is required, such as internal input process, etc. These advantages along etration into the medium-carbon steel can components in a muffler, are a good ex with the added benefits of the remote produce acceptable results. ample. Gas metal arc welding is often used welding process should help the automo Once the type of weld and penetration for these applications because the weld tive market reduce cost and increase pro are established, the weld sequence needs gun is small and can be easily manipulated duction, if it is applied properly. to be determined. Every weld that is cre inside these components with a robot. ated will introduce stress into the part. Conventional laser beam welding may not Conclusions This can cause parts to warp. This may work well because of the small opening have a detrimental effect on subsequent and long distance that the head would Remote laser welding has become an welds if a gap between the parts is created. have to reach into the assembly. Remote accepted method for the joining of parts. Proper sequencing can hold the parts in laser welding is capable of keeping the Many applications can benefit from the place so that no gap is created. For heat- physical components outside of the as positioning speed and the ability to weld sensitive parts, sequencing the welds prop sembly and only the laser beam is directed within a work volume without having to erly can decrease the peak temperature to the weld locations inside the assembly. move the part. Certain process character of the part as it is being welded. Another benefit beyond the long focal istics of remote laser welding need to be The number of welds and placement lengths possible with remote laser weld kept in mind when designing parts and of the welds plays an important part in the ing is that both the welding head and as tooling for assembling the parts. One such total strength of the assembly. It is possi sembly can be stationary. This reduces characteristic is that remote laser welding ble to have too many welds placed on a the amount of tooling and programming works by directing the beam from the cen part, which does not allow the part to flex necessary to complete the welding of the ter of the field to the work surface. properly and can cause a short fatigue life. assembly. Remote laser welding is also a very Testing is necessary to determine the num Remote laser welding also lends itself flexible process and process development ber and location of welds to achieve ac well to spot welding. Applications where work is necessary to achieve the best re ceptable strength and fatigue life for any multiple spot welds need to be placed in sults. Development work should be com particular part. a very short time are prime examples. One pleted to determine weld programmed example would be spot welding plate and traverse, penetration, sequence, and num ring assemblies for oil filters. These as ber of welds. If all of the characteristics Applications semblies are usually resistance welded. of remote laser welding are known and Remote laser welding is finding new Resistance welding can take a signifi taken into consideration during part and applications every day. It is easy to imag cantly longer time to weld the assembly be tooling design, significant improvements ine how remote laser welding can be used cause of having to reposition either the part in manufacturing can be realized.• in the automotive industry. Many assem or the resistance welding machine. Remote

AUGUST 2006 Simulation Software Helps Automakers

One of the newer developments in resistance spot welding is use of simulation software to predict weld results

BY NIGEL SCOTCHMER

en years ago many would have been weld parameters and their predicted re and pressure are applied to metal surfaces surprised that an article would be sults before the weld is performed. for a determined period of time and Tpublished today describing new de breaks it down into small, measurable velopments in resistance welding. After Simulation of RSW steps. In colloquial terms, it "crunches the all, resistance spot welding (RSW) is a ma numbers." ture process, having been developed more Simulation of resistance welding has This means that the software takes into than 100 years ago, and some would say taken off in the last ten years with the ex account the metallurgical, electrical, me it lacks the glamour and performance plosion of powerful laptop and desktop chanical, and thermal processes that will characteristics of the newer technologies computers. It is now possible not only to occur during the welding process, and cal emerging today. simulate and accurately predict weld culates the resultant effects. In effect, the Why, then, is the use of resistance nugget size, but also to optimize welding computer simulates the heat generated by welding, and the total number of spot parameters and even to predict the hard the current and voltage, the heat transfer welds in a car, generally increasing around ness and microstructure of completed across materials, the metallurgical phase the world in new models? The first rea welds prior to welding. Resistance weld transformations caused by temperature son is that resistance welding is an inex ing itself is accomplished with the appli change, and the deformation and strain pensive, understandable joining process, cation of heat generated by the electrical distribution across the contact areas. All with no expensive shielding gases or filler resistance of the material being welded this information is then presented in a metals employed. In addition, the in confined by the application of pressure. graphic form useful to the user — Fig. 2. creased adoption of electronics in the last The typical software package that en t the AWS Detroit Section's Sheet ten years has made resistance welding eas deavors to simulate this process operates Metal Welding Conference, which ier to measure and control with simula on a normal desktop computer found at Awas held in Livonia, Mich., in May, tion software and precise weld controllers. any company. The thickness and type of and at the SAE 2006 World Congress, held Easier to use and more reliable nonde the material being welded, the geometry in Detroit in April, papers were presented structive examination is also available. and material of the electrodes, the cur by organizations such as Honda (Ref. 1), Another reason for the increased interest rent, force, and welding time are entered General Motors (Ref. 2), the University in resistance welding in automotive appli in the computer and the software per of Waterloo (Ref. 3), the Edison Welding cations is the increasing use of advanced forms numerous mathematical calcula Institute (Ref. 4), and Huys Industries high-strength steels for improved crash tions to determine the simulated weld — (Ref. 5) showing how simulation can as performance and fuel economy. Many of Fig. 1. sist the design and choice of materials and these steels have unique and new mi- he branch of mathematics generally geometries, improve process optimiza crostructures that may perform differently used in resistance welding software tion, and aid education through the im after being welded. Thus the simplest Tis called finite element modelling proved understanding of the welding process that is understandable, control (FEM). FEM allows for a solution of a process. lable, and can effectively and inexpen problem to be determined based upon the For instance, Honda's work (Ref. 1) sively weld these new, harder-to-weld ma approximation of an array of elements of explored the complex weld of an indirect terials is of immense interest. complex individual geometric parts with hem projection. The edge of an automo An ideal place to start our understand complicated boundary conditions. The bile door uses a hem; how that hem is ing of RSW is with a discussion of soft computer, in effect, takes the large scien sealed is often a manufacturing challenge. ware that simulates the engineering of tific problem of what happens when heat To explore the design of such a weld in

NIGEL SCOTCHMER (nscotchmer@ huysindustries.com) is president of Huys Industries Ltd., Toronto, Canada.

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FE-25 * Samiwtid be (, 6 larttniMSgrt Fig. 3 — An indirect hem projection weld. Objects 1-4 are machine tools; A, B, and C are workpieces — the hem-inner, hem-outer, and hem-projection, respectively. simulation is a novel application and in with supporting dicative of future possibilities — Fig. 3. test verifications, The simulation work was confirmed and highlight the rapid compared with test results. growth of weld sim General Motors' work (Ref. 2) ex ulation as an estab FE-25 G tonmw,ld&c, 6 Samnugert PinCvU 6 taxamld&ct, 6.5armmscA plored different electrode geometries. lished process. Many opinions are held regarding elec Another appli Fig. 4A —A selection of the electrode styles used in resistance weld trode design, and this work reviewed trun cation for this type ing; B — RSW electrode geometiy FEM models simulated for a tar cated, radius, and parabolic shapes — Fig. of software is the get weld size of'6.5-mm nuggets on 1.6-mm DP800 steel. 4. The University of Waterloo's work (Ref. simulation of pre 3) looked at simulating an unusual pro dicted material jection weld. The Edison Welding Insti characteristics of welded metal sheets. ulated weld nugget are automatically tute explored ways of measuring electrode Since the cooling rate of molten, welded graphed by the software and then can be life and of evaluating the material char metal can determine its hardness, it has compared to the constant cooling trans acteristics of a simulated weld (Ref. 4). been proved useful to compare the simu formation (CCT) diagrams commercially This work presages future development, lated weld nugget to constant cooling rate published, thus predicting weld perform in that the extending and predicting of diagrams to assist in determining weld ance. This is a significant advance, in that electrode life is the Holy Grail of resist strength. In the charts shown in Fig. 5, the the ability to predict weld strength is a fun ance welding. These recent articles, all cooling rates of points A and B in the sim- damental concern of all welding. Thus the

AUGUST 2006 A

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Fig. 6 — A — Weld parameter optimization for the weld lobe; B — Contwiuous Cooling Transformation ECCT) Diagram 11.111.; typical output and welding lobe charting weld current against weld Austenlte \ time. P 800 /ferrlte Peariite • computer, and rep Lowering costs by simulating design of | 600 7 1 "" Bainite ; resents a significant complex welds. Proceedings of the AWS / potential savings in Sheet Metal Welding Conference XII. AWS Mattensit ./ time and money. Detroit Section, Detroit, Mich. ; The rapid ad 2. Chan, K., et al. 2006. Effect of elec

10« vance of simulation trode geometry on resistance spot weld Time, s RSW suggests that ing of AHSS. Proceedings of the A WS Sheet Source: www.matter.org.uk this new procedure Metal Welding Conference XII. AWS De to evaluate and as troit Section, Detroit, Mich. Fig. 5 — The cooling rates of points A and B shown in the top and sist an established 3. Kuntz, M., and Bohr, J. 2006. Mod center figures are automatically graphed by the software. Then, as process has ar eling projection welding fasteners to shown at bottom, predicted cooling rates are compared to published rived. Clearly, it is AHSS sheet using finite-element method. CCT diagrams, with the martensitic microstructure shown above at only a matter of Proceedings of the A WS Sheet Metal Weld right (courtesy University of Liverpool). time before stand ing Conference XII. AWS Detroit Section, alone computer Detroit, Mich. many calculations a computer can do in a simulations are connected on-line to net 4. Gould, J., and Peterson, W. 2006. blink of an eye are put to good use. works controlling the whole welding Analytical modeling of electrode wear oc Other recent work looks at the com process on a complete assembly line. The curring during resistance spot welding gal puter generation of optimized welding pa more we understand the welding process, vanized sheets. Proceedings of the AWS rameters and the investigation into the and can control it in advance, the better Sheet Metal Welding Conference XII. AWS generation of the complete welding lobe the quality and the cheaper the part.^ Detroit Section, Detroit, Mich. — Fig. 6. This will allow the initial setup 5. Chan, K., et al. 2006. Weldability im of welding parameters according to the References provement using coated electrodes for materials and electrode geometry chosen RSW of HDG steel. SAE 2006 World to be determined automatically by the 1. Edwards, P., and Chan, K. 2006. Congress, Detroit, Mich.

WELDING JOURNAL! Achieving quality GTA welds on aluminum is a matter of skill and the application of good weldine practices.

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s we strive to meet the demands tungsten arc welding (GTAW) practices that can lead to incomplete fusion, inclu of increasingly fast-paced indus for aluminum applications — Fig. 1. These sions, or porosity. Most GTAW power Atries, our focus on productivity basics are applicable regardless of sources provide good cleaning action dur can often overshadow some of the basic whether you use a conventional AC power ing the electrode positive (EP) portion of techniques necessary for our welding ap source or power sources with square wave the weld cycle; however, you should never plication. Unknowingly, we may come to or advanced square wave capabilities. rely solely on this cleaning action to do rely too much on technology to solve our the job for you. problems and keep products moving out Instead, first wipe the base metal with the door. Clean Aluminum Is Good a cloth to remove dirt, oil, or grease. This Unfortunately, when we forget the ba Aluminum procedure, though outwardly simplistic, sics, our equipment (no matter how ad is absolutely necessary. vanced) can easily fall short of the job. Cleaning aluminum before GTA weld Equally important is removing the ox Following is a discussion of good gas ing is essential to remove contaminants ides that naturally form on the aluminum.

•I AUGUST 2006 Good welding practices lead to high-quality aluminum gas tungsten arc welds, no matter which type of power source you're using

BY MIKE SAMMONS

This procedure can be done mechanically, by using a scraping tool or a stainless steel wire brush, or chemically, by applying an acidic solution designated for aluminum oxide removal — Fig. 2. If you choose to remove the oxides me chanically, remember to designate the scraping tool or wire brush for that pur pose only — using these tools for multi ple jobs could cause contaminants to be introduced to the aluminum. Using a power brush is not recommended as it can also re-embed contaminants into the metal. Finally, if you are considering using the chemical method to remove oxides, consult your local welding distributor for the best product options. To prevent drawing contaminants from the backside of a joint, remember to clean both sides of the aluminum. Also, be cer tain to use clean filler rods, as they too can contain dirt and/or oxides. Clean the rods using a clean or new Scotch Brite™ Fig. 1 — Following good gas tungsten arc welding practices will result in high-quality alu pad dedicated to the purpose. minum welds such as the one slwwn here. The Basics

Remembering the following basics gas flow too high can lead to problems, in For applications below 100 A on thin about shielding gases and tungsten can cluding but not limited to porosity and/or ner-gauge aluminum (0.005 to 0.093 in.), help you avoid problems when GTA weld pinholes. When using argon and/or an it is best to use 2% tungsten, ceriated, or argon/helium mixture, set your gas flow be thoriated. Sharpening these tungstens to ing aluminum. 3 Gases: Pure argon offers the advan tween 5 to 20 ft /h for flat position alu a point helps prevent distortion by better tage of being more cost-effective than he minum welding and at approximately 20 focusing the arc and also gives better con lium and is a good, all-purpose gas that ft-Vh for all other welding positions — Fig. trol. If you are using an advanced square produces a focused, concentrated arc. 3. When welding overhead, vertical, or hor wave power source, a pointed 2% ceriated Adding helium to your argon mixture izontal, the addition of helium can also be tungsten provides an especially focused can provide greater penetration when beneficial because, being lighter than air, it arc and allows for the use of a smaller di welding aluminum more than % in. thick. floats upward to protect the weld. ameter for even greater arc control. It also increases the arc voltage range from Use approximately one second of pre- Note: Thorium is radioactive; there 13 to 18 V (the range for argon) up to a flow prior to welding aluminum and use fore, you must always follow manufac range of 22-25 V, thus increasing the over one second of postflow for every 15 A with turer's warnings, instructions, and the all power for a given amperage setting. which you have been welding. Both pre- MSDS (Material Safety Data Sheet) for For the infrequent welding of heavier alu and postflow help prevent tungsten and its use. minum, adding helium to gain voltage can weld pool contamination. Tungsten Extension: Regardless of the be helpful; however, if you weld thicker Tungsten Style and Diameter: If you type of tungsten you use to GTA weld alu aluminum on a regular basis, you should are using a conventional AC or square minum, remember that the tungsten invest in a larger power supply. Finally, wave power source, balled pure tungsten should extend no more than the distance adding 3 to 5% of helium can also stabi works well on aluminum applications that that equals the inside diameter (ID) meas lize your arc on low-end applications. are above 100 A. For example, %: tung urement of the nozzle. For example, a Generally, pure helium is used for sten can be used at up to 180 A without number eight nozzle is A in. across, so your GTAW of aluminum only in specialized problems. electrode extension should not exceed 'A applications or for DC aluminum weld You can also use pointed zirconiated in. Following this basic rule increases your ing. Helium is much more expensive, and tungsten for 100-plus-amp applications, visibility of the weld pool and tungsten requires good welding skills and excep but at even higher amperages than pure and reduces the possibility of touching the tional cleanliness. tungsten (a %i zirconiated tungsten can be tungsten to the weld pool. It also provides Gas Flow: Bear in mind that setting your used up to 210 A). better weld pool control.

MIKE SAMMONS (msammons^weldcraft.com) is sales and marketing manager, Weldcraft, Appleton, Wis.

WELDING JOURNAL Other Considerations

Also consider factors such as equip ment, joint preparation, and arc starting during the process of GTA welding aluminum. Equipment: Conventional AC sine wave, conventional square wave, and ad vanced square wave power sources are all acceptable for aluminum GTAW, but you will need basic operator controls includ ing preflow, postflow, and high-frequency arc starting capabilities. Your power supply should also be large enough to handle the amperage requirements of your application. An air-cooled GTAW torch works well for aluminum applications under 200 A or for fieldwork, but you should consider using a water-cooled torch for welding above 200 A or where torch size matters for comfort or limited-access joints. Joints: When welding aluminum above Vv, in. thick, it is a good practice to prepare the joint to be welded beforehand. Creat ing a V groove on 'At- to /2-in.-thick alu minum helps minimize distortion by less ening the amount of heat input required Fig. 2 — To avoid contaminating aluminum, clean both sides of a joint with a stainless steel to create a sound weld. For aluminum that brush designated solely for that purpose. is over Vi in. thick, preparing a J bevel or a U groove works best. Arc Starting and Length: When you are using a power source with high- frequency arc starting capabilities, it is im portant not to touch the tungsten to the aluminum. Instead, hold the tungsten ap proximately Vi in. away or tilt the torch until the arc is initiated and shift into your desired welding position. When using an advanced square wave power supply with lift arc start, do not touch the tungsten to the aluminum for an extended period of time at the risk of contaminating the workpiece. Using a lift arc start with a conven tional AC sine wave machine is not rec ommended for aluminum GTA welding. A good practice is to maintain an arc length equal to the diameter of the tung sten you are using. For example, if you are using %2-in. tungsten, you should have a %-in. arc length.

Slow Down, Remember the Basics

Remember that no amount of technol ogy can replace the skill of a good, knowl edgeable welder, so be careful not to rely solely on your equipment to do the job for you. Instead, consider these basics for GTA welding aluminum as the foundation of your process. Once you have the fun damentals in place, it will be easier to ex periment with your individual application and still achieve the desired results. After Fig. 3 — Using 5 to 20ft3lh of shielding gas when GTA welding aluminum helps avoid poros all, rules are meant to be broken, but only ity and pinholes. after they have first been mastered.•

AUGUST 2006 ^csdUSfPf^. NAVY JOINING CENTER A MANTECH CENTER OF EXCELLENCE OPERATED BY EWI EWI Contributes to Distortion Control for Lightweight Navy Ship Structures

ith a recent major initiative funded by the U.S. Navy, WNorthrop Grumman Ship Sys tems (NGSS) has undertaken a compre hensive assessment of lightweight struc ture fabrication technology. Northrop Grumman has teamed with Edison Weld ing Institute (EWI), Battelle Memorial Institute, University of New Orleans, Uni versity of Michigan, and Penn State Uni versity Applied Research Laboratory (ARL) on this initiative to develop a pre ferred manufacturing plan for lightweight ship structures — Fig. 1. Significant progress has been achieved in the devel opment of distortion control techniques through this collaborative research. Tran sient thermal tensioning (TTT), reverse arching, stiffener assembly sequencing, and other preferred manufacturing tech niques were developed to reduce distor tion and lower the high rework costs as sociated with correcting that distortion. Fig. 1 — High-strength thin steel structures will reduce topside weight, enhance mission ca Shipboard applications of lightweight pability, and improve performance and vessel stability on future Navy ship structures. structures have increased over recent years in both military and commercial ves sels. Buckling distortion of complex light weight structures has emerged as a major from Q-WELD™ were validated with the Mark Your Calendar obstacle to the cost-effective fabrication actual distortions of a series of physical of ships. High-strength thin steel struc test panels (2 ft x 4 ft with a single stiff What: 2006 SNAME Maritime Tech tures reduce topside weight, enhance mis ener and 16- x 20-ft panels with 8 stiffen nology Conference & Expo and Ship sion capability, and improve performance ers, with or without an insert). Analyses Production Symposium and vessel stability, but greatly increase were performed to evaluate the buckling When: Oct. 10-13, 2006 the propensity of structural buckling propensity of each test panel with and Where: Greater Fort Lauderdale/ distortion. without TTT. Q-WELD™ was demon strated as an extremely efficient numeri Broward County Convention Center, Transient thermal tensioning is a par cal tool in comparison with a 3-D elastic- Fort Lauderdale, Fla. ticularly promising technique that mini plastic FE analysis. mizes heat-induced buckling distortion in For more information on the topics Topics to Be Presented a relatively simple process. Without sig mentioned in this article or the upcoming The Edison Welding Institute will nificant loss of productivity, TTT is ap SNAME EWI conference presentations, present the results of two recent Navy plied concurrently to, but some distance contact Nancy Porter, (614) 688-5194; projects for manufacturing lightweight away from, the existing welding torch dur [email protected]. ship structures. The above article will ing fabrication. Transient thermal tension be presented with emphasis on Q- ing has faced the challenge in more com WELD™ for modeling weld distortion. plex panel structures reinforced by long Also to be presented are the final slender stiffeners along with numerous results of the National Shipbuilding cutouts and inserts. This geometric com Research Program (NSRP) project plexity yielded a more complicated buck "High Speed Narrow-Groove Sub ling behavior, which drives the need to de merged Arc Welding for Thin Steel velop a more fine-tuned finite element Panels." In this project, a narrow- (FE) model to determine critical param The Navy Joining Center groove tandem SAW process was de eters and heating patterns for the thermal 1250 Arthur E. Adams Dr. veloped and successfully demonstrated tensioning process. rue Columbus, OH 43221 Phone: (614) 688-5010 on thin plate. The presentation will also Operated by Q-WELD™, developed by EWI, is a FAX: (614) 688-5001 highlight the cost benefits of the shell-element-based numerical module e-mail: [email protected] process and technology transition ac that can effectively predict welding- EUli Web site: www.ewi.org tivity to several shipyards. induced distortions. The numerical results Contact: Larry Brown

WELDING JOURNAL COMING EVENTS NOTE: A DIAMOND (*) DENOTES AN AWS-SPONSORED EVENT.

The Next Industrial Revolution: Nanotechnology and Manufac tional & AWS Welding Show. Contact American Welding Society, turing. Aug. 23, 24, Pollard Technology Conference Center, Oak (800/305) 443-9353, ext. 223; or visit www.aws.org/conferences. Ridge, Tenn. Contact Society of Manufacturing Engineers, www.sme.org/nanomfg. ICALEO 2006, Int'l Congress on Applications of Lasers & Electro-Optics. Oct. 30-Nov. 2, Doubletree Paradise Valley Re 2006 Annual Assembly and Int'l Conf. of the Int'l Institute of sort, Scottsdale, Ariz. Visit www.icaleo.org. Welding (IIW). Aug. 27-Sept. 2, Quebec City, Canada. E-mail the Organizing Committee [email protected], or • Conference on Ways to Weld New Materials in the Automotive visit www.iiw2006.com. Industry. Oct. 31, Georgia World Congress Center, Atlanta, Ga., at the FABTECH International & AWS Welding Show. Contact • Welding in Aircraft and Aerospace Conference. Sept. 19, 20. American Welding Society, (800/305) 443-9353, ext. 223; or visit Dayton, Ohio. Contact American Welding Society, (800/305) 443- www.aws.org/conferences. 9353, ext. 223; or visit www.aws.org/conferences. • FABTECH International & AWS Welding Show. Oct. 31-Nov. 6th Int'l Symposium on Friction Stir Welding. Oct. 10-13, Aero 2, Georgia World Congress Center, Atlanta, Ga. This show is the space Mfg. Technology Center, Manoir Saint-Sauveur (near Mon largest event in North America dedicated to showcasing a full treal), Canada. Sponsored by The Welding Institute (TWI). Visit spectrum of metal forming, fabricating, tube and pipe, and weld www.twi.co.uk. ing equipment and technology. Contact American Welding Soci ety, (800) 443-9353, ext. 462; www.aws.org. Materials Science and Technology Conference 2006. Oct. 15-19, Cinergy Center, Cincinnati, Ohio. Visit www.matscitech.org. • Quality Control in Welding Conference. Nov. 1, Atlanta, Ga., at the FABTECH International & AWS Welding Show. Contact EuroBLECH 2006, Sheet Metalworking Technology Exhibi American Welding Society, (800) 443-9353, ext. 462; or visit tion. Oct. 24-28. Exhibition Grounds, Hanover, Germany. www. a ws. orglconferences. Contact www.euroblech.com. • Spot Welding Conference. Nov. 2, Atlanta, Ga., at the FABTECH • AA/AWS Aluminum Welding Conference. Oct. 30, Georgia International & AWS Welding Show. Contact American Welding World Congress Center, Atlanta, Ga., at the FABTECH Interna Society, (800) 443-9353, ext. 462; or www.aws.org/conferences.

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AUGUST 2006 16th Rolling Conference and 3rd Conf. on Uses of Steel. Nov. 6-9, Hotel Colonial, San Nicolas, Buenos Aires, Argentina. Contact www.siderurgia.org.ar. PIRANH £r i" 1 xx ii a. MetalForm Mexico. Nov. 7-9, Centro Banamex, Mexico City, Tungsten Electrode Mexico. Visit www.metalform.com, or e-mail marcela.ordaz@ giprex.com.

IAS 16th Rolling Conf. and 3rd Conf. on Uses of Steel. Nov. 7-9, Hotel Colonial, San Nicolas, Argentina. Presentations in English. Sponsored by Instituto Argentino de Siderurgia (IAS). Visit www.siderurgia.org.ar/eng/principal.htm.

Aerospace Testing Expo North America. Nov. 14-16, Anaheim Convention Center, Anaheim, Calif. For information, visit www.aerospacetesting-expo.com/northamerica/contact.html.

MetalForm. March 25-28, 2007, Donald E. Stephens Conven tion Center, Rosemont, 111. Sponsored by Precision Metal- forming Assn. Visit www.metalform.com. ECONOMICALLY PRICED TUNGSTEN GRINDER Southeast Asia Wire and Tube Trade Fairs. Oct. 16-18, 2007, Bangkok, Thailand. Contact Messc Diisseldorf North Amer SAFETY: Enclosed diamond wheel grinding area ica, [email protected]; www.indna.com. WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability PRODUCTIVITY: Longitudinal diamond grind your tungsten under 30 seconds Educational Opportunities VALUE: Diamond flat, grind & cut your tungsten economically Fastening Technology and Bolted Joint Design Seminars. Aug.

23, 24, Baltimore, Md.; Nov. 8, 9, Chicago, 111. For details visit DIAMOND GROUND PRODUCTS, INC. ^ py www. SeminarsForEngineers. com. 2550 Azurite Circle Newbury Park CA 9t320 \ I Phone (805) 498-3837 • FAX (805) 498-9347 Managing the Welding Process, Sept. 8; AWS Fabrication Email: [email protected] Criteria, Nov. 3, Atlanta, Ga.; Dec. 6, 7, Chicago, 111.; Basic Tools Visit our website: vvww.diamondground.com Circle No. 24 on Reader Info-Card

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he Nissen' Metal Markers utilize a specially-formulated paint to provide permanent marking under almost any conditions. They will mark on all metals, even if the surface is rusty, wet or oily. The marks withstand weathering and heat; they won't chip, peel, fade, or rub off. The markers are available in both an unbreakable plastic bottle and the standard metal tube. They are available in three point sizes and 12 bright, lead-free, high gloss colors. www.nissenmarkers.com Booth #D-4424 Call, Fax, or Write Chicago, IL Sept. 6-13,2006 for Additional Information Made in USA J.P. Nissen Co. P.O. Box 339 • Glenside, PA 19038 Gradient Lens Corporation gradientlens.com 800.536.0790 (215) 886-2025 • Fax: (215) 886-0707 Circle No. 28 on Reader Info-Card Circle No. 32 on Reader Info-Card WELDING JOURNAL of Quality, Oct. 2, 3, Chicago, 111.; AISC Major Bridge/Building Residual Stress Measurement Certification, Oct. 24-26, Chicago, 111.; Continuing Education for CWI, Nov. 8-10, Chicago, 111. Contact Atema, Inc., (312) 861- Preventing problems before they happen 3000. or visit www.atemasolutions.com.

Residual Stress Affects: Boiler and Pressure Vessel Inspectors Training Courses and Crack initiation Seminars. Columbus, Ohio. Contact Richard McGuire, (614) 888-8320, [email protected], www.nationalboard.org. Crack propagation Stress corrosion cracking CWI/CWE Course and Exam. This 10-day program prepares stu Distortion dents for the AWS CWI/CWE exam. For schedule and entry Fatigue life requirements, contact Hobart Institute of Welding Technology (800) 332-9448, www.welding.org. Laboratory and Portable Residual Stress CWI Preparation. Courses on ultrasonic, eddy current, radiogra Measurement Systems phy, dye penetrant, magnetic particle, and visual at Levels 1-3. Meet SNT-TC-1A and NAS-410 requirements. On-site training available. T.E.S.T. NDT, Inc., 193 Viking Ave., Brea, CA 92821; (714) 255-1500; [email protected]; www.testndt.com.

CWI Preparatory and Visual Weld Inspection Courses. Classes presented in Pascagoula, Miss., Houston, Tex., and Houma and Sulphur, La. Course lengths range from 40 to 80 hours. Contact Real Educational Services, Inc., (800) 489-2890; info@realeducational.com.

EPRI NDE Training Seminars. EPRI offers NDE technical skills training in visual examination, ultrasonic examination, ASME Residual Stress Map Section XI, and UT operator training. Contact Sherryl Stogner, Welded Bar (704) 547-6174, e-mail: [email protected]. www.protoxrd.com 1.800.965.8378 Fabricators and Manufacturers Assn., and Tube and Pipe Assn. Courses. Contact (815) 399-8775; www.fmametalfab.org; [email protected] 1.313.965.2900 info @fmametalfab. org. • Circle No. 39 on Reader Info-Card

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AUGUST 2006 2006 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 DATE EXAM DATE SITE CODE LOCATION SEMINAR DATES EXAM DATE SITE CODE Memphis, TN Aug. 6-11 Aug. 12 TN04907 Milwaukee, WI Sep. 25-29 Sep. 30 CWS 11 Salt Lake City, UT Aug. 6-11 Aug. 12 UT05007 Portland, OR Nov. 6-10 Nov. 11 CWS 12 Miami, FL EXAM ONLY Aug. 17 HQ07807 Houston, TX Aug. 13-18 Aug. 19 TX05207 Charlotte, NC Aug. 20-25 Aug. 26 NC05307 Certified Radiographic Interpreter (RI) LOCATION SEMINAR DATES EXAM DATE SITE CODE Rochester, NY EXAM ONLY Aug. 26 NY08607 Long Beach, CA Nov. 6-10 Nov. 11 RIP16 Syracuse, NY Sep. 10-15 Sep. 16 NY05507 Louisville, KY Nov. 13-17 Nov. 18 RIP17 Miami, FL EXAM ONLY Sep. 21 HQ07907 Minneapolis, MN Sep. 17-22 Sep. 23 MN05607 Radiographic Interpreter certification can be a stand-alone credential or can exempt you from your next 9-Year Seattle, WA Sep. 17-22 Sep. 23 WA05707 Recertification. San Diego, CA Sep. 17-22 Sep. 23 CA05807 Anchorage, AK EXAM ONLY Sep. 23 AK08407 Dallas, TX Sep. 24-29 Sep. 30 TX05907 Certified Welding Educator (CWE) Seminar and exam are given at all sites listed under Certified Detroit, MI Sep. 24-29 Sep. 30 MI06007 Welding Inspector. Seminar attendees will not attend the Code Milwaukee, WI Sep. 24-29 Sep. 30 WI06107 Clinic portion of the seminar (usually first two days). Cleveland, OH (at Lincoln Electric Welding School*) Oct. 1-6 Oct. 7 IC10106 Denver, CO Oct. 8-13 Oct. 14 CO06207 Senior Certified Welding Inspector (SCWI) Phoenix, AZ Oct. 8-13 Oct. 14 AZ06307 Exam can be taken at any site listed under Certified Welding Inspector. No preparatory seminar is offered. Miami, FL EXAM ONLY Oct. 19 HQ08007 Pittsburgh, PA Oct. 15-20 Oct. 21 PA06407 Tulsa, OK Oct. 15-20 Oct. 21 OK06507 Certified Welding Fabricator San Antonio, TX Oct. 15-20 Oct. 21 TX06607 This program is designed to certify companies to specific requirements in the ANSI standard AWS B5.17, Specification for Chicago, IL Oct. 22-27 Oct. 28 IL06707 the Qualification of Welding Fabricators. There is no seminar or Atlanta, GA Oct. 22-27 Oct. 28 GA06807 exam for this program. Call ext. 475 for more information. Reno, NV Oct. 29-Nov. 3 Nov. 4 NV06907 Baltimore, MD Oct. 29-Nov. 3 Nov. 4 MD07007 Code Clinics & Individual Prep Courses Long Beach, CA Nov. 5-10 Nov. 11 CA07107 Dl.l, API-1104, Welding Inspection Technology, and Visual Beaumont, TX Nov. 5-10 Nov. 11 TX07207 Inspection workshops are offered at all sites where the Certified Portland, OR Nov. 5-10 Nov. 11 OR07307 Welding Inspector seminar is offered. Dl.l and API-1104 Code Louisville, KY Nov. 12-17 Nov. 18 KY07407 Clinics are held on Sundays and Mondays and are prep courses St. Louis, MO EXAM ONLY Dec. 2 MO08507 for CWI Exam-Part C. Welding Inspection Technology is held Miami, FL Dec. 3-8 Dec. 9 FL07507 Wednesdays and Thursdays and is a general knowledge course and a prep course for CWI Exam-Part A. Visual Inspection Columbus, OH (at NBBPVI*) workshop is usually held on Fridays and is a prep course for CWI Dec. 11-15 Dec. 16 OH09407 Exam-Part B. Corpus Christi, TX EXAM ONLY Dec. 16 TX08307 On-site Training and Examination * Mail seminar registration and fees for Columbus seminars only to National Board of Boiler & Pressure Vessel Inspectors, 1055 Crupper On-site training is available for larger groups or for programs Ave., Columbus, OH 43229-1183. Phone (614) 888-8320. For Cleveland that are customized to meet specific needs of a company. Call seminar only, call (216) 383-2259. Exam application and fees should ext. 219 for more information. always be mailed to AWS.

9-Year Recertification for CWI and SCWI For information on any of our seminars and certification LOCATION SEMINAR DATES EXAM DATE SITE CODE programs, visit our website at www.aws.org or contact AWS at San Diego, CA Aug. 28-Sep. 2 NO EXAM* * RSV245 (800/305) 443-9353, Ext. 273 for Certification and Ext. 449 for Dallas, TX Nov. 13-18 NO EXAM* * RSV255 Seminars. Orlando, FL Dec. 4-9 NO EXAM* * RSV265 Please apply early to save Fast Track fees. This schedule is "For current CWIs needing to meet education requirements without subject to change without notice. Please verify the dates with the taking the exam. If needed, recertification exam can be taken at any site listed under Certified Welding Inspector. Certification Dept. and confirm your course status before making final travel plans.

American Welding Society

Founded in 1919 to advance the science, technology and application of welding and allied joining and cutting processes, including brazing, soldering and thermal spraying.

Circle No. 4 on Reader Info-Card SAWS 2006 CER1324-08 WELDING WORKBOOK Datasheet 279 Grinding Tungsten Electrodes

To produce optimum arc stability, grinding of thoriated, ceri- tion of better than 10 pin. ated, and lanthanated tungsten electrodes should be done with The grinding wheel should be used only for grinding tungsten the axis of the electrode perpendicular to the axis of the grind to eliminate the possibility of the electrode being contaminated ing wheel and ground on the flat face of the wheel (i.e., the elec with foreign matter. A diamond wheel is preferred over silicon trode should be ground in the longitudinal direction). Circum carbide or aluminum oxide wheels. Exhaust hoods and personal ferential grinding of the electrode tip is not recommended. Elec protective equipment should be used when grinding tungsten trode life will be extended if there is a polished surface condi electrodes. Grinding dust should be removed from the work area.

STEPI STEP II STEP III

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TUNGSTEN CUT TO LENGTH

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-HOLDING FORK

ADJUSTABLE STOP/SCALE

Excerpted from AWS C5.5/C5.5M:2003, Recommended Practices for Gas Tungsten Arc Welding.

AUGUST 2006 -; , ......

I BY HOWARD M. WOODWARD

AWS Nominates National and District Officers for 2007

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Gerald D. Uttrachi Gene E. Lawson Victor Y. Matthews John C. Bruskotter president vice president vice president vice president

lhh e 2004-2005 Nominating Committee has an TInounce d its slate of candi dates who will stand for election to AWS national offices for the 2007 term, which begins January 1,2007. Nominated are the following: Gerald D. Uttrachi for presi dent; Gene E. Lawson, Victor Y. Matthews, and John C. Bruskot ter for vice presidents; Harvey R. Castner and Dean R. Wilson for directors-at-large; and Earl C. Lipphardt for treasurer. (Three Earl C. Lipphardt Harvey R. Castner Dean R. Wilson vice presidents, two directors-at- treasurer director-at-large director-at-large large, and one treasurer are to be elected.) The National Nominating Commit nominees are Russ L. Norris, District 1; Member, is currently completing his tee was chaired by Past President Roy C. Lanier, District 4; Donald C. third term as an AWS vice president. Thomas M. Mustaleski. Serving on the Howard, District 7; Richard A. Harris, Uttrachi is president of his company, committee with Mustaleski were Alan J. District 10; W. Richard Polanin, District WA Technology, LLC. The firm sells Badeaux, Mark D. Bell, Neal A. Chap 13; David Landon, District 16; Neil his patented device that effects major man, Jack D. Compton, J. R. "Rusty" Shannon, District 19; and Dale Flood, cost savings during welding by mini Franklin, Wallace E. Honey, Jesse L. District 22. George Fairbanks, District mizing shielding gas losses. Previously, Hunter, Mike Kersey, Ernest D. Levert 9, was elected to fulfill the remainder of he served as a development engineer, Sr., John L. Mendoza, Tully C. Parker, John C. Bruskotter's term, Jan. 1, project engineer, welding materials and Geoff H. Putnam. Gricelda Man- 2007-Dec. 31, 2008. William A. Komlos laboratory manager, and director of alich served as secretary. will serve as Dist. 20 director Sept. 1, welding market development with 2006-Dec. 31, 2007, filling in for Nancy Linde Div. of Union Carbide Corp. He The Nominating Committees for Carlson, who plans to retire. was vice president of marketing for L- Districts 1, 4, 7, 10, 13, 16, 19, and 22 TEC Welding & Cutting Systems, then have selected the following candidates vice president of equipment marketing for election/reelection as District direc Nominated for President for ESAB Welding & Cutting Products. tors for the three-year term Jan. 1, 2007, Gerald D. Uttrachi Throughout his 39-year career in through Dec. 31, 2009. The Director Gerald D. Uttrachi, an AWS Life

WELDING JOURNAL the welding industry, Uttrachi has been at The Lincoln Electric involved with the development of au Co. in 1963 as a bend tomatic welding processes and weld brake operator. He at ing materials. He has published nu tended Lincoln's weld merous technical papers on welding ing school and earned processes and filler metals. He holds all of the diplomas it master's degrees in mechanical engi had to offer. He pro neering and business management from gressed to work in the New Jersey Institute of Technology. Ut Electrode Research trachi has served on various filler met and Development als committees, the Welding Handbook group for 13 years. Committee, Technical Papers Commit Matthews moved to the tee, and has chaired the Marketing and manufacturing facility PEMCO Committees. He has also acted as plant welding engi as representative to IIW Committees neer where he worked Russ L. Norris on Filler Metals Specifications. Cur for 12 years. He auto Roy C. Lanier District 1 rently, he is chairman of the AWS Met mated many worksta director District 4 director ric Practices Committee, a member of tions and put into production the com the Conference Committee, and an pany's first-ever welding robot for Nominated for Treasurer AWS Foundation trustee. piecework. In 1990, he joined the Ser Earl C. Lipphardt vice Department with responsibility for Earl Lipphardt is completing his Nominated for Vice President engine-driven welding machines. In first term as treasurer. Lipphardt is the Gene E. Lawson 1992, he was assigned responsibility for owner of an H&R Block franchise with Gene E. Lawson is currently com Cleveland-manufactured consumable offices in Girard and Albion, Pa. Prior pleting his second term as an AWS vice products worldwide. Currently, he is re to his retirement in 1999, he served for president. An AWS member since 1974, sponsible for consumables, GTA and 20 years as an outside supervisor, de he received a degree in commercial SMA welding machines, plasma arc cut sign consultant, and sales representa art/advertising from Colorado Institute ting machines, inverters under 300 A, tive for the installation of the manifold of Art. He continued his education at and is liaison to the Italian subsidiaries. for the first General Electric-built nat Denver Community College specializ Lincoln recognized him with its Man of ural gas locomotive. ing in welding and metallurgy. At the Year Award in 1995. Chemetron Corp., he specialized in He is the past president of the Lin Nominated for Director-at-Large sales of welding consumables and coln Electric Employee's Association Harvey R. Castner equipment. In 1975, he moved to south and Sick Benefit Fund. Matthews also Harvey R. Castner is completing ern California as Chemetron's regional is a past chairman of the Cleveland Sec his first term as a director-at-large. He sales manager. Later, Chemetron be tion. He served as national chairman of earned a degree in welding engineering came Alloy Rods Corp., and is now the Liaison Committee for the 1995 from The Ohio State University and an ESAB Welding & Cutting Products. Welding Show held at the Cleveland IX- MBA from Kent State University. He Lawson remains its representative as Center. Currently, he serves on the has more than 30 years in the welding territory sales manager for southern Prayer Breakfast Committee, Standards field. He is a registered professional en California, Arizona, and Hawaii. Law- Council, Districts Council, and the gineer in the state of Ohio. son has served several terms as chair Membership Committee. He served In 1994, Castner joined, and now man of the Los Angeles Section, served eight years on PEMCO, the Executive directs, the Government Programs Of three years as a director-at-large, and Committee, the Professional Develop fice at Edison Welding Institute (EWI), two terms as District 21 director. He has ment Council, TFPS, and Government Columbus, Ohio, including the Navy taken the CWI preparation course and Affairs Liaison Committee. Joining Center, a Navy Manufacturing proctored CWI examinations. Technology (MANTECH) Center of In 1990, he served on the Steering Nominated for Vice President Excellence for materials joining tech Committee for the AWS National Con John C. Bruskotter nology. He is responsible for welding- vention held in Anaheim, Calif. He also John C. Bruskotter is currently related R&D programs to improve the served on the Liaison Committee in serving his second term as District 9 di quality and cost effectiveness of manu 1996 for the Los Angeles show. Lawson rector. He operates Bruskotter Consult facturing and repair operations used by has been a member of the Product De ing Services, working for an independ the U.S. Navy, Department of Defense, velopment, Prayer Breakfast, Member ent oil and gas operator. Previously, he and other government agencies. ship, and Executive committees, and worked for several years as a project Prior to joining EWI, he was vice served on the Government Affairs Li manager with Dynamic Industries, Inc. president of engineering at Hartman aison, National Nominating, and Con From 1986-2000, Bruskotter was em Materials Handling Systems, Inc. He vention Site Committees. He has sat on ployed with Houma Industries, Inc., also served as manager of manufactur the Board of Directors and the Districts, where his positions included fabrication ing automation technology at Allis Communications, and Marketing Coun and quality control manager, vice pres Chalmers Corp. Advanced Technolo cils. Lawson also serves on the advi ident of operations onshore, offshore gies Center. sory board at Orange Coast College. fabrication and coatings, and warehous Castner received the AWS James ing and maintenance. F. Lincoln Gold Medal Award and the Nominated for Vice President Bruskotter joined the AWS New Arsham Amirikian Memorial Maritime Victor Y. Matthews Orleans Section in 1993, where he Welding Award in 1996 and 1999, re Victor Y. Matthews is currently served as its treasurer and vice chair. spectively. He is an AWS Life Member, completing his first term as an AWS vice From 1999 to 2000, he served as both and member of the AWS board of di president. A member of the Cleveland the Section chairman and District 9 rectors. He is also a member of the Section for 37 years, he began his career deputy director. Welding Handbook Committee, SHI

M AUGUST 2006 Donald C. Howard George Fairbanks Richard A. Harris W. Richard Polanin District 7 director District 9 director District 10 director District 13 director

Safety and Health Subcommittee on chairman of the North Eastern Carolina in its executive group. Having held many Fumes and Gases, Conference Commit Section. Lanier has taught in the com offices in the Section, he recently com tee, and Product Development Commit munity college system for the past 30 pleted his sixth term as chairman. He tee, which he chairs. years, performing as an instructor and was the principal instructor for about 15 chairman of the Welding Technology CWI Prep classes, and five CWE classes. Nominated for Director-at-Large Department. At Pitt Community Col Fairbanks holds numerous certifica Dean R. Wilson lege, he held offices on various commit tions, including CWI, CWE, API 653, Dean Wilson is president and CEO tees including its Scholarship Commit NCCER master trainer and welding ed of Wilson Industries, Inc., a manufac tee. He holds CAWI and CWE certifi ucator, VT Level III, RT Film Interpre turer of industrial partitions, clothing, cates. In 1989, Lanier received the tation II, PT Level II, MT Level II, and and safety product accessories for the Howard Adkins Award of Excellence UT Thickness II. In 2004 he was cited welding, laser, materials handling, and for teaching. He recently retired from to receive the National Dalton E. safety markets. He holds a degree in bi the North Carolina National Guard with Hamilton CWI of the Year Award. ology from San Diego State University, 30 years of service. Today, Lanier and graduate studies in business from teaches welding and serves as depart Nominated for District 10 Director San Diego State University and execu ment chairman of the Welding Division. Richard A. Harris tive management at Stanford Univer Richard Harris is completing his first sity. He is an AWS Corporate Sustain Nominated for District 7 Director term as District 10 director. Harris is a ing Member, 2005 chair of WEMCO, Donald C. Howard contributing editor for Penton Publish and a director-at-large for Laser Insti Don Howard is completing his first ing Co. in Novelty, Ohio. tute of America. He is active in the term as District 7 director. He is a tech Gases & Welding Distributors Assn., In nical staff member at Concurrent Tech Nominated for District 13 Director dustrial Fabrics Assn., and the Specialty nologies Corp. in Johnstown, Pa., where W. Richard Polanin Tools & Fasteners Distributors Assn. he has worked in the Advanced materi Rick Polanin received his PhD from als department since 1990. He special the University of Illinois. He is profes Nominated for District 1 Director izes in welding high-strength low-alloy sor and program chair for the Manufac Russ Norris steels for use in shipbuilding. Prior to turing Engineering Technology and Russ Norris began his career in the joining the company, he worked as a Welding Technology programs at Illi welding supply industry in 1979. He cur welder in a truck body manufacturing nois Central College. An AWS member rently serves as a branch manager for plant. He received his welding engineer for 26 years, he has twice served as chair Merriam Graves Corp. in Portsmouth, ing technology degree from Westmore of the Peoria Section. Polanin is a mem N.H. Norris joined the AWS Maine Sec land County Community College, ber of the D16 Robotic and Automated tion in 1992 and, as a member of the where he serves as an adjunct faculty Welding Committee. He is an AWS Cer SkillsUSA/VICA Weld Skills team, as member, teaching courses in its welding tified Welding Inspector and Certified sisted in planning the test and aided in program. Welding Educator, and is a SME Certi the procurement of materials and fied Manufacturing Engineer. He has equipment needed for students to com Nominated for District 9 Director received the District Educator Award pete. The following year, Norris served George D. Fairbanks Jr. and the District CWI Award. Polanin as a judge for the competition as well. George Fairbanks was elected to ful has published numerous papers and He has held many offices in the Maine fill the remaining term of John Bruskot- textbooks, and has made many techni Section including education, certifica ter, who has been nominated for AWS cal presentations in the areas of manu tion, and scholarship chair, secretary, vice president. Fairbanks will serve Jan. facturing, robotics, and manufacturing and chairman. Norris also sits on the 1, 2007, through Dec. 31, 2008. He is education. Polanin is also a consultant Craft Committee of the Seacoast School senior welding inspector at Gonzales In in manufacturing and welding for the of Technology in Exeter, N.H. dustrial X-Ray. His welding career construction equipment and chemical began as a research technician at industries in central Illinois. Nominated for District 4 Director Louisiana State University. The next 16 Roy C. Lanier years he worked as a CWI and an API Nominated for District 16 Director Roy Lanier, an AWS member for 30 653 inspector in a metallurgical and test David Landon years, previously served as District 4 di ing lab. He joined the Baton Rouge Sec David Landon, an AWS member rector for two terms. Currently he is tion in 1980, where he has been active since 1983, has served two terms as

WELDING JOURNAL David London William A. Komlos Neil S. Shannon Dale Flood District 16 director District 19 director District 20 director District 22 director chairman of the Iowa Section. Landon special inspection services for complex Mark Steel Corp., Autoliv ASP, and Arc has chaired the Welding Industry Net building construction in Portland, Ore. Tech, LLC. He holds a patent on con work, and currently chairs the Techni He trained as a welding technician at trolling residual welding stresses, and cal Activities Committee. He is a mem the College of San Mateo, Calif., and has published articles in Welding Jour ber of the D14 Committee on Machin later earned his engineering degree at nal and MC Magazine. ery and Equipment, the International California Polytechnic State University. Standards Activity Committee, and the He has experience in marine construc Nominated for District 22 Director Awards Committee. Landon is a Senior tion, material-handling equipment, rail Dale Flood Certified Welding Inspector and a re road equipment, and robotics in weld Dale Flood has served the Sacra cipient of the District Dalton E. Hamil ing applications. mento Valley Section in numerous ca ton Memorial CWI of the Year Award, pacities including newsletter editor, first and the District Meritorious Award. He Nominated for District 20 Director vice chair, and chairman. Currently holds a welding engineering degree William A. Komlos Flood is a member of the executive com from LeTourneau University. Currently, William Komlos was elected to ful mittee where his involvement contin Landon is the manager of welding en fill the remaining term of Nancy Carl ues as a CWI supervising examiner. On gineering and missions support for Ver- son, who plans to retire. He will serve the AWS national level, Flood is an ac meer Mfg. Co., Pella, Iowa, a manufac Sept. 1, 2006, through Dec. 31, 2007. tive member of the D10 Committee on turer of construction, industrial, and Komlos is a Senior Certified Welding Piping and Tubing, and the D10U Sub agricultural equipment. Inspector, and an associate member of committee on Orbital Pipe Welding. He Structural Engineers Assn. of Utah. He started his career as a welder with the has served as first vice chairman of the Plumbers & Steamfitters Local Union Nominated for District 19 Director AWS Bl Committee on Nondestructive 157 in Terre Haute, Ind. Later, he Neil S. Shannon Examination of Welds. He holds an worked as a weld superintendent for Neil Shannon, an AWS Life Mem MBA from University of Phoenix, and CBI Services at several nuclear facili ber, has been active in District 19 and an MS in civil engineering from Univer ties where he was involved with machine Portland Section activities for 30 years. sity of Utah. He worked as a quality as and automated welding of critical appli He is a project manager and senior spe surance manager at United Precision cation piping. Currently, he is employed cial inspector for Carlson Testing of Machine & Engineering Co. for six years by Tri Tool Inc. as a project manager for Portland, Ore. He is a Senior Certified and as a welding instructor at Salt Lake one of its research and development Welding Inspector, and Int'l Code Community College for 15 years. He has teams. He holds several patents for Council special inspector, and provides held welding engineering positions at welding automation related work. •

Nominations Sought for Robotic Arc Welding Award

ominations are solicited for the tion, contact Reeve at [email protected], etc.) to enable success, and any other ac 2007 Robotic and Automatic Arc or call (800/305) 443-9353, ext. 293. tivity having significantly improved the NWelding Award. The nomination In 2004, the AWS D16 Robotic and state of a company and/or industry. The packet should include a summary state Automatic Arc Welding Committee, Award, funded by private contributions, ment of the candidate's accomplish with the approval of the AWS Board of is presented annually at the AWS ments, interests, educational back Directors, established the Robotic and Awards/AWS Foundation Recognition ground, professional experience, publi Automatic Arc Welding Award. The Ceremony and Luncheon, held in con cations, honors, and awards. award was created to recognize individ junction with the AWS Welding Show. December 31 is the deadline for sub uals for their significant achievements The D16 Committee recognizes the gen mitting nominations. Send the nomina in the area of robotic arc welding. This erous contributions to the award fund tion packet to Wendy Sue Reeve, awards work can include the introduction of received from ABB Robotic Products coordinator, 550 NW LeJeune Rd., new technologies, establishment of the Group and The James F Lincoln Arc Miami, FL 33126. For more informa proper infrastructure (training, service, Welding Foundation, Inc. •

AUGUST 2006 New AWS Supporters

New Supporting Companies Unitech Centre for X-Ray Welding Unitech Bldgs, Bakery Jet. Conan Ind. E. Com de Produtos Trivandrum, Kerala 695001 Eletro-Eletronicos Ltda. South India Av. Capuava No. 260, Santo Andre Sao Paulo 09111-000, Brazil New Affiliate Companies Johnson Welded Products 625 S. Edgewood Ave. Apex Mfg. Services, Ltd. Urbana, OH 43078 494 Foote St. Billings, MT 59101 Mechanical Integrity, Inc. 1423 First St., Ste. A Arc-Tech Welding, Inc. Humble, TX 77338 7760 E. Hwy. 69, C-5 #193 Prescott Valley, AZ 86314 Spotwelding Consultants, Inc. 4209 Industrial St. Fusion Werks Welding & Fabrication Rowlett,TX 75088 PO Box 656 A WS President Damian J. Kotecki (right) Pearl City, HI 96782 is shown May 25 with Prof. Dr. Ing. Dorin Educational Institutions Dehelean, general director of the Geocon Inland Empire, Inc. National R&D Institute for Welding and Alpine High School 6280 S. Valley Blvd. # 624 Material Testing, Timisoara, Romania. 300 E. Hendryx Las Vegas, NV 89118 Kotecki represented the American Alpine, TX 79830 Welding Society in a conference with the Grizzly Materials Testing and Romanian Welding Society, and the Buckeye Career Center Inspection Services Society for Advancement of Welding in 545 University Dr. NE 6280 S. Valley View Blvd., Ste. 722 Serbia. The 180 attendees included par ticipants from southeast Europe. New Philadelphia, OH 44663 Las Vegas, NV 89118 Louisiana Technical College — Holler Welding Membership Greater Capital Area Dist. 2 10010 W Gardner Rd. 3250 N. Acadian Thruway E. Bloomington, IN 47403 Counts Baton Rouge, LA 70805 Member As of Pederson Bros., Inc. Grades 7/1/06 Pickens Tech 3974 Bakerview Spur 500 Airport Blvd. Bellingham, WA 98226 Sustaining 451 Aurora, CO 80011 Supporting 255 Steel Service Corp. Educational 376 2260 Flowood Dr. San Jacinto College Central Affiliate 346 8060 Spencer Hwy. Jackson, MS 39232 Welding distributor 49 Pasadena, TX 77505 Total corporate members 1,477 Tri-Tech Construction Sheridan High School 34 S. 30th Individual members 44,615 Keokuk, IA 52632 • 1056 Long Dr. Student + transitional members 4,975 Sheridan, WY 82801 Total members 49,590

Nominations for Prof. Koichi Masubuchi Award

ominations are sought for the the world. educational background, professional 2007 Prof. Koichi Masubuchi The candidate need not be an Amer experience, publications, honors, and N Award, sponsored by the Dept. ican Welding Society member. awards. of Ocean Engineering at Massachusetts The nomination package should be The award was established to recog Institute of Technology. prepared by someone familiar with the nize Prof. Masubuchi for his contributions It is presented each year to one per research background of the candidate. to the advancement of the science and son who has made significant contribu It should include a resume and three technology of welding, especially marine tions to the advancement of the science to five letters of recommendation from and outer space structures. and technology of materials joining researchers familiar with the candidate. December 1, 2005, is the deadline. through research and development. The resume should include a sum Submit your nomination to Prof. John The candidate must be 40 years old mary statement of the candidate's re DuPont [email protected]. • or younger, and may live anywhere in search interests and accomplishments,

WELDING JOURNAL Tech Topics

TECHNICAL COMMITTEE by ANSI, require that all standards be velopment of International Standards for MEETINGS open to public review for comment dur welding, contact Andrew R. Davis, (305) ing the approval process. This column also 443-9353, ext. 466, [email protected]. ll AWS technical committee advises of ANSI approval of documents. ISO/DIS 5182, Welding—Materials for meetings are open to the public. The following standards are submitted for Resistance Welding Electrodes and Ancil APersons wishing to attend a public review. The review expiration date lary Equipment. meeting should contact the listed sec is listed with the document. A draft copy ISO/DIS 14343:20021 Amendment 2, retary at (800/305) 443-9353. may be obtained from Rosalinda O'Neill, Welding Consumables — Wire Electrodes, Aug. 16. International Standards Ac (800/305) 443-9353, ext. 451, or e-mail: Strip Electrodes, Wires and Rods for Fusion tivities Committee. Columbus, Ohio. [email protected]. Welding of Stainless and Heat Resisting Contact: Andrew R. Davis, ext. 466. A5miA5SnM:TMX,Filkr Metal Stan Steels — Classification Amendment 2. Aug. 17. Technical Activities Com dard Sizes, Packaging, and Physical Attrib ISO/DIS 21952, Welding Consumables mittee. Columbus, Ohio. Contact: Peter utes. New standard —$25.7/31/06. — Wire Electrodes, Wires, Rods and De Howe, ext. 309. G2.4/G2.4M:200X, Guide for the Fu posits for Gas Shielded Arc Welding of Sept. 12-15. Dl Committee on sion Welding of Titanium and Titanium Al Creep-Resisting Steel — Classification. Structural Welding. Vancouver, BC, loys. New Standard — $30.8/7/06. ISO/DIS 24598, Welding Consumables Canada. Standard preparation and gen — Solid Wire Electrodes, Tubular Cored eral meeting. Staff Contact: John SO Draft Standards for Public Review Electrodes and Electrode-Flux Combina Gayler, ext. 472. Copies of the following draft Interna tions for Submerged Arc Welding of Creep- tional Standard is available for review and Resisting Steels — Classification. Standards for Public Review comment through your national standards AWS was approved as an accredited body, which in the United States is ANSI, Revised Standards Approved by ANSI standards-preparing organization by the 25 W. 43rd St., Fourth Floor, New York, A5.9/A5.9M:2006, Specification for American National Standards Institute NY, 10036; (212) 642-4900. In the United Bare Stainless Steel Welding Electrodes and (ANSI) in 1979. AWS rules, as approved States, if you wish to participate in the de Rods. Approved 5/24/06.*

D14 Helps Move Mountains to Build Our Highways BY PETER HOWE, director, National Standards Activity

he AWS D14 Committee on Ma chinery and Equipment is an in Ttegral cog in the wheel of manu facturing the rugged, durable, reliable, and safe equipment needed to build and improve the nation's highway system. Without good welding specifications for the equipment that moves these "moun tains," this country's highway infrastruc ture would not be what it is today. Welds hold this equipment together, and without good specifications for these welds, the reliability and safety of this durable equipment could be signif icantly compromised. That is why AWS D14.3, Specification for Welding Earth- Shown are the members of the D14 Committee on Machinery and Equipment. Seated moving, Construction, and Agricultural (from left) are Dave Landon, Tom London, Bill Svekrik, and Ed Yevick. Standing (from Equipment, plays such an integral part left) are Bernard Banzhaf, Chairman Jerry Wan-en, Larry Schweinegruber, Jim Nelson, in assuring that the weld quality is the Corey Reynolds, Don Malito, and Secretary Pete Howe. best possible in such equipment. Beside earthmoving equipment, AWS D14.3 also dards for which the D14 Committee is • D14.1, Specification for Welding In covers welding specifications for construc responsible. Other standards that the dustrial and Mill Cranes and Other Ma tion and agricultural equipment, which D14 Committee authors are equally im terial Handling Equipment (DMA Sub move different "mountains" of dirt that portant. These specifications and rec committee on Industrial and Mill help create housing and the food for our ommended practices cover welding fab Cranes); households. Without such equipment and rication of cranes, presses, rotating • D14.3, Specification for Welding the quality welds that hold it together, the equipment, and cladding or recondi Earthmoving, Construction, and Agricul efficiency of our construction and food tioning of industrial mill rolls. The D14 tural Equipment (D14C Subcommittee production sectors would be significantly standards are handled by its six subcom on Earthmoving, Construction, and reduced. mittees: D14A, D14B, D14C, D14E, AWS D14.3 is but one of six stan- D14G, andD14H. — HOWE continued on page 67

AUGUST 2006 Recruit Members and Win All-New Prizes in the 2006-2007 AWS Member-Get-A-Member Campaign

Limited Edition MISSION: Looking for a few good Members. 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 2006-2007 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: Participants will also be eligible to win prizes in For every new member you sponsor, your name Recruit 1-2 new Individual Members and receive an specialized categories. Prizes will be awarded at the is entered into a quarterly drawing. The more new AWS dog tag key chain. close of the campaign (June 2007). members you sponsor, the greater your chances of winning. Prizes will be awarded in November President's Club: Sponsor of the Year: 2006, as well as in February and June 2007. Recruit 3-8 new Individual Members and receive an The individual who sponsors the greatest number of American Welder™ camouflage hat and an AWS dog new Individual Members during the campaign will Prizes Include: tag key chain. receive a plaque, a trip to the 2007 FABTECH International & AWS Welding Show, and recognition • Complimentary AWS Membership renewal President's Roundtable: at the AWS Awards Luncheon at the Show. • American Welder™ camouflage t-shirt • American Welder™ camouflage hat Recruit 9-19 new Individual Members and receive an Student Sponsor Prize: American Welder™ camouflage t-shirt, hat and an AWS Members who sponsor two or more Student SUPER SECTION CHALLENGE AWS dog tag key chain. Members will receive an AWS dog tag key chain. The AWS Section in each District that achieves the President's Guild: The AWS Member who sponsors the most Student highest net percentage increase in new Individual Recruit 20 or more new Individual Members and receive Members will receive a free, one-year AWS Members before the June 2007 deadline will receive a Timex camouflage watch, an American Welder™ Membership, an American Welder™ camouflage special recognition in the Welding Journal. camouflage hat, a one-year free AWS Membership, the t-shirt, hat and an AWS dog tag key chain. The AWS Sections with the highest numerical "Shelton Ritter Member Proposer Award" Certificate and International Sponsor Prize: increase and greatest net percentage increase in membership in the Winner's Circle. Any member residing outside the United States, new Individual Members will each receive the Neitzel Winner's Circle: Canada and Mexico who sponsors the most new Membership Award. All members who recruit 20 or more new Individual Individual Members will receive a complimentary Members will receive annual recognition in the AWS Membership renewal. American Welding Society Welding Journal and will be honored at FABTECH 550 N.W. LeJeune Rd. • Miami, FL 33126 International and the AWS Welding Show. Visit our website http://www.aws.org

*The 2006-2007 MGM Campaign runs from June 1, 2006 to May 31, 2007. Prizes are awarded at the close of the campaign. SPECIAL OFFER FOR NEW AWS INDIVIDUAL MEMBERS - TWO YEARS FOR $135 (a $25 savings) *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) GZ' Mail this form, along with your payment, to AWS NOTE: Only New Individual Members are eligible for this S Call the Membership Department at (800) 443-9353, ext. 480 selection. Be sure to add $25 to your total payment. 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Select one of the four listed publications for an additional LI Marine P.O. Box 440367 J2s; International Members add J" (J25 for book selection and $50 for international shipping): Multi-Year Discount: LI Piping and tubing Miami, FL 33144-0367 First year is (80. each additional year is Jo. No limit on years (not available to Student Members). tt+Studenl Member: LI Pressure vessels and tanks Telephone (800) 443-9353 Any individual wtio attends a recognized college, university, technical, vocational school or high school is eligible. Domestic • Sheet metal LI Structures FAX (305) 443-5647 Members are those students residing in Norh America (incl. Canada & Mexico). This membership includes the lie!<% • Other Visit our website: www.aws.org journal magazine. Student Memberships do not include a discounted publication. Airmail Postage Option: International LI Automation Member Services Revised 5/4/06 Members may receive their magazines via Airmail by adding J99 to the annual dues amount. LI Robotics LI Computerization of Welding — HOWE continued from page 64 Rotating Equipment); the D14 Committee who are willing to • D14.7, Recommended Practices for volunteer their time and expertise to re Agricultural Equipment); Surfacing and Reconditioning of Indus view and revise these standards. If you • D14.4, Specification for Welded Joints trial Mill Rolls (D14H Subcommittee on are interested in experiencing the satis in Machinery and Equipment (D14B the Surfacing of Industrial Rolls and faction of having a part in writing D14 Subcommittee on General Design and Equipment). standards contact Pete Howe at Practices); The officers of the D14 Committee [email protected] or (800/305) 443-9353, • D14.5, Specification for Welding are Chair Jerry Warren, Vice Chairs ext. 309. Presses and Press Components (D14E Don Malito and Larry Schweinegruber, An application for committee or sub Subcommittee on Welding of Presses); and Secretary Pete Howe. committee membership will be pro • D14.6, Specification for Welding of Participation on the D14 Committee vided, or you may apply online at Rotating Elements of Equipment and its Subcommittees is open to all www.aws. orglwlslsurvey I standard ? sur (D14G Subcommittee on Welding of welding experts in the areas covered by vey _start=techapplication. •

Technical Committees Drive Auto Welding Standards BY ANNETTE ALONSO, standards program manager

ozens of volunteer committee nership Joining Technology Committee, ponents that are joined by resistance members are working hard to it has prepared a new document, spot welding. Jim Dolfi of Ford serves Dcreate and update ANSI- D8.1M, Specification for Automotive as chair. approved technical standards for the Weld Quality — Resistance Spot Welding Chaired by Frank Armao of The Lin automobile and transportation indus of Steel. It will contain both visual and coln Electric Co., the D8G Subcommit try. The AWS D8 Committee on Auto measurable resistance spot weld accept tee on Automotive Arc Welding of Alu motive Welding is responsible for the ance criteria as well as weld surface fin minum has been working on a revision development of AWS standards on all ish standards for resistance spot welds Of D8.14M/D8.14, Specification for Au aspects of welding in the automotive in in steel. The information may be used tomotive Weld Quality —Arc Welding of dustry. The officers of the D8 commit as an aid by designers, resistance weld Aluminum. The document will cover the tee are Chair John Bohr of General ing equipment manufacturers, welded arc welding of automotive and light- Motors, and Vice Chairs Bill Brafford product producers, and others involved truck components manufactured from of Tuffaloy Products and Dennis in the automotive industry and resist aluminum alloys. Kolodziej of Ford. Six subcommittees ance spot welding of steels. D8.17M:20XX, Specification for develop automotive standards on arc The D8D Subcommittee is also Automotive Weld Quality — Friction welding, resistance spot welding, and working on an updated revision of Stir Welding, is a new document being friction stir welding. D8.9M, Test Methods for Evaluating the drafted by the D8H Subcommittee on The D8C Subcommittee on Auto Resistance Spot Welding Behavior of Au Automotive Friction Stir Welding, motive Arc Welding of Steel, chaired tomotive Sheet Steel Materials. This stan chaired by John Bohr of General Mo by Jeffrey Noruk of Servo Robot dard will contain a number of tests and tors. The standard will specify post- Corp., has been working on an up test methods useful in determining the weld acceptance criteria to be used dated edition of D8.8 that will super spot welding performance of coated and for evaluating continuous friction stir sede D8.8-97. D8.8M, Specification uncoated automotive sheet steels of all welds and friction stir spot welds in for Automotive Weld Quality — Arc strength levels and compositions. automotive applications. Welding of Steel, covers the arc and The Subcommittee also developed The Jl Committee on Resistance hybrid arc welding of coated and un- the recently published D8.7M:2005, Welding Equipment is a new commit coated steels, and provides the mini Recommended Practices for Automotive tee responsible for the preparation of mum quality requirements for arc Weld Quality — Resistance Spot Welding. standards related to resistance welding welding of various types of automo Dennis Kolodziej of Ford Motor Co. consumables, components, and machin tive and light truck components. chairs the D8E Subcommittee on Au ery, including standards previously pro John Bohr of General Motors also tomotive Laser Welding. This subcom duced by RWMA (Resistance Welding chairs the D8D subcommittee on Auto mittee has been working toward draft Manufacturers Alliance, an AWS motive Resistance Spot Welding of ing D8.10, Specification for Automotive Standing Committee). The standards Steel. As a subcommittee, D8D devel Laser Beam Welding. The standard will developed by Jl will relate to the de oped D8.6:2005, Standard for Automo address butt joint and lap joint config sign, construction, calibration, safe op tive Resistance Spot Welding Electrodes, urations as well as weld quality in laser eration, and maintenance of resistance which was recently published. It serves beam welding of precision components. welding equipment. as a supplement to RWMA Bulletin 16, The D8F Subcommittee on Automo The Jl Committee is chaired by Resistance Welding Equipment Stan tive Resistance Spot Welding of Alu David Beneteau of Centerline (Wind dards, and specifies chemical composi minum is currently preparing a new doc sor) Ltd. Roger Hirsch of Unitrol Elec tions, physical requirements, dimen ument, D8.13M, Specification for Auto tronics is vice chair. The Committee in sions, and identification of various motive Aluminum Resistance Spot Weld vites professionals interested in prepar shapes and nose configurations of elec Inspection. It will specify visual and ing standards on resistance welding trodes, electrode caps, and cap-adapter measurable inspection criteria, and equipment to apply for membership. shanks used in the automotive industry. weld surface finish standards for resist The Cl Committee on Resistance This D8D Subcommittee has also ance spot welding of aluminum. The Welding prepares standards related to begun work on two other standards. In document will apply to aluminum alloys resistance welding processes and their cooperation with the Auto/Steel Part used for automotive sheet metal com applications for various materials,

WELDING JOURNAL generic weld acceptance criteria for the tivities Group (TAG) for the Interna ests. Volunteers from AWS Technical resistance welding industry, and certifi tional Organization for Standardization Committees such as D8, Cl, and J1, cation of equipment operators. The (ISO) Technical Committee 44/Sub- comprise the U.S. TAG of this ISO committee is currently working on the committee 6 on Resistance Welding subcommittee. comprehensive C1.1M/C1.1, Recom have been reviewing several current If you are interested in taking part mended Practices for Resistance Welding, ISO drafts on resistance welding, resist in developing the U.S. position on ISO and Cl .4M/C1.4, Specification for Resis ance welding equipment, and quality documents in the area of resistance tance Welding of Uncoated Carbon and management and testing. welding, or if you are interested in par Low-Alloy Steels. Cl also developed The mission of the U.S. TAG for ticipating in the writing of any of the Cl, C1.5:2005, Specification for the Qualifi ISO TC 44/SC6 is to establish a U.S. D8, or Jl standards, contact Annette cation of Resistance Welding Technician. position on ISO drafts and documents Alonso at [email protected] or call Members of the U.S. Technical Ac that accurately represents U.S. inter (800/305) 443-9353, ext. 299. •

B2 Committee Seeks Volunteers

he American Welding Society is Soldering Procedure and Peiformance meetings, participate in discussions, recruiting volunteers to serve on Qualification, and additional standard and respond to correspondence, with Tthe B2 Committee on Procedure welding procedure specifications. the support of their companies or and Performance Qualification. The committee invites profession organization. This is an active committee that als interested in qualification rules To apply or learn more about the B2 meets spring and fall each year. for these standards to apply for com Committee's work, contact Secretary Membership consists of a balance of mittee membership. Selvis Morales at (800) 443-9353, ext. consultants, educators, general interest, Members are expected to attend 313, or e-mail [email protected]. • producers, and users. Its published standards include B2.1, Specification for Welding AWS Foundation's 2006 Section Membership Awards Procedure and Performance Silent Auction Notice Qualification; B2.2, Standard for Brazing Procedure and Performance he AWS Foundation is currently The Houston Section, District 18, Qualification; B2.4, Specification for soliciting gifts to be auctioned off has been awarded the Henry C. Neitzel Welding Procedure and Performance Tduring its 2006 Silent Auction. National Membership Award for the Qualification for Thermoplastics; and 62 The event will be held during the greatest net numerical increase in mem Standard Welding Procedure FABTECH International & AWS Weld bership for the year 2005-06. Specifications. The new standards in ing Show, scheduled for Oct. 31-Nov. 2 development are B2.3, Specification for in Atlanta, Ga. The winner of the Henry C. Neitzel All funds raised from the auction will National Membership Award for the go toward scholarships. greatest net percentage increase for We suggest donations of national 2005-06 is the Mid-Plains Section, Dis District Director Awards company gift cards to be put up for bid trict 16. at the Silent Auction. You may either send us gift cards of Following are Sections in each Dis The District Director Award pro $200-$250 you purchased yourself, or trict that achieved the greatest percent vides a means for District Directors to send a check payable to the AWS Foun age increase in membership for the year. recognize individuals who have con dation, and the Foundation will pur tributed their time and effort to the af chase the cards. District and Section fairs of their local Section and/or Dis Some national companies offering 1 — Green & White Mountains trict. popular gift cards include Omaha 2 — New Jersey District 15 Director, Mace Harris, Steaks, Tony Roma's, Bass Pro Shops, 3 — Cumberland Valley has nominated LaVonne Heikkinen, Ar JC Penney, Home Depot, etc. 4 — Carolina rowhead Section, as a recipient for the For more information, contact 5 — Atlanta 2005-06 District 15 award. Nazdhia at (800) 443-9353, ext. 250, 6 — Twin Tiers District 20 Director, Nancy Carlson, [email protected]. 7 — Wheeling has nominated the following to receive Special thanks to the first of our 8 — Nashville the award for 2005-06: Silent Auction donors: 9 — Pascagoula Bill Komlos and Richard "Woody" Abicor Binzel Corp. 10 — Northwestern Pennsylvania Cook - Utah Section. Hugh and Wanda Adams 11 — (no Section qualified) Paul Tremblay, Denis Clark, Tim AWS Atlanta Section 12— Lakcshore Mcjunkin, and Bruce Madigan — AWS Detroit Section 13 —Illinois Valley Idaho/Montana Section. AWS San Antonio Section 14 — Sangamon Valley Tom Lienert, Peirrette Gorman, AWS T\vin Tier Section 15 — Northern Plains Danny McCallum, and Mike Thomas Nancy and Barry Carlson 16 —Mid-Plains — New Mexico Section. Sam Gentry 17— East Texas John Cantlin and Lee Corn — IWDC, Inc. 18 — Corpus Christi Southern Colorado Section. MCD Plastics/Robb Howell 19 — Spokane Russell Rux - Wyoming Section. John L. Mendoza, District 18 Director 20 —Utah Jim Corbin and Farren Elwood — Pf'erd, Inc. 21 — Cuautitlan Izcalli (Mexico) Colorado Section. • Ray and Sandy Shook* 22 — Sierra Nevada •

AUGUST 2006 SECTIONA/EWS

DISTRICT 1 Director: Russ Norris Phone: (603) 433-0855

District 1 Conference MAY 20 Activity: District 1 Director Russ Nor ris conducted the District 1 annual con ference at Holiday Inn by the Bay in Portland, Maine. Chris Pollock, AWS director of education and product de velopment, presented a report on na tional AWS activities. Gus Marisca, Montreal Section, was chosen as the Shown are the attendees at the District 1 Conference, held May 20 in Portland, Maine. District representative at this year's Leadership Symposium, and Neil Mansfield, Boston Section, was chosen for the Instructor's Institute. Russ Nor ris was nominated to serve a second term as District 1 director, and Tom Ferri was chosen as deputy District di rector. Scholarships were presented to Joseph Yurko, Ezra Berry, Henry Cote Jr., Brian Hebert, and Daniel Charko. DISTRICT 2 Director: Kenneth R. Stockton Phone: (732) 787-0805

The Lancaster Section board members are (from left) Michael Sebergandio, Chairman John Ament, Trina Siegrist, Tim Siegrist, Claudia Bottenfield, George Bottenfield, and DISTRICT 3 Joe Taylor. Director: Alan J. Badeaux Sr. Phone:(301)753-1759 LANCASTER MAY 16 Activity: The board of directors met to finalize the end of the year reports, vote on District scholarship nominations, nominate officers for the upcoming year, and prepare the meeting sched ule.

LEHIGH VALLEY Activity: The Section has created an un dergraduate scholarship to honor one of its most distinguished members, Robert D. Stout. Dr. Stout has a 60-year career as a welding scientist and educa tor. On hand for the announcement were Robert D. Stout, AWS President Damian J. Kotecki, and Alan W. Pense, professor emeritus at Lehigh Univer Shown at the Lehigh Valley Section program are (from left) Robert D. Stout, A WS Pres sity. ident Damian J. Kotecki, and Alan W. Pense.

WELDING JOURNAL Speaker Bill Burkey (center) is shown with Joe Young (left) and David Butkus, Reading Section vice chairs, at the March program. York-Central Pennsylvania Section Chair Claudia Bottenfield (left) poses with Kelly Smith and Feeney Repoley IV, recent graduates of York County School of Technology.

YORK-CENTRAL PA. JUNE 1 Activity: The Section hosted its annual student awards presentation program at York County School of Technology in York, Pa. Seventy people participated in the event. Presenting the awards were Student Chapter Advisor Brian Yarri son, York-Central Pennsylvania Section Chair Claudia Bottenfield, and George Bottenfield. Kelly Smith, a Student Chapter executive board member, was honored for her recent graduation from Shown at the May 18 Reading Section program are (from left) Treasurer Dave Hibsh- York County School of Technology. man, Chairman Chris Ochs, presenter Patrick Belsole with his daughter, Denis Ginder, and Joe Young. York County Student Chapter MAY 13 Activity: The York County School of Technology Student Chapter hosted its second annual car show, held at the school. Organized entirely by the stu dents, more than 100 unique cars were entered in the competition. ESAB pro vided the trophies and Richard Petty Driving Experience certificates. Ken Rosencrant won a certificate for his 1929 Ford "Huckster" truck entry. The award was presented by Student Chap ter Advisor Brian Yarrison.

_ Advisor Brian Yarrison (far left) poses with some of the attendees at the York-Central DISTRICT 4 Director: Ted Alberts Pennsylvania Section's students' night program. Phone: (540) 674-3600, ext. 4314

READING MAY 18 Central Piedmont C. C. MARCH 16 Activity: The Reading Section hosted a Student Chapter Speaker: Bill Burkey plasma arc cutting and technology pro MARCH 6-9 Affiliation: Flexovit Abrasives gram with demonstrations and hands- Activity: The Student Chapter, led by Ibpic: Grinding wheel safety on activities 1 ed by Patrick J. Belsole, Advisor Steve Gore, traveled from Activity: The program was held at Su- district sales manager for Hypertherm, Charlotte, N.C., to Florida to first perking Buffet Restaurant in Reading, Hanover, N.H. The event was held at tour the Florida Solar Energy Cen Pa. Lancaster Mennonite High School. ter at the University of Central

AUGUST 2006 Puerto Rico meeting attendees pose at the May program held in San Juan. Florida, then participate in activities at the U.S. Space Walk Hall of Fame. The final day was spent touring NASA's Kennedy Space Center in Cape Canaveral, Fla.

DISTRICT 5 Director: Leonard P. Connor Phone: (954) 981-3977 N. CENTRAL FLORIDA MAY 16 Activity: Richard Carter and Steve Crawford, Airgas sales representatives, demonstrated the features of their com Shown at the York County School of Tech pany's mobile welding display unit. Sec Acting Chair Ronald Bernstein discussed nology Student Chapter car show are Ken tion members were offered the oppor gas metal arc welding at the Puerto Rico Rosencrant (on the left) and Student tunity to try the latest equipment. The program in May. Chapter Advisor Brian Yarrison. incoming Section officers were in stalled. Host Mark Geiger did the cook NORTH FLORIDA ing chores. Outgoing Chair Michael FEBRUARY 23 Bannester received a certificate of ap Speaker: Don Hurst, vice president preciation for his services. The program Affiliation: Quality Inspection Service was held at Bradford-Union Area Tech Topic: Nondestructive testing using dig nical-Vocational Center in Starke, Fla. ital radiographics Activity: The program was held at Tulsa Welding School in Jacksonville, Fla. Puerto Rico Meeting MAY 9 Central Piedmont Community College Speaker: Ronald Bernstein, acting chair Student Chapter members pose during Topic: Basic principles of GTAW DISTRICT 6 their four-day tour of Florida sites. Activity: Prof. David Collazo led the Director: Neal A. Chapman group on a tour of the Mech Tech Col Phone:(315)349-6960 lege campus to describe its automation, BATON ROUGE body works, and welding facilities. MAY 18 David Alvarado discussed safety issues Activity: The Section members toured related to welding for the students. Wig- DISTRICT 7 the American Alloys facility in St. berto De La Cruz explained the differ Director: Don Howard Gabriel, La., to study the manufacture ent types of current used in welding Phone: (814) 269-2895 of carbon steel and chrome moly prod processes. National Mechanical Con ucts. Pat Moore, executive vice presi tractors provided an orbital GTA weld dent, discussed how the steel industry ing machine and demonstrated its uses. has changed over the past 50 years. Mr. Carrasquillo of Steel & Pipes do DISTRICT 8 Homer Garza discussed material speci nated two hand-held mechanical grind Director: Wallace E. Honey fications to consider when qualifying a ing machines for a raffle. The ticket Phone: (256) 332-3366 welding procedure. Operations Man sales were used to raise funds to finance ager Donnie Hoffman discussed prod future Section activities. The Puerto uct quality control and tracking opera Rico members are in the process of re DISTRICT 9 tions. The incoming Section officers organizing in order to be chartered as were introduced. About 56 members Director: John Bruskotter an AWS Section. and guests participated in the program. Phone: (504) 394-0812 WELDING JOURNAL w ^| 7 *i|J

^7 ^1 1 f W m

Pat Moore discussed the history of the steel industry for the Baton Rouge Section Shown at the Baton Rouge Section are (from left) Robert Eppinett, Tom Shelton, Calvin members in May. Pepper, and George Fairbanks.

Jim Sullivan (left), Mobile Section chair, presents the Section Meritorious Award New Orleans redfish winners were (from to Randy Henderson. left) Brian Scott, Paul Ranger, and Greg Smith. Phillip Coe proudly displays the certifi cate citing him as the recipient of the Law- MOBILE son State Community College Student MAY 25 Chapter Member Award, presented by the Activity: The Section held a past chair Birmingham Section. men's night program at Fire Mountain in Spanish Fort, Ala. Chairman Jim Sul livan presented Steve Veal the CWI of the Year Award. James Smith was pre sented the Section Educator of the Year Award, and Randy Henderson received the Section Meritorious Award. Steve Veal (left) receives the CWIAward from Mobile Section Chair Jim Sullivan. NEW ORLEANS MAY 6 Activity: The Section held its annual fishing rodeo, chaired by Mike Skiles, who originated the competition eight years ago. The event is a popular fund New Orleans speckled trout winners were raiser for the Section's scholarships pro (from left) Donald Gros, Ron and Robert gram. Fifty-eight members and guests Pamplin. participated. Donating food for the fish ermen were Owensby & Kritikos, Inc., and Dynamic Industries. The rodeo BIRMINGHAM winners included Donald Gros, Ron JUNE 2 Pamplin and son Robert (speckled Activity: The Section presented Phillip trout contest); and Brian Scott, Paul Mobile Section Chair Jim Sullivan (left) Coe the Student Chapter Member Ranger, and Greg Smith (redfish cate presents James Smith the Section Educa Award at Lawson State Community gory). The Calcutta winners were Paul tor Award. College. Ranger, and Ron and Robert Pamplin.

AUGUST 2006 Calcutta contest winners in the New Or leans fishing rodeo were (from left) Paul Ranger, Ron and Robert Pamplin.

DISTRICT 10 Shown at the Milwaukee Section tour are (from left) Ken Coryell, Steven Ruder, Chair Director: Richard A. Harris man Craig Wentzel, Membership Chair Karen Gilgenbach, and Vice Chair Jerry BlaskL Phone: (440) 338-5921 DISTRICT 11 Director: Eftihios Siradakis Phone: (989)894-4101 DISTRICT 12 Director: Sean P. Moran Phone: (920) 954-3828 MILWAUKEE MAY 18 Activity: The section toured the Bruno Independent Living Aids facility in Oconomowoc, Wis., a manufacturer of mobility assistance devices, including staircase chair elevators, turning-seats for vehicles, electric scooters, and wheelchairs. Leading the tour were Tom Campen displays the prize he earned Steve Ruder, Jerry Gnabasik, Rich in the Peoria Section's high school stu Schroder, Tracy Milbrath, and Mike Ro- dent welding contest. Craig Tichler (left) presents the past chair galski. The dinner was held at Olympia man appreciation award to Chuck Hub Resort and Conference Center in and union apprentices. The winners in bard at the Chicago Section's board meet Oconomowoc. the high school category were Tom ing. Campen, Shea Dickson, Nick Pesha- Athen, Billy Brickley, and Adam Ham let. The winners in the advanced cate DISTRICT 13 gory were Wayne Hayes, Lane Sparrow, Director: Jesse L. Hunter Joe Szaltis, Shane Seals, and Kyle Phone: (309) 359-3063 Stonebock. The judges for the event in CHICAGO cluded Mark Kerley, Ray Long, Les MAY 31 Hacker, Ed Kuebler, Eric Ockerhausen, Activity: The Section held a board meet and Dennis Ludwig. ing to plan activities for the upcoming year. Chuck Hubbard received his past chairman appreciation award from Craig Tichler. DISTRICT 14 Director: Tully C. Parker Phone: (618) 667-7744 PEORIA MARCH 16 INDIANA Activity: The Section hosted its annual MAY 22 student welding contest at Illinois Cen Activity: The Section held a roundtable Peoria Section judge Mark Kerley con tral College welding shop. The event discussion and planning meeting hosted gratulates Wayne Hayes for his win in the featured two categories, one for high by Chairman Bennie Flynn. The pro welding competition, advanced categoiy. school welding students, and the other gram was held in Greenwood, Ind. See Hayes is an apprentice at Boilermaker for trade school and college students, photo on next page. Local 60.

WELDING JOURNAL Indiana Section members are shown at their planning meeting in May.

Mace Harris (left), District 15 director, presents Augustin Marisca with the Saskatoon Section charter at the Dis trict 15 conference. DISTRICT 15 Director: Mace V. Harris Phone:(952)925-1222

District 15 Conference MAY 19,20 Activity: District 15 Director Mace Har ris chaired the conference in Bemidji, Minn. Harris presented Augustin Marisca with the charter for the Saska toon, Saskatchewan Section. Ross Han Shown are the attendees at the District 15 conference held in Bemidji, Minn., in May. cock was the AWS staff representative.

DISTRICT 16 Director: Charles F. Burg Phone:(515)233-1333 KANSAS JUNE 1 Speaker: Seth Johnson, CWI Affiliation: Tindle Construction Co., an AWS Accredited Test Facility Topic: Submitting a request for taking the CWI test Activity: District 16 Director Charles Burg was celebrated for his many years of service as District 16 Director and his commitment to the Society. The pro gram was held at Tindle Construction Co. in Neodesha, Kan.

DISTRICT 17 Charles Burg (far left), District 16 director, is shown with Kansas Section members at Director: Oren P. Reich the June meeting. Phone: (254) 867-2203

AUGUST 2006 District 17 Conference JUNE 9,10 Activity: The Central Texas Section hosted the District 17 conference in Czech Inn of West, Tex. Oren Reich, District 17 director, chaired the pro gram. J. Jones was elected incoming District 17 director, to take office Jan uary 1, 2008. Rhenda Mayo was the AWS staff representative. Howie Sif- ford, chairman of the North Texas Sec tion, was presented the District Educa tor Award.

CENTRAL TEXAS MAY 17 Speakers: J. Jones and Paul Brewster Shown are the attendees at the District 17 conference held June 9, 10, in West, Tex. Affiliation: Thermadyne Industries, Denton, Tex. Topic: Cutting processes Activity: The Section held a student ap preciation program in the Texas State Technical College welding department. Demonstrated were the oxyfuel, slice, and plasma arc cutting processes. The students had an opportunity to work with the various machines.

MAY 25 Activity. The Central Texas Section held an executive meeting for the election of officers and planning for the District 17 conference.

NORTH TEXAS MAY 15 Speaker: Robert Klug, chair, ASM Int'l, North Texas chapter Affiliation: Trinity Industries That's J. Jones on the left with Paul Brewster showing the students some tricks of the Topic: Mutual ASM-AWS interests metal-cutting trade at the May 17 Central Texas program. Activity: This was a joint meeting with the local ASM Int'l chapter. Section Chair Howie Sifford was honored for receiving the District Educator Award, Bill Hall for earning the District Private Sector Educator Award, and Vernon Rollins for the District CW1 of the Year Award. Roy Lack received a Section scholarship.

DISTRICT 18 Director: John L. Mendoza Phone:(210)353-3679

Howie Sifford (right), North Texas Sec Oren Reich (left) District 17 director, tion chairman, receives the District Edu DISTRICT 19 greets J. Jones, District 17 director-elect, cator Award from Oren Reich, District 17 Director: Phil Zammit at the District 17 conference. director, at the District 17 conference. Phone: (509) 468-2310, ext. 120 WELDING JOURNAL Past Utah Section Chair Pete Hanges (left) is shown with current Chair Gr Bugni at the March program.

Shown at the Utah Section program are (from left) ASM Chair Bob Hipley, Past Utah DISTRICT 20 Section Chair Wayne Western, speaker Marcel Korach, and incoming District 20 Direc Director: Nancy M. Carlson tor Bill Komlos. Phone: (208) 523-9128

District 20 Conference JUNE 2, 3 Activity: The conference was hosted by the Albuquerque Section. Nancy Carl son, retiring District 20 director, chaired the meeting. Elected to fulfill the re mainder of Carlson's term as District 20 director is Bill Rondos, a Senior Certi fied Welding Inspector with ArcTech, LLC. Farren Elwood of the Denver Sec tion received the National CWI of the Year Award, and Wayne Western of the Utah Section received the Educator of the Year Award. Rhonda Mayo served as the AWS staff representative.

UTAH MARCH 16 Speaker: Marcel Korach Topic: Aerospace welding Activity: This was a joint meeting with members of the local chapter of ASM District 20 conference attendees take a break in Albuquerque, N.Mex. Int'l. I DISTRICT 21 Director: Jack D. Compton Phone: (661)362-3218 I DISTRICT 22 Director: Kent S. Baucher Phone: (559) 276-9311 •a SAN FRANCISCO JUNE 10 B Activity; The Section hosted its annual picnic held at the Western Railway Mu seum where they toured the car restora tion shop. Fred Krock conducted the Fred Krock led the San Francisco Section members on a tour of the Western Railway tour. Museum restoration shop.

AUGUST 2006 Special congratulations to the following 2005-2006 MGM Campaign standouts: Eleanor Ezell for most new Individual Members. Charles Daily for most new Student Members. Nicolaas Bothma, International Sponsor winner. Listed below are the May 31 standings for participants in the 2005-2006 Campaign. See page 65 of this Welding Journal for the rules and prize list. For more information, contact the AWS Membership Department (800/305) 443-9353, ext. 480.

Winner's Circle D. Wilson, Inland Empire — 4 S. Robeson, Cumberland Valley — 22 Members who have sponsored 20 or R. Wright, Southern Colorado — 4 D. Combs, Santa Clara Valley — 20 more new Individual Members, per P. Zammit, Spokane — 4 J. Daugherty, Louisville — 20 year, since 6/01/99. The superscript de A. Mattox, Lexington — 3 T Geisler, Pittsburgh — 20 notes the number of times the member H. McKeown, Niagara Frontier — 3 C. Hobson, Olympic — 20 has achieved Winner's Circle status, if J. Mendoza, San Antonio — 3 R. Boyer, Nevada — 19 more than once. R. Merreighn, Mississippi Valley — 3 R. Shrewsbury, Tri-State — 19 J. Compton, San Fernando Valley6 G. Merriman, Chicago — 3 T. Buchanan, Mid-Ohio Valley — 18 E. Ezell, Mobile4 R. Quintero, Corpus Christi — 3 C. Donnell, Northwest Ohio — 18 J. Merzthal, Peru2 R. Sands, Northwest — 3 G. Smith, Lehigh Valley — 18 G. Taylor, Pascagoula2 J. Smutny, Spokane — 3 T. Strickland, Arizona — 18 B. Mikeska, Houston L. Taylor, Pascagoula — 3 D. Griep, New Jersey — 17 R. Peaslee, Detroit M. Tsai, Taiwan Int'l — 3 D. Ketler, Willamette Valley — 17 W. Shreve, Fox Valley T Alston, Sierra Nevada — 2 D. Parker, Idaho/Montana — 17 M. Karagoulis, Detroit R. Bernstein, South Florida — 2 R. Zabel, Southeast Nebraska — 16 S. McGill, Northeast Tennessee J. Carney, Western Michigan — 2 M. Arand, Louisville — 15 T. Weaver, Johnstown/Altoona J. Cusick, Kansas — 2 R. Munns, Utah— 15 G. Woomer, Johnstown/Altoona J. Durbin, Tri-River — 2 C. Overfelt, Southwest Virginia — 15 R. Wray, Nebraska M. Fedoruk, Baltimore — 2 A. Stute, Madison-Beloit — 15 M. Goint, Nevada — 2 A. Mattox, Lexington — 14 President's Guild L. Guzman, Houston — 2 J. Carey, Boston — 13 Members sponsoring 20 or more new M. Hill, Lexington — 2 R. Hutchison, Long Beach/Or. Cty. — 13 Individual Members. M. Hobbs, Louisville — 2 C. Jones, Houston — 13 E. Ezell, Mobile — 26 J. Hobgood, J.A.K. — 2 A. Reis, Pittsburgh — 13 J. Compton, San Fernando Valley — 24 R. Iarussi, Cleveland — 2 M. Koehler, Milwaukee — 12 M. Haggard, Inland Empire — 22 J. Kozeniecki, Milwaukee — 2 J. McCarty, St. Louis — 12 W. Kuchta, Cleveland — 2 B. Olson, Sangamon Valley— 12 President's Roundtable E. Levert, North Texas — 2 J. Smith, Jr., Mobile—12 Members sponsoring 11-19 new P. Newhouse, British Columbia — 2 H. Browne, New Jersey — 10 Individual Members. R. Olson, Siouxland — 2 J. Pawley, Lexington — 10 C. Daily, Puget Sound — 17 R. Rux, Wyoming — 2 M. Batchelor, Boston — 9 G. Taylor, Pascagoula — 17 C. Schiner, Wyoming — 2 C. Chancy, L.A./Inland Empire — 9 D. Wright, Kansas City — 12 T Shirk, Tidewater — 2 W Galvery, Long Beach/Or. Cty.— 9 N. Bothma, International — 11 H. Shore, Johnny Appleseed — 2 F. Gorglione, Connecticut — 9 G. Fudala, Philadelphia— 11 S. Siviski, Maine — 2 D. Roskiewich, Philadelphia — 9 R. Robles, Corpus Christi — 11 K. Stelzl, New York — 2 T. Moffit, Tulsa — 8 J. Vansambeek, Lakeshore — 2 A. Badeaux, Washington, D.C. — 7 President's Club H. Villela, San Francisco — 2 P. Bedel, Indiana — 7 Members sponsoring 6-10 new Indi L. White, Green & White Mts. — 2 J. Boyer, Lancaster — 7 vidual Members. H. Wilden, Reading — 2 R. Chase, L.A./Inland Empire — 7 J. Williams, Houston — 10 G. Gammill, Northeast Mississippi — 7 G. Gardner, Ozark — 9 Student Sponsors C. Schiner, Wyoming — 7 T White, Pittsburgh — 9 Members sponsoring 5 or more new J. Carney, Western Michigan — 6 F. Burkart, Northwest — 8 Student Members. J. Craiger, Indiana — 6 R. Ellenbecker, Fox Valley — 8 C. Daily, Puget Sound — 210 C. Kipp, Lehigh Valley — 6 D. Norum, North Texas — 8 G. Euliano, Northwestern Pa. — 96 D. Kowalski, Pittsburgh — 6 J. Christianson, Saginaw Valley — 7 R. Durham, Cincinnati — 39 R. Robles, Corpus Christi — 6 W Shreve, Fox Valley — 6 G. Seese, Johnstown-Altoona — 37 L. Davis, New Orleans — 5 H. Stevens, Western Michigan — 6 R. Evans, Siouxland — 35 W. Harris, Pascagoula — 5 H. Winters, Wheeling — 33 R. Hilty, Pittsburgh — 5 President's Honor Roll T Kienbaum, Colorado — 32 T. Parker, Wheeling — 5 Members sponsoring 1-5 new Indi D. Newman, Ozark — 26 R. Rux, Wyoming — 5 vidual Members. M. Anderson, Indiana — 24 J. Smith, Tri-River — 5 T. Buchanan, Mid-Ohio Valley — 5 S. Siviski, Maine — 24 J. Sullivan, Holston Valley — 5 J. Krall, Dayton — 5 H. Hughes, Mahoning Valley — 23 B. Taves, Puget Sound — 5 J. Roberts, Inland Empire — 4 A. Baughman, Stark Central — 22 J. Compton, San Fernando Valley — 44

WELDING JOURNAL Guide to AWS Services 550 NW LeJeune Rd., Miami. FL 33126 Phone (800) 443-9353; (888) WELDING; FAX (305) 443-7559 Mww.atvs.org (Plume extensions shown in parentheses.)

AWS PRESIDENT PUBLICATION SERVICES CERTIFICATION OPERATIONS Damian J. Kotecki Department Information (275) Department Information (273) Damian Kotecki@lincolnekctric. com TfTe Lincoln Electric Co. Managing Director Director, Technical Services 22801 St. ClairAve. Andrew Cullison.. [email protected] ... .(249) Tina Burke .. [email protected] (215) Cleveland, OH 44117-1199 Welding Journal Director, Operations Publisher/Editor Terry Perez., [email protected] (470) ADMINISTRATION Andrew Cullison.. [email protected] (249) Executive Director Director, Int'l Business Accreditation Ray W. Shook., [email protected] (210) National Sales Director and Welder Certification Rob Saltzstein.. [email protected] ... .(243) Walter Herrera.. [email protected] (475) CFO/Deputy Executive Director Provides information on personnel certifica Frank R. Tarafa.. [email protected] (252) Society and Section News Editor tion and accreditation services. Howard [email protected](244) Associate Executive Director Cassie R. BurrelL [email protected] (253) Welding Handbook Welding Handbook Editor TECHNICAL SERVICES Associate Executive Director Annette O'Brien., [email protected] ... .(303) Department Information (340) Jeff Weber., [email protected] (246) Publishes the Society's monthly magazine, Managing Director Executive Assistant for Board Services Welding Journal, which provides information on Andrew R. Davis., [email protected] (466) Gricelda [email protected] . .(294) the state of the welding industry, its technology, Int'l Standards Activities, American Council and Society activities. Publishes Inspection of the International Institute of Welding (IIW) Administrative Services Trends, the Welding Handbook, and books on Director, National Standards Activities Managing Director general welding subjects. Jim Lankford.. [email protected] (214) Peter [email protected] (309) Machinery and Equipment Welding, Robotic IT Network Director and Automatic Welding, Computerization of Armando [email protected] .(296) MARKETING COMMUNICATIONS Welding Information Director Manager, Safety and Health Director Ross Hancock., [email protected] ... .(226) Stephen P. Hedrick.. [email protected] . .(305) Hidail [email protected] (287) Metric Practice, Personnel and Facilities Assistant Director Qualification, Safety and Health, Joining of Adrienne Zalkind. [email protected] .. .(416) Plastics and Composites COMPENSATION and BENEFITS Director Luisa Hernandez., [email protected] (266) Senior Manager, Marketing Technical Publications Linda [email protected] ... .(298) AWS publishes about 200 documents widely used in the welding industry. INT'L INSTITUTE OF WELDING Senior Manager Senior Coordinator MEMBER SERVICES Rosalinda O'Neill., [email protected] (451) Sissibeth Lopez .. [email protected] (319) Department Information (480) Provides liaison services with other national Staff Engineers/Committee Secretaries and international professional societies and Associate Executive Director Annette Alohso.. [email protected] (299) standards organizations. Cassie R. BurrelL. [email protected] ... .(253) Welding in Sanitary Applications, Automotive Welding, Resistance Welding, High-Energy Director Beam Welding, Aircraft and Aerospace, Oxy- GOVERNMENT LIAISON SERVICES Rhenda A. Mayo... [email protected] ... .(260) fuel Gas Welding and Cutting Hugh K. Webster [email protected] Serves as a liaison between Section members Webster, Chamberlain & Bean and AWS headquarters. Informs members about John L. [email protected] (472) Washington, D.C. AWS benefits and activities. Structural Welding, Welding Iron Castings (202) 466-2976; FAX (202) 835-0243 Identifies funding sources for welding educa Rakesh Gupta., [email protected] (301) tion, research, and development. Monitors leg EDUCATION SERVICES Filler Metals and Allied Materials, Int'l Filler islative and regulatory issues of importance to Director, Education Services Administration Metals, Instrumentation for Welding, UNS the industry. and Convention Operations Numbers Assignment John Ospina.. [email protected] (462) Cynthia Jenney .. [email protected] ... .(304) Brazing and Soldering Director, Education and Government Advocacy Definitions and Symbols, Brazing and Soldering, Manufacturers' Committee Richard J. DePue.. [email protected] ... .(237) Brazing Filler Metals & Fluxes, Technical Editing Jeff Weber., [email protected] (246) Director, Education Product Development Brian McGrath . [email protected] ... .(311) Christopher Pollock., [email protected] (219) Methods of fnspection, Mechanical Testing of RWMA — Resistance Welding Welds, Thermal Spray, Arc Welding and Cut Manufacturing Alliance Tracks effectiveness of programs and devel ting, Welding in Marine Construction, Piping Assistant Manager ops new products and services. Coordinates in- and Tubing, Titanium and Zirconium Filler Met Susan Hopkins., [email protected] (295) ptant seminars and workshops. Administers the als, Filler Metals for Naval Vessels S.E.N.S.E. program. Assists Government Liai son Committee with advocacy efforts. Works Selvis Morales [email protected] • . .(313) WEMCO — Welding Equipment with Education Committees to disseminate in Welding Qualification, Friction Welding, Join Manufacturing Committee formation on careers, national education and ing of Metals and Alloys, Railroad Welding Manager training trends, and schools that offer welding Natalie Tapley.. [email protected] (444) training, certificates, or degrees. Also responsible for conferences, exhibitions, Note: Official interpretations of A WS standards and seminars on topics ranging from the basics may be obtained only by sending a request in CONVENTION and EXPOSITIONS to the leading edge of technology. Organizes writing to the Managing Director, Technical Ser Associate Executive Director/Sales Director CWI, SCWI, and 9-year renewal certification- vices. Oral opinions on AWS standards may be Jeff Weber., [email protected] (246) driven seminars. rendered. However, such opinions represent only the personal opinions of the particular in Corporate Director, Exhibition Sales dividuals giving them. These individuals do not Joe Krall.. [email protected] (297) AWS AWARDS, FELLOWS, COUNSELORS speak on behalf of A WS, nor do these oral opin Senior Manager ions constitute official or unofficial opinions Organizes the annual AWS Welding Show and Wendy S. Reeve., [email protected] (293) or interpretations of AWS. In addition, oral Convention, regulates space assignments, regis Coordinates AWS awards and AWS Fellow opinions are informal and should not be used tration items, and other Expo activities. and Counselor nominees. as a substitute for an official interpretation.

AUGUST 2006 Nominees for National Office AWS Publications Sales Purchase AWS Standards, books, and other publications from nly Sustaining Members, Mem a member of the Society, other than a Stu World Engineering Xchange (WEX), Ltd. bers, Honorary Members, Life dent Member, must be frequently avail Members, or Retired Members able to the national office, and should be Toll-free (888) 935-3464 (U.S., Canada) O (305) 824-1177; FAX (305) 826-6195 who have been members for a period of of executive status in business or indus at least three years shall be eligible for try with experience in financial affairs. www. aws. orglstandards election as a director or national officer. Director-at-Large: To be eligible for It is the duty of the National Nominat election as a director-at-large, an individ ing Committee to nominate candidates for ual shall previously have held office as Welding Journal Reprints national office. The committee shall hold chairman of a Section; as chairman or vice Copies of Welding Journal articles may be an open meeting, preferably at the Annual chairman of a standing, technical or spe purchased from L. Brigman, call toll-free Meeting, at which members may appear to cial committee of the Society; or as Dis (800/443) 9353, ext. 453; [email protected] present and discuss the eligibility of all trict director. candidates. Interested parties should write a let Custom reprints of Welding Journal To be considered a candidate for the po ter stating which office they seek, includ articles, in quantities of 100 or more, sitions of president, vice president, treas ing a statement of qualifications, their may be purchased from urer, or director-at-large, the following willingness and ability to serve if nomi FosteReprints qualifications and conditions apply: nated and elected, and 20 copies of their Toll-free (866) 879-9144, ext. 121 President: To be eligible to hold the biographical sketch. [email protected] office of president, an individual must This material should be sent to James have served as a vice president for at least E. Greer, Chairman, National Nominat one year. ing Committee, American Welding Soci Vice President: To be eligible to hold ety, 550 NW LeJeune Rd., Miami, FL the office of vice president, an individual 33126. must have served at least one year as a di The next meeting of the National rector, other than executive director and Nominating Committee is scheduled for AWS Foundation, Inc. secretary. October 31, 2006. The term of office for The AWS Foundation is a not-for-profit Treasurer: To be eligible to hold the candidates nominated at this meeting will corporation established to provide support office of treasurer, an individual must be commence January 1, 2008.* for educational and scientific endeavors of the American Welding Society. Information on gift-giving programs is available upon request.

Honorary Meritorious Awards Chaitman, Board of Trustees Ronald C. Pierce

he Honorary-Meritorious Awards Committee makes recommendations for the nom Executive Director, AWS inees presented for Honorary Membership, National Meritorious Certificate, Ray Shook William Irrgang Memorial, and the George E. Willis Awards. These awards are pre T Executive Director, Foundation sented during the AWS Exposition and Convention held each spring. The deadline for submissions is December 31 prior to the year of awards presentations. Send candidate Sam Gentry materials to Wendy Sue Reeve, Secretary, Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL 33126. Descriptions of the awards follow. 550 NW LeJeune Rd., Miami, FL 33126 (305) 445-6628; (800) 443-9353, ext. 293 National Meritorious Certificate International Meritorious Certificate e-mail: [email protected] Award: This award is given in recognition Award: This award is given in recogni general information: of the candidate's counsel, loyalty, and de tion of the candidate's significant con (800) 443-9353, ext. 689 votion to the affairs of the Society, assis tributions to the worldwide welding in tance in promoting cordial relations with dustry. This award should reflect "Ser industry and other organizations, and for vice to the International Welding Com the contribution of time and effort on be munity" in the broadest terms. The half of the Society. awardee is not required to be a member of the American Welding Society. Mul William Irrgang Memorial Award: This tiple awards can be given per year as the AWS Mission Statement award is administered by the American situation dictates. The award consists of Welding Society and sponsored by The Lin a certificate to be presented at the coln Electric Co. to honor the late William awards luncheon or at another time as The mission of the American Welding Irrgang. It is awarded each year to the in appropriate in conjunction with the Society is to advance the science, dividual who has done the most to enhance AWS President's travel itinerary, and, if technology, and application of welding the American Welding Society's goal of ad appropriate, a one-year membership in and allied processes, including vancing the science and technology of the American Welding Society. joining, brazing, soldering, welding over the past five-year period. cutting, and thermal spraying. George E. Willis Award: This award is Honorary Membership Award: An Honorary Member shall be a person of administered by the American Welding So It is the intent of the American ciety and sponsored by The Lincoln Elec acknowledged eminence in the welding Welding Society to build AWS to the tric Co. to honor George E. Willis. It is profession, or who is accredited with ex awarded each year to an individual for pro ceptional accomplishments in the devel highest quality standards possible. moting the advancement of welding inter opment of the welding art, upon whom The Society welcomes your suggestions. nationally by fostering cooperative partic the American Welding Society sees fit to Please contact any staff member, or ipation in areas such as technology trans confer an honorary distinction. An Hon AWS President Damian J. Kotecki, fer, standards rationalization, and promo orary Member shall have full rights of as listed on the previous page. tion of industrial goodwill. membership.*

WELDING JOURNAL GTAW BEST PRACTICES Gas Tungsten Arc Welding

The gas tungsten arc welding (GTAW) • Very useful process for joining reactive • Possible contamination or porosity can process is adaptable to manual, semiau metals such as titanium be caused by leakage from water-cooled tomatic, mechanized, and automatic ap • Filler metal additions and heat source torches. plications. The process can be used on es can be controlled independently. • Arc blow can be a concern. sentially all joint designs and geometries, and on a wide range of thicknesses of Process Limitations Current Selection plate, sheet, pipe, tube, and structural shapes. Unlike other arc welding Efficient gas shielding is required with Direct current electrode negative processes, GTA can produce autogenous this process. The basic requirement tends (DCEN) and direct current electrode posi- (no filler metal) welds since it uses a non- to limit the process to indoor applications, tive(DCEP) are two types of direct current consumable electrode. although with proper shielding tech used with GTAW. Since DCEN produces niques, it can be used outdoors. Some lim the greatest amount of heat at the work- Advantages of GTAW itations are as follows: piece, it offers the advantages of deep joint • Deposition rates are low compared to penetration and faster welding speeds. Di The combination of GTAW for root processes with consumable electrodes. rect current electrode negative is the most pass welding with either shielded metal • There is a need for more dexterity and used configuration for GTAW It is used arc (SMA) and or gas metal arc (GMA) coordination for manual welding than with argon, helium, or mixtures of gases for welding for fill passes is particularly ad with other arc welding processes. most metals. vantageous for pipe. The GTAW process • Shielding the weld zone is difficult if Alternating current (AC) and pro is especially effective in producing qual there are drafty conditions. grammed current are other currents used ity root passes. Some other major bene with GTAW. Programmed current com fits of the process are as follows: Potential Problems bines the features of AC and DC. Vari • Produces quality welds able polarity is considered a subset of pro • Free of spatter • If the electrode is allowed to touch the grammed current and replaces AC or bal • Can be used with or without filler metal. weld pool or becomes overheated, pieces anced AC in many applications. • Excellent control of root pass joint of the tungsten may become embedded in In practice, AC and VP are usually used penetration the weld creating problems. when cathodic cleaning action is needed • Produces inexpensive autogenous welds • The weld metal may become contami on metals whose oxides create problems, • Uses economical power sources nated if the filler metal is not properly such as magnesium and aluminum. • Precise control of welding variables shielded by the gas stream or if the shield • Very good for joining thin base metals ing gas does not properly protect the weld Electrode Classification • Especially good for joining aluminum pool. and magnesium, both of which form hard • There is a low tolerance for contami Tungsten electrodes are classified on the refractory oxides nants on filler and base metals. basis of their chemical compositions —

Table 1 — Chemical Composition Requirements for Tungsten Electrodes'"

Weight Percent (wt-%)

Other Oxides AWS Color UNS WMin. or Elements 2 Classification Code «>)• 07) Number < ) (Difference) (3) eOz La 20^ ThO, Zr02 Total EWP<5) Green R07900 99.5 0.5 EWCe-2(5) Orange*8) R07932 97.3 1.8-2.2 — — — 0.5 EWLa-l(5) Black R07941 98.3 — 0.8-1.2 — — 0.5 EWLa-1.5 Gold R07942 97.8 — 1.3-1.7 — — 0.5 EWLa-2 Blue R07943 97.3 — 1.8-2.2 — — 0.5 EWTh-LW Yellow R07911 98.3 — — 0.8-1.2 — 0.5 EWTh-2(5) Red R07912 97.3 — — 1.7-2.2 — 0.5 EWZr-K5) Brown R07920 99.1 — — — 0.15--0.40 0.5 EWG<4> Gray — 94.5 Not Not Not Not 0.5 Specified Specified Specified Spec fied

General Note: Sec AWS A5.12/A5.12M-9K, Specification for Tungsten and Tungsten-Alloy Electrodes for Arc Welding and Cutting. Table 1. Notes: (1) The electrode shall be analyzed for the specific oxides for which values are shown in this table. If the presence of other elements or oxides is indicated in the course of the work, the amount of those elements or oxides shall be determined to ensure that their total does not exceed the limit specified for "Other Oxides or Elements. Total" in the last column of the table. (2) SAE/ASTM Unified Numbering System for Metals and Alloys. (3) Tungsten content shall be determined by subtracting the total of all specified oxides and other oxides and elements from 100%. (4) Classification EWG must contain some compound or element additive and the manufacturer must identify the type and minimal content of the additive on the packaging. (5) See AWS A5.12/A5.12M for closely matching grades in ISO 6848. (6) The actual color may be applied in the form of bands, dots, etc. at any point on the surface of the electrode. (7) The method of color coding used shall not change the diameter of the electrode beyond the tolerances permitted. (8) Color varies is ISO 6848, Tungsten Electrodes for Inert Gas Shielded Arc Welding and for Plasma Cutting and Welding.

TOT AUGUST 2006 Table 1. The requirements are given in the and welding current are influenced by the electrode diameters and current ranges. latest edition of AWS A5.12, Specification type and thickness of base metals being Electrode tip geometries affect the for Tungsten and Tungsten Alloy Electrodes welded. See Table 2 for help in the selec weld bead shape and size. Typically, as the for Arc Welding and Cutting. In the AWS tion process. Electrodes are available included angle increases, weld penetra classification system the E stands for elec commercially in standard lengths from tion increases and the width of weld bead trode; the W stands for tungsten (also called 2-24 in. (50-610 mm). Table 3 provides decreases. wolfram); and the final letters indicate the some typical current ranges for various To create a ball, strike on arc away from alloying elements or oxide additions. The electrode diameters based on the use of your workpiece on a copper block or other Zr is for zirconiated, Th is for thoriated, Cc argon as the shielding gas. suitable material using AC or DCEP. In is ceriated, La is for lanthanated, and G crease the current until the end of the stands for general or unspecified. The num Electrode Configurations tungsten begins to heat up causing a small bers specify the nominal alloying composi ball to form at the end. Downslope the tion in wt-%. For example, EWTh-1 is a The shape of the tungsten electrode current and extinguish the arc. Maintain thoriated tungsten electrode containing tip is an important variable. With AC gas flow while the electrode cools. The nominally 1 wt-% thoria. Pure tungsten welding, pure or zirconiated tungsten ball should be approximately 1-1/: times electrodes are identified by EWP. There is electrodes form a hemispherical balled the diameter of the electrode. no intentional alloying elements in them end. Thoriated, ceriated, and lanthanated and their current- carrying capacity is lower tungsten electrodes do not ball as readily, Electrode Contamination than those with alloying elements. Each and they are typically used with DC. For tungsten electrode classification also has a these electrodes the end is typically Metal contamination of the tungsten color code as shown in Table 1. beveled to a conical shape (Fig. 1) with a electrode is most likely to occur when a specific included angle. A small flat at the welder accidentally dips the tungsten into Choosing Electrodes tip of the electrode is important to avoid the molten weld pool or touches the tung the end from breaking off. Table 4 offers sten with the filler metal. The tungsten elec The right electrode classification, size, suggested included angles for different trode may also become oxidized by use of

Table 2 — Recommended Types of Current, Tungsten Electrodes, and Shielding Gases for Welding of Various Metals and Alloys

Type of Alloy Thickness Type of Current 0). (2) Electrode^) Shielding Gas Aluminum All AC Pure or zirconiated Argon or argon-helium >'/* in. (3 mm) DCEN Thoriated Argon-helium or argon <'/«in. (3 mm) DCEP Thoriated or zirconiated Argon Copper, copper alloys All DCEN Thoriated Helium or argon-helium <% in. (3 mm) AC Pure or zirconiated Argon Magnesium alloys All AC Pure or zirconiated Argon <% in. (3 mm) DCEP Zirconiated or thoriated Argon Nickel, nickel alloys All DCEN Thoriated Argon Plain carbon, low-alloy steels All DCEN Pure or zirconiated Argon or argon-helium

Notes: (1) Where AC is listed, variable polarity or pulsed current could be used. (2) AC = Alternating current: DCEP = Direct current electrode positive; DCEN = Direct current electrode negative. (3) Where thoriated electrodes arc recommended, ceriated or lanthanated electrodes may also be used.

Table 3 — Typical Current Ranges for Tungsten Electrodes ll) and Recommended Gas Cup Sizes

Direct Current, A Alternating Current, A DCEN*-1) DCEPW Electrode Diameter Gas Cup I.D. (DCSP) (DCRP) Unbalanced Wave AC<3 Balanced Wave AC*1) in. mm in. mm EWX-X(2) EWX-X EWP EWX-X EWP EWX-X 0.010 0.30 % () Up to 15 N/A Up to 15 Up to 15 Up to 15 Up to 15 0.020 0.50 % 6 5-20 N/A 5-15 5-20 10-20 5-20 0.040 1.00 % 10 15-80 N/A 10-60 15-80 20-30 20-60 0.060(4) 1.6(1 X 111 70-150 10-20 50-100 70-150 30-80 60-120 0.093(>y 2.40 13 150-250 15-30 100-160 140-235 60-130 100-180 0.125«) 3.20 'A 13 250^*00 25-40 150-200 225-325 100-180 160-250 0.156^) 4.00 Vi 13 400-500 40-55 200-275 300-400 160-240 200-320 0.187W) 4.80 16 500-750 55-80 250-350 400-500 190-300 290-390 0.250(0 6.40 19 750-1000 80-125 325-450 500-630 250-400 340-525

Notes: (1) All values are based on the use of argon as a shielding gas. Other current values may he employed depending on the shielding gas, type of equipment, and application. (2) EWX-X refers to the X-X dopant and percantage of dopant in the tungsten electrode. See the latest AWS A5.12. Ce-2. La-1. La-1.5. La-2.Th-l.Th-2, Zr-1 mid others may be included in this category. (3) DCEN = Direct current electrode negative (straight polarity); DCEP = Direct current electrode positive (reverse polarity): AC = Alternating current. (4) Although the metric size 1.6 mm (0.063 in.) is closer to Kt in. (0.0625 in.), it has been common industry practice to refer to the U.S. customary size 0.060 in. as 'A-. in.

WELDING JOURNAL an improper shielding gas, insufficient gas should be inhaled by the grinder or adja lower flow rate requirements. flow, or leaking fittings or gas nozzle. cent personnel. Consult the manufac Argon-hydrogen mixtures and some When the tungsten becomes contami turer's suggested procedures and follow times argon-nitrogen mixes are used for nated, the welding operation should be company safety requirements. special applications. Different gas mix stopped and the contaminated portion cut tures are used to tailor the penetration, off and the electrode properly redressed. Gas Shielding bead geometry, and travel speeds. Table 5 gives some suggestions for shielding Dust Precautions Argon and helium or mixtures of the two gases and their advantages when welding are the most common types of inert gases certain metals. Sharpening the tungsten electrode used for shielding. Argon is preferred for generates tungsten metal dust, which can most applications, except where helium's be a health hazard. Use transparent eye higher heat input is required for welding shields, dust extractors, and filters. A vac thick sections of metals with high heat con Excerpted from AWS C5.5/C5.5M:2003, uum or exhaust system should be used. No ductivity such as aluminum and copper. Ad Recommended Practices for Gas Tungsten dust produced by the tungsten grinding ditionally, argon has a lower unit cost and Arc Welding.

Table 4 — Tungsten Electrode Tip Shapes and Examples of Current Ranges

DCEN (Electrode Negative/Straight Po)arity)(i),(2) Electrode Diameter Diameter at Tip Included Constant Pulsed Angle. Current Current in. mm in. mm Degrees Range, A Range, A 0.040 1.00 0.005 0.125 12 2-15 2-25 0.040 1.00 0.010 0.25 20 5-30 5-60 0.060 1.60 0.020 0.5 25 8-50 8-100 0.060 1.60 0.030 0.8 30 10-70 10-140 0.093 2.40 0.030 0.8 35 12-90 12-180 0.093 2.40 0.045 1.1 45 15-150 15-250 0.125 3.20 0.045 1.1 60 20-200 20-300 0.125 3.20 0.060 1.5 90 25-250 25-350

(1) All values are based on (he use of argon as the shielding gas. Other current values may be used, depending upon the shielding gas. type of equipment and application. (2) These values will vary depending on duty cycle, pulse frequency, peak/background ranges, etc.

Table 5 — Advantages of Shielding Gases

Metal Welding Type Shielding Gas Advantages Aluminum and Manual Argon Better arc starting, cleaning action and weld quality; lower gas consumption. Magnesium Argon-helium High welding speeds possible. Machine Argon-helium Better weld quality, lower gas flow than required with straight helium. Helium (DCSP) Deeper penetration and higher weld speeds than can be obtained with argon-helium.

Carbon Steel Spot Argon Generally preferred for longer electrode life. Better weld nugget contour, ease-of-starting, and lower gas flows than helium. Manual Argon Better pool control; especially for position welding. Machine Helium Higher speeds obtained than with argon.

Stainless Steel Manual Argon Excellent control of penetration on light gauge materials. Argon-helium Higher heat input, higher welding speeds possible on heavier gauges. Machine Argon-hydrogen Prevents undercutting, produces desirable weld contour at low current levels, (up to 35%-H2) requires lower gas flows. Argon-helium An excellent selection for high-speed tube mill operation. Helium Provides highest heat input and deepest penetration.

Copper. Nickel, and Argon Ease of obtaining pool control, penetration, and bead contour on thin-gauge metal. Cu-Ni Alloys Argon-helium Higher heat input to offset high heat conductivity of heavier gauges. Helium Highest heat input for welding speed on heavy metal sections.

Titanium Argon Low gas flow rate minimizes turbulence and air contamination of weld; improved heat-affected zone. Helium Better penetration for manual welding of thick sections (inert gas backing required to shield back of weld against contamination).

Silicon Bronze Argon Reduces cracking of this "hot short" metal.

Aluminum Bronze Argon Less penetration of base metal.

AUGUST 2006 growth vision.

2006 SEMINAR AND EXAM LOCATIONS

Long Beach, CA Seminar: Nov. 6-10 Exam: Nov. 11

Louisville, KY NDE professionals and Seminar: current AWS CWIs: Nov. 13-17 Exam: Get certified as an AWS Nov. 18 Radiographic Interpreter.

The AWS Radiographic Interpreter training and certification program assures employers and practitioners alike that the principles of radiographic interpretation are reliably applied to the examination of welds. If your job responsibilities include reading and interpretation of weld radiographs, this program is for you. You'll learn proper film exposure, correct selection of penetrameters, characterization of indications, and use of acceptance criteria as expressed in the AWS, API and ASME codes.

NEW! If you are a CWI, certification as an Radiographic Interpreter (Rl) can now exempt you from your next 9- Year CWI Recertification Exam.

For more information on the course, qualification requirements, certification exams, and test locations, visit our website at American Welding Society Founded in 1919 to advance the science, technology and www.aws.org/certification/RI or call 1-800-443-9353 ext 273 application of welding and allied joining and cutting (outside U.S., call 305-443-9353). processes, including brazing, soldering and thermal spraying. Circle No. 6 on Reader Info-Card NEW LITERATURE FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD.

Mechanized Cutting vs. laser beam. Compared in detailed cordless tools powered by lithium-ion bat Guide Offered chart form are cut quality, productivity, teries. In this collection are drill/drivers, a operating costs, and maintenance factors. reciprocating saw, a rotary hammer, and Another chart compares air plasma vs. a four-piece combination kit. Another sec oxygen plasma vs. LongLife ™ oxygen tion pictures new drills, screwdrivers, plasma vs. HyPerformance™ plasma for grinders with the company's Vibratech an- cut quality, mild steel weldability, produc tivibration grinder handles, and a new bur tivity, consumable life, process flexibility, nisher. Detailed diagrams and charts sim features, application ranges, and price. plify tool selection. Included is a list of au The technical features of the company's thorized service centers. machines for plasma cutting are presented in chart form for easy comparison of data. Metabo Corp. Ill 1231 Wilson Dr., West Chester. PA 19380 Hypertherm, Inc. 110 Etna Rd„ PO Box 5010, Hanover. NH 03755 Literature Review Is a Valuable Resource

Catalog Pictures Shop Tools The 20-page, full-color Product Litera ture Review presents a source of informa The 130-page, full-color, 2006/2007 tion for myriad topics of interest to all Power Tools, Accessories, and Abrasives welding and industrial personnel. Re Catalog illustrates and describes the com viewed are the product and services of the pany's lines of drills, screwdrivers, bench- industry leaders conveniently keyed to a The 16-page, full-color, brochure top woodworking machines, rotary ham postage-paid literature request card that measuring 5'A x 8!^ in., compares the pros mers, jig saws, sanders, grinders, abrasives, may be faxed to the service bureau for and cons of cutting with oxyfuel vs. plasma and accessories. Featured is a new line of faster response. Topics include develop-

2006 AWS IMAGE OF WELDING AWARDS What's your image of welding?

The American Welding Society is seeking nominations for its • Educator: an educator who has demonstrated an exemplary fourth annual Image of Welding Awards. These awards recognize commitment to furthering welding's image. individuals and organizations that have excelled in promoting the • Educational Facility: an educational facility that has image of welding in their communities. The awards are issued in demonstrated an exemplary commitment to furthering welding's seven categories, and winners will be announced and recognized image. , / at the FABTECH Int'l & AWS Welding Show in \ Nominations will be judged by the Welding Atlanta in October 2006. The seven award Equipment Manufacturers Committee categories are: [WEMCO], a standing committee of • Individual: a person showing AWS. Executives from welding- exemplary dedication to the industry suppliers serve on the promotion of welding. WEMCO committee to promote the • AWS Section: an AWS Section that I welding equipment market through has excelled in projects to further customized plans and programs. welding's image in its community. Enhancing the image of welding as a • Large Business: a business with more crucial industry has been identified as a than 200 employees that has funded and/or top-priority program. conducted projects aimed at promoting welding's To nominate an individual, company, educator, or facility for image locally or nationally. these award categories, submit a written explanation of the • Small Business: a business with less than 200 employees that nominee's qualifications, along with your name, address, phone has funded and/or conducted projects aimed at promoting number, and e-mail address. Please e-mail submissions to welding's image locally or nationally. [email protected] or mail them to AWS Image Awards, 550 NW • Distributor: a distributor of welding related products that has LeJeune Rd., Miami, FL 33126. Deadline for nominations is funded or assisted in promoting welding's image nationally or Sept. 1, 2006. locally.

Circle No. 16 on Reader Info-Card

INCLUDING: NEW PRODUCT SPOTLIGHT

ing welding skills, welding guns, elec trodes, welding helmets, welding wires, hardfacing products, shape cutting machines, welding clamps, electrode grinders, fluxes, safety products, welding positioners, software, DVDs, etc. Included is a 6-page new product spotlight section displaying the latest in welding equipment, software, gas regulators, plasma cutting machines, and torches.

American Welding Society 112 550 NW Lejeune Rd., Miami, FL33I26 Circle No. 17 on Reader Info-Card

NEW PRODUCTS — continued from page 25 WELDHUGGER COVER GAS DISTRIBUTION SYSTEMS • Flows gas evenly over and behind the weld pool. liable/ • Reduces oxidation and discolorization • Designed for trailing shield and a variety of other applications. • 316L Stainless steel nozzles and manifolds.

Trailing configured to meet the requirements of Shield Kit welding with E-6010 cellulosic electrodes. • The unit provides a consistently stable arc. Simulated nozzle flow When the arc is shortened, the arc force makes weld penetration easier. The unit's vertical static characteristics keep a con stant current, regardless of cable length or arc voltage, while the dynamic character istics ensure a stable arc and control of the molten weld pool. The units are equipped with hot start, arc force, and automatic an- tistick functions. It provides 240 A at 100% duty cycle, 310 A at 60% duty cycle, and 400 A at 35% duty cycle. The setting range is 10 A/20 V to 400 A/36 V. The main volt run age is 230/460 VAC, 3-60 Hz. HUGGER Toll Free: (877) WELDHGR (877) 935-3447 Fax: (480) 940-9366 ESAB Welding & Cutting Products 109 Visit our website at: www.weldhugger.com 411 S. Ebenezer Rd., PO Box 100545, Florence. SC 29501-0545 Circle No. 44 on Reader Info-Card WELDING JOURNAL PERSONNEL

President Selected at Farr ducer of seamless and welded tubular Mercedes-Benz, Sindelfingen, Germany. products serving the energy industry, has The Education Award was presented to Farr Air Pollution appointed Patrick J. B. Donnelly chair Peter Kopacek, head of the department Control, Jonesboro, man of the board and a member of the ex of intelligent handling and robotics at Vi Ark., has named Lee ecutive committee. He succeeds Clifford enna University of Technology, Vienna, Morgan president. R. Borland who was appointed chairman Austria. The Technology Development Morgan, with the emeritus and continues as a director of Award was earned by Jean-Paul Boillot, company since 1997, the company. Donnelly has served as a di chairman and CEO at Servo Robot Inc., has held a variety of rector of the company since 1981. Saint-Bruno, Quebec, Canada. management posts in the air pollution con Engelberger Robotics Alcoa Fills Two Posts in trol business unit. Awards Announced China Operations Lee Morgan Alcoa, New York, N.Y., and Beijing, The Engelberger Robotics Awards China, has appointed Randy E. Phillips ESAB Names Marketing were presented to four industry leaders as president, China corporate develop during the 37th Int'l Symposium on Ro Manager ment, and Bob Larson as president, China botics held May 16 during AUTOMAT- mill products. Phillips joined the company ICA in Munich, Germany. The awards, in 2003 as director of corporate develop ESAB Group has appointed Steve Pur- named for Joseph F. Engelberger, the "fa nell as marketing manager, arc welding ment. Larson, with the company for 28 ther of robotics," recognize significant years, most recently was vice president, products, for both ESAB and Murex achievements in the areas of leadership, branded products. Purnell previously sales and marketing, for the company's application, education, and technology mill products business. worked at Orbimatic, an orbital welding development. The Leadership Award equipment manufacturer. went to Kevin Ostby, vice president re gional operations at FANUC Robotics August Mack Names NS Group Selects Chair America, Inc. The Application Award was Six to Key Posts received by Hans Josef Haepp, head of NS Group, Inc., Newport, Ky., a pro production and materials technology at August Mack Environmental, Inc., In-

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Circle No. 12 on Reader Info-Card

AUGUST 2006 dianapolis, Ind., has appointed Darci Thomas and Joshua Flood to project man agers. Matthew Folz was named a staff sci entist, Jason Moening was appointed to staff engineer, Stephen Hohman was named senior compliance manager, and Sherri Chambers was appointed business development representative. Thomas, with 11 years of experience in the field, previously served the company as a staff scientist. Flood formerly was a staff scien tist specializing in regulatory quality as-

Stephen Hohman Sherri Chambers surance inspections and reporting. Folz formerly served for two years as a field sci entist specializing in underground storage tank removal. Moening earlier worked as a field engineer specializing in industrial ventilation. Hohman previously worked for Alcoa for 20 years in various environ- Circle No. 38 on Reader Info-Card

The American Welding Society (AWS), understands that one size does not fit all. For that reason, we've created FOUR different levels of corporate membership allowing you to select a program that best fits with the way your company operates. With a rich history in the welding industry, and nearly 50,000 members worldwide, AWS Corporate Memberships offer your company the ability to INCREASE ITS EXPOSURE and IMPROVE ITS COMPETITIVE POSITION.

AWS Corporate Memberships start for as little as $150 per year, so whether you're an independent welding shop, or a large manufacturer, AWS has the perfect membership for you.

For more information on which AWS Corporate Membership fits your company best, call the AWS Membership Department at (800) 443-9353, ext. 480 or visit us on-line at www.aws.org/membership.

Circle No. 11 on Reader Info-Card

WELDING JOURNAL mental, health, and safety positions. ics sector. Most recently, Mehmetli was Wall Colmonoy Appoints Chambers previously worked nine years an account manager for the member serv in property-management positions at ices group. The engineers include Alpesh Business Manager J. C. Hart and AMLI Residential. Shukla and Kevin Clear as project engi neers in the Engineering, NDE & Mate Morris Warino has SME Taps Community rials group; Brad Nagy as an applications been appointed busi ness development Relations Manager engineer in the Arc Welding, Lasers & Au tomation group; and Greg Firestone as an manager for Wall applications engineer in resistance and Colmonoy Corp., Ok The Society of Manufacturing Engi lahoma City, a part of neers, Dearborn, Mich., has named Susan solid-state welding. Shukla is completing his PhD in materials engineering at Rens- the WCC Aeronauti Sprentall as industrial laser community cal and Aerospace relations manager. Sprentall, who also selaer Polytechnic Institute. Clear previ ously was a welding engineer at the Naval Group. Warino has 17 operates American Laser Management years' experience in Co., Inc., will coordinate efforts of the In Surface Warfare Center. Nagy formerly served as engineering coordinator at Morris Warino national marketing dustrial Laser Group to have competitors and sales. work together in promoting the use of Honda of America. Firestone earlier lasers in the manufacturing arena, and worked as a research assistant and chief uniting the number of exhibitions and machine operator in the Ultra Precision Lincoln Chooses Global conferences. Manufacturing Lab at The Ohio State Director University. Quality Manager Appointed Lincoln Electric Holdings, Inc., Cleve land, Ohio, has appointed Phillip Wittke at Stillwater Technologies Jancy Engineering Hires Director of Market global director, offshore development, a newly created position. Wittke, with more Stillwater Tech Development than 24 years of experience in the weld nologies, Inc., Troy, ing industry, joined Lincoln Electric in Ohio, a contract tool Jancy Engineering, 2001 as managing director, greater China. ing and machining Inc., Davenport, company supplying Iowa, has named Honda and Toyota, William Hildebrand Obituary has named Patrick J. director of market Haren to the position development. Hilde Wendall Duane Johnson of quality manager. brand has more than Haren has more than 25 years of experi Wendall Duane Johnson, 56, died 20 years of industry ence in the metal- PatrickJ. Haren April 6 in Ridgefield, Wash. A long-time experience, most re working industries. member of the AWS cently as quality man William Hildebrand Portland Section, Mr. ager at Tipp Machine & Tool, Inc., based Johnson held various in Tipp City, Ohio. positions on its exec- Rexarc Appoints Two • utive committee, in- EWI Announces Staff Account Managers I eluding chairman for Additions I several terms. Mr. Rexarc International, Inc., West Alexan Johnson began his ca Edison Welding Institute (EWI), dria, Ohio, has appointed two regional ac reer in welding as an Columbus, Ohio, has named a market count managers. James M. Dev-lin will pro instructor in a high school metals shop, leader and hired four experienced engi vide sales and technical support for the W. D. Johnson neers. Candice Mehmetli was named mar northeast states region, and Bob Dobbs is progressed to welding ket leader for the medical/microelectron- assigned to its western states region. instructor, then be came department chair at Mount Hood Community College. He was noted for his gentle spirit, wise council, and willingness to help everyone in need. Mr. Johnson is survived by his wife, Phyllis, four children, COR-MET and three grandchildren. SPECIALTY CORED WIRE Do You Have Some News to Share? AND COATED ELECTRODES If you have a news item that might (810) 227-3251 FAX: (810) 227-9266 interest the readers of the Welding Jour www.cor-met.com nal, send it to the following address: Welding Journal Dept. Attn: Mary Ruth Johnsen 550 NW LeJeune Rd. Miami, FL 33126. Items can also be sent via FAX to (305) 443-7404 or by e-mail to mjohnsen @aws.org. Circle No. 21 on Reader Info-Card

AUGUST 2006 CLASSIFIEDS

CAREER OPPORTUNITIES

WELDING ENGINEER INDUSTRIAL SALES REP OUR ENERGY FLOWS THROUGH YOU with 15 years experience working with OEMs, End users & Distributors, The future of energy is being developed everyday at Pacific Gas and Electric (PG&E) seeks sales position with an aggres Company as we create new and more innovative ways to supply 14 million Californians. sive Manufacturer looking for a true We want our energy to become your power. We need your expertise to bring that power professional who delivers the goods. to the people. We are seeking a Welding Engineer for our Technical and Ecological Illinois/Chicago territory or will travel Services Group located in San Ramon, CA. Regionally/Nationally. Please forward You will plan and direct laboratory development projects and major weld repair projects inquiries to: [email protected]. as well as administer outside contract work. You should have 5-10 years weld engineer ing experience; in-depth knowledge of welding metallurgy and welding processes; strong experience with both NDE Techniques and ASME codes sections I, III, VIII, IX, XI and B31.8, ANSI 331.1, API codes, AWS codes and regulatory guidelines; and expe rience performing welded repairs including post-weld heat treatments. This position will WANTED run the PG&E nuclear welding control manual, developing new procedures and imple ment code changes and manual revisions. Strong oral and written communication skills Welding Alloy Sales Reps with a customer focus and a can do attitude are required. BS Engineering degree required in welding, metallurgical, or equivalent areas. AWS - CWI desired. Work expe Vulcan Systems is seeking rience in nuclear generation required with work in gas pipeline or other power genera professionals for the next level of tion industries a plus. profitability. Unique opportunity to Pacific Gas and Electric Company offers an exceptional compensation and benefits package including: Matching 401 (k), performance incentive program, medical/ dental/ build and secure your future. vision benefits, developmental opportunities, tuition reimbursement, and a whole lot Protect your profits and income. more! Learn more about us and apply at www.pge.com/careers. Search for "welding" under Contact Bob Turner Keywords on the management and professional jobs Search Page. Job # PSX42625. (800) 642-9885 Equal Opportunity Employer, M/F/D/V Pacific Gas and ¥&: Efectfic Company* SERVICES

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m AUGUST 2006 CERTIFICATION & TRAINING

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WELDING JOURNAL Win all-new prizes in the 2006-2007 AWS Member-Get-A-Member Campaign.

Give back to your profession, strengthen AWS and win great limited-edition prizes by recruiting new Members to AWS. Use the AWS Membership application located in this issue of the Welding Journal, or visit www.aws.org/mgm to get a Membership application. Learn more, and get started today by visiting: wvvw.aws.org/mgm American Welding Society

Circle No. 45 on Reader Info-Card

ADVERTISER INDEX

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AUGUST 2006 s i I

SUPPLEMENT TO THE WELDING JOURNAL, AUGUST 2006 Sponsored by the American Welding Society and the Welding Research Council Evaluation of Chemical Composition Limits of GMA Welding Electrode Specifications for HSLA-100 Steel

A Turbo C++ algorithm evaluates chemical composition limits of selected GMAW electrode specifications for potential application to welding HSLA-100 steel

BY K. SAMPATH AND R. VARADAN

ABSTRACT. A PC-based Turbo C++ al (HSLA) type steels with a specified mini rent fabrication practices primarily use gorithm was developed to quantitatively mum yield strength of 80 or 100 ksi are Ar-5%C02 as weld shielding gas, al evaluate chemical composition limits of gaining traction as high-performance though Ar-2%02 can also be used. AWS selected GMAW electrode specifications structural materials for the construction of A5.28, Specification for Low-Alloy Steel and two relevant U.S. patents for potential ships, aircraft carriers and submarines Electrodes and Rods for Gas Shielded Arc application to HSLA-100 steel. The algo (Ref. 1), off-shore structures, off-highway Welding (Ref. 4), specifies ER100S, rithm chiefly consisted of three parts: the vehicles, bridges, pressure vessels, and ER110S, and ER120S wire electrodes as first part defined boundary conditions for storage vessels including those for long- welding consumables suitable for joining obtaining a predominantly low-carbon term radiation containment of nuclear HY-80 and HY-100 steels. Currently, bainitic weld metal; the second part cov waste. these electrodes are used for fabricating ered chemical composition ranges for four U.S. Navy initially developed the HSLA-80 and HSLA-100 steels because principal elements — carbon, manganese, HSLA steels in the 1980s as potential al electrodes that could recreate or retain nickel, and molybdenum — as specified in ternatives to HY-80 and HY-100 steels, the metallurgical characteristics of HSLA AWS A5.28, MIL-E-23765/2E for primarily in an effort to reduce preheat- steels are not yet commercially available. ER100S- and ER120S-type welding elec related fabrication costs (Ref. 2). The Table 1 specifies the chemical compo trodes, or as claimed in U.S. Patents HSLA-100 steels (Ref. 3) are character sition range and mechanical property re 5,523,540 or 5,744,782; and the third part ized by a low carbon content (0.06 wt-% quirements for ER100S and ER120S addressed "mutually inclusive" computa maximum in ladle analysis, and 0.07 wt-% GMAW consumable solid wire electrodes tional requirements. Results showed both maximum in product analysis) and exhibit (Ref. 4). These electrodes often exhibit a A5.28 and MIL-E-23765/2E specifica a bainitic microstructure. The low-carbon carbon content in excess of 0.05 wt-%. tions did not contain any acceptable bainitic microstructures exhibit little or no Consequently, when welding HSLA-100 ER100S type composition, but contained susceptibility to hydrogen-assisted crack steel, these welding consumables require 177 of ER120S-type compositions, with ing (HAC) in the weld heat-affected zone significant preheat to eliminate the occur carbon content ranging from 0.03 to 0.08 (HAZ). Therefore, HSLA-100 steels re rence of HAC in the weld metal (Ref. 5). wt-%. Both U.S. Patents contained thou quire much less preheating controls than Since the currently available ER100S and sands of ER100- and ER120S-type elec HY-80 and HY-100 steel grades, thus of ER120S solid wire electrodes require pre trode chemical compositions, and ap fering a tremendous potential for low-cost heat and interpass controls, and post soak peared quite robust for application to fabrication of very large structures. temperature control for ER120S, their use welding HSLA-100 steel. The algorithmic The gas metal arc welding (GMAW) precludes the full economic benefits of approach clearly demonstrated that a process is commonly the preferred fabri HSLA-100 steel, thus raising an acute high-strength steel welding electrode cation process for constructing various need for the commercial availability of ad specification could not allow simultane structures for the above applications. Cur- vanced high- strength steel welding elec ous increases in carbon and nickel con trodes. tents, or concurrent increases to any three As the prime user of HSLA-100 steel, or all four of the principal alloying ele the U.S. Navy has identified that candi KEYWORDS ments near their respective specified date advanced GMAW electrodes for upper limit. HSLA-100 steel should exhibit the follow Turbo C+ + Algorithm ing characteristics: 1) eliminate or sub Electrode Specifications Background stantially reduce the need for preheat con Chemical Composition Limits trols; 2) show adequate resistance to HSLA-100 Steel In recent years, high-strength low-alloy HAC; 3) meet or exceed the mechanical GMAW property requirements of the existing US Patent 5,523,540 ER100S and ER120S electrodes; 4) allow K. SAMPATH is a technology/business consultant US Patent 5,744,782 welding over a broad operational enve in Johnstown, Pa. R. VARADAN is a graduate stu ERIOOS-Type Electrode lope in terms of plate thickness, welding dent in Electrical Engineering at the University of ER120S-Type Electrode position, and weld energy input; and 5) Texas, Arlington, Tex.

WELDING JOURNAL Ig i1I3 1 i I ! « 8 i !TO^!T!T!TT ranges, one for ERIOOS-type, and another for ER120S-type. These characteristics of the advanced welding electrodes allow fabricators to meet or exceed various re quirements for improved weldability (i.e., reduced preheat controls), strength and o mri low-temperature toughness. The underly > ing metallurgical relationships among mi chemical composition, welding conditions i> T3 (operational envelope or weld cooling rate), microstructure development and g 80 mechanical properties enable such high < performance. 20 40 60 80 The above three metallurgical charac Weld Cooling Rate at 1000°F (°F/s) teristics and their numerical ranges are also useful in identifying carbon, man ganese, nickel, and molybdenum as prin Fig. 1 — Variation of weld metal yield strength with calculated weld cooling rate at 1000°F. cipal elements for compositional control, thus allowing one to specify the composi tional ranges for the individual alloy ele ments. To demonstrate the utility of this Table 1 — Chemical Composition Ranges and Mechanical Property Requirements novel approach, a 23 factorial design of ex periments with one low and another high AWS A5.28 level for manganese (aim 1.5 wt-% and 1.8 Element ER100S ER120S wt-%), nickel (aim 2.5 wt-% and 3.8 wt- Carbon 0.08 0.10 %), and molybdenum (aim 0.5 wt-% and Manganese 1.25-1.80 1.40-1.80 1.0 wt-%) was used in developing a batch Silicon 0.20-0.55 0.25-0.60 of eight, low-carbon (aim 0.03 wt-%) bare Phosphorous 0.010 0.010 solid wire electrodes, '/u- in. in diameter. Sulfur 0.010 0.010 All of the eight electrodes, based on the Nickel 1.40-2.10 2.0-2.80 Fe-C-Mn-Ni-Mo-Ti system, were essen Chromium 0.30 0.60 Molybdenum 0.25-0.55 0.30-0.65 tially free from chromium, but contained Vanadium 0.05 0.03 other elements such as silicon, phospho Titanium 0.10 0.10 rus, and sulfur at some nominal values. Zirconium 0.10 0.10 The electrode chemical compositions also Aluminum 0.10 0.10 included approximately 0.03 wt-% tita Copper 0.25 0.25 nium as a deoxidizer and 'nitrogen getter.' Other Elements, Total 0.50 0.50 Titanium addition is critical to control the Iron Balance Balance amount of oxygen and nitrogen in the weld Mechanical Property metal. Additionally, titanium also served Tensile Strength (ksi) 100 120 to refine weld metal grains. Yield Strength (ksi) 88 105 Elongation (%) 16 14 Minimum CVN at 0°F (ft.lb) Evaluating Electrode Performance Minimum CVN at 60°F (ft.lb) 50 50 Initially, limited GMA welding experi Single values for chemical composition are maximum ments were carried out to evaluate the performance of the above eight welding show minimal variation in weld mechani selected parameters. This approach is ex electrodes, and to select a candidate elec cal properties (especially yield strength) tremely powerful for use with complex trode with the most potential for addi when welded over a broad operational en materials systems characterized by a num tional evaluation. Results showed that two velope. ber of critical processing parameters in of the eight electrodes consistently met or which conclusions are hard to draw be exceeded ER100S requirements, while Recent Pioneering Research cause of the many interrelated effects. In one of the eight electrodes consistently such cases, statistical or mathematical met or exceeded ER120S requirements. A recently published research work models can be helpful to clarify data and Additional weld evaluations were per (Ref. 6) has described the use of an inno allow ease of interpretation of results. formed over a much wider welding opera vative constraints-based modeling ap Initially, specific U.S. Navy require tional envelope using 1-in.- thick HSLA- proach in successfully specifying the ments for advanced consumable elec 100 or HY-100 steel plates, and one of the chemical composition range for advanced trodes were converted into a set of "mu eight electrodes that contained chiefly consumable electrodes based on the Fe-C- tually inclusive" constraints that related 0.03 wt-% carbon, 1.5 wt-% manganese, Mn-Ni-Mo-Ti system for GMA welding of chemical composition of steel electrodes 3.8 wt-% nickel, 0.5 wt-% molybdenum, HSLA-100 steel for critical U.S. Navy ap or weld metals with three statistically de and 0.03 wt-% titanium. Table 2 shows rel plications. This pioneering approach es termined metallurgical characteristics - evant welding conditions and the corre tablished a set of mathematical tools to B5Q temperature, Ms temperature and Yu- sponding weld metal mechanical property describe and support experimental data. rioka's carbon equivalent number (CEN). test results. All of the weldments showed Specifically, this approach relied on statis These three metallurgical characteristics acceptable weld mechanical properties for tical fit of chemical compositional data to are specified in terms of a set of numerical ER100S over the entire range of welding

AUGUST 2006 :=W=M-.M conditions. Figure 1 illustrates the above results as variation in weld metal yield START strength with calculated weld cooling rate at 1000°F (Ref. 6). The trend line showed the following statistical relationship, at a 2 Define boundary conditions r value of 0.99: tor RR 100S or ER 120S Type Welding Electrodes Yield strength (in ksi) = 75 x (Calculated weld cooling rate at 1000°F)n-<» The above test results revealed that a Define compositional range for C, Mn, Ni and Mo a welding electrode containing chiefly 0.03 claimed in Specifications or US Patents wt-% carbon, 1.5 wt-% manganese, 3.8 wt- % nickel, 0.5 wt-% molybdenum, and 0.03 wt-% titanium and characterized by a cal culated B5Q temperature of 440°C, Ms temperature of 422°C, and a 0.32 CEN Calculate specific metallurgical characteristics for the provided weldments with acceptable vari compositional range - start from low end of C, Mn, Ni and Mo; progressively go to high end of the range alter ation in weld mechanical properties, con designated increments sistently meeting or exceeding specific U.S. Navy requirements. However, the chemical composition of this high-perfor mance electrode showed a higher nickel content, much wider than the limit speci Allow designated increments to C. Mn. Ni and Mo, fied for either ER100S electrodes in AWS one element at a time A5.28 specification, or the military equiv alent MIL-100S electrodes (Table 3) spec ified in MIL-E-23765/2E specification (Ref. 7). Furthermore, two related U.S. patents (Refs. 8, 9) on low-carbon bainitic steel welding electrodes also claim a much wider range for nickel content compared with the above two specifications (Table 3). Both these patents claim chemical composition ranges for welding electrodes that are useful for GMAW of high- strength steels such as HSLA and HY Fig. 2 — Flow chart of the algorithmic approach. steels used as hull materials for naval ships, aircraft carriers, and submarines. E-23765/2E specifications primarily ad low-carbon bainitic steel system, if the The welding electrodes provided in these dress chemical composition limits of con electrodes were to consistently meet or ex two patents are claimed to form weld de ventional medium-carbon high-strength ceed U.S. Navy requirements? The pre posits with a low-carbon bainitic ferrite steel electrodes that provide a tempered sent work was carried out primarily to an microstructure that offer yield strength in martensitic weld metal. This may explain swer this vital question. excess of 80 ksi. the observed variation in nickel content Obtaining an appropriate answer to this Readers might recognize that while the between these two classes of welding elec question is also critically important particu two U.S. patents address chemical com trodes. However, what should be the spec larly to standards-setting organizations such position limits of low-carbon bainitic steel ification limits of individual alloy elements as the American Welding Society and vari welding electrodes, AWS A5.28 and MIL- of welding electrodes that are based on the ous end users. In recent years, within the

Table 2 — GMA Welding Conditions and Weld Mechanical Property Test Results

Calculated Room-Temperature All-Weld Tensile Test CVN Impact Test Weld Energy Welding Metal Cooling Yield Ultimate Reductior Weld No. Base Plate Input Position Transfer Rate at Strength Tensile Elongation in Area (kj/in.) 1000°F (ksi) Strength (%) (%) At-60° F At0°F (ksi) ER 100S HY-100/HY-80 — — cm— 100.0 min — — 50 min — 1 HSLA-100 30 Flat Spray 95 114.0 119.2 19.2 63 86 124 2 HSLA-100 45 Flat Spray 57 108.2 114.8 21.3 68 74 90 3 HY-100 45 Flat Spray 57 109.2 116.2 22.3 67 76 96 -I HSLA-100 55 Flat Spray 47 105.7 114.6 22.0 69 75 102 5 HSLA-100 111) Flat Spray 11 92.6 105.1 23.5 71 73 112 6 HSLA-100 111) Uphill Pulsed 7 87.0 109.0 24.3 72 125 146 7 HSLA-100 111! Flat Spray 5 88.3 102.8 24.3 71 49 95 8 HY-100 11(1 Flat Spray 5 87.0 102.8 25.8 72 99 129

Tensile test results represent an average of 2 tests; CVN impact test results represent an average of 5 tests.

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Table 3 — Chemical Composition Ranj es of AWS A5.28, MIL-E-23765/2E, U.S. Patent 5,523,540 and U.S. Patent 5,744,782

Element A5.28-05 MIL-E-23765/2E U.S. Patent 5,523,540 U.S. Patent 5,744,782 Experimental Range Range Claimed Experimi ntal Range Range Claimed ER 100S ER 120S MIL-100S MIL-120S Minimum Maximum Minimum Maximum

Carbon 0.08 0.10 0.08 0.10 0.012 0.035 0.01-0.05 0.026 0.030 0.06 Manganese 1.25-1.80 1.40-1.80 1.25-1.80 1.40-1.80 0.89 1.69 0.70-1.80 1.49 1.82 1-2 Phosphorus 0.010 0.010 0.008 0.012 0.001 0.001 0.01 Sulfur 0.010 0.010 0.003 0.012 0.0018 0.023 0.01 Silicon 0.20-0.55 0.25-0.60 0.20-0.55 0.25-0.60 0.27 0.36 0.20 -0.40 0.33 0.37 0.2-0.5 Chromium 0.30 0.60 0.3 0.6 0.01 0.60 0.80 0.01 0.02 Nickel 1.40-2.10 2.0-2.80 1.40-2.10 2.0-2.80 2.46 5.92 2.0-9.0 2.38 3.78 2^1 Molybdenum 0.25-0.55 0.30-0.65 0.25-0.55 0.30-0.65 0.44 0.96 0.40-1.50 0.51 0.99 0.3-1 Vanadium 0.05 0.03 0.004 0.01 0.01 0.001 0.003 Copper 0.25 0.25 0.25 0.25 0 0 1.0 0.001 0.20 0.5 Titanium 0.10 0.10 0.10 0.10 0.003 0.045 0.03 0.0025 0.0033 0.05 Aluminum 0.10 0.10 0.10 0.10 0.001 0.038 0.035 Boron 0.0003 0.0057 0.01 Oxygen 47 ppm 82 ppm 300 ppm Nitrogen 4 ppm 10 ppm 50 ppm Hydrogen 1. 15 mL/100 £ 2.35 mL/100 g 5 mL/100 g

Single values are maximum.

Table 4 — Analy ,is of Algorithm Results for ERIOOS-Type Electrode Chemical Compositions

Boundary Specified Ranges for Evaluation Number of Acceptable ERIOOS-Typi: Electrode Chemical Compositions Conditions Four Critical Criterion 0.01 wt-% 0.02 wt-% 0.03 wt-% 0.04 wt-% 0.05 wt-% 0.06 wt-% Total Elements c c C c c c AWS A5.28/ MIL-E-23765/2E C, 0.01 to 0.08; Mn, 1.25 to 1.8; (B50-Ms)>0 I) 0 (1 0 0 0 (1 Ni, 1.40 to 2.10; Mo, 0.25 to 0.55

U.S. Patent 5,523,540 (B50-Ms) > 0 1(129 1228 1313 1253 893 — 5716 0 o B5(1:417 ^161 C C, 0.01 to 0.05; MS:410°-451°C Mn, 0.70 to 1.8; Jpper Limit for Nickel 6.6 6.3 6.0 5.8 5.5 — — CEN: 0.29-0.38 Ni. 2.0 to 9.0; wt-% wt-% wt-% wt-% wt-% — Mo, 0.40 to 1.50

U.S. Patent 5,744,782 (B50-Ms)>0 495 588 652 668 556 346 3305 C, 0.01 to 0.06; Mn, 1.0 to 2.0; Ni, 2.0 to 4.0; Upper Limit for Nickel 4.0 4.0 4.0 4.0 4.0 4.0 — Mo, 0.30 to 1.0 wt-% wt-% wt-% wt-% wt-% wt-%

U.S. Navy, the strengthening of materials high-strength steel welding electrode, Seawolf submarine (Ref. 10) has quoted specification development and approval even though the welding electrode explic that "only 39% of (U.S. Government) process assumed center stage following the itly met the M1L-E-23765 specification re specification parameters were supported events associated with the construction of quirements for carbon content, but on the by historical data and less than 5% of the the first Seawolf submarine. These events high side, and despite the use of previously parameters were supported by test data," included extensive HAC of weldments in certified welding procedures. Contents of thereby, strongly underscoring a need for the HY-100 pressure hull, subsequent other critical elements that adversely af further strengthening of the specification techno-economic analyses, development, fect weldability were also found to be at a development and approval process. qualification, certification, and implemen higher level in the electrode, very near To this end, the present work describes tation of appropriate repair procedures that their respective maximum allowed in the the development of a PC-based Turbo also led to considerable schedule delays, sig electrode specification. C++ algorithm for quantitatively evaluat nificant cost overruns, etc. In a follow-up investigation, a U.S. ing the chemical composition limits of se Among other things, HAC of the Government Accountability Office report lected GMAW electrode specifications for welded pressure hull was attributed to the that examined the lessons learned from potential application to the welding of high carbon content of the MIL-120S the manufacturing experience of the first HSLA-100 steel.

AUGUST 2006 Table 5 — Analysis of Algorithm Results for ERIOOS-Type Electrode Chemical Compositions with Microstructure Control

Boundary Conditions Source and Specifi id Evaluation Criterion Number of Acceptable ER100S Type Electrode Chemical Compositions Ranges for Four (B5(rMs) 0.01 wt-95 0.02 wt-% 0.03 wt % 0.04 wt % 0.05 wt % 0.06 wt-% Total Critical Elements C C C C C C U.S. Patent >20°C 41 207 377 532 634 — 1791 5,523,540 Upper Limit for Nickel 4.3 wt-% 6.1 wt-% 5.8 wt-% 5.8 wt-% 5.3 wt-% — — C, 0.01 to 0.05; > 30°C — 1 49 126 231 — 407 Mn, 0.70 to 1.8; Upper Limit for Nickel — 4.5 wt-%. 5.7 wt-% 5.3 wt-% 5.4 wt-% — — Ni, 2.0 to 9.0; > 40°C — — — 1 15 — If) BS0:417°-461°C Mo, 0.40 to 1.50 Upper Limit for Nickel — — — 5.3 wt-% 5.1 wt-% — — Ms: 410°-451°C CEN: 0.29-0.38 U.S. Patent 20°C 31 113 210 305 397 346 1402 5,744,782 Upper Limit for Nickel 4.0 wt-% 4.0 wt-% 4.0 wt-% 4.0 wt-% 4.0 wt-% 4.0 wt-% — C, 0.01 to 0.06; > 30°C — — 14 57 141 231 443 Mn, 1.0 to 2.0; Upper Limit for Nickel — — 4.0 wt-% 4.0 wt-% 4.0 wt-% 4.0 wt-% — Ni, 2.0 to 4.0; >40°C — — — — 2 23 25 Mo, 0.30 to 1.0 Upper Limit for Nickel — — — — 4.0 wt-% 4.0 wt-% —

Table 6 — Analysis of Algorithm Results for ER120S-Type Electrode Chemical Compositions Source and Number of Acceptable ER120S-Type Electrode Chemical Compositions Boundary Conditions Specified Ranges Evaluation Criterion 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Total for Four Critical (B5I1-MS) wt-% wt-% wt-% wt-% wt-% wt-% wt-% wt-% Elements C C CCC CCC

AWS A5.28/ (B5()-Ms) > 0 22 31 38 45 35 177 MIL-E-23765/2E C, 0.01 to 0.10; Upper Limit for Nickel 2.8 2.8 2.8 2.8 2.8 2.8 Mn, 1.4 to 1.8; wt-% wt-% wt-% wt-% wt-% wt-% Ni, 2.0 to 2.80; Mo, 0.30 to 0.65

U.S. Patent 5523540 (B51l-Ms) > 0 57 434 ()I0 1320 1501 4222 C, 0.01 to 0.05; B5(l:404°Cto461° CMn, 0.70 to 1.8; Upper Limit for Nickel 5.5 6.5 6.3 6.2 5.9

Ms: 403°C to 430° C Ni, 2.0 to 9.0; wt-% wt-% wt-% wt-% CEN: 0.32-0.41 Mo, 0.40 to 1.50

U.S. Patent 5,744,782 (B5I1-MS) > 0 39 211 4(. I 698 800 725 2934 C, 0.01 to 0.06; Mn, 1.0 to 2.0; Upper Limit for Nickel 4.0 4.0 4.0 4.0 4.(1 4.0 Ni, 2.0 to 4.0; wt-% wt-% wt-% wt-% wt-% wt-% Mo, 0.30 to 1.0

Objectives reliably assuring the quality of high- parts. The first part defined a set of base strength steel welding electrodes while al line ranges or boundary conditions, one The specific objectives of this work lowing flexibility in quantitatively evaluat each for ER100S- and ER 120S-type weld were to develop a PC-based Turbo C+ + ing relevant electrode specifications and ing electrodes, for calculated B5() temper algorithm that would prove a useful tool in patented claims. Figure 2 provides a flow ature, calculated Ms temperature, and 1) quantitatively evaluating chemical com chart of the algorithmic approach. Ap Yurioka's CEN. Prior research on a new position limits of current AWS A5.28, pendix A shows the developed Turbo metallurgical model to speed the develop MIL-E-23765/2E welding electrode spec C++ algorithm for evaluating the chemi ment of consumable electrodes (Ref. 11) ifications for potential application to the cal composition ranges claimed in U.S. has identified specific or desirable base welding of HSLA-100 steel; and 2) com Patent 5,744,782 for ERIOOS-type elec line ranges for both ER100S- and paring the results with similar quantitative trode chemical composition. Selected ER120S-type electrodes following an evaluations performed on the chemical parts of this algorithm were modified to analysis of the chemical compositions of composition ranges claimed in two related allow the evaluation of electrode chemical solid, flux-cored, and metal-cored wire U.S. patents. compositions for both ER100S and electrodes or weld metals obtained ER120 types specified in AWS A5.28 and thereof. This approach to identifying de Algorithm Development MIL-E-23765/2E and chemical composi sirable or acceptable baseline ranges as tion ranees claimed in U.S. Patent boundary conditions is also comprehen The primary emphasis of the algorithm 5,523,540. sive as it included all three types of development effort was to capture current For the purpose of this work, the Turbo GMAW electrodes. Furthermore, this ap knowledge into a definitive baseline for C++ algorithm consisted of three main proach likely removed any inherent bias

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Table 7 — Analy sis of Algorithm Results for ER120S-Type Electrode Chemical Compositions with Microstructure Contro

Boundary Source and Specified Ranges Evaluation Criterion Number of Acceptable ER120S Type Electrode Chemical Compositions Conditions for Four Critical Element* (B5„-Ms) 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Total wt-9? wt-% wt-% wt-% wt-% wt-% wt-% wt-% C C C C C C C C AWS A5.28/MIL-E- >20°C — — 2 20 30 38 45 35 170 23765/2E Upper Limit for Nickel — — 2.8 2.8 2.8 2.8 2.8 2.8 — C, 0.01 to 0.10; wt-% wt-% wt-% wt-% wt-% wt-% Mn, 1.4 to 1.8; >30°C — — — 3 16 28 38 35 120 Ni, 2.0 to 2.80; Upper Limit for Nickel — — — 2.7 2.8 2.8 2.8 2.8 — Mo, 0.30 to 0.65 wt-% wt-% wt-% wt-% wt-% >40°C — — — — — 2 11 28 41 Upper Limit for Nickel 2.7 2.8 2.8 wt-% wt-% wt-%

B50: 404°-461°C U.S. Patent 5,523,540 >20°C — 71 393 668 — 1132 Ms: 403°-430°C C, 0.01 to 0.05; Upper Limit for Nickel — — 5.0 6.2 5.9 — — — — CEN: 0.32-0.41 Mn, 0.70 to 1.8; — — wt-% wt-% wt-% — — — — Ni, 2.0 to 9.0; >30°C — — — 57 240 — — — 297 Mo, 0.40 to 1.50 Upper Limit for Nickel — — — 4.9 5.9 — — — — — — — wt-% wt-% — — — — >40°C — — — — 9 — — — 9 Upper Limit for Nickel 5.1 wt-% — — —

U.S. Patent 5,744,782 >20°C 58 252 401 497 1208 C, 0.01 to 0.06; Upper Limit for Nickel — — 4.0 4.0 4.0 4.0 Mn, 1.0 to 2.0; wt-% wt-% wt-% wt-% — — — Ni, 2.0 to 4.0; >30°C — — — 45 141 239 — — 425 Mo, 0.30 to 1.0 Upper Limit for Nickel — — — 4.0 4.0 4.0 — — — wt-% wt-% wt-% — — — >40°C — — — — 2 23 — — 25 Upper Limit for Nickel 4.0 4.0 wt-% wt-%

toward either type of welding electrodes where the calculated value of Ms is 410° to its of the above four elements while main or specific welding conditions. Electrode 451°C for ERIOOS-type electrodes, or 403° taining all other elements identified in the chemical compositions that met the base to 430°C for ER120S-type electrodes. electrode specifications at some nominal line ranges for calculated B50 tempera value. Within the chemical composition ture, calculated Ms temperature, and CEN = C + A(C) x {Si/24 + Mn/6 + ranges specified, the combined effect of CEN for either ER100S- or ER120S-type Cu/15 + Ni/20 + (Cr + Mo + V + Nb)/5 all these other elements (silicon, electrodes have already been shown to + 5B) (3) chromium, copper, niobium, boron and consistently meet or exceed U.S. Navy re where A(C)=0.75 + 0.25 tanh [20 x (C- vanadium) on the calculated values of B5l) quirements when welding HSLA-100 steel 0.12)], and where the calculated value of temperature, Ms temperature and CEN is over a broad operational envelope (Ref. CEN is 0.29 to 0.38 for ERIOOS-type elec not significant, relative to that of a set of 6), thereby providing validity to this ap trodes, or 0.39 to 0.41 for ER120S-type nominal (or mean) values used in this al proach. electrodes. gorithm for each of these elements. Nom An electrode chemical composition The second part of the algorithm con inal (or mean) values used in the algo having the desirable features specific to sisted of chemical composition ranges for rithm for silicon, chromium, copper, this algorithm is based on the Fe-C-Mn- carbon, manganese, nickel, and molybde niobium, boron, and vanadium are shown Ni-Mo-Ti system. Specific amounts (in wt- num either as specified in AWS 5.28, MIL- in Appendix A. %) of carbon, manganese, nickel, E-23765/2E, or as claimed in the two U.S. The third part of the algorithm ad chromium, molybdenum, silicon, copper, Patents. As outlined in a previous section, dressed "mutually inclusive" computa vanadium, niobium, and boron concur prior research (Ref. 6) has clearly estab tional requirements. This part of the algo rently satisfy the following three equa lished that carbon, manganese, nickel, and rithm used four "FOR-NEXT" or "DO" tions; molybdenum are critical elements for loops to allow computation of B50 tem compositional control of these high-per perature, Ms temperature, and CEN B50 (°C) = 770 - (270 x C) - (90 x Mn) formance welding electrodes. Secondly, based on chemical composition data. -(37xNi)-(70xCr)-(83xMo) (1) these electrodes might also contain about These four loops pertained one each for where the calculated value of B5() is 417° to 0.03 wt-% titanium for controlling the carbon, manganese, nickel, and molybde 461°C for ERIOOS-type electrodes, or 404° amount of dissolved oxygen and nitrogen num, and allowed small incremental vari to 461°C for ER120S-type electrodes. in the weld metal (Ref. 12). As titanium is ation to their values starting from the re not a part of the above equations for B5u spective lower limit to the upper limit of

Ms (°C) = 561 - (474°C) - (33 x Mn) - (17 temperature, Ms temperature, and CEN, the ranges specified for these elements for xNi)-(17xCr)-(21xMo) (2) the algorithm development focused on ER100S and ER120S in AWS A5.28 spec evaluating the chemical composition lim ification, for MIL-100S or MIL-120S in

AUGUST 2006 Table 8 — A Comparison of U.S. Patents 5,523,540 and 5,744,782 Evaluation Criterion Number of Acceptable Electrode Chemical Compositions (B50-Ms) U.S. Patent 5,523,540 U.S. Patent 5,744,782 C, 0.01 to 0.05; Mn, 0.70 to 1.8; C. 0.01 to 0.06; Mn, 1.0 to 2.0; Ni, 2.0 to 9.0; Mo, 0.40 to 1.50 Ni, 2.0 to 4.0; Mo, 0.30 to 1.0 Total Over 4.0 wt-% Nickel At or below 4.0 wt-% Nickel At or below 4.0 wt-% Nickel ERIOOSType >0°C 5716 1923 3793 3305 >20°C 1791 709 1082 1404 > 30°C 407 233 174 444 >40°C 16 15 1 25 ER120SType >0°C 4222 1739 2483 2934 > 20°C 1132 460 672 1208 > 30°C 297 138 159 425 >40°C 9 8 1 25

Table 9 — Proposed Revisions to AWS A5.28 Specification for Application to HSLA-100 Steel Chemical Composition Element ER100S ER 20S Current Proposed Current Proposed Carbon 0.08 0.06 0.10 0.06 Manganese 1.25-1.80 1.0-2.0 1.40-1.80 1.0-2.0 Phosphorus 0.010 0.010 0.010 0.010 Silicon 0.20-0.55 0.20-0.55 0.25-0.60 0.20-0.60 Sulfur 0.010 0.010 0.010 0.010 Nickel 1.40-2.10 2.0-4.0 2.0-2.80 2.0-4.0 Chromium 0.30 0.30 0.60 0.30 Molybdenum 0.25-0.55 0.30-1.0 0.30-0.65 0.50-1.0 Vanadium 0.05 0.05 0.03 0.05 Titanium 0.10 0.10 0.10 0.10 Zirconium 0.10 0.10 0.10 0.10 Aluminum 0.10 0.10 0.10 0.10 Copper 0.25 0.25 0.25 0.25 Other Elements, Total 0.50 0.50 0.50 0.50 Iron Balance Balance Balance Balance

Mechanical Property Tcnsilc/lmpact Property ER100S ER120S Current Proposed Current Proposed

Yield Strength (ksi) 82-120 105-122 Minimum Tensile Strength (ksi) LOO 100 120 120 Minimum Tensile Elongation (%) 16 15 Minimum CVN at 0°F (ft.lb) 80 80 Minimum CVN at -60°F (ft.lb) 50 50 50 50

Single values for chemical composition are maximum.

MIL-E-23765/2E specification, and the characteristic. This feature allowed fur austenite. Furthermore, it is also widely specific ranges claimed in the U.S. Patents ther discrimination of the acceptable elec known that in bainitic steels, the B50 tem 5,523,540 and 5,744,782. The lower limit trode chemical compositions. The pur perature is often higher than the Ms for carbon was held at 0.01 wt-% to allow pose of this feature is primarily to identify temperature. ease of computation and comparative chemical compositions that would allow As both bainite and martensite form evaluation. The incremental values used adequate control of the relative amounts only from austenite, one could manipulate in the computation are also consistent of bainite and martensite in weld metal this characteristic to further evaluate the with typical accuracy values commonly re based on known relationships among chemical composition of a high-perfor ported for the respective elements when chemical composition, B50 temperature, mance welding electrode and ascertain its performing quantitative chemical analysis and Ms temperature of bainitic steels. It is ability to form low-carbon bainitic weld of low-carbon, high-strength steels. quite well known that B5() temperature in metal. In other words, the difference in

This part of the algorithm also allowed dicates the temperature at which 50% bai temperature between the calculated B5(, one to introduce the difference between nite forms from austenite, and Ms tem temperature and the calculated Ms tem calculated values of B5() temperature and perature indicates the temperature at perature could be used in microstructural Ms temperature as another desirable which martensite begins to form from selection or control. As used in this algo-

WELDING JOURNAL i rithm, when the difference in temperature specification and MIL-100S in MIL-E- ing carbon levels, thus clearly indicating between the calculated B5() temperature 23765/2E specification, the algorithm did that a specification for a high-perfor and the calculated Ms temperature in not return any acceptable electrode chem mance welding electrode could not allow creases from 0° to 60°C, the bainitic steel ical composition. Readers might recog simultaneous increases in both carbon and will have progressively higher amounts of nize that this result is rather expected as nickel contents, or for that matter in bainite, starting at about 50% bainite. both AWS A5.28 and MIL-E-23765/2E creases to any three or all four of the prin When the difference in temperature be specifications primarily address chemical cipal alloying elements near their respec tween the calculated BS(I temperature and composition limits of conventional tive specified upper limit. the calculated Ms temperature exceeds medium-carbon high-strength steel elec Furthermore, it is common knowledge 60°C, one could expect the microstructure trodes that provide a predominantly tem that a higher nickel content (together with to be entirely or about 100% bainitic. pered martensitic weld metal with a spec other austenite stabilizers such as carbon, The algorithm did not explicitly con ified minimum yield strength in the 80 to manganese, or copper) may promote a sider the effect of "delta quantities" (Ref. 100 ksi range. This null result does not primary austenitic type of weld solidifica 13) to compensate for the loss or gain of mean the current ER100S or MIL-100S tion that may lead to unacceptable tough alloying elements across the arc column electrodes are not suitable for welding ness behavior of weld metal, especially at from the welding electrode to weld metal. HSLA-100 steel. Rather, the null result low temperatures. In fact, a previous in In GMA welding, delta quantities of alloy means that the above electrodes are suit vestigation (Ref. 14) that studied the ef elements vary with alloy element, shield able for welding HSLA-100 steel when ap fect of manganese and nickel on the vari ing gas type, flow rate, and weld energy propriate preheat controls and limits on ation in microstructure and mechanical input. For example, when Ar-5% C02 is welding operational envelope are strictly properties of low-carbon (0.02 wt-%) Fe- used as a shielding gas, the delta quantity in force. Indirectly, the above null result C-Mn-Ni system of weld metals suitable for carbon is +0.01 wt-%, i.e., one would also served to validate the utility of this al for HSLA-100 steel had shown that in a commonly observe a 0.01 wt-% pickup in gorithmic approach. low-manganese (less than 1.0 wt-%) com the carbon content of the weld metal rela position, nickel additions increased hard tive to that of the welding electrode. Like U.S. Patent 5,523,540 ness without sacrificing impact toughness wise, under similar welding conditions, the whereas in a high-manganese (over 1.5 wt- delta quantity for manganese is -0.2 wt-%, For the chemical composition ranges %) composition, nickel additions deterio i.e., one would commonly observe a 0.2 wt- claimed for carbon, manganese, nickel, rated the impact toughness quite seriously % decrease in the manganese content of and molybdenum contents in U.S. Patent as it promoted intergranular fracture. The the weld metal relative to that of the weld intergranular fracture path appeared to 5,523,540 and with calculated value of B5n ing electrode. The effect of "delta quanti temperature equal to or greater than the follow columnar grain boundaries that ties" may be addressed in a more elabo were identical to prior austenite grain calculated value of Ms temperature, the rate future effort that could also consider algorithm returned over 5700 acceptable boundaries since no 8-ferrite phase various shielding gases, flow rate, and ERIOOS-type electrode chemical compo formed during solidification. Accordingly, weld energy input. sitions (Table 4) indicating the robustness these boundaries without having primary Following appropriate computations, of the patented claims. Admittedly, a 8-ferrite phase were susceptible to crack the algorithm allowed the output to be di wider range for nickel content (2.0 to 9.0 ing under dynamic loading. Based on rectly imported into a Microsoft Excel wt-%) as claimed in U.S. Patent 5,523,540 hardness and impact resistance reported spreadsheet that also allowed further ma is likely responsible for the above over in this investigation, the optimum levels nipulation of results, and printing of de whelming number of results. Of these, for manganese and nickel have been sug gested to be 0.5-1 wt-% and 4-5 wt-%, re sirable ranges for B5II temperature, Ms over 1900 electrode compositions con temperature and CEN, along with the spe tained nickel in excess of 4.0 wt-%. Classi spectively. Evidently, and as shown in cific individual chemical compositions fication of the results based on carbon Table 4, one would expect the specified upper limit for nickel content to decrease that offered valid B50 temperature, Ms content showed a maximum number of temperature, and CEN values in the above 1313 acceptable electrode chemical com further from the 5 wt-% level with a higher range. positions at the 0.03 wt-% carbon level. carbon and manganese content in a Fe-C- Mn-Ni-Mo-Ti weld metal system. Based on the number of valid chemical This indicated that electrodes (or weld compositions that showed desirable metals) with 0.03 wt-% carbon may toler ranges for B5(l temperature, Ms tempera ate a wide variation in chemical composi U.S. Patent 5,744,782 ture, and CEN, or an appropriate mini tion, thus would be more "forgiving" while mum difference between the calculated meeting performance requirements. Co- For the chemical composition ranges values of B50 temperature and Ms tem incidentally, electrode manufacturers claimed for carbon, manganese, nickel, perature, the individual electrode specifi might benefit when formulating their and molybdenum contents in U.S. Patent quality control measures for these types of cation or patented claim was considered 5,744,782 and with calculated value of B5() robust and suitable for application to electrodes if they focus their electrode temperature equal to or greater than the manufacturing and quality assurance ef welding HSLA-100 steel. calculated value of Ms temperature, the forts on the 0.03 wt-% carbon level. algorithm returned over 3300 acceptable Results and Discussion Table 4 also provides a classification of electrode chemical compositions (Table the results based on the maximum possi 4). These results are less robust compared ER100S-Type Electrode Composition ble or upper limit for nickel content at to those obtained with U.S. Patent each of these carbon levels. The upper 5,523,540. Despite claims for a slightly AWS A5.28/MIL-E-23765/2E limit for nickel content did not exceed 6.6 wider range for carbon content (up to 0.06 Specification wt-%, and this likely represents a possible wt-%), the lower range claimed for nickel specification upper limit. Interestingly, content (2.0 to 4.0 wt-%) in U.S. Patent For the chemical composition ranges the maximum possible (or allowable) 5,744,782 is mostly responsible for the cited for carbon, manganese, nickel, and nickel content at each of these carbon lev above reduction in the number of accept molybdenum for ER100S in AWS A5.28 els progressively decreased with increas able electrode chemical composition re-

AUGUST2006 suits. Furthermore, a classification of the in U.S. Patents 5,523,540 and 5,744,782 with proach allows one to reject a rich or a lean results based on the maximum possible or the following boundary conditions that are electrode heat even when the ladle (melt) upper limit for nickel content returned a appropriate for ER120S-type welding elec composition is well within AWS 5.28, MIL- value of 4.0 wt-% at each of these carbon trodes — B50: 404° to 461°C; Ms: 403° to E-23765/2E specifications, or the cited U.S. levels. This indicated that the upper limit 430°C; and CEN: 0.32 to 0.41. Interestingly, patents. When the metallurgical criteria are for nickel content claimed in U.S. Patent both AWS A5.28 and MIL-E-23765/2E not met, a rich or a lean heat becomes an 5,744,782 is somewhat conservative as it specifications returned 177 chemical com "out-lier." This ability to distinguish at an clearly discounted for the adverse effect of positions, ranging from 0.03 to 0.08 wt-% early stage of electrode processing elimi higher nickel content on microstructure carbon. Classification of the results based nates or substantially reduces subsequent development and low-temperature impact on carbon content showed that 80 of these processing costs and associated risks. Read toughness of weld metal. 177 compositions contained 0.07 or 0.08 ers may recognize that this level of reliabil wt-% C, a level that was also higher than the ity and risk reduction while specifying an Microstructural Control specified upper limit for carbon content in electrode chemical composition is not com (ladle or product analysis of) HSLA-100 monly achieved. The above algorithm was subsequently steel. Additionally, these 80 compositions Thus, use of the above algorithmic ap used in additional evaluations that pro are likely to provide weld metals that may proach greatly reduces various risks inher vided more insight on the ability of elec exhibit unacceptable variations in yield ent in specifying electrode chemical com trode chemical compositions in offering strength relative to weld cooling rate. In position, and is powerful in identifying high- microstructural selection or control. The comparison, chemical composition ranges performance electrode chemical composi chemical composition ranges claimed in claimed in U.S. Patents 5,523,540 and tions that have a higher reliability in meet U.S. Patents 5,523,540 and 5,744,782 were 5,744,782 contained thousands of ER120S- ing or exceeding mechanical property re further evaluated using the difference in type electrode composition, and appeared quirements when welding HSLA-100 steel, temperature between the calculated B5(1 quite robust for application to welding over a wide welding operational envelope. HSLA-100 steel. U.S. Patent 5,523,540 re temperature and the calculated Ms tem In strengthening the electrode specifica perature as an additional criterion for eval turned 4222 chemical compositions, of tion development efforts and approval uation. Results were obtained for more which 1739 contained over 4.0 wt-% nickel. processes, the algorithmic approach pro than 20, 30, and 40°C difference in temper U.S. Patent 5,744,782 returned 2934 chem vides a quantitative basis for including the atures. Table 5 provides the algorithm re ical compositions, all of which contained 4.0 latest advances in the understanding of the sults as total number of acceptable elec wt-% or less nickel. relationships among chemical composition, trode chemical compositions, and these Table 8 provides a comparative evalua welding conditions, weld microstructure de results are classified on the basis of carbon tion of the two U.S. Patents when 4 wt-% velopment and resultant weld mechanical content, and the corresponding upper limit nickel is considered the upper limit for ei properties, and fracture characteristics of for nickel content at each carbon level. ther ER100S- or ER120S-type welding high-strength, low-carbon bainitic steel In general, the results reported in Table electrodes. This comparison is based on the weld metals. 5 are similar to those reported in Table 4, ex premise that at over 4 wt-% nickel content, cept the acceptable upper limit for nickel one might witness primary austenitic type of Conclusions content in U.S. Patent 5,523,540 dropped weld solidification and the attendant loss of further to 6.1 wt-%. Furthermore, when a impact toughness in weld metal, especially 1) A Turbo C++ algorithm has been de predominantly (over 75%) bainitic mi at low temperatures. As shown in Table 8, veloped to quantitatively evaluate the crostructure is desired, the total number of when using microstructural control as an chemical composition limits of selected acceptable electrode compositions dropped evaluation criterion, the available number GMAW electrode specifications and two down dramatically, and these compositions of acceptable ER 100S and ER 120S elec relevant U.S. Patents for potential applica required a minimum of 0.04 wt-% carbon. trode compositions clearly indicates that tion to welding HSLA-100 steel. Additionally, when considering a tempera the claimed ranges in U.S. Patent 5,744,782 2) For the chemical composition ranges ture difference of over 30°C, the claimed provide additional flexibility over the cited for carbon, manganese, nickel, and ranges for the four critical elements in U.S. claimed ranges in U.S. Patent 5,523,540. molybdenum for ER 100S in AWS A5.28 Patent 5,744,782 appeared to provide some specification and MIL-100S in MIL-E- what more flexibility in designing accept Benefits 23765/2E specification, the algorithm did able electrode chemical compositions com not return any acceptable electrode chemi pared to those in U.S. Patent 5,523,540. The chief advantage of this algorithmic cal composition. This flexibility is further reinforced when approach to evaluating electrode chemical 3) For the chemical composition ranges the upper limit for nickel in U.S. Patent composition is that this offers a powerful cited for carbon, manganese, nickel, and 5,523,540 is limited to 4 wt-%, and the nu tool in distinguishing high-performance molybdenum for ER120S in AWS A5.28 merical advantage shifts decidedly in favor welding electrode chemical compositions specification and MIL-120S in MIL-E- of U.S. Patent 5,744,782, presumably be from "rich" and "lean" welding electrode 23765/2E specification, the algorithm re cause of the marginally higher limit for chemical compositions. It is well known that turned 177 acceptable electrode chemical carbon. the use of rich and lean welding electrode compositions. Of these, 80 compositions chemical compositions often limits the op contained 0.07 or 0.08 wt-% C, more than ER120S-Type Electrode erational envelope, shows unacceptable the specified upper limit for carbon in sensitivity of yield strength to weld cooling HSLA-100 steel, thus making them unsuit Composition rate and, reduces performance, while in able for welding HSLA-100 steel. creasing overall cost of weld fabrication. 4) For the chemical composition ranges Tables 6 and 7 provide results of similar Secondly, the algorithmic approach is quite claimed for carbon, manganese, nickel quantitative evaluations performed on elec useful in readily identifying an acceptable and molybdenum contents in U.S. Patent trode chemical composition ranges in AWS electrode heat which has a melt composi 5,523,540, the algorithm returned thou A5.26 and MIL-E-23765/2E specifications, tion that meets the desired metallurgical sands of acceptable ER100S- and ER120S- and chemical composition ranges claimed criteria. Alternatively, the algorithmic ap type electrode chemical compositions indi-

WELDING JOURNAL eating the robustness of the patented shown to impair low-temperature tough American Welding Society, Miami, Fla. claims. ness of high-strength steel weld metal. Con 13. Oldland, P. X, Ramsay, C. W, Matlock, D. 5) For the chemical composition ranges sequently, there also exists a need to recon K., and Olsen, D. L. 1989. Significant features of claimed for carbon, manganese, nickel, and sider allowing titanium and aluminum high-strength steel weld metal microstructures. molybdenum contents in U.S. Patent concentrations as high as 0.10 wt-% in Welding Journal 68(4): 158-s to 168-s. 5,744,782, the algorithm returned a lesser ER100S- and ER120S-type high-strength 14. Kang, B. Y., Kim, H. J., and Hwang, S. K. number of acceptable ER100S- and steel welding electrode specifications. 2000. Effect of Mn and Ni on the variation of the ER120S - type electrode chemical composi Some of the mechanical property ranges microstructure and mechanical properties of tions, but seemed to rightly discount for the proposed in Table 9 are derived from MIL- low-carbon weld metals. ISIJ International adverse effects of nickel content over 4 E 23765/2E(SH) specification (Ref. 7). 40(12): 1237-1245. wt-% in drastically reducing low-tempera 15. Dorschu, K. E., and Lesnewich, A. 1964. ture impact toughness of weld metal. Acknowledgment Development of a filler metal for a high-tough 6) This algorithmic approach is quite ness alloy plate steel with a minimum yield helpful in distinguishing high-performance The authors express their deep appreci strength of 140 ksi. Welding Journal 43(12): 564-s welding electrode chemical compositions ation to AWS Principal Reviewer for en to 576-s. from rich and lean welding electrode chem couragement and helpful comments on the 16. Dorschu, K. E. 1965. U.S. Patent ical compositions, and may serve a vital manuscript. 3,215,814. Welding of high yield strength steel. need in strengthening electrode specifica 17. Lyttle, J. E., Dorschu, K. E., and Fragctta, tion development efforts and approval References W A. 1969. Some metallurgical characteristics of processes. tough, high-strength welds. Welding Journal 48 1. Montemarano, T. W, Sack, B. P., Gudas, J. (ll):493-sto498-s. Future Work P., Vassilaros, M. G. ,and Vanderveldt, H. H. 18. Dorschu, K. E. 1970. U.S. Patent 1986. High strength low alloy steels in naval con 3,527,920. Welding of alloy steels. One could expect that populating this al struction. Journal of Ship Production 2(3): gorithmic approach with test results from 145-162. Appendix A other experimental welding electrode de 2. Holsberg, P. W, Gudas, J. P., and Caplan, I. velopment work based on the Fe-C-Mn-Ni- L. 1990. Navy's welding research picks up steam. A Turbo C++ Algorithm for Evaluating Mo-Ti system would provide a powerful tool Advanced Materials & Processes 138(1): 45-49. Chemical Composition Limits of GMAW in further strengthening welding electrode 3. MIL-S-24645A (SH). 1990. Steel Plate, Electrode Specifications standards development and certification ef Sheet or Coil, Age-Hardening Alloy, Structural, forts. Based on the above work, and the re High Yield Strength (HSLA-80 and HSLA-100). //57447S2 _USP.CPP sults of other recent work performed under 4. A5.28, Specification for Low-Alloy Steel #include the auspices of U.S. Navy and commercial Electrodes and Rods for Gas Shielded Arc Welding. #include electrode manufacturers, the AWS A5 1996. American Welding Society, Miami, Fla. #include Committee on Filler Metals and Allied Ma 5. Holsberg, P. W.. and Wong, R. J. 1990. #include terials may consider introducing a subset of Welding of HSLA-100 for naval applications. #include main() ER100S and ER120S electrodes suitable Weldability of Materials. R. A. Patterson and K. W. (FILE *flp: for welding HSLA-100 steel. The chemical Mahin. eds. ASM International. Materials Park, float CarMax, CarMin, MnMax, MnMin, NiMax, composition ranges specified in A5.28 Ohio, pp. 219-239. NiMin, MoMax, MoMin; Specification for Low-Alloy Steel Electrodes 6. Sampath. K. 2005. Constraints based mod // Carbon, Manganese. Nickel & Molybdenum for Gas Shielded Arc Welding, may be revised eling enables successful development of a weld float SiMean, CrMean. TiMcan, CuMean, as shown in Table 9 for both ER100S- and ing electrode specification for critical Navy appli NbMean, BMean. VMcan: ER120S-typc welding electrodes suitable cations. Welding Journal 84(08): 131-sto 138-s. //Silicon, Chronium, Titanium, Copper, Nio for HSLA-100 steel that are based on the 7. MIL-E-23765/2E (SH). 1994. Electrodes bium, Boron, Vanadium Fe-C-Mn-Ni-Mo-Ti system. and Rods — Welding, Bare, Solid, or Alloy Cored; float ccnMax, cenMin, tanvar, addvar, cencalc, i, The revisions in Table 9 chiefly address and Fluxes, Low Alloy Steel. j, k, 1, difcen, b50calc, b50dif; carbon, manganese, nickel, and molybde 8. Coldren, A. P., Fiore. S. R„ and Smith, R. num contents of ER100S- and ER120S- B. 1996. U.S. Patent: 5523540, Welding Elec float msdif. mscalc; type welding electrodes. Further, the chem trodes for Producing Low Carbon Bainitic Fcr- ical compositions of these electrodes are rite Weld Deposits. int b50Max, b50Min, count, msMax, msMin; essentially free from chromium addition, 9. Sampath. K.. and Green, R. S. 1998. U.S. except that the chromium content is limited Patent: 5,744,782, Advanced Consumable Elec signed int b50_mscalc_diff = 0; to 0.3 wt-%, a representative value com trodes for Gas Metal Arc (GMA) Welding of monly obtainable from re -melting of scrap High Strength Low Alloy (HSLA) Steels. char compfile[20].tmpname[20],ch; steel. Additionally, titanium addition is crit 10. Navy Ships: Lessons of Prior Programs clrscr(); ical to the performance behavior of these May Reduce New Attack Submarine Cost In cenMin = 0.29; welding electrodes. Furthermore, titanium creases and Delays, GAO/NSIAD-95-4, United cenMax = 0.38; addition is preferred over aluminum for States General Accounting Office GAO Report b50Min = 417; achieving desired levels of deoxidation, and to Congressional Requesters, p. 7, October 1994. b50Max = 461; adequate control over nitrogen content and 11. Sampath, K., Green, R. S., Civis, D. A., msMin = 410; weld metal grain size. Prior research (Refs. Williams, B. E., and Konkol, R J. 1995. Metallur msMax = 451; 15-18) has shown that a titanium content of gical model speeds development of GMA weld 0.01 to 0.03 wt-% in the welding electrode is ing wire for HSLA steel. Welding Journal 74( 12): CarMin = 0.01; desirable for achieving exceptional low- 69-76. CarMax = 0.06; temperature impact toughness. Although 12. Wong, R. J., and Hayes, M. D. 1990. The MnMin = 1.0; not revised in Table 9, titanium and alu Metalling}; Welding & Qualification of Microal- MnMax = 2.0; minum in excess of 0.03 wt-% have been loyed (HSLA) Steel Weldments. pp. 450-489, NiMin = 2.0;

AUGUST 2006 ! iiiimmui

NiMax = 4.0; count = 0; for(l=MoMin;l<(MoMax+.01);l + = .l) MoMin = 0.30; } { MoMax = 1.0; // addvar SiMean = 0.30; //If Filename is NULL display Error =((SiMean/24) + (j/6)+(CuMean/15)+(k/20)+( CrMean = 0.10; if((flp=fopen(tmpname,"wr")) = =NULL) (CrMean+1+VMean+NbMean)/5) + (5 * BMea TiMean = 0.03; { n)); CuMean = 0.10; printf("Error! The file %s could not be cencalc =i+((.75+.25*tanh(tanvar))*addvar); NbMean = 0.005; opened",compfile); BMean = 0.0002; } if(cencalc < cenMax && cencalc > cenMin){ VMean = 0.005; // b50calc=(770-(270*i)-(90*j)-(37*k)- (70*CrMean)-(83*l)); //Display //—If filename is OK then continue calcs- printf("\n\n\t\t\tWelding Electrode Composition if(b50calc < b50Max && b50calc > b50Min){ EvaluationV); else mscalc=561-(474*i)-(33*j)-(17*k)- {fprintf(flp,"CENMin,CENMax,B50Min,B50M (17*CrMean)-(21*l); //Receive input value for b50_mscalc_diff from ax,MsMin,MsMax\n"); user fprintf(flp,"%4.2f,%4.2f,%4d,%4d,%4d,%4d\n", if(mscalc < msMax && mscalc > msMin){ printf("\n\n\tEnter integer difference in temper cenMin,cenMax,b50Min,b50Max,msMin,msMa if((mscalc + b50_mscalc_diff) fprintf(flp,"CarMin,CarMax,MnMin,MnMax,Ni TiMean,CuMean,NbMean,BMean,VMean,cen- 50)){ Min,NiMax,MoMin,MoMax\n"); calc,b50calc,mscalc); printf("\n\n\tRange incorrect enter value be fprintf(flp,"%4.2f,%4.2f,%4.1f,%4.1f,%4.1f,%4. tween 0 & 50(included)"); lf,%4.1f,%4.1f\n",CarMin,CarMax,MnMin,Mn printf("\n\n\tPress Enter & Run Program again to Max,NiMin,NiMax,MoMin,MoMax); re-enter value"); fprintf(flp,",,\n"); getch(); } fprintf(flp,"C,Mn,Si,Ni,Cr,Mo,Ti,Cu,Nb,B,V,CE else{ N,B50,Ms\n"); //Receive File name from user. for(i=CarMin;i<(CarMax+0.00l);i + = .01) printf("\n\n\tEnter filename to store weld metal { chemical compositions"); tanvar = 20*(i-0.12); return 0; printf("\n\n\tFilename with .csv (comma sepa fprintf(flp,", , \n"); rated values) would be best for viewing"); for(j=MnMin;j<(MnMax+.01);j + = .l) printf("\n\n\t .csv:"); { scanf("%s",compfile); for(k=NiMin;k<(NiMax+.01);k+ = .l) strcpy(tmpname,compfile); {

Errata

Three equations that appeared in the welding research supplement titled "In vestigating the Bifurcation Phenomenon in Plate Welding" by C. L. Tsai, M. S. Han, and G. H. Jung on page 160-s in the July 2006 Welding Journal were incorrect. Below are the corrections. The Welding Journal apologizes for the errors.

Tma x -a (T ^ (3)

-a ™*(T-T ) v h o' T R (4) H MMT-T

-a^l+R )(T-r) (5)

WELDING JOURNAL Using a Hybrid Laser Plus GMAW Process for Controlling the Bead Humping Defect

The heat input from a defocused laser beam applied in front of a GMAW pool suppresses formation of weld bead hump defects and allows higher travel speeds

BY H. W. CHOI, D. F. FARSON, AND M. H. CHO

ABSTRACT. A novel LBW + GMAW hy adjacent solid substrate, and weld pool problem. Because the high-energy- brid process was investigated, and its abil fluid flow were identified as factors im density processes are inherently high ity to suppress weld bead hump formation portant in hump formation, documented speed and produce narrow deep welds, was characterized. The hybrid process experimentally to various degrees and an weld metal flow is generally identified as had a relatively low-power-density laser alyzed. Implicit in the discussions is the being more important in humping than spot focused a short distance in front of role of solidification since the humped surface tension. Although the deep nar the leading edge of the GMA weld pool. geometry must be preserved by freezing row welds associated with high-energy- The laser power and spot size were varied the melt to be observed. It was noted that density processes are not the same as the in tests and it was found that, for given the hump defect was observed only at a GMA weld bead of interest in this work, GMAW process settings, bead humping high travel speed, that a leading ("push") it is interesting that the dual heat source was suppressed by laser heat input of suf weld gun travel angle suppressed hump strategy for weld humping suppression ficient power density. Comparison of the formation, and oxygen in the shielding gas was not adopted in arc welding and laser toe angles of humped and nonhumped or from the weldment surface exacerbated beam welding (Refs. 17, 18) until some weld beads made by the hybrid process hump formation. years later. A novel humping suppression and by the GMAW process suggested that Subsequent literature (Ref. 3) dis method for laser welding that is based on capillary instability was likely a factor in cussed these factors in more detail, of Lorentz force exerted by a current flow weld bead hump formation, but it was not fered some new ones (effect of gravity in specifically introduced for this purpose the sole factor in at least some of the tests. uphill welding (Ref. 4 )), and described has been demonstrated (Ref. 19). Observations made during the experi how humping could be suppressed (e.g., One can conclude from the above cited ments suggested that weld pool fluid flows two-electrode arc process (Ref. 5)). literature that two factors are identified as may have been an important factor in Marangoni flow was proposed as a factor dominant causes of the humping defect in weld humping. in hump formation (Ref. 6) and was later arc weld beads. Both were mentioned in noted as a relatively small effect in a paper the seminal work by Bradstreet. Capillary Introduction dealing with the theoretical analysis of instability is one key factor that is empha hump formation (Ref. 7). Studies aimed at sized in that work, and also in the overview This article investigates a novel hybrid understanding and controlling the bead and theoretical analysis by Kapadia and laser beam welding (LBW) plus gas metal humping phenomena through the adjust Dowden. However, longitudinal flow in arc welding (GMAW) process that pro ment of weld parameters and the dual the weld pool, which becomes faster as vides for control of weld bead shape and torch welding approach continue to the travel speed and corresponding wire de suppression of the weld bead humping de present time (Refs. 8-10). position rate increases for filler-added fect. Weld bead humping is a defect that As high-energy electron beam (EB) processes, is a second factor that is com often sets an upper limit on the travel and laser beam welding processes became monly identified. speed that can be used with a welding important, a high-speed bead shape Bradstreet identified a submerged flow process. Because of its importance, bead defect mode quite similar to arc weld stream that originates from the bottom of humping has been the subject of research bead humping was identified and ana the weld pool crater and sweeps backward for many years. lyzed (Refs. 11-16). Interestingly, the first along the centerline solidification bound A first, relatively thorough qualitative archival article cited on this subject pro ary to the trailing edge of the pool. Two study was reported by Bradstreet (Ref. 1). poses a dual electron beam solution to the other rearward-directed streams originate Humping was defined as a quasi-periodic higher up on either side of the crater and weld bead shape defect that was always as merge with the centerline flow somewhere sociated with undercutting; a failure of the between the crater and the trailing edge of molten weld deposit to completely fill a the weld pool. At this point, the longitudi groove defined by the fusion boundary KEYWORDS nal flow, which has been attenuated from generated by arc heat input. Capillary or energy removal due to solidification, Rayleigh instability (Ref. 2) of the molten Laser Beam Welding (LBW) emerges on the melt surface and some weld deposit due to liquid metal surface Gas Metal Arc Welding (GMAW) times is seen moving relatively sluggishly tension, wetting of the weld metal on the Weld Bead Humping toward the leading edge of the pool as a Hybrid Process surface flow. Nguyen et al. (Ref. 8) noted Bead-on-Plate Welds these same flows in high-speed pho H. W. CHOI, D. F FARSON (farson.4feosu.edu), Capillary Instability tographs and identified them as the dom and M. H. CHO are with The Ohio State University: inant cause of humping in his welds. Welding Engineering Program, Columbus, Ohio. For arc welding processes, most of the

1 AUGUST 2006 0.1-0.27 in. „ a 2 8 • 18 *- -7- o °T 1 6 - • • • GWIA sound K o • a 5 - • • GMA humped 0.12-0.20 in. co2 (0 • • • .-, Laser ? 4 J o hybrid humped GWIA torch beam £ 1 • • > hybrid sound •o m ^ a

*n 1 y / jr \ 60° 50 100 150 200 90y ^H Travel speed (in./min.)

<" II Material travel direction

Fig. 1 — Hybrid process setup. Fig. 2 — Travel speed limits of the GMA W and hybrid processes for bead-on- plate welds. Sound (nonhumped) weld beads were not possible at 80 in./min with the Ci MAW process, but were possible at 150 in./min (3.75 m/min) and with a higher deposition rate with the hybrid process.

broad area that will allow the molten weld Table 1 — Welding Apparatus and Process Settings metal to spread laterally, decreasing the GMAW power source ESAB Digipulse 450i evee toe angle and thereby decreasing the cap GMAW pulse mode/trim Synergic/99-122 illary instability of the molten deposit. The Filler material/diameter ER70S-6/0.045 in. (1.1 mm) ability to adjust this additional heat source Base material/thickness HR 1008 steel plate/14. 16 gauge so as to prevent weld bead humping is 3 Shielding gas/flow rate Ar, 90% Ar-10% C02/ 35 ft /h (14 L/min) characterized, and its effects are analyzed. Contact tip-to-work distance 0.875 in. (22 mm) In particular, the effects of capillary forces Laser Rofin Sinar RS850 and flow on weld bead humping are de Laser focus optic/focal length Parabolic mirror/10 in. (25.4 mm) duced from the experimental results. Laser focus spot width Wj 0.1-0.27 in. (2.54-6.86 mm) Laser power P| 2.0-3.5 kW Arc laser spot spacing 0.13-0.2 in. (3-5 mm) Experimental Apparatus and Procedure research literature deals with the bead-on- stability. This result is in agreement with A GMAW apparatus that allowed for plate weld geometry. No literature can be the earlier isothermal analysis. flexible integration of a laser beam heat found for bead humping in the more use Another key result from nonisother source was integrated. A sketch of the po ful lap-fillet and T-fillet groove geome mal wetting analysis is that melt spreading sition and orientation of the GMAW tries. For this research, it is also interest speed is controlled by surface energies and process and laser beam focus is shown in ing that dual-torch processes have been resulting contact angle, very much as in an Fig. 1, and details of the welding process found to be less susceptible to hump for isothermal wetting case. However, the settings are given in Table 1. A pulsed mation than single-torch processes. maximum extent of nonisothermal GMAW power source was used to deposit Independent of the welding applica spreading is ultimately limited by heat bead-on-plate welds in the flat position on tions research into weld bead humping, transfer and phase transformation; simply hot-rolled steel sheet with as-received sur closely related, but more fundamental, put, when the metal freezes, it ceases to face condition. With the exception of wire studies into wetting and spreading (both spread. This is a key insight that is useful feed and travel speed, the GMAW process isothermal and nonisothermal) of liquid when configuring laser heat input so as to settings remained fixed during all tests. and solid substrates have been proceed produce desired weld bead shapes. The laser beam focus spot was positioned ing. Dynamic nonisothermal wetting and In this article, we return to the original in front of the leading edge of the GMAW spreading of a linear "bead" of liquid de concept of humping as a capillary instabil weld pool, and the focal point elevation posited on a solid surface has been ana ity for inspiration that suggests a new tech was adjusted to produce a laser focus spot lyzed and conditions for instability (essen nique that may permit control of the de diameter measured normal to the travel tially, capillary-force driven instability) fect. We propose that a defocused laser direction. were determined (Ref. 20). beam can be used as an auxiliary heat Relative positions and orientations of Even more pertinent to welding, a non source to control the shape of the de the arc and laser processes and other isothermal analysis of a similar situation posited weld metal. In the experiments de welding process variable settings are sum that allows for heat transfer and solidifi scribed in this article, the laser beam is de- marized in Fig. 1. The laser beam inci cation of the liquid has also been carried focused into a relatively broad spot that dence angle setting remained fixed during out (Ref. 21). In this work, it is reported travels with the arc and is directed onto the tests, and the relative position of the that liquid deposits that are well wetted to the weldment in advance of the leading laser spot and the arc were fixed at 0.1 -0.2 the substrate (i.e., have an internally mea edge of the weld pool. in. (0.25-0.5 mm). However, the laser sured contact angle of less than jr/2) are It is hoped that this additional surface power and focus spot size were varied to not susceptible to humping by capillary in heat input will heat and melt a shallow, determine their effects on hump preven-

WELDING JOURNAL . IHIli IIIIIII I u ...

D 7 - o • ra 6 • -

•D <" 5 • GMA sound a. n GMA humped f 4 • • hybrid sound 0 D > o hybrid humped 2 3 I2 1 - 0 50 100 150 200 Travel speed (in./min.)

Fig. 3 — Travel speed limits of the GMA W and hybrid processes for lap-fillet Fig. 4 — Surface contour images of a GMAW-only weld with hump defects and welds. Sound (nonhumped) weld beads were not possible at 60 in./min with hybrid process weld with desired weld bead shape. Travel speed was 80 in./min the GMA W process, but were possible at 160 in./min (4 m/minj and with a (2 m/min), and GMA Wprocess settings were the same in both cases. higher deposition rate with the hybrid process. 160 in. Imin (4 mlmin) was the maximum travel speed of the motion system.

0.14 0.14 0.12 d 2 0.12 ^ 0.1 0) ft 0-1 ' E 0.08 1 0.08 4= [ i "5 0.06 o> 0.06 • o £ 0.04 004 t I CroD 0.02 J 0.02 - I 1

U 1 1 2 3 () 0.1 0.2 0.3 Laser power (kW) Laser spot width (in.)

Fig. 5 — Variation of BOP weld bead hump height variation as a function of Fig. 6 — Variation of BOP weld bead hump height variation as a function of laser power for conditions WL = 0.2 in. (5 mm), Ar shielding gas, 14-gauge laser spot width for conditions Ar+10%CO2 shielding gas, 14-gauge material, material. Laser power was not constant for the tests.

tion. Argon was used as a shielding gas for speed, travel speed, and other process was sufficiently large. Humped beads some initial tests because it is known to ex variable settings. Bead humping severity were defined as those having a bead height acerbate weld bead humping. However, as was quantified by measuring the range of variation along their length more than more experience was gained with the bead weld bead height over the length of the 0.03 in. (0.75 mm). humping defect, it was found that hump weld, and the effect of various process set A graphical illustration of the hump ing was obtained at feasible travel speeds tings on bead height variation was deter prevention capability of the hybrid with the more conventional 90% argon- mined. Laser beam heating was found to process is shown in Fig. 4. Two bead-on- 10% CC>2 shielding gas, which was used suppress weld bead humping in both bead- plate welds made with the same GMAW for the majority of the tests. After welding, on-plate (Fig. 2) and lap-fillet (Fig. 3) settings are shown — the one made with the standard deviation and range (maxi weld geometries. These figures show that the hybrid process has a smooth contour, mum-minimum) of the height and the for comparable deposit areas, the hybrid while the other made with the GMAW weld toe angles of the bead-on-plate welds process was able to operate at a higher process alone is severely humped. were measured using a laser line scan weld travel speed without bead humping — the The bead-on-plate welds were studied inspection system (Servo-Robot WISC). speed for acceptable (nonhumped) bead- in more detail to determine parameter on-plate and lap-fillet welds was nearly a effects on humping. The experimental re Experimental Results factor of two higher for the hybrid process. sults are compiled in Table 1, and the However, it is also interesting to note that effects of laser power and laser spot size Hybrid and GMA bead-on-plate welds beads deposited with the hybrid process weld bead humping are quantified in Figs. were made over a range of wire feed also formed humps when the travel speed 5 and 6. For these tests, the conditions

AUGUST 2006 .]I!M;|=M=M:M!

— 0.14 a 0.12 • '<>•.: 0) D) 0.1 c o 0.08 • Width variation b > i s - » • heigh t (mm ; o Hybrid j x: Power variation a> 0.06 S 0.4 - • GMA a o 0.04 o o ° « 0.2 - TO 0.02 • •o 2 n m 0 h 5> ° 1 90.0 100.C 110.0 120.0 130.0 14( 1 10 100 1000 Max toe angle (deg.) Laser spot power density (kW/cm2)

Fig. 7— Variation of BOP weld bead hump height variation as a function of Fig. 8— Weld bead height variation vs. maximum toe angle for argon shield- laser power spot density from Figs. 5 and 6. A threshold power density of about ing gas and varying process settings. The hybrid welds generally had larger toe 16 kWlcm2 is observed. angles and were of comparable smoothness to GMA welds.

? 1 E r o.8

o Hybrid » 0.6 - 0 Hybrid • GMA 2 0.4 1 GMA •Q I 0.2

o©o © en 125.0 130.0 135.0 140.0 145.0 150.0 120.0 125.0 130.0 135.0 140.0 145.0 Max. toe angle (deg.) Max. toe angle (deg.)

Fig. 9 — Weld bead height variation vs. maximum toe angle for C02 shielding Fig. 10 — Weld bead height variation vs. maximum toe angle for 16-gauge ma gas and varying process settings. The hybrid welds generally had larger toe an terial and varying process settings. The hybrid welds generally had larger toe an gles and were smoother than GMA welds. Hybrid and GMA welds with com gles and were smoother than GMA welds. parable angles are marked.

were S = 100 ties, the results from Figs. 5 and 6 are plot 1 in./min (42 mm/s) ted against laser power density in Fig. 7. -. and Sw = 550 These results show that irrespective of 0.8 in./min (233 mm/s). width or power variation, a laser power For a fixed laser density of approximately 16 kW/cm2 was spot size of 0.2 in. sufficient to suppress bead humping. Also, I 0.6 (0.5 mm), a power it was noticed that the power density of the O Hybrid "ro humping. Laser This research was initiated with a hy 0.2

Fig. 11 — Actual standard deviation of weld bead height (adH) compared to power was adjusted observed humping suppression was due to the standard deviation predicted by a linear regression equation with inputs of during the tests de this effect, toe angles (external angles laser power, travel speed, wire feed speed, and maximum toe angle for the 12- picted in Fig. 6 to measured by laser scanner) were com 2 gauge argon welds. The correlation coefficient was R = 0.94, indicating that maintain compara pared to the critical angle of 90 deg for the linear combination of these variables explained most of the bead humping ble power densi various welding conditions. Note that the in these experiments.

WELDING JOURNAL VJ=1I»J !M:1:«=M:H: where the symbols are as defined in Table Table 2 — Experimental Conditions and Results 2. The predictions of the equation are com pared to the actual weld bead height stan Condition Sw S P| W, Range adH dard deviation in Fig. 11. The data were in./min in./min dH Standard Max. Toe Angle relatively well fit by the linear combination in. Deviation (deg) of these variables, with a correlation coef dH mm ficient of R2 = 0.94. The sign of the coeffi 12 gauge. 500 80 0 0 0.044 0.411 114.3 cients indicates that larger maximum toe Argon 500 70 0 (I 0.017 0.259 111.2 angle and laser power decreased bead 500 60 0 0 0.018 0.174 113.5 height variation, while higher travel speed 500 80 3 0.1 0.01 0.257 121.9 and wire feed speed increased it. When a 500 100 3 0.1 0.03 0.471 118.6 regression was done with coded variables 550 100 3.35 0.21 0.068 0.473 118.1 so that coefficients could be easily com 550 100 3.35 0.2 0.016 0.158 131.9 pared, it was found that they were all of the Mil) 100 3.35 0.2 0.08 0.363 124.0 same order of magnitude, indicating that 630 100 3.35 0.2 0.021 0.271 131.4 550 !()() 3.1 0.2 0.086 0.916 122.6 the contribution of process settings to the 550 100 3.25 0.2 0.045 1.413 123.2 bead humping was comparable to the toe 550 100 3.25 0.2 0.026 0.364 125.0 angle. It is noted that linear regression fit 550 100 0 0.2 0.106 0.926 99.3 ting of the data of Figs. 9 and 10 produced 550 LOO 3.4 0.2 0.011 0.232 125.0 correlation coefficients of R2 = 0.77 and 680 100 3.35 0.2 0.025 0.142 130.3 R2 = 0.68, suggesting that a model with 680 100 0.938 105.7 0 0 0.121 higher order terms would be needed to more accurately represent the data. 12 gauge, 600 LOO 0 0 0.101 0.904 130.5 Ar+C02 600 100 3.35 0.2 0.101 0.068 134.4 Further analysis showed more vividly 600 100 3.35 0.2 0.022 0.259 133.5 that hump formation is sometimes af 650 LOO 3.1 0.2 0.013 0.104 146.3 fected by factors other than capillary in 650 LOO 3.1 0.2 0.008 0.446 132.0 stability. All other process settings being 600 LOO 3.3 0.2 0.03 0.713 131.7 equal, additional laser heat input would 600 LOO 3.35 0.05 0.018 0.284 134.8 600 LOO 3.55 0.13 0.074 0.419 138.3 inevitably result in a longer weld pool and 600 100 0 0.17 0.105 0.869 132.0 more time for capillary instability to form 650 LOO 3.35 0 0.145 0.12 143.0 a humped weld bead. Thus, for the same 700 100 3.35 0.188 0.1525 0.115 140.3 weld toe angle and GMA process settings, 650 LOO 3 0.178 0.1545 0.37 133.0 it might be expected that bead height vari 650 100 3.25 0.26 0.143 0.301 136.2 ation of the hybrid weld beads would prob 650 LOO 134.5 3.5 0.26 0.156 0.163 ably be worse than GMA weld beads if capillary forces were the sole factor in 16 gauge, 500 100 0 0 0.063 0.53 123.9 Ar+CO-, 500 LOO 2.5 0.167 0.005 0.157 135.7 humping. However, several data points for 300 100 2 0.15 0.013 0.075 143.4 this case (three points on the left side of 300 LOO 0 0 0.058 0.157 126.0 Fig. 9; data are highlighted in Table 2) 300 130 2 0.15 0.005 0.141 133.6 show that a hybrid weld with the same toe 300 150 2 0.15 0.013 0.324 124.8 angles as GMA welds was humped less. 375 L50 : 0.15 0.006 0.126 129.1 Thus, it may be concluded that the bene 375 120 2 0.17 0.003 0.044 140.4 ficial effects of the hybrid process were not 350 LOO 2 0.2 0.011 138.6 0.051 solely due to improved weld bead shape. 375 150 2 0.16 0.016 0.182 131.9 375 120 2 0.16 0.005 0.051 139.1 A likely additional effect of the hybrid 450 140 : 0.162 0.007 0.12 130.4 process was noticed while doing the ex 440 L30 2 0.16 0.005 0.072 134.6 periments — it was observed that the 400 130 2 0.16 0.005 0.056 138.0 leading edge of the weld pool was located : further in advance of the welding arc for Sw: wire feed speed; S: travel speed; P|: laser power; Wp laser spot width; O\]H standard deviation of weld bead height variation; 6 : maximum weld toe angle. the hybrid process when laser power was m high enough to be effective. This change would significantly effect weld pool fluid maximum toe angle is used based on a sup toe angles are significantly greater than flow by decreasing the conversion of position that the stability of an asymmet the critical static angle of 90 deg. In itself, downward droplet momentum into back rical weld deposit should be controlled by this indicates that factors besides capillary ward weld pool jet momentum. Consider the larger of the two toe angles. instability play a role in the bead hump ing this affect, it is conjectured that the The results, summarized in Figs. 8-10 formation in our experiments. mechanism of humping suppression of for noted conditions, show that the laser To quantify the role played by other the hybrid process investigated in this hybrid welds did indeed have larger toe welding parameters in the toe angle-bead work may be similar to that of the two-arc angles and less height variations as quan humping relationship, a multilinear regres or dual-beam processes mentioned in the tified by the standard deviation of weld sion was carried out on the data of Fig. 8. literature survey. bead height over the length of the weld. The result was a linear equation of the form However, there is considerable scatter in the correlation between the two variables. Conclusions o- ,=-0.0249 •0.011S- 0.00045 This variability is due to the fact that the uH n points in Figs. 8 and 9 represent many dif -0.010/^ + 2.056 (I) A novel LBW plus GMAW hybrid ferent GMA and hybrid process settings. process was investigated, and its ability to It is also notable that all of the measured suppress weld bead hump formation was

AUGUST 2006 characterized. It was found that, for given ing./. Japan Weld. Soc. 49(4): 259-265. humping head formation in electron beam GMAW process settings, bead humping 6. Mills. K. C, and Keenc. B. J. 1990. Fac welding. Trans. Nat. Res. Inst. Metals 25(2): was suppressed by laser heat input of suf tors affecting variable weld penetration. Inl. 62-67. ficient power density. Comparison of the Mater. Rev. 35: 185-216. 14. Tsukamoto, S., Irie, H., Inagaki, M, and 7. Gratzke, U„ Kapadia, P. D., Dowden, J., Hashimoto, T 1984 Effect of beam current on aspect ratios of humped and nonhumped Kroos, J., and Simon, J. 1992. Theoretical ap humping bead formation in electron beam weld beads made by the hybrid process proach to the humping phenomenon in welding welding. Trans. Nat. Res. Inst. Metals 26(2): and by the GMAW process suggested that processes. J Phys. D: Appl. Phys. 25(11): 133-140. capillary instability was not the only factor 1640-1647. 15. Tomic, M., Abe. N., and Arata, Y. 1989. in bead humping. Observations made dur 8. Nguyen, T. C, Wcckman, D. C. Johnson, Tandem electron beam welding. Report 9: High ing the experiments suggested that weld D. A., and Kerr, H. W. 2005. The humping phe speed tandem electron beam welding. Trans. pool fluid flows were also important. nomenon during high speed gas metal arc weld JWRI18(2): 175-180. ing. Sci. Techno!. Welding Joining 10(4): 16. Albright, C. S.. and Chiang. S. 1988. References 447-459. High speed laser welding discontinuities. J 9. Mendez, P. F„ and Eagar, T. W. 2003. Pen Laser Applications 1(1): 18-24. 1. Bradstreet, B. J. 1968. Effect of surface etration and defect formation in high-current 17. Iwase, T, Sakamoto, H., Shibata, K., tension and metal flow on weld bead formation. arc welding. Welding Journal 82(10): 296-s to Hohenberger, B., and Dausinger, F. 2000. Dual Welding Journal 47(7): 314-s to 322-s. 306-s. focus technique for high-power Nd:YAG laser 2. Rayleigh, J. W. S. 1892. On the stability of 10. Ueyama, T, and Ohnawa, T 2005. Ef welding of aluminum alloys. Proc SPIE 3888: cylindrical fluid surfaces. Phil. Mag. 5(34): fects of torch configuration and welding current 348-358. 177-180. on weld bead formation in high speed tandem 18. Xie, J. 2002. Dual beam laser welding. 3. Savage, W. R, Nippes, E. R, and Agusa, K. pulsed gas metal arc welding of steel sheets. Sci. Welding Journal 81(10): 223-s to 230-s. 1979. Effect of arc force on defect formation in Techno!. Welding Joining 10(6): 750-759. 19. Kern. M.. Berger, P., and Hugcl, H. 2000. GTA welding. Welding Journal 58(7): 212-s to 11. Arata, Y„ and Nabegata, E. 1978. Tan Magneto-fluid dynamic control of seam quality 224-s. dem Electron Beam Welding (Report 1). Trans. in C02 laser beam welding. Welding Journal 4. Scotti, A., Larson, U., and Norrish, J. JWRI7(\0): 101-109. 79(3): 72-s to 78-s. 1991. Bead instability of mechanised P-M1G 12. Tsukamoto, S., Iric, H., Inagaki, M, and 20. Davis. S. H. 1980. Moving contact lines [pulsed M1G] welding in vertical-up position. Hashimoto, T. 1982. Humping bead formation and rivulet instabilities. Part 1. The static Inl. J. Joining Mater. 3(1): 18-24. in electron beam welding. Report 2: Effect of rivulet. J. Fluid Mech. 98: 225-242. 5. Kokura, S., Nihei, M., Kozono, U., beam current on humping bead formation. J 21. Schiaffino, S., and Sonin, A. A. 1997. Ashida, E., and Onuma, A. 1980. Twin elec Japan Welding Soc. 51(10): 867-873. Formation and stability of liquid and molten trode switching arc welding method. Report 1: 13. Tsukamoto, S., Irie, H., Inagaki, M, and beads on a solid surface. J. Fluid Mech. 343: High speed twin electrode switching TIG weld Hashimoto, T. 1983. Effect of focal position on 95-110.

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WELDING JOURNAL I 1 I * S 8 I i 1 I , tJ.iliS « Si If * .Ssl^lS*^ IMJIiitiiMW^^W 1i nnrTJi!T?^rw! End Point Detection of Fillet Weld Using Mechanized Rotating Arc Sensor in GMAW A sensing model was developed to detect the end points of joints in fillet welds using gas metal arc welding with a rotating arc

BY W.-S. YOO, Y.-H. SHI, J.-T. KIM, AND S.-J. NA

plied to detecting the end point of the weld joint because the shape KEYWORDS of the joint is reflected on the electrical signals such as welding current and voltage, which are related to the CTWD. Rotating arc Gas Metal Arc Welding (GMAW) welding has two prominent features in detecting the end point: Rotating Arc Sensor One is that the effect of weld pool can be reduced when the arc Contact Tip-to-Work Distance rotates along the front half-circular path. The other is that its en Fillet Welds hanced responsiveness ensures the rapid detection of an end point. In this paper, the following topics are investigated: a) A math ABSTRACT. In this paper, a geometrical sensing model was de ematical model that investigates the GMA welding system; b) a veloped for the rotating arc sensor in gas metal arc welding geometrical sensing model of the rotating arc sensor in fillet weld (GMAW) of fillet joints that have open and closed ends, consid ing that has open and closed ends; and c) current simulations and ering the mathematical model of the GMA welding system. By experiments in open and closed fillet structures in steel welding. using the two developed models, simulations of welding current of the rotating arc sensor were performed and compared with the Mathematical Model of GMA Welding System experimental results of current waveform in open and closed fil let joints in steel welding. Figure 1 shows the equivalent electrical circuit of the conven tional GMA welding system with a constant voltage power source. Introduction In the equivalent electrical circuit, the output voltage of the weld ing power source, Vs, and the voltage drop in the welding power Through-arc sensing using the electric signals obtained from cable, Vp, can be written as follows: the welding arc is the most effective way to track the weld joint. During gas metal arc welding (GMAW) with a constant voltage V =V -RI-L (1) power source, the welding current and the voltage generally vary (It with the contact tip-to-work distance (CTWD) (Ref. 1). The gun weaving method is widely used to intentionally stimulate the vari ations of the CTWD. But the conventional gun weaving methods have a relatively poor resolution and limit the oscillation fre V = RI + L * (2) quency due to the mechanical restraints. To overcome these short P P P dt comings, the arc sensing systems enhanced using the mechanical The voltage drop in the welding arc, V , can be written as follows: arc rotation or the electromagnetic arc oscillation have been in a vestigated and successfully developed (Refs. 2, 3). V =V +R I + EL (3) The rotating arc sensor can improve the sensor characteristics a ao a a a such as the sensitivity and the responsiveness due to the high speed rotation frequency. During high-speed rotating arc welding, where Voc is the internal voltage of the welding power source; Rs self-regulation of the welding arc is not fully performed because is the internal electrical resistance of the welding power source; the period of rotation is shorter than the time constant of the self- L is the internal inductance of the welding power source; V , R , regulation process (Ref. 1). The rapid change in CTWD generates s p p and Lp are the voltage drop, the resistance, and the inductance of the variation in the arc length rather than in the electrode exten the welding cable, respectively; V is the constant in the welding sion length. Therefore, the rotating arc sensor operates in a dy ao model; and Ra, La, and Ea are the resistance, the length, and the namic state enhancing its sensitivity (Ref. 4). This insufficient self- electric field of the arc, respectively. regulation enables development of the arc sensor for aluminum For the modeling of the GMA welding system, many re alloy welding for which it is known that the application of the searchers investigated the welding wire melting phenomenon at weaving arc sensor is limited (Ref. 5). Moreover, the rotating arc the end. Lesnewich (Ref. 6) investigated the relation between the can increase the responsiveness, which is inherently related to the wire melting rate, the wire extension length, and the welding cur oscillation frequency. rent experimentally. Halmoy (Ref. 5) induced the same relation In addition to joint tracking, through-arc sensing can be ap- in the static state that the welding wire feeding and melting rate are equivalent. Mao and Ushio (Ref. 4), and Shepard and Cook W.-S. YOO is with LS Cable Ltd., Production Engineering Center, Gyeonggi- (Ref. 7) introduced the idea of action integral. They integrated the do, Korea. Y.-H. SHI is with South China University of Technology, School square of the welding current during the time that the welding of Mechanical Engineering, Guangzhou, China. J.-T. KIM and S.-J. NA are wire moves from the gun tip to the molten pool. Zhu et al. (Ref. with Korea Advanced Institute of Science and Technology, Department of 8) investigated the welding wire melting phenomenon by the tran Mechanical Engineering, Daejeon, Korea. sient temperature analysis model. Kim (Ref. 9) presented the dy-

AUGUST2006 iiiiiiiMliliilliiiiiiiiii

Power source model Contact tube

-JWV-

Rs Lp Rp Electrode extension

Vc = Re 1 J-c Arc voltage

Fig. 1 — Equivalent circuit ofGMA welding system using CVpower source. Fig. 2 — Definition of coordinate systems for simulation.

\yu

Fig. 3 — Dimensional parameters for welding wire extension end position. Fig. 4 — Bead model in fdlet welding.

namic simulation of welding wire melting by using the variable non and vm is wire melting speed. space network method and by modeling the heat flux from the If the quantity of heat necessary to heat the welding wire to molten end of the welding wire into the electrode. melting temperature is denoted by H0, the following equation is In Halmoy's (Ref. 5) melting model, the voltage drop at the established from the energy conservation rule. welding wire extension (Ve) is written as follows: H =H +H (7) o e a v.S aL I bvcS V =^—H (4) The equation of the melting characteristics can be obtained S 1 from Equations 5-7, as follows:

where a is the resistance at the welding wire extension; b is the Al thermal energy of welding wire at room temperature; Le is the (8) 2 welding wire extension; Vf is the welding wire feed rate; and S is l-B\LelvfU the welding wire cross-sectional area. In Equation 4, Joule heat at welding wire tip, He, is written as follows: _ * ah Vj2 A S H +b S2\H H =—* b (5) [ o ) .*") s\ where, and

The welding wire extension length, Le, can be obtained from The quantity of heat from the arc at welding wire tip, Ha, is writ Equation 8 as follows: ten as follows: dL Al V , -V =v (9) dV m // (6) clt f f \~B\L IvAl a v S <-' / m where is the equivalent arc voltage for wire melting phenome Through simultaneous solution of Equations 1-4, it is possible

WELDING JOURNAL to determine the variation in welding current depending on the wire extension and arc length as follows: aL R +R +R +—e dl V -V 1 2wm (x,c,>,c,:,J l/2w„ s p a g I •<' -&f* dt L +L L +L <—:—& bSv •3s >'.W Xsi |- (10) I h\„„ L +L )l L+L„ s p s P Fig. 5 — Bead model after fillet end in open fillet welding

Geometrical Model of Fillet Welding ( Start j To simulate the waveform of welding current during actual fil let welding, geometrical models of fillet welding are developed. Figure 2 shows the target weld geometry and the definition of co ordinate systems. W is the frame fixed to the weld structure and M is the frame moving along to the weld joint, while A is the frame Input moving with the gun. The origin of A is defined as the center of the rotating gun tip. The frames W, M, and A have the same di rection cosine, but different origins. B is the frame moving with Calculate Initial condition the same origin of A and rotated by the angle of with respect to the axis x of A. T is the frame moving with the same origin as A and rotated by the angle of \|/ with respect to the axis y of B. Transformation matrices between frames defined in Fig. 2 are • Increase Time t=t+At determined as follows:

1 0 0 V wfcfing Calculate Bead Surface Profile 0 1 0 y offset do I) 0 1 0 Calculate Contact Tip Position 0 0 0 1

Calculate CTWD 1 0 0 () 0 1 0 y M; I (12) 0 0 1 2 Solve Electrode Extension Length (L ) 0 e 0 0 0 1 and Welding Current (I)

i (i 0 (i 0 oos<| -sin0 (i (13) 7=V*)= 0 sin

cosy 0 sinv|/ 0 Fig. 6 — Flow chart for calculation of electrode extension length and welding 0 1 0 0 (14) current. *r=iVM= -sini|/ 0 cos\j/ 0 0 0 0 1 r oos9 where v „ is the welding speed; t is the time elapsed; a.ndy ^ r sin 9 veidin 0 sa (15) is the distance of the joint along the y axis of the frame W. (y0, z0) -L is the coordinate point of the origin of A referenced to the frame e M. Figure 3 shows the dimensional parameters needed to deter i mine the welding wire end position. where r is the rotation radius and 0 is the rotating angle of the gun The coordinate point of the welding wire end position, pH.e, with respect to the frame T. with respect to the frame T can be expressed as follows: Rotating speed of the gun can be obtained by the rotating fre quency,/)., as follows:

AUGUST 2006 . H:=H=M:W

Fig. 7— Weld structures for simulation. A — Open fillet joint welding; B — closed fillet joint welding.

350 - D X l\ I \ 300 - 1 \ 1 \

c l\ \j 3 o 250 -

1 25 2.6 27 Time (sec)

Fig. 8 — Simulation results (open structure, $ = -45 deg, y = 0 deg). A — Simulated waveform of welding current; B —fillet joint region; C — transition re gion; D — after end point.

WELDING JOURNAL i'.'J=HJI!M:l=H=M:M

Experiment Experiment 400-, Simulation 4CC Simulation --Lowpass filtered • Lowpass filtered 350- I i.'i - 300- 14 ; rV/iJf Vl JIJ I T\ A \i * \ it ! f i Y 8 Curren t (A )

200 150-

100- 150 1.80 1.85 1.90 1.95 2.00 10.90 1095 11.00 11.05 11.10 Time (sec.) Time (sec.)

Fig. 9 — Simulated and experimental welding current waveform in fillet joint Fig. 10 — Simulated and experimental welding current waveform in transition region of open structure (if = -45 deg, Mf=0 deg). region of open structure ($ = -45 deg, V|/= 0 deg).

Experiment 400-, -•2nf (16) - Simulation dt - Lowpass filtered The coordinate point of the welding wire end position with re spect to W can be obtained from the previous equations as follows:

we M A B T we rcasQcasvi-L sinw + v ,,. t e wading

rsinQoostii + roasBsinfiisinvf + L siniicosvi+yT J + y T e o q (17) rsinQsin$-raxQcos§sin\ii-L cosi/axy + z 1

It is necessary to know the bead geometry to simulate the weld 150 ing current from the previous equations. To model the weld bead 11.65 11.70 11.75 11.80 11.85 shape, the following two conditions were assumed: Time (sec.) 1) Volume of the welding wire fed equals the volume of the bead formed Fig. 11 — Simulated and experimental welding current waveform after the end 2) Cross-sectional view of the bead is trianglular. of the fillet joint region of open structure (0 = -45 deg, i|/ = 0 deg). After the welding gun was passed, the cross-sectional view of the bead from the x direction was approximated as a right-angle triangle. When the bead is forming under the rotating arc gun, the cross-sectional area of the bead from the x direction was approx M. bead . M , (19) imated as linearly decreasing along the direction the gun was mov k ing. Figure 4 shows the bead shape modeled in the joint of the fil bead M M let weld. The relations between welding conditions and bead where, ( ztc, ytc) is the coordinate value of the origin of frame T parameters are established as follows: with respect to frame M. Horizontal and vertical leg length can be calculated from

1 Equations 18 and 19 as follows: ,2 1 i (18) — TlCt~'V =— V */Z •V A w f n bead bead wdamg nd2.v.My w f Jtc (20) bead where dw is the diameter of the welding wire; vy is the wire feed 2v • z rate; vwdding is the welding speed; and vbead and hbead are, respec tively, the leg length in the vertical direction and in the horizon di rection. If the line between the origin of frame M and the origin \ml2.v.Mz of frame T pass through the mid-point of the bead surface's pro W f jected line, Equation 19 can be obtained. (21) bead 2v M .

AUGUST 2006 iimmimmiiJiii iiHurmm

The surface equation of the bead with respect to frame M can be Simulation Results and Discussion obtained as follows: The mathematical model of the GMA welding system, the (22) electrode melting model, and the geometrical model of the weld bead bead were used to simulate the current waveform of the rotating arc. Equations 9, 10, 23, and 27 were calculated simultaneously. If the arc is generated in the shortest way from the tip to bead or To solve the differential equation, a 4th order Runge-Kutta workpiece, the arc length during fillet joint welding can be ob method was used. Simulations were done as shown in Fig. 6. Table tained as follows: 1 shows the welding conditions and parameters used in the simu lations. Two series of simulations are presented and discussed for two different types of welding end of the fillet joint. Wx My Mz end Open Fillet Structure [Mx | 2 M | 2 M Z -\ w w I h v (23) L -min bead bead Figure 7A shows the open fillet structure adopted for simula (

Closed Fillet Structure

Figure 7B shows the closed fillet structure adopted for simula tions, and simulation results of the current waveform for this struc (26) ture are shown in Fig. 12. Before approaching the fillet end, the welding current fluctuates twice during each cycle of arc rotation, which is the same as it does in the open fillet structure (as shown in Fig. 9). Approaching the fillet end, however, the welding current tends to fluctuate three times during each cycle of arc rotation. The The arc length after the fillet end can be obtained as follows: reason for these different current waveforms is due to the varia-

My ,Mz

L =min (27)

y K ,

tc__v> + bead bead

WELDING JOURNAL ;I=M=M:M!

Table 1 — Welding Conditions and Parameters for Simulations Table 2 — Welding Conditions for Experiments

Welding Parameters Welding current (I„) 280 A Welding Machine 600 A, SCR Welding wire feed rate (v,) 135 mm/s Welding Wire DW100 1.2-mm wire Contact tip to work distance (CTWD) 15 mm Shielding Gas CO, 20 L/min Welding speed (vwdtling) 6 mm/s Gun Angle 45 deg Rotation diameter 2 mm CTWD 15 mm Welding Machine Inductance (Ls+L_) 0.00018 H Rotation Diameter 2 mm Parameters Resistance (RS+RP) 0.008 Q Base Metal, 12-mm thick, mild steel Rotating frequency (fr) 211 11/ Stiffencr Source voltage (V0c) 35 V Arc Parameters Electric field parameter (Ea) 2.0 V/mm Resistance (RJ 30.7 mCl Arc diameter (w.lrc) 5 mm Arc voltage (V.,) 15.22 V Shielding Gas Specific heat (H0 = Ha+He) 11.1 J/mm' Parameter (C02) Equivalent voltage (O) 3.48 V Welding Wire Diameter (Dw) 1.2 mm Resistance length (a) 1.2 x Kb' Qmrn Thermal energy (b) 3.98 J/mm3

350 n A 350-i

300 300- A A A A A /"\ A A

250- 250

200 200 0.0 0.2 0.4 06 1 0 01 0.2 03 Time (sec.) Time (sec.)

350-n C - Simulation Experiment - Lowpass filtered

300-

< 300

250-

20O 0.7 08 0.9 0.90 Time (sec.) Time (sec.)

Fig. 12 — Simulation results (closed structure, d> = -45 deg, \y= -15 deg). A Fig. 13 — Simulated and experimental welding current waveform at the end — Simulated waveform of welding current; B —fillet joint region: C — in of the fillet joint of closed structure (0 = -45 deg, \|/ = -15 deg). front of the end plate.

AUGUST 2006 tions of arc length during arc rotation, de welding system model was derived from application to arc sensors. Proc. 11th Interna pending on the distance between the weld the equivalent electrical circuit of the con tional Conf. on Computer Tech. in Welding, ing wire end and the bead geometry or the ventional welding system with a constant Columbus, Ohio. pp. 47-54. fillet joint geometry with a vertical end voltage power source and Halmoy's weld 3. Na, S. J.. Kim, C. H., and Kang, Y. H. plate. The variation of the current wave ing wire melting model, which was known 2002. Gas metal arc welding with controlled ro form is, however, less distinct than that of to be well suited to experimental results. tating and oscillating arc. 7th Inter-University the open fillet structure, which cause a dif Geometrical bead models were developed Research Seminar, Bratislava, Slovakia, June ficulty in implementing the algorithm of under the simple assumptions for fillet 21, pp. 111-120. end point detection of fillet welds for welding with an inclined rotating arc. 4. Mao, W., and Ushio. M. 1997. Measure GM AW with a rotating arc. To validate the Welding current simulations were per ment and theoretical investigation of arc sensor simulation results, the current waveform formed by the developed sensing model of sensitivity in dynamic state during gas metal arc of simulations at the fillet end is compared the rotating arc and compared to the ex welding. Science and Technology in Welding and with that of experiments (as shown in Fig. perimental results in gas metal arc welding Joining2(5): 191-198. 13). The average current value of the ex of open and closed joints in fillet welds. 5. Halmoy, E. 1980. Wire melting rate, periment is a little higher than that of the The comparison results show that the de droplet temperature and effective anode melt simulation. It is caused by the decrease in veloped sensing model is well suited to the ing potential. Arc Physics and Weld Pool Behav the average value of arc length during each experimental results in steel welding and ior, The Welding Institute, Cambridge, U.K. pp. rotation cycle, which is due to the abnor can be applied for the end point detection 49-54. mal increase in the weld bead height at the of joints in GMAW fillet welds with a ro 6. Lesnewich, A. 1958. Control of melting end of the closed fillet structure because tating arc. rate and metal transfer in gas shielded metal-arc the vertical end plate blocked the flow of welding. Welding Journal 37(8): 343-s to 353-s. the melted metal. Figure 13 shows that the Acknowledgment 7. Shepard. M. E„ and Cook, G. E. 1992. A simulation result and the experimental re frequency-domain model of self regulation in sult are in fairly good agreement with re This work was supported by the Brain gas-metal arc welding. Conference Proceedings spect to the signal frequency, although very Korea 21 Project of the Ministry of Edu 3rd International Conference on Trends in Weld careful measurement will be essential for cation and Human Resources Develop ing Research, Gatlinburg, Tenn. June 1-5, pp. the application of the end point detection ment of the Republic of Korea. 899-903. algorithm for a closed fillet structure in 8. Zhu, P., Rados, M, and Simpson, W W. GMAW with a rotating arc. References 1997. Theoretical prediction of the start-up phase will improve weld quality. Welding Jour Conclusions 1. Cook, G. E. 1983. Robotic arc welding: nal 76(7): 269-s to 274-s. Research in sensory feedback control. IEEE 9. Kim, C. H. 2002. A Study on Automatic A mathematical sensing model of a ro Transactions on Industrial Electronics IE-30 (3): Welding by Using Measurement of GMAW Bead tating arc, which contains the GMA weld 252-268. Geometry Using Rotating Arc. PhD dissertation, ing system model and the geometrical 2. Kim. C. H., and Na, S. J. 2001. Develop Korea Advanced Institute of Science and Tech bead model, was developed. A GMA ment of rotating GMA welding system and its nology (KAIST).

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