PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING vitf.uiiailJ;lilH*;siJ.iii:iHli|ili;itff|iii:iLMt1i:l;f:^i;[HMi]|i]qili:[H|»ilITTING . AND THERMAL SPRAYING Demand Select-Arc Low Alloy Electrodes
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"ircle No. 32 on Reader Info-Card INTERWATlflNfl&Al W WELDING SHOW
Coining in November. Compelling seminars. Breakthrough insights. FABTECH INTERNATIONAL & AWS WELDING SHOW November 13-16,2005 McCormick Place South, Chicago, Illinois
Register now for these American Welding Society Programs and Events: • Professional Program— including Education Program • Second AWS Professional Welders Competition • Conferences and Seminars • Interview with a Legend
American Welding Society To register for the FABTECH International & AWS Welding Show, visit our Web site Founded in 1919 to advance the science, technology and application of welding and allied processes including joining, at www.aws.org/expo brazing, soldering, cutting and thermal spray.
Circle No. 13 on Reader Info-Card i American Welding Society 2005 CONTENTSAugust 2005 • Volume 84 • Number 8 AWS Web site http:IIwww.aws.org Features Departments Washington Watchword 4 23 Guidelines for Laser Welding of Sheet Metal Proper design of sheet metal components can help you Press Time News 6 take advantage of the benefits of laser beam welding H. Zefferer and T. Morris Editorial 8
30 International Welding Fair: Schweissen & News ol the Industry 10 Schneiden 2005 Aluminum Q&A 14 A preview of the e\ ent that has been called the "Olympics of welding engineering" Brazing Q&A 16
34 A Look at Remote Laser Beam Welding New Products 18 Benefits of laser-based remote welding systems include fast cycle times and small footprints Navy Joining Center 65 J. Cann Coming Events 66 38 2005 AWS Welding Show in Review Society News 69 Welding's best was spread out for the world to see at this year's Show Tech Topics 70 A. Cullison, M. R. Johnsen, and H. M. Woodward Guide to A WS Services 83 46 Make Laser Assist Gas Delivery Flexible Various assist gas supply modes are evaluated Welding Workbook 86 R. Green New Literature 88 49 One Head Does It All Personnel 90 New technology allows one Iase r head to weld and cut D. Petring tied Hot Essen 92 52 What Makes a Winning Weld: Tips from the Pros Classifieds 94 Three top-notch welders describe their techniques for making successful welds Advertiser Index 96 K. Campbell
56 *The Fiber Laser — A Newcomer for Material Welding and Cutting A new type of laser offers another choice for deep penetration keyhole welding G. Verhaeghe
61 Anatomy of a Welding Tournament An in-depth look at what it takes to put on the Mid-West Welding Tournament H. M. Woodward
Welding Research Supplement Welding Journal (ISSN 0043-2296) is published monthly by the American Welding Society for 125-s Determination of Optimal Welding Conditions S90.00 per year in the United States and posses with a Controlled Random Search Procedure sions. S130 per year in foreign countries: S6.00 per A controlled random search can determine the near- single issue for AWS members and S8.00 per sin optimal settings for weld process parameters using a gle issue for nonmembers. American Welding So small number of experiments ciety is located at 550 NW LeJeune Rd., Miami, FL 33126-5671: telephone (305) 443-9353. Periodi D. Kim et al. cals postage paid in Miami, Fla., and additional mail ing offices. POSTMASTER: Send address changes 131-s Constraints-Based Modeling Enables Successful to Welding Journal. 550 NW LeJeune Rd.. Miami. Development of a Welding Electrode Specification FL 33126-5671.
for Critical Navy Applications Readers of Welding Journal may make copies of ar A constraints-based modeling approach reduced the ticles for personal, archival, educational or research risks inherent in developing a high-performance welding purposes, and which are not for sale or resale. Per electrode specification for U.S. Navy applications mission is granted to quote from articles, provided K. Sampath customary acknowledgment of authors and sources is made. Starred (*) items excluded from Cover Photo — Laser processing of 3-D parts, courtesy of copyright. TRUMPF, Inc., Farmington. Conn.
WELDING JOURNAL WASHINGTON BY HUGH K. WEBSTER WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
New International Standards Notification and Comment Service Offered The Climate Stewardship Act of The National Institute of Standards and Technology (NIST) has replaced its Export Alert! service with "Notify U.S." This 2005 includes a provision to new offering is intended to provide U.S. companies with the op portunity to review and comment on proposed foreign technical promote nuclear energy by regulations that can affect their businesses. Members ofthe World Trade Organization (WTO) are re authorizing a partnership to quired under the Agreement on Technical Barriers to Trade to report proposed technical regulations that may affect trade to develop protocols for the the WTO Secretariat, who in turn distributes them to all WTO latest reactor designs and members. United States companies can receive, via e-mail, notifications by constructing three of drafts or changes to foreign regulations for a specific industry sector and/or country. Notifications of the proposed foreign reg demonstration plants. ulation contain a description of the regulation, the country issu ing the regulation, and a final date for comments. tions. work in substations, and other special conditions and equip ment unique to the transmission and distribution of electrical Nuclear Energy Industry Getting a Boost energy. Key changes include new provisions specific to host employ Nuclear energy is being scrutinized increasingly as a positive ers and contractors, adding new requirements to protect work avenue for U.S. energy needs, and, equally important, an envi ers against flame and electric arc hazards, a requirement for em ronmentally clean energy source. ployers to provide flame-resistant clothing, and additional Senators John McCain (R-AZ) and Joe Lieberman (D-CT) training. have introduced the bipartisan Climate Stewardship Act of 2005. which would, among other things, encourage the development and implementation of new policies that foster technological in Anti-Counterfeiting Legislation Introduced novation to address global warming, and promote the commer cialization of zero and low-emission technologies. This legisla United States industry has wrestled with the problem of coun tion also includes a provision to promote nuclear energy, specifi terfeit goods for many, many years, but there is clearly a percep cally, by authorizing a federal partnership to develop engineer tion, and probably the reality, that the situation is only growing ing protocols for the latest reactor designs, and then to construct worse. This is the impetus for the "Stop Counterfeiting in Man three demonstration plants. ufactured Goods Act" recently introduced in Congress. In addition, the recently enacted Energy Policy Act of 2005 in This bill would enhance criminal penalties for those who traf cludes several provisions favorable to nuclear energy, including fic in counterfeit products and would expand current federal • Incentives to stimulate investment in the first new nuclear power criminal prohibitions to include penalties for those who traffic in plants that the industry expects to be ordered later this decade. counterfeit labels, symbols, or packaging of any type with knowl • Renewal of the Price-Anderson Act, the framework for indus edge that a counterfeit mark has been utilized. Equally impor try self-funded liability insurance, for 20 years. tant, this legislation would require the forfeiture not only of any • Authorization of funding for research and development aimed the counterfeit goods themselves, but also any property used to at developing advanced nuclear power plants. manufacture those goods. • Direction to the Department of Energy to research cost- The top five offending countries of origin for counterfeit goods effective technologies for increasing the safety and security of are China, Hong Kong, Mexico, South Korea, and Malaysia. nuclear facilities. • Authorization of funding for the Department of Energy to es tablish an advanced reactor for hydrogen production at the Effort to Make R&D Tax Credit Permanent Idaho National Laboratory. Legislation is progressing in Congress that would be the cur rent research and development tax credit, which is set to expire OSHA Proposes Revised Rule on at the end of 2005, a permanent provision of the U.S. Tax Code. While Congress has invariably renewed the tax credit as it ap Electric Power proaches an expiration deadline, proponents argue that a per manent tax credit would provide the predictability and stability The Occupational Safety and Health Administration (OSHA) needed. More than 15,000 companies claimed the tax credit in has issued a Notice of Proposed Rulemaking (NPRM) to update 2003, the most recent year for which data are available. the standard for the construction of electric power transmission and distribution installations to make it consistent with the re cently revised general industry standard. It is accepting public comments on the proposal until October 13, 2005. Contact the AWS Washington Government Affairs Offiee at The proposed standard includes requirements relating to en 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail closed spaces, working near energized parts, grounding for em [email protected]; FAX (202) 835-0243. ployee protection, work on underground and overhead installa-
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AWS and RWMA Announce Alliance Publisher Andrew Cullison Editorial The Resistance Welder Manufacturers' Association (RWMA) has become a standing Editor/Editorial Director Andrew Cullison committee within the American Welding Society (AWS). Its Executive, Education, Mar Senior Editor Mary Ruth Johnsen keting, Membership, and Technical subcommittees will exist within the RWMA standing Associate Editor Howard M. Woodward committee. The AWS staff and volunteers will support these committees, and the RWMA Assistant Editor Kristin Campbell will have access to AWS's electronic meeting infrastructure. Peer Review Coordinator Doreen Kubish The RWMA membership will bc open to companies that manufacture resistance weld ing equipment. Three new membership categories will be added to the existing member Publisher Emeritus Jeff Weber ship categories: Sales and Marketing, Consultants, and Supplies. The RWMA members must be AWS Supporting or Sustaining members. New RWMA Graphics and Production members began paying joint RWMA/AWS dues after June 1. Managing Editor Zaida Chavez Publication inventory and RWMA financial reserves will be transferred to AWS. The Production Assistant Brenda Flores RWMA will establish two perpetual $50,000 scholarships under the AWS Foundation um Advertising brella. Each fund will grant one $2500 scholarship per year. The RWMA will determine National Sales Director Rob Saltzstein the selection criteria for its scholarships: however, the function of the scholarship sub Advertising Sales Representative Lea Gairigan Badwy committee will be transferred to the AWS Foundation. Advertising Production Frank Wilson Textron Systems Awarded Contract for Vehicles Subscriptions Leidy Brigman Textron Marine & Land of New Orleans, La., an operating unit of Textron Systems, [email protected] has been awarded a contract by the U.S. Army Tank-Automotive & Armaments Com mand to manufacture 724 additional Armored Security Vehicles (ASV). American Welding Society 550 NW LeJeune Rd., Miami, FL 33126 All 724 vehicles have been designated for use by the U.S. Army. Fifty percent funding has been awarded, and when the contract is fully defined, it could be worth $500 million (305) 443-9353 or (800) 443-9353 subject to final contract terms. Publications, Expositions, Marketing Committee Currently, there are 130 ASVs deployed in support of Operation Iraqi Freedom. R. D. Smith. Chair "We've been working closely with the Army to expedite getting these important vehi The Lincoln Electric Co. cles to our soldiers," said Richard Millman. president of Textron Systems. "We've signif D. L. Doench. Vice Chair icantly increased our production rate and, with this order, will proceed to achieve a rate Hobart Brothers Co. of 48 vehicles a month." J. D. Weber. Secretary Textron Marine & Land, based in New Orleans, has been modifying its production line, American Welding Society expanding its manufacturing space, and hiring the necessary workforce. The first deliver R. L. Arn. WELDtech International ies of the ASVs are expected by February 2006, and full delivery is to be completed by T. A. Barry. Miller Electric Mfg. Co. June 2007. All work will be completed at Textron's facilities in Louisiana. M. Balmforth, Sandia National Labs R. Durda, The Nordam Group J. R. Franklin, Sellstrom Mfg. Co. El Paso Natural Gas Co. Gives Status of Pipeline Project R. G. Pali. J. P. Nissen Co. L. Pierce, Cee Kay Supply EI Paso Natural Gas Co., Houston, Tex., a wholly owned subsidiary of El Paso Corp., J. F Saenger. Jr., Edison Welding Institute has received certificate approval from the Federal Energy Regulatory Commission for its S. Smith. Weld Aid Products Line 1903 Project, an 88-mile, 502 million-cubic-foot-per-day pipeline extending from S. Liu. Ex Off.. Colorado School of Mines Ehrenberg, Ariz., to Cadiz, Calif. Acquired in March 2000, Line 1903 was previously used D. C. Klingman, Ex Off, The Lincoln Electric Co. to transport crude oil and will be converted to a natural gas pipeline. D. J. Kotecki, Ex Off, The Lincoln Electric Co. The approximately $74-million project also includes the construction of a new six-mile D.J. Landon. Ex Off. Venneer Mfg. Co. pipeline that will connect the converted Line 1903 pipeline to El Paso's Mojave Pipe Co. E. D. Levert, Sr., Ex Off, Lockheed Martin E. C. Lipphardt. Ex Off.. Consultant facilities near Cadiz. The project is scheduled to be in service late this year. Construction R. W. Shook, Ex Off, American Welding Society and conversion will begin once El Paso receives approval from California's State Land D. W. Wilson. Wilson Industries Commission and the U.S. Interior Department's Bureau of Land Management.
Reliance Steel & Aluminum Co. Completes Acquisition
Reliance Steel & Aluminum Co., Los Angeles, Calif., has completed its previously dis closed acquisition of Chapel Steel Corp., headquartered in Spring House (Philadelphia),
Pa. The company paid $94.2 million in cash, plus the assumption of approximately $16.8 Copyright © 2005 by American Welding Society in both printed iind elec million of debt for all of the outstanding common stock of Chapel, a privately held met tronic formats. Tiic Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors als service center company founded in 1972. of specific articles are for informational purposes only and are not in Chapel processes and distributes carbon and alloy steel plate products from five facil tended for use without independent, substantiating investigation on the ities in Pottstown (Philadelphia). Pa.; Bourbonnais (Chicago), 111.; Houston, Tex.; Birm part of potential users. ingham, Ala.; and Portland, Ore. In addition, it warehouses and distributes its products in Cincinnati, Ohio, and Hamilton, Ont., Canada. BPA
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Circle No. 24 on Reader Info-Card WELDING I CUTTING I FILLER METALS EDITORIAL American Welding Society Founded in 1919 to Advance the Science. Technology and Application of Welding
Officers The Cycle of Sharing President Damian J. Kotecki The Lincoln Electric Co. Continues Vice President Gerald D. Uttrachi WA Technology, LLC The recent U.S. Weld Trials competition, which was held at the 2005 AWS Welding Show in Dallas, is an excellent example ofthe value of belonging to a professional asso Vice President Gene E. Lawson ciation that is a sharing community. The competition represented the coming together ESAB Welding & Cutting Products of competitors from several nations supported by educators, parents, friends, classmates, vendors, suppliers, corporations, and countless volunteers who organized, judged, pro Vice President Victor Y. Matthews moted, and encouraged this showcase of youth welding talent. The U.S. winner received The Lincoln Electric Co. welding gear, assistance with the expenses to the WorldSkills competition — held this Treasurer Earl C. Lipphardt year in June in Helsinki, Finland — and a four-year scholarship valued at $40,000 from Consultant Miller Electric Manufacturing Co. Companies, Sections, Districts, members, and friends of welding donated items to Executive Director Ray Wl Shook the silent auction held during the Show at the AWS Foundation booth to raise funds for American Welding Society the National Scholarship program. Showgoers purchased raffle tickets and photos of Miller Electric's 75th anniversary bike built by Orange County Choppers. Volunteers, AWS staff members, and high school welding students worked collaboratively to make Directors show attendees aware of our Society's scholarship programs and the donation opportu T. R. Alberts (Dist. 4). New River Community College nities to support those programs. B. P. Albrecht (At Large), Miller Electric Mfg. Co. It may take time, however, for givers to see the value of their donated dollars. That point was made clear to me as I spoke with a young man at the AWS Foundation booth 0. Al-Erhayem (At Large), JOM who was interested in buying raffle tickets. After a few minutes of talking to him about A. J. Badeaux. Sr. (Dist. 3), Charles Cty. Career & Tech. Center what he does in welding, I learned he was involved in welding research at a national lab K. S. Baucher (Dist. 22). Technicon Engineering Services, Inc. oratory. With that fact and his name, the pieces fell into place. He started his welding J. C. Bruskotter (Dist. 9). Bmskotter Consulting Services career at a two-year program, moved on to a four-year welding program, and received one of the first AWS national scholarships. More than ten years later, he had completed C F. Burg (Dist. 16). Ames Laboratory IPRT his doctorate degree. Along the way he received both scholarship and fellowship assis N. M. Carlson (Dist. 20), Idaho National Laboratory tance from AWS Foundation programs. And, now as a welding researcher at a national H. R. Castner (At Large). Edison Welding Institute laboratory, he was donating funds to start the cycle again. N. A. Chapman (Dist. 6). Entergy Nuclear Northeast It truly takes a sharing community of volunteers to make AWS the professional soci ety it is. Your donation of time, materials, encouragement, and knowledge is just as im S. C. Chappie (At Large). Consultant portant as the donation of funds for fellowships and scholarships. Sharing of yourself N. C. Cole (At Large). NCC Engineering with our next generation of welding professionals as well as current members renews J. D. Compton (Dist. 21), College ofthe Canyons everyone's passion for the welding profession. The Education Scholarship Committee is honored to be part of this spirit of commu L. P. Connor (Dist. 5), Consultant nity and is looking forward to working with the Foundation trustees to increase the funds J. E. Greer (Past President). Moraine Valley C C. available for welding studies and research. As we move forward over the next few years M. V. Harris (Dist. 15). Reynolds Welding Supply with a capital campaign to endow our scholarship and fellowship programs, do what you R. A. Harris (Dist. 10), Penton Publishing Co. can to get involved in this enduring cycle of sharing to ^^^m^^^^^^^^^M ensure the future for all welding professionals. W. E. Honey (Dist. is). Anchor Research Corp. D. C. Howard (Dist. 7). Concurrent Technologies Con). J.L. Hunter (Dist. 13), Mitsubishi Motor Mfg. of America, Inc. J. L Mendoza (Dist. 18). City Public Service S. P. Moran (Dist. 12), Miller Electric Mfg. Co. T. M. Mustaleski (Past President). BWXTY-12. LLC R. L. Norris (Dist. 1). Merriam Graves Corp. T C. Parker (Dist. 14), Miller Electric Mfg. Co. 0. P. Reich (Dist. 17), Texas State Technical College al Waco Nancy M. Carlson Chair, A WS National Education Scholarship Committee W. A. Rice (At Large). OKI Bering. Inc. E. Siradakis (Dist. 11). Airgas Great Lakes K. R. Stockton (Dist. 2). PSE&G. Maplewood Testing Sen: P. F. Zammit (Dist. 11). Brooklyn Iron Works. Inc.
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Lockheed Martin LCS Team Lays Keel on Nation's First Littoral Combat Ship
The keel was laid for Freedom (LCS 1) on June 2. marking a milestone in production of the U.S. Navy's first littoral combat ship (LCS). Birgit Smith, the ship's sponsor, and Chief of Naval Operations Adm. Vern Clark authen ticated the keel, assisted by veteran Marinette Marine welder Jim Renner. Smith, who was selected as sponsor for Freedom (LCS 1) by Secretary ofthe Navy Gordon R. England, is the widow of Sgt. 1st Class Paul Ray Smith, who was posthumously awarded the Medal of Honor for his bravery and gallantry above and beyond the call of duty in Operation Iraqi Freedom. A new class of surface combatant, LCS is designed to defeat enemy threats in shallow coastal waters. It provides the Navy with fast, maneuverable, and shallow-draft ships aimed at maximizing mission flexibility. The ship's Jim Renner, a veteran Marinette Marine welder, welds the authenticating initials of first missions will include mine warfare, anti Chief of Naval Operations Adm. Vein Clark and Freedom (ECS 1) sponsor Birgit submarine warfare, and surface warfare. Smith during the keel laying ceremony in Marinette, Wis., for the Navy's first littoral The Lockheed Martin design, a semiplan- combat ship. Freedom will be delivered to the Naxy in late 2006. ing steel monohull, provides agility and high speed maneuverability with known seakeep- ing characteristics to support launch and re covery operations of manned and unmanned vehicles, mission execution, and crew comfort. The Lockheed Martin-led team includes naval architect Gibbs & Cox, shipbuilders Marinette Marine, a subsidiary of The Manitowoc Co., Inc., and Bollinger Shipyards, as well as domestic and international teammates. Freedom is under construction at Marinette Marine and is scheduled to be delivered to the Navy in late 2006.
Rensselaer Partners with Cornell to Test ber of near full-scale tests using Cornell's Large Displacement Effects of Earthquakes on Critical Soil-Structure Interaction Facility for Lifeline Systems, and then compare their results with those obtained from a larger number Pipeline Systems of small-scale centrifuge tests at Rensselaer. In addition, researchers at Rensselaer will develop computer- Rensselaer Polytechnic Institute, Troy, N.Y., is partnering with based numerical models and conduct advanced numerical simu Cornell University to test earthquake effects on underground lations to benchmark results from the near full-scale and small- pipeline systems used for water, electric power, gas and liquid scale physical tests. fuel, telecommunications, transportation, and waste. This four-year project, funded by a $2 million National Sci ence Foundation Network for Earthquake Engineering Simula Transformational Space Corp. tion research grant, will be led by Cornell University with Rens- Demonstrates New Air-Launch Technology sclacr's portion of the grant totaling S746.822. The research team, through the use of physical modeling and Transformational Space Corp. (t/Space) and Burt Rutan's simulation, will test welded steel pipe and polyethylene pipe to Scaled Composites recently drop-tested dummy boosters from improve the safety and reliability of critical underground infra an aircraft using a technique that caused them to rotate toward structure by improving future design and construction methods, vertical without requiring wings, a technique that could safely according to Michael O'Rourke, professor of civil and environ launch future passenger-carrying rockets using a carrier aircraft. mental engineering at Rensselaer and coprincipal investigator This allows an aft-crossing trajectory in which the rocket crosses on the critical lifelines research team. behind the aircraft, greatly enhancing safety. Also, eliminating Rensselaer researchers will conduct small-scale earthquake the weight of wings increases the payload the rocket can take to simulation tests in the Institute's 150 g-ton geotechnical cen orbit. trifuge, spinning models of buried pipe systems to produce forces The innovation developed by t/Space is a mechanism that up to 200 times the Earth's gravitational pull. holds on to the nose ofthe booster for about a half-second after Researchers at Cornell University will perform a limited num the center of the rocket is released. This slight tug on the nose
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COBALT & NICKEL BASE BARE CAST ROBS, ELECTROOES, CAST COMPONENTS, WIRES ANO POWOERS. Three drop tests from May 24 through June 7 proved a new Trans formational Space Corp. technique that eliminates the need for Cobalt Alloys 1, 3, 4, 6, 6H, 12, 20, 21, 25, wings on air-launched vehicles. These Images, taken at half-second 32,190, 694, 800. intervals, show the release of a test article built to 23% scale ofthe Nickel Alloys 40, 50, 56, 60, C. CXV capsule and the QuickReach II booster. Rod Dia. 3/32" (2.4mm) - 3/8" (10mm) Meets AWS/SFA 5.13 & 5.21 starts the booster rotating as it drops. A small parachute on the MILITARY SPECIFICATIONS rocket's nozzle ensures the rotation happens slowly. The dummy booster dropped on June 14 was the third and final in the t/Space program, with previous drops on May 24 and June 7. ISO 9001 All test articles dropped were inert — two steel tanks welded together with a fiberglass nose and nozzle. They were 23% of the w size of the actual rockets to be developed for sending a four- person capsule into orbit. They had no engines and each eventu CERTIFIED ally crashed onto the dry Cuddeback Lake, about 35 miles north east of Mojave, Calif. The wreckage was collected and removed. Bob Morgan managed the Scaled Composites side of the test WORLD HEADQUARTERS program that demonstrated the new air launch method, called 13032 Park Street Trapeze-Lanyard Air Drop launch, which improves simplicity, Santa Fe Springs, CA 90670, U.S.A. safety, cost, and reliability of launching personnel into low Earth orbit. Tel: 562-698-7847 • Fax: 562-945-5664 t/Space is one of eight companies funded by NASA's Explo Internet: www.weartech.net ration Systems Mission Directorate to develop concepts for the Made in USA agency's Crew Exploration Vehicle that will take over noncargo duties from the Space Shuttle. Circle No. 39 on Reader Info-Card
WELDING JOURNAL Tata Steel to Set Up Operations in Iran
Tata Steel, India, recently signed a joint venture agreement with Iranian Mines and Mining Industries Development and Ren ovation Organization (IMIDRO) to join it in its proposed steel making projects and mining operations in Iran. Tata Steel would partner IMIDRO in the ongoing Hormoz- gan Steel project, which would establish steel-making operations in the Persian Gulf Special Economic Zone (PGSEZ) at the port city of Bandar Abbas. The first phase of this gas-based steel proj ect would establish a 1.5 million metric tons per annum (mtpa) steel slab-making facility, which would be followed by the sec ond phase to establish 1.5 mtpa of steel billet-making capacity. In a separate venture, the company would partner with IMIDRO in exploration and mining of unexplored iron ore mines at the Gol- e-Gohar mines in Kerman province of Iran, and would establish a gas-based pellet plant at Gol-e-Gohar using this iron ore. The companies also signed a memorandum of understanding A Bassett Mechanical employee welds a piece of stainless steel that expressing Tata Steel's intent to establish a separate 3-mtpa ex will make up one of the Twin Towers for the WTC 9/11 PENT-T port-oriented steel plant in two modules of 1.5 mtpa each at PGSEZ Memorial. The lighted memorial will be engraved with the names in Bandar Abbas in the vicinity of the Hormozgan steel plant. ofthe 3030 victims. Using stainless steel donated by the company, several employ Bassett Mechanical Gives Time, ees are volunteering their time to fabricate the pieces, and will Talents to 9/11 Memorial donate approximately 100 hours to the cause. Their involvement in the project includes welding end to end three 10-ft sections of At Bassett Mechanical, Kaukauna, Wis., a group of employ stainless steel that will make up each tower. ees in the fabrication department will fabricate a stainless steel The lighted memorial, which will consist of 30-ft-tall stainless replica of the Twin Towers for a World Trade Center 9/11 memo steel twin towers on a 15 ft wide by 4 ft high pentagon-shaped rial. This will serve as a tribute to the victims of the September granite base, will be engraved with the names of the 3030 victims. 11, 2001, terrorist attacks. It will include a 36-in.-long piece of debris from Ground Zero The WTC 9/11 PENT-T Memorial will be located at Veterans and will be surrounded by a 5-ft-wide walkway. Parkway, Dousman Street, Green Bay. In addition to the company, several Wisconsin businesses are
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AUGUST 2005 donating materials for the project. The WTC 9/11 PEN-T Memorial is dedicated to the families of the victims of the 9/11 attacks, as well as fire and rescue per sonnel, police officers, first responders, the military, and the airlines. The project was spearheaded by the WTC 9/11 Memorial Committee, a group of Wisconsin residents who want to pay trib Take Your Welding Skills ute to the victims of the September 11, 2001, terrorist attacks. Headed by Barb Jack, George Ecker, and Paul VanderHeyden. Underwater. Train In the committee is working to have a memorial located in each of 5 Months For A High-Paying the 50 states and the city of Washington, D.C. And Exciting Career As An] College Welding Program Receives ^Underwater Welder Equipment Dive In, Get Wet... And See Sparks Fly In
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Circle No. 23 on Reader Info-Card weld .the industry standard..
The University of Rio Grande/Rio Grande Community College weld ing program received five welding machines and one plasma arc cutting machine from Big River Electric and Lincoln Electric. Pic tured from left to right is Owen Meston, technical representative of Lincoln Electric; Mike Dyer, instructor for the welding program at Rio Grande; and Kelly Counts, president of Big River Electric in Gallipolis, Ohio. (Photo courtesy of K. J. Musser.)
The welding program at the University of Rio Grande/Rio AWSD1.1 Grande Community College, Rio Grande, Ohio, has six new pieces of state-of-the-art equipment thanks to donations from 287/ friends of the college, the help of a local business, and the assis tance of the company that manufactures the equipment. On May 24, the welding program received five new Lincoln Elec tric Precision TIG 185 welding machines and a Pro-Cut 55 plasma VVPQ* arc cutting machine. Rio Grande bought the five new welding ma chines at a savings through Big River Electric in Gallipolis, Ohio. Lincoln Electric then donated the plasma arc cutting machine. Mike Dyer, instructor for the welding program at Rio Grande, Industry standard QA/QC software for thanked the Office of Institutional Advancement and everyone automatic creation and management of who has donated already to the capital campaign at Rio Grande. Welding Procedures and Welder Qualifications One main theme of the capital campaign is for the funding to help Rio Grande enhance its educational programs and improve the capabilities of its graduates. The new welding equipment will www.weld .com help in that way, as it will allow the students to be trained in areas that they could not be trained in before, and it will better prepare Have your documents finished in minutes them to work in the region. Call (888) 673-9777 today! Circle No. 20 on Reader Info-Card WELDING JOURNAL ALUMINUM Q&A BY TONY ANDERSON
lower ductility than that of 5356. If form assist with choosing the most appropriate Q: With regard to the most appropriate ing after welding, consider this fact when filler metal. In addition, conduct procedure filler metal to use on a particular aluminum choosing the appropriate filler metal. In qualification testing to evaluate the filler fabrication project, the most common ques addition, if 4043 is used, special bending metal selected, and verify its performance tion is, "Should I use a 4043 or a 5356 filler requirements may be necessary when characteristics. AWS D1.2, Structural metal?" conducting guided bend tests for weld Welding Code —Aluminum, is an excel ing procedure and welder performance lent resource for welding procedure de qualification. velopment and testing. If you need a filler- A: Occasionally, I find misconceptions metal selection chart, please e-mail me at within the aluminum welding industiy. One tanderson (a esab. com. • such erroneous belief is that you can suc • The shear strength of 4043 is lower than cessfully weld all aluminum base alloys with that of 5356. This is important when cal either 4043 or 5356 filler metal. This is not culating the size of fillet welds. The typi correct, and there are often applications cal transverse shear strength of 4043 is TONY ANDERSON is Corporate Technical around 15 ksi, and the shear strength of where other filler materials are required to Training Manager for ESAB North America. He produce welding procedures suitable to the 5356 is around 26 ksi when loaded in the requirements. same transverse direction. These differ is a Senior Member of TWI and a Registered ences are substantial and, if not fully un However, I understand how this misun derstood and taken into consideration, Chartered Engineer. He is Chairman of the derstanding could take place. The most may affect the service performance of a commonly used aluminum filler metals welded structure. Aluminum Association Technical Advisory within the industry are, by far, 4043 and 5356. In addition, many commonly used Committee for Welding and Joining and holds structural aluminum base alloys can be • When compared to 5356, 4043 is a softer numerous positions including Chairman, Vice welded with either 4043 or 5356. The 5xxx alloy in the form of spooled welding wire. series base alloys with less than 2.5% mag Typically, when gas metal arc welding Chairman, and Member of various A WS techni nesium (Mg), such as 5052, a commonly (GMAW), feedability will not be as criti used material, can be welded successfully cal when feeding the more rigid 5356 cal committees. Questions may be sent to Mr. alloy. Feedability of any aluminum weld with both the 4043 or 5356 filler metal. The Anderson clo Weldingjoumal, 550 NW LeJeune 6xxx series (Al-Mg-Si) base alloys, such as ing wire, when compared to steel, can be 6061 and 6063, which are extensively used an issue, especially with the smaller-di Rd., Miami, FL 33126, or via e-mail at in aluminum fabrication, can be welded ameter wires. The less rigid alloys, such with either the 4043 or the 5356 filler as 1100 and 4043, can compound this [email protected]. metals. problem.
Choosing Between 4043 • For welding any of the magnesium base and 5356 metals (5xxx series) that contain more Do You Have than 2.5% Mg, such as 5086 or 5083 ma If the filler metal selection chart lists terials. 4043 is not recommended. The Some News to both 4043 and 5356 as acceptable for a par 5% silicon in the 4043 filler metal when ticular base material, how do you choose combined with the higher magnesium in Tell Us? between the two? As a guide, consider the these base alloys can produce undesir following facts about each of these popular able mechanical properties in the weld. If you have a news item that filler metals before making your choice: might interest the readers of the • For weldability and slightly lower crack Welding Journal, send it to the fol lowing address: • As a basic description, 4043 is an alu sensitivity, 4043 will typically provide a Welding Journal Dept. minum filler metal with 5% silicon added higher rating. Also, 4043 will also gener Attn: Marv Ruth Johnsen and 5356 is an aluminum filler metal with ally produce welds with improved cos 550 NW LeJeune Rd. 5% magnesium added. metic appearance, smoother surfaces, less spatter, and less smut. For this rea Miami. FL 33126. Items can also be sent via FAX • If you want the best color match after son, 4043 is sometimes more appealing to (305) 443-7404 or by e-mail to postweld anodizing, 4043 is not a good to the welder. mjohnsen(ctaws.org. choice because it will typically turn dark gray in color after the anodizing process. Conclusion A much closer color match after anodiz ing will be provided by 5356, particularly There are many aluminum base metals on the 6xxx series base alloys. that provide the option of welding with ei Want to be a ther 4043 or 5356 filler metal. However, Welding Journal • For service temperatures above 150°F. based on the facts listed above, understand Advertiser? 4043 is appropriate. However, 5356, be and select the most appropriate filler metal cause of its 5% magnesium content, is for the job. The application and service con For information, contact not suitable for prolonged elevated- ditions of the finished welded structure is Rob Saltzstein at temperature applications and, if used generally a governing factor, and will often (800) 443-9353, ext. 243, in such environments, may result in pre dictate the most suitable filler metal or via e-mail at mature failure of the welded structure. selection. [email protected]. • In the as-welded condition, 4043 has a Use a filler metal selection chart to
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For more information on the AWS Certified Welding Supervisor program, visit our website at American Welding Society www.aws.org/certification/cws Founded in 1919 to advance the science, technology or call 1 -800-443-9353 ext 470. Circlmt*u,e No N.o 5 so no nReade R» r Info-Card and application of welding and allied processes including joining, brazing, soldering, cutting and thermal spray. BRAZING Q&A BY R. L PEASLEE Q: We are looking for brazing filler met brazing filler metals for jet-engine rupture data of AMS 5770 base metal als with excellent creep rupture strength applications. tested at 1500°F (816°C). These data were at 1250°F. The design requires a long life, At that time, the only high-tempera for butt brazed test specimens that were 15 years (—150,000 hours), with continu ture brazing filler metal was the 85Ag- fully diffusion brazed. The graph shows ous service at 1250T. Among the poten 15Mn (now BAg-23 I silver brazing filler the comparison between the unprocessed tial base metals being considered for this metal that had been used in the German base metal from the manufacturer's data, design are Alloy 625, UNS No. 6625; Alloy jet engines during WW II to make hollow, and the butt brazed specimens diffusion 230, UNS No. 6230; or Alloy 214, UNS No. high-temperature turbine blades. After brazed with Nicrobraz 125 (AWS BNi-1, 7214. Do you have creep rupture data for WW II, the filler metal was introduced to AMS 4775) at 2150°F (1121°C). The dif these alloys? Do you have data out to the United States. In the middle 1940s, jet fusion brazed and aged stress-rupture 10,000 or 100,000 hours? engines were running hotter, and if an en data followed the lower range of the base gine overheated, the 85Ag-15Mn would metal stress-rupture data from the man A: Unfortunately, I only have limited in melt and be blown out of the joint and jet ufacturer. This was to be expected, as the formation on the stress rupture proper engine. Therefore, need arose for a braz brazing temperature was higher than the ties of brazed joints. ing filler metal that would braze at nor recommended solution temperature for In the middle 1940s, when I developed mal brazing temperatures that would have that base metal. The brazed specimens the nickel-based brazing filler metals for a high-remelt temperature. The nickel- failed at around 220 hours when loaded the aircraft jet engine high-temperature based filler metal that was developed, to approximately 12,000 lb/in.2, at 1500T applications, we ran many physical prop when fully diffusion brazed, had a remelt (816°C). Thus the diffusion brazed test erty tests. Among these was the test for temperature in excess of 2500°F (1371°C). data were comparable to the base metal the stress rupture strength of both butt- The paper that was published in the data. brazed test specimens and single-lap- August 1952 Weldingjoumal is titled "De A later stress-rupture test was run on shear specimens. These data were pub sign Properties of Brazed Joints for High- a diffusion brazed V-type joint of A286, lished in the August 1952 Welding Journal, Temperature Applications," by Robert L. UNS S66286 iron base metal, brazed with along with the summary of the three years Peaslee and Willard M. Boam. BNi-1 at 2150°F (1177°C). A stress- of testing, to qualify the nickel-based The referenced paper included stress rupture test was run at 1350°F (732°C) and T X^X:i)X m hyjpjjjff Oujjfjj'ijfjj-dyj (large and small) and Educational Institutions : i y-y , i .i'-j Ige of the materials joining industry! ING COMPANY MEMBERSHIP Join an elite group of over for a competitive edge For more information 400 AWS Sustaining Company • An attractive AWS Sustaining Company wall plaque on AWS Corporate Members and enjoy: • Free hyperlink from AWS's 40,000-visitors-a- • Your choice of one of these money- month website to your company's website Membership, call saving benefits: • Complimentary VIP passes to the (800) 443-9353, ext. 253 1. AWS Standards Library {$6,500 value) AWS WELDING SHOW 2. Discount Promotional Package - save • An additional 5% discount off the already- or 260. E-mail: on Weldingjoumal advertising. reduced member price of any AWS conference 3. 10 additional AWS Individual or seminar registration [email protected] Memberships {$870 value) • Up to 62% off Yellow Freight shipping for an application. Plus... charges, outbound or inbound, short or • 10 AWS Individual Memberships long haul ($870 value); each Individual Membership includes a FREE subscription to the Welding AND MUCH MORE... American Welding Society Journal, up to an 87% discount on an Also available AWS Supporting AWS publication, Members'-only discounts Company Membership, 550 N.W. LeJeune Rd. and much more Miami, Florida 33126 • Free company publicity - give your AWS Welding Distributor Visit our website at www.aws.org company a global presence in the Membership and AWS Educational Weldingjoumal, on the AWS Website, Institution Membership Your organization and at the AWS WELDING SHOW • Exclusive usage of the AWS Sustaining needs solutions. Company logo on your company's AWS means answers. letterhead and on promotional materials Circle No. 11 on Reader Info-Card the failure occurred at the same number base metal and brazing filler metal make brazed joints in high-temperature base of hours that the manufacturer's data the joint area respond the same as the metals. We would appreciate receiving in predicted. original base metal; thus the stress- formation on any papers containing these I have two papers in my file containing rupture properties of the joint will equal data. Please send detailed reference in stress rupture data: those ofthe base metal. formation, so that we can pass it on to in 1. "Diffusion Brazed Inconel 713C," When BNi-1, la. 2, 3, or 4 are used in terested parties. • by A. Sokamoto and M. Ohsumi of a joint that is fully diffusion brazed, the Nagoya Aircraft Works, Mitsubishi Heavy filler metal will be completely dissolved, Industry, Ltd. This is a 29-page manu and only nickel-based metal grains will be R. L. PEASLEE is Vice President Emeritus, script presented at the Japanese Welding apparent in the joint area. Society Meeting held April 8 and 9, 1980. In reference to nickel brazing filler Wall Colmonoy Corp., Madison Heights, Mich. The paper discusses the stress-rupture metals containing silicon or phosphorus Readers may send questions to Mr. Peaslee c/o data, and contains butt-brazed-joint data, as the melting point depressant, I do not Welding Journal, 550 NW LeJeune Rd., Miami, micrographs of joints, and chemical ele have any data. These brazing filler met FL 33126, or [email protected]. ment traces across the joints. The paper als can also be diffusion brazed, but re is very detailed but, unfortunately, no quire special consideration. As an exam comments on the data are included. ple, BNi-7 can be diffusion brazed with 304L, if the joint is a light-press fit and 2. "High-Temp Stress-Rupture Proper held at the brazing temperature of 1950CF ties of Brazed Joints in Heat-Resistant Al or higher for 60 min. The resulting joint loys," Research Report A1250, Septem will exhibit 50 to 90% base metal. With a Dear Readers: ber 1959, by A. Cibula, published by The higher temperature, and/or longer diffu British Non-Ferrous Metal Research As sion time, the brazed joint area would be The Welding Journal encourages sociation. Stress rupture data were ob 100% base metal in appearance on a an exchange of ideas through tained using a plug-in socket-type brazed micro specimen when viewed at 100 or 500 letters to the editor. Please send joint. Austenitic steels were tested at power magnification. your letters to the Welding Journal 500°C (932°F). Nimonic 90 tested at 800°C While I do not have all the data that Dept., 550 NW LeJeune Rd., (1472T) and 900°C (1652T). Later tests would be desirable, what I have seen in Miami, FL 33126. You can also were run on Nimonic 90 at 950°C (1742°F) dicate that a fully diffusion brazed joint reach us by FAX at (305) 443-7404 and NimoniclOO at 800°C (1472°F) and with a boron-containing brazing filler or by sending an e-mail to Kristin 950°C (1742°F). metal will give the desired long-term It is my belief, from the work that has stress-rupture properties. Campbell at [email protected]. been done, that when full diffusion braz Currently, there is much interest in the ing takes place, the interdiffusion between stress-rupture and creep properties of
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Circle No. 16 on Reader Info-Card WELDING JOURNAL NEW PRODUCTS FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD.
throughout the entire production process. Lasers Utilize Twin-Rod Oscillator Design A split-cabin, sliding pallet design allows it to continuously cut parts without any The company's second generation of pulsed Nd: YAG lasers combines its patented idle time during the unloading/reloading TR Technology for high beam quality with state-of-the-art control and beam delivery process. It operates with Cenit Software's technology. The JK450HP and JK600HP, which utilize a twin-rod oscillator design to v5/LaserCUT technology. Its machine increase efficiency and beam quality, offer rep rates up to 1000 Hz and minimum structure, laser, CNC, and electro- pulse lengths of 0.2 ms for fast and precise mechanics are integrated into a can welding, cutting, and drilling applications. tilevered, compact architecture. Featur The JK-HP Series introduces a number of ing a patented safe impact protection sys features as standard across the JK product tem, its cutting head is protected from line, and these include LaserView™ con damage to the head, nozzle, or sensor due trol technology, which enables complete to errors that cause interference between cycle programming triggered by a single the head and workpiece. The Join-It™ sys command, in-process viewing, video cap tem allows the 5-in. standard cutting head ture, and real-time graphical displays of key to be easily reconfigured from cutting to parameters; patented Luminator™ plug- welding applications with a 7.5-in. cutting and-play fiber optic beam delivery with kit, B-axes for welding with 8.7- and 11.2- built-in back reflection protection; pulse in. parabolic mirrors, and B-axis for sur shaping, which allows tailoring of pulse face treatment. shape to optimize process requirements; faster shutter interface protocol for quicker response on parameter changes and more PRIMA 102 precise timing in time-share mode; and fully integrated time and energy shares. 711 E. Main St.. Chicopee. MA 01020
GSI Lumonics, Inc. 100 Abrasive Flap Discs Grind 22300 Haggerty Rd., Nurthville. MI 48167 and Finish in One Step Welding End Prep Tool cutting fluids. The tool is capable of bevel ing and facing or beveling and boring in Built for Hard-to-Machine one operation, and it uses the EscoLock™ Materials blade lock system and TiN-coated cutting blades. An optional cross-feed attachment that advances another blade in 0.003-in. increments to sever the heat-affected zone and permits flange facing and grooving for couplings is offered.
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Laser System Increases Productivity
The Tiger® Disc line of abrasive flap discs are for applications such as weld blending, grinding, deburring, deflashing, stock removal, and surface finishing. The discs can be used to grind and finish in one step, resulting in fewer changeovers and The Esco Prepzilla MILLHOG® pipe increased productivity. As the disc wears milling end prep tool features one man down, new abrasive grain is continuously drel and eight sets of easily interchange exposed. The company's line of abrasive able clamps to cover the full 1^-in. I.D. to flap discs includes the Original Tiger Disc 8%-in. O.D. operating range of the tool. for jobs that require a high cut rate and Designed for hard-to-machine materials The RAPIDO 3-D laser beam cutting long life; the Vortec Pro™ line of flap discs such as stainless steel, it has a 2M-hp pneu system has a focal position control that for a high cut rate with a value price; the matic motor, a rugged gear head design, automatically manages the laser's focal BigCat® high density discs for increased generates 1500 ft-lb of torque at the cut position according to the specific applica conformability on contoured parts; the ting blade, and pulls a thick chip without tion and controls the head position Tiser Disc for stainless steel; and the Bob-
AUGUST 2005 Cat™ Discs for use with air and electric welding machines C lass 1 CDRH compli right angle die grinders. ant enclosure with safety viewing window, fume extraction ports, vibration isolation Weiler Corp. 103 footings, and a control panel that meets One WUdwood Dr.. Cresco, PA 18326-0149 the user's welding specifications. Optional accessories include up to four axes of CNC Nozzle Changer Provides motion control: heavy-duty floor-stand Flexibility for Automation ing base; CCTV \ iew ing system with cross hair generator: cover gas module; pneu matic access door: interior lighting; and tooling. Also, the workstations are avail able with the user's choice of precision, multiaxis (XYZ6) CNC motion stages, and Windows®-based user interface soft ware, with industry-standard G & M code programming features.
Unitek Miyachi Corp. 105 1820 S. Myrtle Ave.. Monrovia. CA 91016 Foam Seal Vacuum Cups Handle Treadplate, Rough DE-STA-CO's new line of Surfaces pneumatic swing cylinder clamps offers enhanced The company's nozzle changer facili sensing capability, allowing tates automated laser beam cutting oper for precise position control and ations. It eliminates the need for opera monitoring. The new clamps tor intervention during job setup, en exert a clamping force ranging hances process safety, and provides addi from 20 lbs. to 1 60 lbs., without tional flexibility in unmanned multishift deforming delicate parts. operations. The nozzle changer is avail These versatile clomps offer a able on the TC L 3050, TC L 4050, and combination of features making TC L 6050 machines. them uniquely adaptable to welding and assembly operations including: TRUMPF, Inc. 104 111 Hyde Rd.. Farmington. CT 06032 • 90° swing minimizes obstruction in the workplace and reduces cycie time Laser Workstation Anver Small Foam Seal Vacuum Pads • 3/8 in. to 1/2 in. clamping Equipped with Control are molded from black Delrin® and fea stroke allows clamping of a Panel Matched to User ture foam inserts that securely fit into the wide variety of part sizes pads and are offered in several softness Specs • Improved design features grades to conform to the surface of the hardware to effectively secure material being handled. The foam inserts, clamp housing which arc designed for lifting steel and aluminum treadplate and other rough sur • Threaded body permits three mounting options, allowing faces, wear well and can bc changed in less for minimal installation time than a minute. Available in 3.78-in.-diam- AUTOMATE. eter size with a 35-lb rated load capacity • Internal piston design at 22-in. Hg vacuum, when used in a hori features new seal technology zontal plane and based on a 2X safety fac • Quick swing-and-clamp tor, the pads come with a double female movement reduces cycle time NPT X- or G !4-in. coupling, which makes DE-STA-CO's pneumatic them ready to screw into the firm's J^-in. swing cylinder clamps are well suspensions. Actual capacity depends suited to operation in variant upon the load surface and vacuum gener temperatures, ranging from ating system. -40° to 250°F. Together with our other families of products Including manual, Anver Corp. 106 pneumatic, hydraulic, electric, So 36 Parmcnter Rd.. Hudson. MA 01749 workholding and automation Many solutions, DE-STA-CO provides Possibilities. the perfect manufacturing One Lasers Feature Air-Cooled improvement for your needs. Company. Function
A characteristic of the PP series of the The Delta Series laser welding work destaco.com diode-pumped INNOSLAB lasers lies in 1.248.594.5600 stations come equipped with one of the the air-cooled function, which permits 1.888.DESTACO company's A-Series pulsed Nd:YAG laser compact dimensions of the laser and Circle No. 21 on Reader Info-Card
WELDING JOURNAL makes it easily and flexibly integrateable recessed pit for installation. Other fea Laser Alternative and manageable in machines. The laser tures include the following: 102 x 108 in. delivers average power up to 30 W, pulse usable platform size; indexing capability; maximum power up to l MW, and pulse 10-hp pumping unit that provides 12 s lift frequencies up to 50 kHz. The pulse du time; high cycle packaging consisting of ration lies between 4 and 15 ns. In addi spherical bearings at all pivot points for tion, the lasers are suitable for plasma gen precise alignment and cam followers in erating, deep drilling, separating, struc place of standard-duty leg rollers; hy a Fraction of the Cost turing, cleaning, polishing, marking, inte draulic velocity safety fuse to prevent free- rior engraving of transparent materials, fall if the hydraulic is severed; and • New/Used Equipment and rapid prototyping. PentaFlow hydraulic cylinders. • Tools Service • Technical Support EdgeWave GmbH 107 Pentalift Equipment Corp. 108 ABI Link-it Schumanstrabe 1811, D-52146 Wiirsclen, Germany PO Box 1510. Buffalo, NT 14240-1510 Link Welder Loopers Table Contains Hydraulic Cutting Head Offers Quick Auto& Velocity Safety Fuse Lens Change Manual Fusion Stud Welders
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Purifiers Designed for Laser Market
Circle No. 15 on Reader Info-Card UNDERWATER
The line of Smart Indicating Purifiers is designed to purify a laser cutting ma chine's gas stream and protect the laser resonator and provide early warning of im purities. If the gas contains contaminants, or if the contaminants enter the gas stream during cylinder change out, the purifier media begins to turn color. When the pu rifier is depleted, the cartridge is easily H - changed with a patented quick-change base, allowing the user to change the pu rifier without interrupting gas flow. ADDITIONAL TRAINING: Airgas, Inc. 110 • Diver Medical Technician 259 N. Radnor-Chester Rd., Ste. 100, Radnor, PA 19087-5283 • Underwater Welding • Underwater Burning • continued on page 89 • NDT Level I & II -888-974-2232. • Chamber Operations Correction • Emergency Dive Accident Management In the June 2005 issue, on page 23, the HD3070® is a product of Hyper therm, Inc., and not Thermal Dynamics 1-888-974-2232 SJig Corp. Jacksonville, Florida « . www.commercialdivingacademy.com Circle No. 17 on Reader Info-Card
WELDING JOURNAL •A X rUiny Take Up The Torch Week September 12-16,2005 I I TO TAKE UP THE TORCH TODAY-Visit www.takeupthetorch.org Become an Industry Partner and link your website to ours. Mentor those starting out—Sign up for the Speakers' Bureau in your area. Students— Explore the benefits of a career in welding, by visiting the site and requesting a FREE poster, video and career information package. For more information, visit www.takeupthetorch.org, call 800-443-9353, ext. 308 or email: [email protected] Circle No. 14 on Reader Info-Card Guidelines for Laser Welding Through proper component design, even companies with low-volume needsShee can take advantaget ofthe Meta benefits of laser beaml welding BY HARTMUT ZEFFERER company, has been utilizing its own To answer this question, a project AND TIM MORRIS machine tools (i.e., laser beam cutting, team was assigned the task of analyzing punching, and bending machines) for laser beam welding of sheet metal com production of low-volume machine com mall and mid-sized sheet fabrication ponents. This paper summarizes the sta ponents. The typical volume for these tus of that effort to date. companies can now profit from the components is several hundred parts per Spotential of laser beam welding year. Over the past several years, laser (LBW) in modern sheet metal processing. beam welding has seen increased applica Laser Beam Welding Laser beam welding is a well-established tion for these low-volume components. Technology process in quality-critical applications High quality, increased productivity, with volumes above 100,000 parts per and low part cost are well-known attrib One of the unique properties of laser year. These laser systems are highly auto utes of laser beam welding for high-vol light is its focusability. For high-speed mated with dedicated tooling and part ume components. Thus, the challenge has sheet metal welding applications, the typ handling. This is the typical application been how to successfully implement laser ical laser power ranges from 1 to 4 kW that justifies the use of highly automated welding for low-volume sheet metal com The laser beam is focused to a spot size of LBW systems. ponents. The goal is to benefit from the less than 0.5 mm (0.020 in.) The resulting On the other hand, TRUMPF, as an technical advantages of laser welding power densities are greater than 1 example of a mid-size manufacturing while reducing the manufacturing costs. MW/cm2. These power densities are suf- HARTMUT ZEFFERER is Senior Project Manager, Lasers and Systems, TRUMPF Laser & Systemtechnik, Ditzingen, Germany. TIM MORRIS ([email protected]) is Technical Sales Manager, TRUMPF Inc., Laser Technology Center, Plymouth, Mich. Based on a paper presented at the AWS Detroit Section's Sheet Metal Welding Conference XI, Sterling Heights, Mich., May 11-14, 2004. WELDING JOURNAL joints, focus positioning and edge prepa Sheet thickness d Gap widths: Offset k ration are critical. In flange joints the laser beam is 0.5 - 3 mm 0.05 xd 0.15 xd aimed at the contact line of the two com > 3 mm 0.03 X d 0.10 x d ponents. By multiple reflections at the Molten material interface of the joint, almost all of the laser power reaches the contact line and is utilized for welding. Flange welds Travel Direction k 1 1' result in a narrow joint, with high pene I i tration depth resulting in a high depth- s to-width ratio. Fig. 1 —A process diagram and picture ofthe y^m The self-focusing effect at the joint welding process for deep penetration welding. _, interface makes flange welds relatively insensitive to lateral focus positioning. Each joint has unique benefits and Fig. 2 — Tolerances for root opening and requirements for successful welding. Part offset or mismatch in laser beam welding. tolerances, edge preparation, and clamp ing techniques are critical for laser weld ing. The following sections address these issues and give design guidelines and best practices for designing laser beam welds for producing high-quality, cost-effective parts. Process Requirements Laser beam welding is a thermal fusion process. The combination of a highly focused laser spot with high weld Fig. 3 — Laser beam welding of multiple layers in a single setup or multiple setups. ing speeds leads to quick thermal cycles and high thermal gradients. These heat ing and cooling rates far exceed the rates ficient to vaporize metal. A metal vapor joint types for laser beam welding. Butt seen in conventional arc welding, induc keyhole is formed as illustrated in Fig. 1. joints allow for complete penetration tion welding, and resistance spot welding. Through this keyhole the laser power is welding of the workpieces with single- Thus, the heat input is very low for laser directly transferred, as heat, into the bulk sided access. Butt joints give high welding. material. This process is called deep pen strength because the entire welded cross This low heat input and rapid solidifi etration welding. The keyhole formation section carries the load. cation can impact the weldability of some process is the unique feature that differ Additionally, butt joints require the metals. Typically metals that are difficult entiates laser beam welding from conven laser focus position relative to the joint to weld with conventional welding tional arc welding processes. to be accurately controlled. Edges have processes will also pose challenges for Deep penetration welding makes full to be sharp and straight to ensure good laser beam welding. Consult standard use of the outstanding focusing proper part fitup. Typically the edges are pre welding handbooks for general material ties of laser light compared with conven pared with precision shears, laser beam welding properties. tional heat sources. The primary process cutting machines, or mechanical machin Table 2 summarizes guidelines for advantages of LBW are as follows: ing in order to ensure optimum welding weld joint preparation and cleanliness, • Very narrow weld joint conditions. along with methods on how to achieve • Large depth-to-width ratio In lap joints, two or more layers of these conditions. • Minimized heat-affected zone (HAZ) components are stacked. By deep pene In general, the surfaces shall be clean and • Minimized thermal load and stress to tration welding, the laser beam melts dry. Contamination may vaporize during adjoining parts through the layers. Subsequent resolidifi the welding process, but the risk remains • Virtually no distortion cation fuses the components together at that residues will adversely affect weld • Oxide-free joints possible the interface. Compared with butt joints, properties. Coated surfaces, especially • No mechanical contact with workpiece lap joints have reduced weld strength due zinc-coated surfaces, can be laser welded • Good accessibility to hard-to-reach to the smaller joining area. if special design rules allowing for ventila joints Compared to butt joints, lap joints tion of evaporating zinc are observed. • High welding speeds allow for significantly wider focus posi Figure 2 summarizes the best-practice • Easily automated process tioning tolerances and, therefore, is a part tolerances for laser beam welding. • Increased design flexibility preferable technique to compensate for Because laser welding typically uses no The key for the various joint designs in part tolerances. Clamping along the weld filler material the components to be weld laser beam welding is to bring the compo interface ensures contact between the ed have to be in good contact, with mini nents in direct metal contact with rela components to be welded. mal root opening. The given tolerances tively high precision. The laser beam is Fillet welding is effective for welding for weld root openings and mismatch focused at the contact line. In deep pene T-joints. Welding from one side, the fillet take typical laser spot sizes into account. tration welding, both components are weld gives a symmetrical joint across the In butt joints, fillet joints, and flange molten and subsequently fuse together joining area. It offers good weld strength joints, too large root openings can result while resolidifying. because the cross section equals the in undercut or, in extreme cases, incom Table 1 summarizes the most common material thickness. Comparable to butt plete fusion. The laser beam, having a AUGUST 2005 Table 1 — Joint types in laser welding Table 2 — Surface and Edge Condition Guidelines for Laser Beam Welding Guidelines Remarks Clean surface: no dirt. rust, oxides Ultrasonic bath or washer No grease, heavy oil. heavy oil-based lubricants • Ultrasonic bath or washer • Light protective oil film is acceptable • Water-based lubricants are usually acceptable for steel. No water or water-based lubricants for Al Will cause porosity No coatings: paint, chrome, zinc, phosphate • Remove mechanically. • Coated surfaced may be welded with special techniques. No case hardened layer Remove mechanically No sand-blasted surface Sand residue may cause porosity No grinding residues May cause porosity small focused spot size, can pass through large root openings and may not contact the material. In lap joints, the laser beam always contacts the material, but, if the root opening exceeds allowable values, the interface width is reduced or, in ^J. I extreme cases, no fusion will occur. Partial penetration, hem weld Fillet joint Flange joint Conduction weld Edge straightness for butt joints and fillet welds is also critical. Non-square, sheared, or chamfered edges result in insufficient material and lead to incom Fig. 4 — Laser beam welding of visible surfaces (class A). In each example the visible sur plete volume and the same weld defects face is toward the bottom. as encountered with too large a root opening. Precision shears, laser cutting machines, and machining centers are the preferred tools for edge preparation. Mismatch gives a reduced weld inter face and thus reduces the resulting weld I I I =1 A strength. Proper matching of the parts i=09=i c has to be controlled by clamping. > Attention to design details and toler WELDING dOURNAL show how this can be achieved by using a lap joint design with partial penetration. A fillet joint design is depicted in the center. It offers greater interface and ^x~ weld strength. Also, laser power and weld speed do not have to be controlled as tightly to avoid affecting the visible x surface. The flange joint is a design where the X I top surface of the weld joint is on the vis -mm ible surface. This design almost masks the weld surface roughness and is acceptable in many applications without postweld finishing. The conduction weld is a r\WX unique weld process without a keyhole. This process is used for thin material (<0.5 mm). The edge of the thin sheet is Box design Frame design molten and it fuses with the thicker base material. This process gives a very smooth surface finish. Figure 5 gives suggestions about how Fig. 7 — Box and frame designs. to compensate for fabrication tolerances. Using multiple butt joints in a product design requires tight fabrication toler ances. Using lap joints reduces the required tolerances. The same joint design can be used for adding compensa tion capabilities in the fabrication of box- shaped products. The examples in Fig. 6 illustrate how laser beam welding can save weight by reducing flange size. In spot welding, typ ical flange width is about 0.75 in. This can be reduced to about 0.5 in. in continuous laser beam welding. By going from con Fig. 8 — Joint design and corner layout for bending of 90-deg corners. tinuous welding to stitch welding the flange width can be reduced further to about 0.25 in. Similar width is achieved, if a flange joint is possible. This joint allows for a continuous weld with greater weld strength. Figure 7 shows two different design concepts for building boxes, covers, and other similar parts (box design and frame design). The box design is fabricated by cutting and subsequent bending to final shape. It is good for 90-deg corners. The box design gives minimal number of parts and reduced weld length. Frame design is good for non-90-deg Fig. 9 — Design suggestions for non-90-deg corners. corners. A longer weld length is accept able due to the low heat input of laser welding. Bending tolerances add up, thus it is advised to finish the sequence of bends with a lap joint for tolerance compensation. Figure 8 addresses the joint design for 90-deg corners. Special attention is required to ensure good contact between the surfaces to be welded. The typical corner situation as depicted in example A would require filler material. Examples B and C show alternative designs not requiring filler material. Examples D and E indicate strategies Fig. 10 — Use of assembly tabs to locate pails. An asymmetrical design as shown in exam for preparing 90-deg corners for bending. ple C helps to minimize assembly errors. The demonstrated strategies incorporate a small circle in the corner and a cut slot, AUGUST 2005 each of which could be created with laser beam cutting. Both strategies allow for minimized material interference in the corner and ensure suitable fitup for laser welding. Figure 9 addresses the same issues for non-90-deg corners. One method is to chamfer the edges as shown in example B. Another technique is to redesign so that the components do not meet in the cor ner. The joint is redesigned for either a butt joint (example C) or a fillet joint/lap joint (example D). The discussion so far has focused on Fig. 11 — Lightweight cross beam with var Fig. 12 — Cover for z-axis on moving gantry design aspects driven by part functionality ious examples for utilization of assembly of laser beam cutting machine. and the laser beam welding process. The aids (ribs, tabs, etc.). next step is to expand the scope to include the assembly and tooling aspects by uti lization of assembly tabs. Laser beam welding can greatly benefit from the use of tab and slot assembly methods, which facilitate precision part placement. The designs in Fig. 10 give three exam ples for the efficient use of assembly tabs. Example C shows how asymmetrical tabs effectively help to eliminate assembly errors. Figure 11 gives a practical example where various types of assembly aids are Fig. 13 — Current design ofthe cover. applied to support the assembly of a light weight cross beam. Fig. 14 — Example of new cover design incorporating design aspects for laser beam A Case Study welding. Main cover (A) with insert (B) and reinforcement (C). The following case study discusses the cover for a laser beam cutting machine as shown in Fig. 12. The current design uses conventional gas metal arc welding (GMAW). The task was to redesign the part by applying the previously discussed design guidelines and conduct a cost com parison for the two designs. The part is a z-axis cover. The z-axis Fig. 15 — Detail of corner design (left) and travels on the moving gantry of the cutting new insert design (right). Laser weld of Fig. 16 — Reinforcement (green) to add machine. Thus, the cover is subject to sub insert is designed to be behind the visible stiffness to the cover with additional bend stantial accelerations. The cover is also in surface. to support assembly, fixturing, and welding. an aesthetically critical area as it is in direct sight of the operator. Figure 13 shows the current part in detail. Following are the basic design criteria for the cover: • Design visible edges with radius Table 3 — Budgetary Cost Comparison of Previous Design (GMAW) and new design (LBW) of • High part stiffness the Cover • Aluminum required to minimize weight • High fabrication accuracy for assembly GMAW LBW • Annual demand of 250 parts Fixture Cost $250 $1500 The current cover design can be char One-time programming cost $0 $100 acterized as follows: Prepare working area 5 min 15 min • Welded assembly with four aluminum Pick up part, weld, return part 12 min 2 min parts Time for grinding 9 min 0 min • High degree of visible edges and labor- Time for straightening 0 min 0 min intensive postweld finishing required Cost for grinding material $0.20/pc $0.00/pc • Part distortion during welding Lot size 10 pc 50 pc 100 pc 10 pc 50 pc lOOpc • Improved stiffness required Total manufacturing time per min 21.50 21.10 21.05 3.50 2.30 2.15 From a production point of view, it is Machine hourly rate for weld station $18.50/h $38.16/h Operator hourly rate $80.00/h $80.00/h desirable to reduce the number of compo Part cost without fixture cost $35.30 $34.64 $34.56 $6.89 $4.53 $4.23 nents. Also, as the cover is easily visible, Part including fixture cost $60.30 $39.64 $37.06 $166.89 $36.53 $20.23 the current production process includes a Break-even annual lot size 44.6 significant amount of postweld finishing. Comparison GMAW vs. LBW -63.87% 8.51% 83.14% 176.79% -7.85% -45.40%> In addition to the labor cost associated WELDING JOURNAL | with this process, it also generates a con joint. Thus, no postweld surface finishing cessing (grinding and straightening), and siderable amount of dust and dirt. This is is required. Also, the open U-shape form returning the finished part. The welding undesirable and requires frequent clean allows compensation for fabricating tol time per part is given for lot sizes of 10, ing of the production site. erances. 50, and 100 parts. This distributes the The current production method is crit The reinforcement is welded to the setup time over the lot and includes weld ical with regard to part functionality. Due back of the visible surface by a series of ing and finishing per part. to heat input, the part distorts excessively. fillet welds following the reinforcement The part cost for arc welding is prima Thus, in order to meet the assembly tol contours (not indicated in the drawing) rily due to the postweld processing erances, the parts need to be straightened — Fig. 16. It is fitted into the main body required when GMA welding the cover. after welding. Finally, from a mechanical by an additional bend along the left side However, GMAW has lower cost for the point of view, the current design needs to (see arrow). Also, it is welded to the tab fixture and for operating the machine. be revised because the cover requires of the main body's right bracket. This Thus, there is a break-even point where increased stiffness. gives additional strength to the cover. GMAW becomes more expensive than Figure 14 shows an example of a In summary, the redesigned cover LBW. In this example, the break-even lot redesigned cover that incorporates the incorporates all of the previously dis size is calculated to be 44.6 parts. previously discussed design guidelines for cussed design criteria. The number of laser welding. The proposed design con components is reduced from 4 to 3, stiff Summary sists of three pieces: a main body (A), an ness is increased significantly, and post insert (B), and a reinforcement (C). weld processing is completely eliminated. Even small and mid-size fabricators The main body is designed following This example uses a number of design can directly benefit and profit from the the box design concept. The insert is an guidelines as described and discussed following advantages of laser welding: example ofthe frame design concept. The previously. In general, the example • Increased processing speed reinforcement adds stiffness to the part. demonstrates the flexibility and creativity • Decreased heat input Laser beam welding allows welding of the that the laser beam welding process • Decreased thermal distortion reinforcement to the back of the main allows for designing sheet metal compo • Increased design flexibility body's visible surface. nents with enhanced features. The faster processing speeds achievable Figure 15 shows in detail the solution Finally, in Table 3, a cost comparison with laser beam welding allow, indirectly, for the complex corner and transition. between the old design (GMAW) and the for higher utilization of supporting preweld The design ensures proper fitup of edges new design (LBW) is given. The cost to processes (i.e., cutting, bending, etc.). and incorporates the slotting technique fabricate the completely welded part Laser beam welding does require spe discussed previously to minimize materi from prefabricated components is com cial attention to joint fitup, but this al built up in bent corners. The insert pared. The steps included are preparing requirement can be managed through basically fits behind the visible surface. It and using the work area, retrieving the assembly techniques and with laser is welded to the main body by a fillet raw components, welding, postweld pro friendly joint designs. • HIRE JOB SEEKERS WHO STAND OUT {g? www.iiwsiobfind.com BETTER CANDIDATES, BETTER RESDLTS AWS JobFind works better than other job sites because it special izes in the materials joining industry. Hire those hard-to-find Certified Welding Inspectors (CWIs), Welders, Engineers, Welding Managers, Consultants and more atwww.awsjobfind.com You'll find more than 2,000 resumes of top job seekers in the industiy! THE TOOLS TO DO MORE AWS JobFind provides companies with the tools to post, edit and manage their job listings easily and effectively, any day or time, have immediate access to an entire resume database of qualified candidates, look for candidates who match their employment needs: full-time, part-time or contract employees, receive and respond to resumes, cover letters, etc. via e-mail. Circle No. 12 on Reader Info-Card AUGUST 2005 f,^^^H Sink your teeth into an unmatched assortment ...of forming, fabricating, tube & pipe, and welding technology. Compare 800 exhibits and more lhan 2,000 machines in action. Consult with thousands of technical experts who can help you work smarter and run a leaner, more competitive operation. Evaluate more than 300 new products to boost your productivity. Select from over 50 conference sessions lo maximize performance. At last, there's one show where you can easily evaluate options, upgrade critical skills and stay on top ofthe latest innovations. It really doesn't get any sweeter than this! November 13-16, 2005 PARTECH McCormick Place South IEERKON A&„. _ Chicago, Illinois USA Ot AWS North America's Largest Metal Forming, WtLUINU OlfUW Fabricating & Welding Event Register online today for free show admissionl www.aws.org/expo <£> (CSS^ ^fe Circle No. 8 on Reader Info-Card International Welding Fair: Schweissen & Schneiden 2005 The fair in Essen, Germany, will revolve around the key technologies of welding, cutting, joining, coating, and allied processes Restaurant Grugapark BI u m e n h ofZ/V. MESSE Kurhaus / / ESSEN Place of Events Congress Center West- Saal Europa - Saal Berlin - Saal New York - Saal Mailand - Saal Briissel - Saal Panorama - Presse-Center West - Messe-Lounge West - Restaurant Piazza - Fig. 1 — The ground plan of Messe Essen where the 16th Schweissen & Schneiden 2005 fair will take place. m AUGUST 2005 ^ ill » 1 B. » i a « "^ ?t- * aW , a - 2 Bl •o Fig. 2 —A view ofthe 15th Schweissen & Schneiden 2001 fair. he 16th International Trade Fair, Annual Welding tors on the exhibition area of the forum. Schweissen & Schneiden, spon It is planned to present, among other sored by the German Society for Conference items, space frames from modern auto bodymaking. Remote welding using a Welding and Allied Processes, Lectures on welding, cutting, adhesive TDeutscher Verband fur SchweiBen (DVS) welding-arm robot as well as the process bonding, joining, and brazing/soldering of hybrid laser beam welding using a will be held September 12-17 at the will be presented by the Annual Welding diode-laser box will be demonstrated. Messe Essen fair site in Essen, Germany. Conference, which will take place This event, dubbed as the "Olympics September 12-14 in the Congress Centre The program will be rounded off by of Welding Engineering," has been held South/West. It will provide an up-to-date discussions with American researchers at every four years since 1952. overview of the latest developments, the Meet American Scientists event. About 1000 exhibitors from all over results, and applications of welding tech the globe will show their innovations to nology with its allied processes. Historic Exhibits Relating around 70,000 visitors expected from This year, a total of 60 lectures are more than 90 nations. The occupied fair scheduled. For the first time, the main to Welding Technology area will consist of 17 fair halls and the subject areas in German will be supple Galeria — Figs. 1, 2. mented by a section in English. Also, two Historical exhibits will be provided According to the motto "Experience workshops on the subjects of Power- from DVS archives, which currently com Technology Live," it will be possible to sec Station Construction and Designing prises around 800 exhibits from the sol technological innovations and advances in Suitable for Joining will be offered. dering lamp to the welding power source. action in a lively, graphic, and practical way The exhibition will bc organized and in the exhibition halls — Fig. 3. designed by the DVS working group Shown will be the latest devices, Innovation Forum "History of Welding Technology." The machines, materials, and installations for The Research Association for Welding exhibition will illustrate what an enor welding, cutting, adhesive bonding, braz and Allied Processes of DVS will stage an mous leap in development welding and ing/soldering, thermal spraying, and heat Innovation Forum where 30 research the allied processes have made in the past treatment. Furthermore, the range of institutes will present the latest results decades. automation on display at the fair will from their cooperative research in joining include not only industrial robots, data technology. U.S. Pavilion processing, fully mechanized and auto The presentations will feature devel mated processes as well as testing systems opments from the fields of arc and beam The American Welding Society and procedures, but also CNC and welding processes, brazing/soldering, (AWS) and the Welding Equipment process control systems, CAD/CAM sys thermal coating, and microjoining tech Manufacturers Committee (WEMCO) tems, monitoring facilities, quality assur nology, as well as the calculation, will sponsor the U.S. Pavilion, located in ance, workshop and workplace equip strength, and design of welded structures. Hall 7. As of press time, the following is ment, safety facilities, database and A number of exhibits from the insti a list of companies that will be exhibiting expert systems, and health and safety. tutes will be awaiting specialists and visi in the U.S. Pavilion: WELDING dOURNAL Sigma TEK Corp. Special Metals Welding Products Co. Uniweld Products Weld-Aid Products Weld Engineering Co. Structural Bonding International Premieres There will be two special events — Structural Bonding International (SBI) and Quality Testing International (QTI). With SBI and QTI, Schweissen & Schneiden will offer forums for manufac turers and service providers to present themselves at the fair. Structural Bonding International will have its premiere in Hall 4. For the first time, companies and institutions active in the field of adhesive-bonding technology will have the opportunity to present the advantages of this technology. Quality Testing International, in Hall 4 and the Galeria, will offer manufacturers and service providers in the fields of measurement technology, quality assur ance, and materials testing an interna tional platform to establish worldwide customer contacts. Additional Features During the Show Messe Essen has improved its service for exhibitors and visitors by setting up the "Business Centre" at a central loca tion on the fair site in Hall 4A. Here, fair- goers can confirm orders by fax, retrieve or send e-mails, search the Internet, make photocopies, and find out about hotel rooms or tickets for a theatre or musical. In addition, new for the exhibitors and visitors is an improved traffic service. A parking guide system that directs the traf fic to the free parking spaces has been installed in the vicinity of the fair site. For guests arriving by airplane, the Airport Express Bus will operate between Dusseldorf Airport and Messe Essen. Also, a wellness oasis has been created in the Grugapark, just a few steps away Fig. 3 —At the 2001 show, this welded dinosaur drew a lot of attention. Made of chrome- from the fair halls. Fair guests will be able nickel cut out of different elements, fitted together, and welded, the "Laser-Chrom-Nikolus" to get massages, oxygen therapy, relax on weighs 280 kg, is 2 meters tall, and 3.5 meters long. sunbeds, jog, perform gymnastics, or power train on ultramodern fitness equipment. American Torch Tip Co. •J.P. Nissen Co. American Welding Society • Jetline Engineering, Inc. Contact Information Aquasol Corp. • LA-CO Industries Arcon Welding Equipment, LLC • Mathey Dearman, Inc. Additional information about exhibit Centerline (Windsor) Ltd. • MTC - Limited ing or visiting at Schweissen & Schneiden CK Worldwide • Pipeline Technic UC 2005 can be found at 49(0)201-7244-227; Esco Tool Co., A unit of Esco • Rexarc FAX 49(0)201-7244-435; www.messe- Technologies • Sellstrom Manufacturing Co. essen.de; and www.schweissenuschnei- AUGUST 2005 welding n%\mm " . - '• J The National Scholarship Program This scholarship is available to students pursuing a minimum four year degree in a specific field at an accredited four-year university. There are currently twenty National scholarships available. Awards range from $2,500 to $3,000, and are granted on an annual basis. The deadline to apply is January 15,2006. For specific information on each of the twenty scholarships, please visit our website at www. a ws. org/founda tion. The District Scholarship Program Awarded to students enrolled in a welding-related vocational or college program, this highly successful program has helped hundreds of students across the country. Applicants must be high school graduates or possess a G.E.D. equivalent. Awards average between $500-$1,000, and are granted on an annual basis. The deadline to apply is March 1,2006. Application forms can be downloaded from www.aws.org/foundation. The AWS International Scholarship Program This scholarship is awarded to a full time international student pursuing undergraduate or graduate study in joining sciences. The applicant can be matriculating in accredited joining science programs at institutions anywhere in the world. The student must be in the top 20% of the institution's grading system. The deadline to apply is April 1,2006. Eligibility requirements are available on the website at www.aws.org/foundation. The award is $2,500 U.S. dollars. If you or your company is interested in establishing a National Scholarship, the AWS Foundation office can be reached by calling (800) 443-9353, extension 293 or email to [email protected]. Foundation, Inc. Building Welding's Future through Education Circle No. 9 on Reader Info-Card AL • it kat Remote Laser Beam Welding BY JIM CANN RWS process offers many advantages. length, the focused spot size can get too Although tooling and part 2 This article will explain the process in large if the M > 2. A larger spot size can more detail and compare it to traditional result in lower power density that is below fitup requirements are more welding methods. the threshold of "keyhole" welding (1 x 106 watts/cm2) and the weld process will become unstable as shown in Fig. 3. demanding than with other Remote Laser Beam Welding Beam Scanning Motion System processes, laser-based The concept of laser scanning is not The beam scanning motion is based on new. Laser markers have been around for high-speed linear or "galvo" motors de more than 20 years and are used to mark pending on the manufacturer. This en remote welding can prove or etch features on various components. ables very high speeds when moving from Figure IA shows a lower-powered laser one weld location to the next with move beam (typically less than 100 watts) ma times less than 50 ms. The scanner also al beneficial for many nipulated by two galvo-driven mirrors and lows custom programmable weld shapes focused on the work surface. (stitches, circles, weaves, and other pat In the late 1990s, high-powered (3 kW terns). This allows the user to be able to applications and above) COi lasers became available apply the best path profile for the partic with very high beam quality. This high ular weld joint. beam quality provided the ability for "key remote laser beam welding system hole" welding with very long focal lengths (RWS) uses the beam from a high- — Fig. IB. A typical RWS is shown in Fig. Comparing Welding IC. The system includes a high-power (up Characteristics Apowered C02 laser together with a moving mirror to apply the energy to to 6 kW) C02 laser and a "remote" scan weld sheet metal components. The advent ner system with a very long focal length Resistance Welding (typically 1000-1600 mm). A computer- of high-powered C02 lasers with excellent beam quality has made this technology driven motion system plays back a pro A resistance or "spot" weld has the fol feasible for working areas of 1 m x 1 m or grammed path much like a robot or CNC lowing typical parameters: more. The benefits of this process include controller to complete the laser beam • Weld time ffi 0.75 seconds welding of the sheet metal subassembly. faster cycle times and smaller "footprint" • Can weld two to three layers with a typ (plant floorspace) as compared to tradi ical total material thickness ffi 2-4 mm tional processes. Laser Beam Quality • Can weld coated or uncoated steels While remote welding is a relatively Characteristics • Weld gun acts as a "clamp" and pulls the new laser application, today there are material together while welding more than 50 RWS installations in actual Beam quality or "mode" refers to the production and many more installations power distribution within the laser beam. Arc Welding to come. While lasers are a relatively ex It is characterized as the "M- value" with pensive welding power source as com an M2 = 1 representing a perfect Gauss A gas metal arc (GMA) weld has the pared to resistance or arc welding ian distribution. This beam quality affects following typical parameters: processes such as gas metal arc welding, the focused spot size "d" as shown in the • Weld speed ® 1 m/min the overall system cost is similar and the equation in Fig. 2. With a long focal • Uses wire feeder to weld two layers in JIM CANN (][email protected]) is Regional Manager. Rofin-Sinar, Inc., Plymouth, Mich. Based on a paper presented at the A WS Detroit Section's Sheet Metal Welding Conference XI, Sterling Heights, Mich.. May 11-14, 2004. AUGUST 2005 various joint configurations (fillet, butt, etc.) • Material thickness is typically 1-3 mm with a total thickness of 2-6 mm • Can weld coated or uncoated steels • Can tolerate a fitup "gap" of around one-half the wire diameter. Laser Beam Welding A C02 laser beam weld has the follow ing typical parameters: • Weld speeds © 3-6 m/min • Welding time is around 0.2-0.3 s assum ing a 15-mm-long stitch is approxi mately one spot weld • Can weld two to three layers with a typ ical total material thickness ffi 2-4 mm • Can weld coated or uncoated steels, but must accommodate zinc outgassing • Requires weld joint fitup with maximum root openings of around 0.1-0.2 mm. Cycle Time Comparisons A*JZ9> As noted previously, the welding time for lasers is faster than traditional Control syste processes. However, the significant gain in cycle time also comes from the "rapid Laser source moves" or repositioning moves between welds. A robot will typically take 2-3 sec onds to move to the next weld location, while a remote laser beam welding ma Scanning box chine takes less than 50 ms. When com bining the welding and "rapid move" times, we can conclude that remote laser beam welding cycle times are 6-10 times faster than resistance or arc welding processes. Floorspace Comparisons If remote welding speeds are 6-10 times faster than a single arc or spot weld ing robot, then it will require 6-10 robots to do the same work as a single RWS sta tion. It is not feasible to put this many ro bots in one welding station. Multiple sta Fig. 1 — A — A laser marker; B — remote tions are typically required with traditional laser beam welding mac/tine; C — typical re processes and the part is transferred be mote laser beam welding system. tween the stations. The following case study illustrates this point and was pro vided by Utica Enterprises. operators and consists of two turntables, available for a different part. This option An excellent candidate for a remote three spot welding robots, two pedestal offers a more flexible solution. laser beam welding application would be welding machines, two conveyors, and one As shown by this case study, an RWS a rear shelf assembly. This stamped auto material handling robot. installation takes up much less floor space motive subassembly component is rela If this same assembly were welded than a traditional welding installation, ap tively flat, uncoated steel, and has a large using a remote laser beam welding ma proximately a 4:1 ratio in floorspace sav number of spot welds (approximately 50 chine, it could be done in one station with ings. In addition, the RWS option is not a welds). A typical rear shelf assembly con the same throughput as the traditional dedicated line and offers much greater sisting of five separate stampings is shown process illustrated previously. This laser flexibility. in Fig. 4. beam welding layout is shown in Fig. 5B. The traditional method to assemble This system requires one operator and Flexibility this rear shelf would be to spot weld the consists of one turntable and one 5-kW five components together. This would bc laser with remote scanning head. The As the case study shows, a key point of done in multiple workstations with trans turntable has two sets of fixtures (notated the RWS option is flexibility. Since there fer equipment between the stations as as A and B). The rear shelf assembly only is no actual contact to the part with a weld shown in Fig. 5A. This system requires two requires fixture "A" leaving fixture "B" gun (therefore the term "remote"), the WELDING dOURNAL PMSTML flfiUdhQ raoj* Diameter _Focus mirror Power 3 Beamf ft l / f (focal length) LM2 (mode factor) \ / | j d (spot size) "~/\—4 01 = 1^* (4W/7tD) 2 m =5 (TEM02) iir \tf 10- intensity in Wfatf F/g. 2 — Spot size as related to beam quality. Fig. 3 — Keyhole welding threshold. B 6E53-5446690 6E53-5446510 6E53-54465A42 FINAL ASSEMBLY ^P-^fc. Cv 6E53-5444822 6E53-54465A59 V Fig. 4 —A — Rear shelf stamped components; B — rear shelf completed assembly. weld station can be easily changed over metal. Therefore, laser welding requires 3.5 kW), the plasma is more intense and to a different part simply by changing out the tooling to locate and clamp the area nozzles will need to be incorporated into the tooling and calling up a different pro to be welded. the tooling. For higher power applica gram. This provides the ability to design In addition, laser beam welding zinc- tions, helium, nitrogen, or air can be used one station to handle a family of low- to coated materials requires a method to as the shielding gas depending on the medium-volume stamped sheet metal allow the outgassing to vent. Otherwise application. part assemblies. the zinc will outgas through the weld cre Line of Sight Considerations. Since the ating excessive porosity and blowouts. For laser beam is steered by a mirror that is Tooling and Part Design zinc-coated materials, the tooling must some distance from the part, line of sight Considerations work along with special part features to considerations must be kept in mind. provide an outgassing method. Imagine attaching a string to a point about Tooling. While the remote laser solu Plasma suppression. Regardless of 1 meter above the part and moving the tion offers a faster process and takes up the metal coating (zinc or bare), C02 string to the point to be welded. If there much less floorspace, it does have tooling welding typically requires a method to is a clamp or some feature of the part that and part fitup challenges that must be con dampen and/or blow away the plasma cre prevents a straight line (the string) from sidered. The laser light has no force, un ated during the laser welding process. reaching the weld location, then the laser like spot welding where the electrodes are This is because the plasma interferes with beam will have the same interference attached to a gun or cylinder-driven the laser beam and can cause the weld problem. This "line of sight" issue must clamping mechanism. As noted earlier. process to become unstable or lose the be considered when laying out the weld the arc welding process uses wire filler weld completely. For laser powers of 3.5 ing process. metal and this allows for a gap in the weld kW or lower, a simple fan can be used to Part Design. Stamping suppliers that joint. Laser welding is accomplished au blow across the area of the part to be weld using lasers have solved this out togenously, meaning there is no filler welded. For higher power lasers (above gassing issue by embossing a feature or AUGUST 2005 B i \\\T SW Fig. 5 A — Rear shelf assembly spot welding layout; B — Rear shelf assembly laser beam welding layout. dimple in the area to be welded. This fea 2 conveyors. North America installation followed ture can be incorporated into the stamp Remote laser welding system capitol shortly after. The advantages such a sys ing die or can be added after the stamp cost of approximately $ 1,000,000 of equip tem offers include the following: ing process. The end result is that a gap ment consists of • Up to ten times higher throughput as of 0.1-0.2 mm is created and allows a path 1 5-kW laser compared to traditional processes for the zinc to outgas. 1 remote welding scanner head and • System layout can be three to four times Unlike spot welding, the laser weld is structural stand smaller than traditional processes very narrow and only requires single-sided 1 turntable. • Allows greater flexibility on the manu access to the part. The RWS scanning mir The point of this illustration is to show facturing floor ror can be programmed to create various that the initial investment cost for capitol • Part design can be tailored to fit laser weld shapes or patterns. In addition, laser equipment can be approximately the same welding, resulting in lighter, yet stiffer welded parts are stiffer and more rigid for traditional vs. remote laser welding parts. than spot welded parts. These concepts processes. This is due to the high process One of the challenges to the continued must bc kept in mind very early in the part ing speed of the RWS. While the laser sys growth of remote laser welding installa design process to take full advantage of tem is relatively expensive, it can do the tions is that the tooling and part fitup re laser welding. Weld flanges can be made work of multiple robots, welding ma quirements are more demanding than tra smaller providing a potential weight sav chines, and material handling equipment. ditional processes. However, there is ings. Access holes required for many spot tremendous interest in this new sheet welding applications are not necessary for Operating Costs metal welding process, and there are suc laser welding. cessful installations where this fitup issue Safety Considerations. The main haz Operating costs need to be considered is being managed. ard of a laser is damage to the eye due to when evaluating a potential remote weld While this process will not be appropri a reflected line. Unlike traditional ing application. In general, the following ate for every part assembly, it has been processes, laser welding systems must be items should be considered when compar shown to be a beneficial alternative to tra enclosed in a CDRH rated Class I enclo ing remote welding to traditional ditional welding processes for the correct sure. This creates a "lighttight" environ processes: application. A proper analysis should be ment during the welding cycle. • Cost of electricity done in the early stages of a part design • Consumables and manufacture cycle to determine if it is System Cost Considerations • Spot welding tips suitable for laser-based remote welding. • • Filler metal (for arc welding) • Laser consumables (gas and optics) Capital Expenditures • Long-term cost of maintenance and repair What do you get for $1,000,000? For These costs will differ from part to part, the rear shelf assembly case study dis and each case should be considered indi cussed previously, this is the approximate vidually. However, the long-term cost of cost of the welding and material handling running a laser system actually compares Change of Address? equipment. very favorably with traditional operating Traditional spot welding capitol cost of costs. Moving? approximately $1,000,000 of equipment consisting of Summary and Make sure delivery of your Welding 3 spot welding robots with welding Considerations Journal is not interrupted. Contact the accessories Membership Department with your 1 material handling robot with 7th axis The concept of C02 laser-based re new address information — (800) 443- and tooling mote welding of sheet metal came about 9353, ext. 217; [email protected]. 2 pedestal welding machines in the mid-1990s. The first production sys 2 turntables tems were installed in Europe; the first WELDING JOURNAL . and bustle within during this year's A WS Welding Show. BY ANDREW CULLISON, MARY RUTH JOHNSEN, AND HOWARD M. WOODWARD ig D received an A+ from everyone showgoers checking out the latest welding large crowd assembled for the AWS An in attendance at this year's AWS products, and exhibitors seeking to reach nual Business Meeting, when he said, "I BConvention and Welding Show at the South's welding fabricators. want to emphasize AWS is not restricted the Dallas Convention Center. This year's to a domestic presence. We are a global event had it all: Eager welding students Kotecki Addresses AWS Annual organization." He noted that many of our trying to win a spot to compete in their Business Meeting members find jobs and live internation trade's Olympics, top-notch welders and ally, and of the AWS Sustaining Corpo young engineers looking to better their President-elect Damian J. Kotecki of rate members, 121 are international. The employment positions, welding re Lincoln Electric Co. set the tone for his Certified Welding Inspector program has searchers presenting their latest findings. upcoming presidency when addressing the 3500 international individuals, and "I'm AUGUST 2005 A WS says good-bye in vl1[iMK$Wt WimV^Lift k mmt ICiffi^ r§) i J of stand-alone welding shows The Show floor was and busy place for three days April. glad we are taking this program to the world. "During my term I want to emphasize - global cooperation," he continued. He ; stated how the AWS is already active in the International Institute of Welding (IIW) and in standards development with ISO. He recalled how 22 years ago when he began his involvement with interna tional standards, there was no inclusion of AWS standards in the international "4gu arena. Now there are 17 ISO published standards that include AWS, and he will I ! Xy •• • ' r be actively supporting more. Realizing a balanced approach is best, he reminded the audience, "I will not neg lect the domestic side. To grow strong in ternationally, AWS must grow strong at home." He noted the recent move of the Resistance Welding Manufacturers Asso ciation to come under the umbrella of the AWS brought along 16 international com panies. He also spoke of the AWS's new alliance with the Fabricators and Manu facturers Association (FMA) and the So Fig. 1 — Damian J. Kotecki (left), AWS president-elect, and NASCAR driver Casey Mears ciety of Mechanical Engineers (SME) to plan their show-opening entrance strategy. produce a single trade show. The new FABTECH International and AWS Weld ing Show premiering this coming Novem ber will showcase exhibitors in all areas of cussion of the evaluation of hot crack sus augmented strain. A crack is more likely metalforming, cutting, and welding, mak ceptibility with the Varestraint tests. He to occur with an increasing concentration ing it a great attraction for both a domes then went on to cover other indexes for of strain at the grain boundary. tic and international audience. hot cracking susceptibility such as critical • Evaluation of critical straining rate strain rate to time required to cause crack would be better for assessing hot crack ing, critical strain rate to temperature susceptibility of the welded joint; how The Adams Lecture drop required to cause cracking, brittle ever, evaluation of high straining rate is In his introductory comments for this ness temperature range, and solidification valuable in comparing crack susceptibil year's Comfort A. Adams Lecture, titled ductility curves. ity of materials. "Hot Cracking: Approaches to the Mech Matsuda's research over the years has • Harmful elements that expand the anism," Fukuhisa Matsuda noted he first led him to the following conclusions: brittleness temperature range can be es began studying hot cracking in 1965 under • Cracks usually initiate near the nom timated by a simple modeling. Professor Warren F. Savage at Rensselaer inal solidus temperature of material in which the residual liquid between grain Polytechnic Institute. Matsuda, emeritus The 2005 Welding Show professor, Osaka University, Osaka, boundaries shows a film-like stage. Japan, began the lecture at the same place • Hot crack susceptibility is consider The Dallas Exhibition got off to a roar his research did 40 years ago, with a dis- ably influenced by the strain rate of the ing start when Casey Mears, one of the WELDING JOURNAL Fig. 3 —A real welding gun is manipulated as a simulated welding condition is viewed through a head-mounted device. Grinder Designed to Reduce Fatigue. For those who use grinders on the job for a length of time know physical hand fa tigue can be a problem. To address that concern, Bosch has designed its 1700 and 1800 series angle grinders with a side- assist handle that reduces vibration by up Fig. 2 — The excitement built for this year's Show opening as Mears revved the engine and to 60% of what was previously typical — Kotecki readied himself for the ride of his life. Fig. 4. The units have vibration-absorbing rings built into the handle that dampen vi young stars of the NASCAR Nextel Se the-best welding-related products dis bration between the trigger handle and ries, drove President-elect Damian played by knowledgeable vendors is ex the motor housing. The 1700 units accom Kotecki down the Show aisles in Mears's pected at every AWS Welding Show. This modate 4'A, 5-, and 6-in. discs, while the Target Chip Ganassi Racing Team 41 car year was no exception. Descriptions of a larger 1800 series are available in 7- and — Fig. 1. Kotecki's employer, The Lin few of the more innovative, unusual, or 9-in. sizes. The units have tool-free disk coln Electric Co., is another of Mears's just plain interesting products follow. changing capability. Robert Bosch Tool sponsors. At a press briefing prior to the Corporation, Mount Prospect, III.; (877) Show opening, the 27-year-old driver 267-2499; www.boschtools.com. spoke about the importance of welding in Product Highlights his sport. Virtual Training Makes a Debut. A vir "Welding is a big part of our program. tual reality welder training system was un Ganassi Racing has a 78,000-sq-ft shop. A veiled at the Show — Fig. 3. Developed huge part of that is the fab shop. Welding by SGI (Silicon Graphics, Inc.) and is going on all the time," Mears related. VRSim, the technology is intended to ex "Eighty percent of our sport is mental, pand the training capabilities of an in but we must be in good physical shape," structor, while making the whole teach he said. "The best way to stay in shape is ing process more efficient. A real welding to do your job." Nothing prepares a per gun is used, but through a head-mounted son for the amount of heat inside the car, viewer, the student sees a 3-D computer Mears stated. "You're sitting right next to image that simulates a welding process the transmission and your feet are right and position. The student can feel pres Fig. 4 — Bosch angle grinders have a side- by the header and engine. The tempera sure and resistance as he moves the weld assist handle designed to reduce vibration. ture inside may be 140 degrees," he ex ing gun according to the welding condi plained. "They do things to insulate and tions being viewed. The student's manip to circulate the air, but it's very hot." ulation ofthe welding gun and the result It's also a tight fit. There's not much ing simulated weld are displayed on a Orbital Welding and Saddle Rings room for the driver inside, let alone a pas computer monitor. This enables multiple Combined. Two long-established compa senger, which explains why Kotecki could students to view the welding process, and nies in the welding industry, Mathey Dear- not get his lanky frame inside the vehicle, allows the instructor to make suggestions man and Arc Machines, Inc. (AMI), have but instead had to perch on the door — and evaluate the welding in real-time. collaborated to come up with a natural com Fig. 2. Data for the simulations were generated bination of their products. Arc Machines's from actual welding tests, and the devel The Dallas event ended the 53-year gas tungsten arc orbital welding unit can opment of the system was funded by the tradition of AWS stand-alone welding now be mounted on Mathey Dearman's Navy. The system is just being launched. shows on a high note. All future shows will pipe cutting saddle rings — Fig. 5. A single The developers look forward to eventu be held with FABTECH International in AMI front-end assembly will fit any three ally offering it commercially to educa the fall of each year, beginning with the different saddle rings for pipe diameters tional facilities. The return on investment November 13-16, 2005, show in Chicago. from 3 to 20 in. It works with all AMI power is projected to come from savings in ma This year, with total exhibitor space supplies and can be combined with saddle terial, equipment, and consumables, while rings already in the field. Arc Machines, Inc., surpassing 90,000 sq ft, the more than 5600 allowing more practice time for students. attendees had a lot to see and do while Pacoima, Calif, (818) 896-9556, www.arc- SGI, Mountain View, Calif; (650) 933- machines.com; Mathey Dearman, Inc., walking the blue-carpeted aisles of the 7777; www.sgi.com. Dallas Convention Center. The best-of- Tulsa, Okla., www.mathey.com. AUGUST 2005 Multiprocess Capabilities and Quick steel. The cut is smooth, requiring little, Change. A new 350-A power source of if any, additional machining to remove fers shielded metal arc (SMA), gas tung burrs or loose metal. The cut is performed sten arc (GTA). gas metal arc, and flux dry, and no liquid coolants are recom cored arc (FCA) welding, as well as puls mended. The three models range in ing capabilities with the gas metal arc weight from 14 to 19 lb, and from 12 to 15 process. The Power MIG 350MP (Fig. 7) A. HITECH USA, Davenport, Iowa, (563) is designed to handle the jobs of small-to 386-3866; www.evolutionpowertools.com. medium-size shops. With its multiprocess Durable Apparel for the Workplace. capabilities, the unit can be used to weld Stanco has every type of protective ap steel, aluminum, and stainless steel. Wave parel a welder will need for any job — Fig. Fig. 5 — Orbital welding assembly mounts forms for new or updated applications can 9. The 100% cotton garments are flame on pipe saddle rings. be downloaded into the machine. Noting resistant, and the leathers are selected the increase in aluminum welding appli from quality cattlehide with no imperfec cations that is taking hold with some fab tions such as brand marks or thin spots. Robotic Short-Circuiting Transfer Im ricators, this machine is equipped with a Color is uniform. Welders' gloves come in proved. Just when you thought robotic ready connect for a push-pull spool gun a variety of designs and leather grades, control couldn't get any faster, it does. and a second gas solenoid for its opera and all are sewn with Kevlar thread for Data processing for the controller, power tion. The unit also features a 115-V AC strong stitching. Gloves for gas tungsten supply, wire feeder, and robot is done auxiliary outlet, something unique for this arc welding are made of soft grain leather from a single CPU board with the new class of machine. The machine housing for flexibility. For special needs, the com TAWERS robot — Fig. 6. The high-speed has a built-in lockable storage compart pany will custom design the glove or gar communication that occurs within the sys ment with a tool tray. Lincoln Electric ment to your specifications. Stanco, At tem allows SP-MAG, a short-circuiting Mfg., Cleveland, Ohio. (888) 355-3213; lanta, Tex., (800) 348-1148; www.stan- transfer process, to operate with minimal www.lincolnelectric.com. comfg. com. spatter. The welding system has a second ary switching circuit and a 100-kHz power supply with a 10-microsecond control cycle. A 64-bit brain provides control of the arc waveform. The mini-explosion that occurs at the arc, which is responsible for much of the spatter typically associated with standard short-circuiting transfer, is minimized by the speed of the arc control with the SP-MAG system, thereby reduc ing spatter and improving transfer effi ciency. This is the first introduction ofthe system in the United States. Panasonic Factory Solutions Company of America, Elgin, III, www.panasonicfa.com. Fig. 7 — The 350MP is a versatile welding machine geared to the multitask needs of Fig. 9—A 1955 Chevrolet Bel Air convert small to medium job shops. ible was used to emphasize the theme "qual ity never goes out of style" for Stanco's line of protective welding apparel. Circular Saw Makes a Cool Cut. A unique metal chip collecting cover built in the Evolution circular saw removes the 'Zip Beveler' Is a Must for Field Pipe hot chips, leaving the cut metal cool to the Operations. Inventor Joe Gormany intro touch — Fig. 8. Fine dust particles are also duced his portable torch guiding assem collected. Three different models offer bly (Fig. 10) for use in tight spots in the cutting capabilities from 'A- to /:-in. mild field where regular pipe-beveling ma steel. Sheet metal, stainless steel, and alu chines won't fit. The smooth-moving minum also can be cut. Typically, a car torch-holding trolley is built into an eas bide blade has a 100-yd life on %-in. mild ily assembled hinged ring clamp that quickly locks onto 6-, 8-, 10-, and 12-in.- diameter pipes. Adjustment screws can easily convert the assembly to process 5-, 6/4-, 6-%-, and 7-in.-diameter pipes. After clamping the trolley around the pipe and installing the torch, the assembly holds the torch rigidly at the ideal 37!4-deg cutting angle and maintains the torch distance from the pipe. The welder is required to simply control the speed of the torch around the circumference of the pipe. Fig. 6 — High-speed communication be Once the job is done, the Zip Beveler can tween the controller and TA WERS robot Fig. 8 — Heat buildup is minimal when cut be quickly disassembled and stored, ready allows short-circuiting transfer with mini ting metal with the Evolution circular saw. for the next job. The assemblies are eas mal spatter. ily adjusted for centering and to accom- WELDING JOURNAL modate out-of-round and other pipe anomalies. The list price ofthe complete Jesse James Unveils Product Line assembly is $4600. Zip Beveling, Kingman, Ariz.; (928) 753-9586; FAX (928) 757- 1919. The Jesse James Signature Series of welding equipment manufactured by ESAB Welding and Cutting Products was introduced by James personally at the Show. James has attained fame from Discovery Channel's Monster Garage TV series and the cus tom-designed motorcycles from his company West Coast Choppers. His popularity was reflected in the large crowd attracted to the introduction. The Signature Series is painted an attractive gray and red with distinctive trim and the West Coast Choppers logo. James took a personal involvement in its design, and ESAB equipment is now used exclusively in his shop. The initial launch includes three products: Jesse James Multimaster 260, a multiprocess inverter for SMA, GMA, and GTA welding; Jesse James PowerCut 650, a plasma arc machine for manual cutting of up to %-in. metal; and Jesse James Purox® MetalMaster, an oxyfuel general-purpose welding and cut ting outfit. The unique series is available through distributors nationwide. Fig. 10 — The Zip Beveler can fit into tight spaces. Welding Current Triggers Helmet Visor to Darken. Sellstrom introduced its new ImpulseEMF'" line of welding helmets fea turing patented variable optomagnctic sen - .* & sors — Fig. 11. The technology darkens the visor when a detector built into the helmet senses current flow through the workpiece. Superior to optical sensors, it prevents pre mature switching-off and flickering when the arc is temporarily obscured. The con trols (inset) for adjusting the filter's switch ing sensitivity and density (between 9 and KZMra 13), are located on the outside of the hel met. The helmets, currently available in black or stratto blue, meet ANSI Z87.1- 2003 requirements, and are covered by a written three-year warranty. Sellstrom Man ufacturing Co., Palatine, III, (800) 323-7402; www.sellstrom.com. one of his We background. Explosive Welding Does the 'Impossi retain their original metallurgical charac ble' Cold-Joining Jobs. PA&E (formerly teristics. Examples of the process include Pacific Aerospace and Electronics, Inc.) bonding various combinations of alu displayed numerous examples of its so minum, stainless steel, steels, titanium, phisticated solid-state explosively welded and copper to make complex assemblies. stack (EWS) welding process that uses Vice President David Cutter said, "Brit controlled explosive energy to join two or tle materials, such as cast iron, require the more otherwise incompatible and exotic addition of a transition metal to enhance materials at the molecular level — Fig. 12. the bonding." In practice, the two metals The weld is a permanent metallurgical to be joined are separated by spacers to bond that displays superior strength and create an impact zone. A layer of explo virtually no heat-affected zone. Useful for sive material is placed on top of the as joining not only very large parts, it is rou sembly, then detonated from one end. The tinely used for very small heat-sensitive Fig. 11 — 77;e ImpulseEMF line of weld impact of the traveling explosion causes electronic parts. The cold explosion ing helmets darkens when a built-in detec the first few molecular layers of both sur welded process permits the parts to re tor senses current flow through the faces to become plasma and effectively main near ambient temperature and thus workpiece. scrubs both surfaces before the parts come AUGUST 2005 together and the welding occurs. PA&E, Wenatchee, Wash; (509) 667-5217; FAX The U.S. Open Trials Tested the Best (509) 664-6868; www.pacaero.com. of the Best Welders at the Show Six top-level young welders from the United States competed against each other for three days on the AWS Welding Show floor to earn the coveted honor to repre sent the United States at the WorldSkills Competition held in Helsinki, Finland. The six U.S. contestants were Joel Stanley II (coach David Hartley), Lincoln, Maine Shawn Powers (coach Bill Figg), Ypsilanti, Mich. David Wagner (coach Jeff Pelster), Garland, Neb. John Sayre (coach Jamey Valega), Pawnee, Okla. Chase Walker (coach Mike Tryon), Ogden, Utah Chance Polio (coach Russel Pontasolo), Douglas, Wyo. Working alongside the United States welders, mainly for the experience, were Je remy Gransden (Australia), Curtis Ritchie (Canada), Matthew Brereton (Ireland), Ivo Vink (the Netherlands), Aksorn Prong-A-Kas (Thailand), and Gareth Rees (U.K.), each of whom was bound for Helsinki. Coordinating the event was Edward R. Bohnart, Welding Education and Consulting. Emerging victorious after the rigorous event was Joel Stanley II, 22, a full-time welder at Fastco Corp. in Lincoln, Maine. His achievement earned him the Miller Fig. 12 — The cold explosion welded Electric Mfg. Co.'s $40,000 scholarship award. process can be used to weld dissimilar At the WorldSkills welding competition in Helsinki, Stanley went up against 24 metals. competitors, including the six non-U.S. welders who participated in the Dallas U.S. Open. Stanley took fifth place after Korea, Australia, Thailand, and Chinese Taipei. Helmet Supplies Temperature- controlled Breathing Air. Featured at the Show was the Fresh-Air II supplied-air system — Fig. 13. Demonstrated with the 3M'M Speedglas'" helmet, the combina tion incorporates a NIOSH-approved supplied-air system to provide respiratory protection from airborne particulates and gases. In addition, lightweight belt- mounted valves permit the welder to raise or lower the temperature of the air enter ing the headpiece by +45°F (25°C) to reg ulate comfort in very cold or hot environ ments. 3M'\ St. Paul, Minn; (800) 243- etitors get briefed 4630; www.3M.com/Occsafety. lay's work. •llrUC^AR Joel Stanley II shows his winning smile after taking first place at the U.S. Open Welding Competition. Everything You Need for GMAW in alone weighs 45 lb; with an 8-in. spool of One Package. The new Millermatic® wire and the shielding gas cylinder, the Passport™ features an inverter-based gas weight increases to 56 lb. The machine metal arc welding power source, wire features the company's multivoltage plug, feeder, self-contained shielding gas sys which allows the unit to connect to 115- tem, and gun in one lightweight unit — or 230-V power with a tool-less switch of Fig. 14. The unit includes a 12-oz cylinder the plugs, as well as its Auto-Line™ power of liquid C02 that provides 25 min of management technology. A flip of a tog welding time. The company built the ma gle switch allows the user to switch from chine with maximum portability in mind the gas cylinder to a shop supply. When and, for that reason, believes it will be es operating on 230-V primary, the unit has Fig. 13 — The Fresh-Air II supplied-air sys pecially useful for maintenance and re an output current range of 30 to 180 A; at tem provides respiratory protection for air pair applications. The gas cylinder is based 115 V. the unit has a 30- to 140-A output borne particulates and gases. on a paintball gun design, and it features current range. Suggested retail price for an impact-resistant plastic case. The unit the system is $1690. Miller Electric Mfg. WELDING JOURNAL Co., Appleton, Wis., (800) 426-4553; FAX (877) 327-8132; www.millerwelds.com. Interview with a Legend R. David Thomas, Jr., a world-recog nized expert on welding consumables, met rication, and international standards, took time to share some of his wisdom and an swer questions at the 2005 Welding Show. Interviewed by Robert Messier, an associ ate professor at Rensselaer Polytechnic In stitute, Troy, N.Y., Thomas reminisced how fortunate he was to have two wonderful parents to guide him through life. In fact, it was his father who inspired him to seek a career in welding. R. David Thomas, Sr., was a charter member of the American Welding Society in 1919 when it was incor Fig. 14 — The Millermatic Passport comes porated, and he started his own company complete with everything needed for gas manufacturing welding electrodes. metal arc welding. "When I was in college my father sent me some metallurgical samples of welds and my professor was absolutely fascinated New Clamps Stay Snug during Vibra and solidification pattern," Thomas said. "I was fascinated by it too, tion Stress. The company introduced its and I decided to do research in welding." He finished his graduate work at Cornell, patented new-generation of Toggle-Lock and his Master thesis was "Chemical Reactions in Arc Welding." During his college Plus™ manual clamps at the Show — Fig. years, his summer job was working with his dad making welding electrodes, and when 15. The clamps help to maintain the over- he graduated he became a technical director in his father's business in 1937. center toggle position in applications When WWII came along, the company was hard pressed to meet the demand for where there is apt to be movement or vi welding electrodes to fabricate war materials. "We were so busy trying to solve prob brations such as transfer lines. Addition lems quickly to get war material out," he remembered. "We also had to learn how to ally, the clamps provide higher levels of produce the electrodes economically." He told how they had to learn all about air- reliability when moving from one work lo conditioning to help speed the electrode drying. "We used all sorts of science to ex cation to the next. Mechanically, the line pand production as fast as we could because of the war requirements," he noted. When features the elimination of pinch points asked whether he thought electrode formulation was more art than science, Thomas for user safety, bushings at major pivot replied, "It is a trial-and-error method, but there certainly is an awful lot of science in points for longer service life, and extended it. Today they have so many new tools to organize data and come up with trends that handle length for improved ergonomics. point to solutions. I remember some years ago talking to a formulist who said it took DE-STA-CO, Madison Heights, Mich.; (248) 397-6700; FAX (248) 397-6733; www.destaco.com. ries, which is a black helmet featuring the Harley-Davidson bar and shield and sig nature logos. The Signature Series comes in a shade 10 passive 4 x 5'A-in. wide view filter, a shade 10 solar-powered autodark ening filter, and a shade 10 passive 2 x 4A* flip-up filter. The top-of-the-line auto darkening helmets retail for $330. The au todarkening models can be adjusted to three different positions to vary the dis tance between the eyes and the filter, a heat-reflecting core that reflects the heat to keep the welder cooler, a sleep mode, and they darken within 0.2 milliseconds once the arc is struck. Bacou-Dalloz, Fig. 16— Three welding helmet designs and Smithfield, R.I.; (401) 233-0333; FAX: (401) 232-2230; www.bacou-dalIoz.com. five safety glass designs are available in the stylish Harley-Davidson line. Abrasive Cleaning Wipes Remove Con taminants Prior to Welding. EZ Wipes are multipurpose, saturated cleaning wipes that Davidson logo welding helmets (Fig. 16) remove oil, grease, marker, paint, grime, and safety glasses. The company is mar and other contaminants from a variety of Fig. 15— These Toggle-Lock Plus manual keting the Harley Davidson products only surfaces. The wipes feature a two-sided fab clamps stay put in applications where there in the United States and Canada. Five ric. The abrasive side provides tough clean is movement or vibrations. styles of safety glasses are available. The ing action for hard-to-remove surface par H-D® Premium Style Series of helmets ticles: the smooth side can be used to rewipe Motorcycle Craze Adds Style to Weld includes the Flames and Racing designs, the surface. Both sides are saturated with a ing Helmets, Safety Glasses. Bacou- which are shade 9-13 solar-powered au proprietary blend cleaner made by Dupont. Dalloz has introduced a line of Harley todarkening filters, and the Signature Se- A welder can use the wipes to clean pipes AUGUST 2005 ily. Designed for heavy fabrication, the from 100 lo 200 experiments to come up with anything usable for the market. I would 100-A system cuts a wide range of metals imagine that with the computer technology of today, the number has improved." from gauge to \[A'm. thick. It is an inverter- Thomas worked 43 years in electrode formulation and manufacturing and in 1956 based system using either single- or three- he became president of Arcos, Corp., holding that position until 1980. During his phase input. Other features include its welding career, which even though hc is 90 years old is still ongoing, he served as AWS ATC ™ quick disconnect for fast process president in 1960-61, authored numerous technical papers; actively served on the changes. The arc remains constant even AWS Filler Metals and Metric Practices Committees; was prominent in IIW activi on expanded metal or grating, and is able ties; was the recipient of the Samuel Wylie Miller Memorial Medal, the George L. to cut directly through paint and rust. Willis Award, and the IIW Edstrom Medal; and became a strong proponent of metri Thermal Dynamics®, a division of Ther cation of AWS filler metal specifications and the harmonization of international and madyne®, St. Louis, Mo.; (800) 752-7621; U.S. domestic standards. In 1991, he was selected for the inaugural class of AWS Fel FAX (800) 221-4401; www.thermadyne. lows, and in 1999 he became an Honorary Fellow of The Welding Institute ofthe U.K. com/thermaldynamics. Following in his father's footsteps, Thomas has long been a strong proponent of standardization and his activities in this arena have earned him respect both domesti cally and internationally. In honor of the efforts of both Sr. and Jr. in promoting stan dardization, a recognized champion of standardization is chosen annually to present the IIW Thomas Medal Lecture. "Henry Ford never could have done what hc did without standardizing the various parts that went into his automobile," said Thomas. "It is very important to mass pro duction, and the same applies to the area of welding." In filler metals, he noted, "We have to be able to take a number of products from a variety of producers and estab lish a set of tests for those products to meet minimum standards. That ensures manu facturers are competing on the same level." Another passion of Thomas is metrication. "Using metrics as our primary unit is how we are going to compete worldwide," he said. "If we don't use the same system that is being used all over the world, we are going to fall behind," he warned. "The scientific community uses metrics, and manufacturers must decide whether to use metrics in production," he continued. "They must teach their customers to get used to metrics to be able to compete with the rest of the world." Thomas noted that one of his most memorable experiences was when he and a Fig. 18— 77;e Cutmaster 151 air plasma group of welding experts visited Russia in 1961. They were introduced for the first arc cutting and gouging system handles time to electroslag welding. "I was fascinated by the process," he said. "With my back heavy fabrication jobs. ground in chemistry, I was fascinated by what was going on with this process." Looking to the future, Thomas would like to see research done in subatomic par ticles and how they react with the known forces of physics. He speculated, "That All-Silver Electrodes Provide Faster knowledge could be used to make new alloys for critical applications." Plasma Arc Cutting Speeds. Thermacut used a ClVAb pure silver ingot to attract at tention to its new ExtraFire line of consum ables. The first ofthe line are SilverEX elec trodes for mechanized plasma arc cutting 70 wipes for use in the shop and retails for — Fig. 19. The electrodes are based on two $30. Aquasol Corp., Amherst, N.Y; properties of silver: that it conducts elec (716) 564-8888; FAX (716) 564-8889; tricity better than copper and that it trans www.aquasolcorporation.com. fers heat better as well. The end result is Flame-Retardant Protective Apparel more power being delivered to the cut and Offered in Navy Blue. For those who a cooler running torch that helps make the would like a color choice, Weldas intro electrodes last longer, especially when cut duced the Yellowjacket® Cool FR line of ting materials K to 2 in. thick, according to flame-retardant protective clothing, the company. Thermacut, Inc., Claremont, which comes in navy blue rather than the N.H; (603) 542-6715; FAX (603) 542-2867; traditional green — Fig. 17. Some people www.thermacut.com. prefer the blue color because it looks more like casual wear. The line of 100% cotton clothing includes coveralls, cape sleeves with bibs, bib aprons, overalls, pants, jack ets, and sleeves. There is also a leather r^arut sleeve jacket. All conform to ASTM D6413-99 flame retardant and washabil- ity test methods. They feature high-qual ity sewing, including hemmed colors for Fig. 17 — The navy-blue-colored Cool FR shape retention and flaps to keep sparks garments feature hemmed colors for in WELDING JOURNAL Make Laser Assist Gas Delivery Flexible How to hold a competitive edge in your laser cutting operations \ ' SIsSS .', MM' • SKflg '•-.' LB'3 ' '••'•• MSS BY RICHARD GREEN Today's ever-changing world Know the Cost Factors mandates that laser job shops process a wider range of materials Oxygen Assist Gas Mode Table 2 illustrates a comparison to maintain market differentiation. of the customer's supply mode cost Keeping sight of cost competitive options. A growth strategy is imper ness, fabricators working with these ative to minimize the total oxygen materials are requiring that assist assist gas acquisition cost per lin gas delivery systems provide ad ear foot cut. Factors such as down vanced levels of flexibility. time, fill loss, vent loss, residual re Following is an evaluation of the turn loss, rental rate, delivery various assist gas supply modes for i charge, facility fee, and asset flexi cutting galvanized steel, mild steel, bility all factor into such a growth titanium, aluminum, and stainless strategy comparison. materials. Liquid Can In reviewing the oxygen assist Table 1 illustrates the pressure 350 psi options, the distributor must con and flow requirements for the vari sider the disadvantages of handling, ous materials mentioned at 16- price, residual return loss, availabil gauge, 'A in. and Vt in. thickness. Gas Pressure (Psi) ity, and footprint requirements of Greater thicknesses are achievable high-pressure cradles. Granted, with today's higher wattage res high-pressure cylinders do not vent onators; however, 16 gauge to Vt in. Fig. 1 — Oxygen assist gas growth mode schematic details during prolonged inactivity. The represents an adequate cross section supply options at various monthly consumptions. cost per linear foot of M-in. mild that sheds light on assist gas deliv steel at 160 in./min. however, is 37% ery challenges. At first glance, you more than that of cryogenic options. will note that oxygen and nitrogen offer cylinders, liquid cylinders, manifold liq In evaluating the cryogenic options, the greatest material flexibility. However, uid cylinders, and microbulk are all capa th distributor should consider the air should be considered a viable alterna ble of supplying the required pressure to $185,000 capital investment and mainte tive for gauge material and those applica the back ofthe laser (i.e., supply pressure) nance costs of the microbulk delivery tions not requiring an oxide-free surface. for monthly consumptions less than truck. This would add approximately $0.21 40,000 cubic'feet (ft3). per hundred cubic feet in oxygen gas cost Calculating Your Needs Take special note of the distinction be to the job shop and reduce the distribu tween nozzle and supply parameters. De tor's profit margin. The 500-gallon low- Using Table 1 to obtain the peak pres pending on the laser manufacturer, the pressure bulk tank can be filled with a con sure and flow requirement for the maxi oxygen supply pressure can range from ventional truck-mounted horizontal grav mum material thickness, the operator 120-290 lb/in.2 (psi). This may eliminate ity fill tank with an initial investment of should then determine the frequency and a low-pressure bulk tank and 230 lb/in.2 $80,000, which adds $.09 per hundred cubic feet in oxygen gas cost. While the duration of each job. Pressure is a more liquid cylinders as viable supply options. microbulk delivery system offers minimal critical factor for oxygen supply because However, nozzle pressure that is less than fill and vaporization losses, the standard the actual flow requirements arc typically the supply requirement is fairly consistent gravity feed tank system has inefficiencies less than 200 cubic feet per hour (ft3/h, for a given nozzle size regardless of the as high as 21% during the fill process. cfh). Figure 1 shows that high-pressure manufacturer. RICHARD GREEN is Product Manager for CONCOA, Virginia Beach, Va., (800) 225-0473, [email protected], www. co n co a. co m. AUGUST 2005 Table 1 — Material Peak Pressure and Flow Requirements at the Laser Nozzle 18 Gauge 'Aia. Kin. 18 Gauge 18 Gauge 18 Gauge Argon A in. !*in. Argon 'A in. 'A in. 'Am. Argon Air Assist O-, Assist N-> Assist Assist Air Av Oi Assist N2 Assist Assist Air Assist OT Assist N2 Assist Assist (psi/cfh) (psi/cfh) (psi/cfh) (psi/cfh) (psi cfh i i p-i cfh) (psi/cfh) (psi/cfh) (psi/cfh) (psi/cfh) (psi/cfh) (psi/cfh) Aluminum 104/424 N/A 149/437 N/A 178/727 N/A 149/598 N/A 208/848 N/A 178/1430 N/A Galvanized Steel N/A 74/303 149/606 N/A N/A 29.8 150 193/973 N/A N/A N/A 240/1210 N/A Mild Steel 75/498 59.6/74.9 180/443 N/A N '-. -.9 60 210/762 N/A N/A 8.9/67 280/1860 N/A Stainless 75/498 89.4/252 208/593 N/A N/A 89.4/449 208/787 N/A N/A 149/748 240/1594 N/A Titanium N/A N/A N/A 119/336 N \ N A N/A 193/973 N/A N/A N/A 223/1754 Nitrogen Assist Gas Mode 500 psi Liquid | Can 640 Series : ..—— — - Gas Pressure (Psil F/g. 2 — Gas switchover device allows flexible use of high-pres Fig. 3 — Nitrogen assist gas growth model details supply options sure and liquid cylinders while reducing vent and return losses. at various monthly consumptions. Determine the Best Option lb/in.2 liquid cylinders. This regulator seat trogen jobs become less frequent, high- design enhances the switchover response pressure cylinder cradles (HP-12 Packs) are a viable alternative for monthly con Depending on demographics and ge by eliminating static and decaying inlet 3 ography, the distributor's existing inven pressure effects. As illustrated in Table 2, sumptions less than 15,000 ft /h. High- tory of 350 lb/in.2 liquid cylinders may pro intelligent switchover-controlled liquid pressure cradles do not require an exter vide the best cost position for both the dis cylinders provide a low gas cost per linear nal vaporizer to obtain the high-flow rates tributor and the job shop. However, to be foot without large capital investment. for a sustained period. successful, the distributor must address the In reviewing Table 1, you will notice However, regardless of the cylinder vent and residual return losses associated that cutting with nitrogen adds peak flow bundle size or fill pressure, the residual with DOT-rated liquid cylinders. Pressure to high pressure as the critical elements return loss can be as high as 15-20%. differential switchover technology does High-pressure (500 lb/in.2) liquid cylin 2 in an assist gas delivery system. Figure 3 not meet the 120-290 lb/in. supply pres illustrates the various nitrogen supply ders offer similar storage capacity with sure range required by today's lasers. modes based on peak pressure and minimal footprint requirements but lim ited gas vaporization capacity (350 ft3/h). Secondly, the technology does not ad monthly consumption. For example, M-in. 2 dress the 230, 350, and 500 lb/in.2 liquid stainless requires 208 lb/in.2 and 1650 ft3 Manifolding multiple 500 lb/in. liquid cylinders pressure building and economizer at the nozzle. Just as with oxygen, there is cylinders via the gas use valve does not dynamics adequately to reduce these losses. a significant difference between the noz provide the vaporization capacity to meet Recent switchover developments have zle and the minimum supply pressure re the supply requirements for an extended demonstrated a technology shift. quirement. Depending on the manufac period of time. The switchover device shown in Fig. 2 turer, the minimum supply pressure can utilizes intelligent controls to analyze the range between 250 and 435 lb/in.2 at flow Configure for Cost Effectiveness output of highly accurate pressure trans rates in excess of 4000 ft3/h. Job frequency ducers to assign cylinder bank priority in and duration become extremely impor The intelligent switchover illustrated a logical manner, reducing vent and resid tant factors when sizing the appropriate in Fig. 2 is a cost-effective option for ual losses. Coupled with balanced stem- nitrogen assist gas system. monthly nitrogen consumptions less than seat technology, the switchover provides For the job shop, growth strategy plan 35,000 ft3 and maximum sustained flow the job shop and the gas distributor with rates less than 2500 ft3/h. The switchover 2 ning with the gas distributor is a must to the flexibility to use either 3000 lb/in. keep the nitrogen assist gas cost-compet enables the job shop to configure the as high-pressure cradles, or 230, 350, or 500 itive. Asset flexibility is a must. When ni sist gas system as a high-pressure cylinder WELDING JOURNAL Table 2 — Cost Comparison per Linear Foot for Oxygen Assist Gas Mode vessels can be used (27-40 bar; 400-600 lb/in.2), but normally are higher in cost, High- Manifolded Micro Bulk Bulk Tank limited in availability, and costly to refill Pressure Liquid 1000L 525 gal. because of downtime and fill losses. Cradle Cylnders Downtime occurs because most deliv ery trucks are not capable of overcoming Linear feet per month (ft/mth) 93755 96000 96000 95717 Cylinder inventory (units) 3 2 1 1 the bulk tank pressure that requires the Cylinder change/Fill time (hr) 0.25 0 0 0.5 tank head pressure to be vented at sub Mode storage capacity (cf) 3.960 5.048 311.(1- 56,465 stantial product loss. Forty-five minutes Mode NER (%) 0 1.2 0.62 0.55 to one hour of production time may be Monthly Consumption (cf) 40.000 40,000 40,000 40.000 lost while the high-pressure bulk tank re Residual Return Loss (%) 10 4 0 0 covers to working pressure. Gas cost ($/ccf) $2.20 $1.60 $1.25 $1.15 There are, however, more cost-effec Gas cost per month ($/mth) $880.00 $640.00 $500.00 $460.00 tive modes utilizing a standard pressure Cylinder rental cost ($/mth) $216.00 $90.00 $225.00 $250.00 2 Facility Fee ($/mth) $9.67 $74.00 $96.66 $96.66 (250 lb/in. ) bulk tank in series with an ex Delivery Charge ($/mth) $48.00 $48.00 $60.00 $40.00 ternal cryogenic pressure building system Vaporization Loss ($/mth) $0.00 $15.51 $18.64 $28.57 that eliminate this downtime. These sys Fill Loss ($/mth) $0.00 $0.00 $2.26 $39.76 tems allow the standard pressure bulk Residual Return Loss ($/mth) $88.00 $25.60 $0.00 $0.00 tank to operate at a low head pressure to Total Cost per month ($/mth) $1241.67 $893.10 $902.56 $915.00 minimize vent loss while being filled. Cost per Linear Foot ($/lft) $0.0132 $0.00093 $0.0094 $0.0096 Two Systems of Delivery The external cryogenic pressure build supply, liquid cylinder liquid phase to a supply is an excellent choice for nitrogen ing mode is available in two formats. One vaporizer supply or a combination of both. monthly consumptions between 35,000 system incorporates an external mechani From an asset management standpoint, it and 100,000 ft3/h. cal cryogenic pump capable of boosting liquid nitrogen pressures in excess of 4500 is important to remember that the distrib Monthly consumption greater than 2 utor must have an equal number of 500 100,000 ft3/h requires a large on-site stor lb/in. before vaporization. lb/in.2 liquid cylinders in inventory to sup age vessel capable of meeting the nitro This format requires an ASME-rated port the job shop. If available, microbulk gen supply requirements. Higher-pressure surge vessel downstream of the vaporizer to serve as a holding tank. The mechani cal system provides excellent pressure and flow performance for those applications requiring supply pressure between 450 and 500 lb/in.2. The cryogenic pump must be sized appropriately to minimize cycling and maintenance. The second format utilizes a PLC de vice that automatically controls the fill ing and switching sequence between two skid-mounted 500 lb/in.2 liquid vessels from a standard bulk tank. The second cryogenic pressure building format offers Stainless, Nickel, excellent performance below 450 lb/in.2. A cost analysis similar to Table 2 should be performed to evaluate which nitrogen Aluminum, and delivery mode offers performance and Low Alloy welding competitiveness. Consumables An Intelligent Strategy When developing the assist gas growth strategy, material thickness, frequency • Consistent High and supply mode must be in agreement. For the ebb and flow nature of job shop Quality Products work, the intelligent gas switchover pro vides the flexibility to use existing liquid • Technical Sunaort or high-pressure cylinder assets at a com petitive cost. Beyond the 35,000 cubic-feet-monthly In stock: St. Louis or Houston plateau, the intelligent switchover can be reallocated to another customer while up grading the job shop to the next mode of 800.776.3300 supply. In this scenario, the job shop in vests only the needed amount of capital ".midalloy.com to maintain competitive rates without sac rificing cut quality.• Circle No. 34 on Reader Info-Card AUGUST 2005 Head Does It All BY DIRK PETRING emands for lHIMMJiA} innovative Dmanufactur head design C03 -laser Nd:YAG-laser ing techniques are cutting ^^^~~ sealed lens optics cutting high. The main tar with coaxiaJ nozzle gets for these tech open lens optics allows 3-D laser niques are greater with crossjet . (weldinq) open mirror optics with crossjet flexibility and higher (weldimy cutting productivity at lower open lens or mirror optics with cutting costs. In many cases, crossjet and autonomous nozzle welding welding this seems to be im beam cutting C o mb i - h 1 a d possible; neverthe less, possibilities can be discovered if Fig. 1 — Matrix of laser types and processing head features for cut process chains are ting and welding. and joining analyzed and conse quential methods to shorten or integrate them are found. without retooling Sheet metal fabrication is one example Two Different Functions in of a complex process chain. Nearly all One Head component assemblies being manufac tured from sheet metal are produced by a In cutting heads, coaxially to the fo sequence of cutting and joining tech cused laser beam, an intense cutting gas niques. Accordingly, machine expenditure flow has to provide for effective melt ejec is high. Even the particularly flexible laser tion out of the kerf. The laser beam is systems are usually either dedicated to a guided through a high-pressure nozzle in single process or valuable time is spent on such a way that the beam focus together changing between applications such as cut with the gas jet meets the workpiece below ting and welding. the nozzle exit. A lens in the laser entrance Laser manufacturing with a combina aperture of the nozzle provides for gas- tion-head is a new, highly flexible solution tight sealing of the nozzle chamber and fo based on old ideas (Refs. 1-5). Recently, cuses the laser beam. In addition, the noz these ideas have been taken up again by zle tip serves as a capacitive clearance sen several groups (Refs. 7-9) who were mo sor, ensuring a constant distance to the tivated by the availability of laser sources sheet surface of about 1 mm by a closed- with simultaneously high power and high loop control of the machine axes. beam quality and by increasing market de In welding heads, with solid-state and mands on flexible production. In a multi diode lasers, lens optics accomplish focus functional laser cell, the combi-head is ing, but usually with C02 lasers mirror op able to perform 3-D cutting and welding tics are used. To create smooth shielding tasks in an arbitrary sequence without re and process gas flow, as required for weld tooling. Part handling, positioning, and ing, mainly off-axis nozzles are applied clamping steps are omitted. This results some millimeters from the laser impinge in shorter and more flexible process chains ment point. In addition, a compressed air and with them reduced production time crossjet is arranged between the optics and the process gas nozzle that blows transver- DIRK PETRING and costs as well as improved manufactur ([email protected]) is with ing accuracy (Refs. 10, 11). Moreover, the sally to the laser axis in order to reliably Fraunhofer Institute for Laser Technology combi-head opens up efficient solutions protect the optics from smoke or spatter ILT, Aachen, Germany. for innovative products from sheet metal emitted from the weld zone. Accordingly, with a wide range of variants. in contrast to the gas-tight optics of stan- WELDING dOURNAL » Coaxial, round nozzle for • high pressure nitrogen jet (fusion cutting) • medium pressure oxygen jet (oxygen cutting) • low flow rate shielding gas jet (welding) * allows use of crossjet force minimal leakage (prevents Autonomous detail Z suction of air by Venturi effect) Nozzle with capacitive distance control y velocity of gas \ aperture for laser beam v2 with c > v2 > v., v3 with c>/ = v3> v2 nozzle exit IHV4 with v4 < v3 v3 = c if P| Fig. 2- - Scheme and principle of 'Autonomous Nozzle " and combi head. Edge weld of laser cut car body sheets (0.8 mm), Nd:YAG laser, lense optics, beam power 3 kW Fig. 3 — Combi-head mounted on a 6-axis robot. Corner weld of laser cut stainless steel sheets (6 mm), CO2 laser, mirror optics, beam power 5 kW tonomous Nozzle is Applications mim rather simple and it Trim-cut of above edge seems predestined The increased flexibility gained weld with the same laser for solving the con through combining the processes is par flict described pre ticularly brought to bear with the utiliza viously — Fig. 2. By tion of robots and fiber-coupled solid- shifting the laser state lasers. In one 3-D application, the entrance aperture upper and lower shells of a car roof frame in the vicinity of the fixed in a single clamping setup were nozzle exit, a welded together, sections were cut out, patented flow de and clips were welded on in a rapid se sign enforces a quence of processes. This was done with Application results produced by the combi-head. minimum process a 4-kW diode-pumped Nd:YAG laser gas leakage and si from Rofin and a 6-axis KR30 HA robot multaneously pre from KUKA. It is also planned to test disc dard cutting heads, a welding head re vents suction of air. That way the nozzle and fiber lasers regarding their capabili quires an open flow section below the op can produce a coaxial process gas flow in ties for combined processing of sheet com tics, which is gas dynamically decoupled a wide pressure range, independent from ponents with the combi-head. from the processing zone — Fig. 1. the focusing optics and without a sealing Carbon dioxide lasers have also proved window. Being "autonomous," it easily to be suitable for applications with the Key Component: permits the integration of a crossjet be combi-head. Powers up to 12 kW have al tween itself and the focusing optics. This 'Autonomous Nozzle' ready been used successfully in the labo is necessary because the smooth process ratory at a thickness range of up to 10 mm. gas jet used during welding cannot pro This conflict between the requirements Nevertheless, industrial applications shall tect the optics from smoke and spatter. of cutting and welding heads can now be at first be limited to a maximum sheet resolved with the "Autonomous Nozzle" Consequentially, a crossjet with a com thickness of 6 mm and beam powers of 8 (Ref. 6), which was developed at Fraun- pressed air supply, an alternating check kW Two application results are shown in hofer ILT more than ten years ago and so valve for cutting and welding gas, and an Fig. 4. far has best proved itself in industrial ap appropriate numerical control program The combi-head particularly shows ad plications with high-power mirror cutting to change process parameters suffice to vantages in the three following product heads up to 12 kW. Besides various job also make a welding head out of the cut groups: shops, it has also been installed at the ting head. The Autonomous Nozzle with • Complex component assemblies requir Blohm & Voss shipyard, where it is used its rotationally symmetrical, slim design ing multiple quick changes between in a mirror cutting head for precise cut and an integrated capacitive clearance welding and cutting operations, ting of ship panels, which are later welded sensor represents the key component of • Products with a wide range of variants, together with the same laser (Trumpf TLF the universal processing head for three- i.e., customized, optional cut-outs and 12000) to produce large ship sections. In dimensional cutting and welding. The weld-ons, this application, a head exchange was still combi-head. as it is shown in Fig. 3, can • Components with a functionality that accepted for switching from cutting to optionally be equipped with lens or mir benefits from the exact positioning and welding and vice versa. ror optics and is suited for solid-state orientation between cut contours and In principle, the idea of the Au lasers as well as for COi lasers. weld joints. <• AUGUST 2005 tn» Fig. 5 — Combi-head during edge-prepa Fig. 6 — Combi-head during edge welding. Fig. 7— Combi-head during trim cutting ration (cutting) for an edge weld. of edge weld. The last point includes applications power and gas pressure. 3. Felleisen, R., and Kessler, B. 1994. where welding flanges of frames, hous These features can lead to the follow Higher productivity by combining CGS ings, or structural components are ing benefits for production when manu laser beam welding and cutting in one pro • First prepared by laser beam cutting facturing sheet component assemblies: cessing head. Proc. of ECLAT '94,5th Eu (perhaps being tack welded first in • Short, integrated process chains for high ropean Conference on Laser Treatment order to improve the stability of the productivity, of Materials, Bremen, Germany, pp. setup) (Fig. 5); • High flexibility and cost-efficient pro 468-474. • Then laser welded using overlap or edge duction of options and variants, 4. Geiger, M., Neubauer, N., and Hoff joints (Fig. 6); • Savings in handling, positioning, and mann, P. 1994. Intelligent processing head • Finally, precisely trimmed along the clamping operations, for COT laser material processing. Pro weld joint, again by laser cutting (Fig. • Savings in machine investment and duction Engineering, 1 (1994) Issue 2. pp. 7), to provide a highly accurate compo floorspace, 93-98. nent with, if required, minimum flange • Increased utilization of the machine, 5. Kaplan, A. F, Zimmermann, J., and width and excellent corrosion resist • Easy reconfiguration of the system for Schuocker, D. 1997. Combined laser weld ance. The constant tool center point new products, ing, cutting and scribing. Proc. of LANE (TCP) of the combi-head easily allows • Short tolerance chain improving accu 97, Laser Assisted Net Shape Engineer this. Another common application is racy of parts and components, ing 2, Erlangen, Germany, pp. 757-766. the cutting of final, sometimes optional, • Good accessibility of narrow workpiece 6. EP 0 741 627 Bl, European patent: apertures into the welded component areas, Nozzle assembly for laser beam cutting, with high functional demands on the • 1-D, 2-D, and 3-D applications, publ. 1997. accuracy of the shape and the relative • Suitable for lens as well as mirror op 7. Appcndino, D. 2003. Saldatura laser position of the cut geometries. tics, flessibile di Tailored Blanks. Proc. of Expo • Suitable for all laser types with appro Laser 2003, Ancona, Italy. Conclusion priate beam quality. 8. NN: Cutting and Welding with One Altogether, investment, organization, Processing Optic. TRUMPF EXPRESS The main technical features of the and operation costs are reduced by a fac July 2003, p. 13. laser combi-head can be summarized as tor of two or more in spite of equally im 9. Schneider, F, Wolf, N., and Petring, follows: proved productivity, time to market, and D. 2003. Cutting and welding with the "Au • Quick, software-controlled switching flexibility. The innovative possibilities tonomous Nozzle." Annual Report 2003, between cutting and welding in arbi opened up by multifunctional processing Fraunhofer ILT, Aachen, Germany, p. 68. trary sequences are expanded as product designers and 10. Schneider, F. and Petring, D. 2004. • One machine, one setting, one tool for production people jointly take up this con Cutting and welding with a combined pro cutting (N2 and Oz) and welding cept and combine their expertize and cessing head without retooling. Annual processes ideas. Flexibility starts in your hcad.^ Report 2004, Fraunhofer ILT, Aachen, • Constant tool center point (TCP) Germany, p. 64. • Rotationally symmetrical, coaxial, and References 11. Schneider. F. Petring, D., and slim head design with the Autonomous Poprawe, R. 2005. Integrated laser pro Nozzle, integrated capacitive clearance 1. JP 60 108 191 A, Japanese patent ap cessing — Cutting and welding with a sensor, and effective crossjet plication: Working head of laser working combined processing head. Proc. of LIM • Gas functions decoupled from the opti device, publ. 1985. 2005, 3rd International WLT-Conferencc cal system 2. GB 2 163 692 A, UK patent applica on Lasers in Manufacturing, Munich, • No principal limits regarding beam tion: Laser apparatus, publ. 1986. Germany, pp. 133-135. WELDING JOURNAL What Makes a Winning Weld: Tips from the Pros The top three winners of the first-ever AWS Professional Welder Competition describe their techniques BY KRISTIN CAMPBELL Creating a weld is no easy job — used is very important. "If the equipment how he is going to run the weld bead on practicing ahead of time, trying to get isn't good, even if you've got the best the joint he is working on. comfortable, and using the correct welding rod made by the best company in Of the four processes — shielded machine settings and electrodes — the world, you're not going to be able to metal arc welding (SMAW), gas metal arc make a good weld," he said. welding (GMAW), flux cored arc welding are all key elements. It also takes skill, He also said that if the equipment has (FCAW), and gas tungsten arc welding experience, hard work, patience, and not been maintained, and has not been (GTAW) — Miller thinks SMAW and dedication. cleaned or had parts maintenance per GTAW are the hardest to achieve a con But that does not discourage An formed on it, then "you're not going to get sistently good weld. drew Miller, Rick Prince, and Ryan the quality that you could get out of it." "It's the most manual type of weld Rummel from giving it their all. Miller feels another very important ing," he said of SMAW, which consists of Making welds to help complete aspect in making a good weld is the elec feeding the electrode and controlling the projects is part of what makes their trode. "If you've got an electrode that rate of its feed and travel speed. With GTAW, he has to feed the filler metal in jobs worthwhile. In fact, they posses isn't correct, say for the material you're welding, you're going to have a tough and control the torch head, which help about 54 years of welding experience time," he explained. control the bead shape. among them. To determine the best machine set To overcome obstacles that come with The Weldingjoumal decided to ask tings, "do a practice piece before you go SMAW and GTAW. he tries to make the these first-, second-, and third-place to the work you're trying to make your feeding and travel speeds transition winners of the American Welding So final weld on," he said. With experience smoothly. In addition, he tries not to get ciety's (AWS) first-ever Professional and practice, a welder will know how an aggravated. Instead, he will think, "What Welder Competition, which was held electrode runs best for a certain diameter, do I have to do to make this work easily last year at the AWS Welding Show in position, and amperage, he added. for me?" Chicago, 111., to share their tips on In Miller's opinion, what constitutes a The most important techniques he quality groove weld in the flat position is uses to get a good weld in the vertical and what it takes to make quality welds. symmetrical, uniform, straight edges, and overhead positions are getting himself in a slightly convex cap on it. "If you don't position so he is going to bc comfortable, Andrew Miller have some of those in the weld, you're and performing a practice run ahead of going to have an inconsistent, not a uni time. "With a vertical up or overhead, Andrew Miller (Fig. IA and B), the form-looking, bead," he stated. you're dealing with gravity, so you're first-place winner at the AWS To him, the most critical variables in technique changes a little bit because Professional Welder Competition, is a achieving that weld are travel speed and you're not in a flat position," he said. First-Class Welder at Rochester Gas & electrode feeding speed. As an example, Miller thinks the most important traits Electric, Rochester, N.Y. He started sometimes he might travel fast, increasing a person needs to be a good welder are welding when he was 18, and has been his rate of speed, if he is welding on a patience, good nerves, and good eye/hand welding for about 26 years. thinner material because he cannot sit coordination. "The weld needs to take Before Miller begins welding, he does and take his time — he will melt through. place at a certain rate — you can't rush the following: With 1-in.-thick steel, he can go slow. things," he said. "If you do. you're not • Makes sure there is a good spot and "You look at the bead and you increase or going to get the quality weld that maybe good, clean bare metal for grounding decrease your speed to make it the way the welding inspector is looking for." his work. you want it to look," he said. • Makes sure his machine settings, includ The techniques he uses to lay down Rick Prince ing the heat, are all correct. the best bead come from experience. He • Looks around to see if there is anything tries to be comfortable, perhaps by using Rick Prince (Fig. 2A and B) lives in combustible. This is to keep his envi a fixture in the weld area for balancing his Farmington, 111., and was the second- ronment safe and not start a fire. elbow while he is holding his two hands place winner at the AWS Professional He stressed that the equipment being on the electrode holder, and practices Welder Competition. He has been weld- KRISTIN CAMPBELL (kcampbell(a aws.org) is Assistant Editor ofthe Welding Journal. AUGUST 2005 Fig. 1 —A — "The more comfortable you can be makes a huge difference on how good a weld you can make, "Andrew Miller said; B - Miller using GMA W on a Harley Davidson motorcycle frame. ing for around 18 years. His dad, Eugene plete control of it. A quality groove weld in the flat posi Prince, was a welder and taught him the • Ground. "With a good ground, you can tion, in Prince's opinion, has good pene basics of welding before he was in high get a proper arc strike," he said. tration, even weld legs, and a smooth school. • Safety Equipment. He makes sure there weld bead. He thinks the most critical He is a Boilermaker with Local 60 and are no holes in his jacket or sleeves, points in achieving that weld is to have recently worked at the University of and that he has the proper gloves on. the machine set appropriately, a steady Illinois for a contractor. The position he He also checks his hood for good, clear hand, the correct electrode angle, and holds is Boilermaker Foreman. glass and a good, clean welding lens. being comfortable. Prince checks the following to make • Preparation. He makes sure the weld "There are a lot of techniques to lay sure everything is ready before he starts surface is clean. down a good bead, but it depends on what welding: • Fire hazards. "Make sure there are no you are welding, what position, thickness, • Machine. He makes sure the machine is flammable materials around the work what rod, and what you are trying to on, and the polarity is set correctly for area," he said. achieve with your weld," he said. the proper weld process that he is To Prince, good equipment is very To consistently achieve a good weld, about to perform. important for welding. "A smooth run he said it does not matter which welding • Set the machine. "I get a scrap piece of ning machine without any fluctuation, process (SMAW, GMAW, FCAW, or metal and try out the machine to make that is set right, will put on a quality GTAW) is being used because it all takes sure the heat is set right and running weld," he stated. practice, proper machine setup, and a smoothly," he said. Additionally, having the right elec steady hand. • Leads. He makes sure the leads are in trode for the job is important as well. "I "All the processes can be difficult or good shape without bare spots. have noticed some brands run smoother easy depending upon what position you • Stinger. He makes sure he has a good than others, but not enough to change the are in, what kind of obstacles are in your electrode holder in order to have com weld quality," he said. way, and if you are looking directly at it or B Fig. 2 — A and B — Rick Prince performing SMA W with 6010, putting a root pass on an ash tank at the University of Illinois. "It is very important to have good equipment with anything you do, but especially welding," Prince said. WELDING JOURNAL Fig. 3 — A — Ryan Rummel (right) passing a bend test for Fluor Daniels. To the left is Texas State Technical College instructor Chris Park/till; B — Rummel (right) and Jimmy Brooks (left) putting an open root into pipe with an E6010 electrode. "Il takes a lot of patience to learn all the different processes, " Rummel said. doing a mirror weld," he explained. In addition, he feels the electrode is on the front," he explained. To overcome obstacles that come with very important in making a good weld, On the other hand, he stated that with the four processes, he tries to make sure and it should be clean. For example, the backing strap, "You'd weld it out reg everything is set right, gets comfortable Rummel said, "If a 7018 is wet, a good ularly, and then once you're done, you and concentrates, and possibly does a welder can tell the difference in how it gouge the strap off the back, and you practice run before he strikes an arc. burns; if this electrode is left outside, it grind it down smooth." The most important techniques he will not burn very well, and it is hard to The most critical variable in achieving uses to get a good weld in the vertical and control the puddle. If the rods are taken that weld is the fitup. "If you have a good overhead positions depend on the elec out of a rod box, they run a lot smoother. fitup in a weld, sometimes you won't take trode being used and the material to be You have a better looking weld, and you as much weld metal, which cuts down on welded on. In the vertical position, for have less to worry about on the weld." weld time, and everybody knows time is 7018, Prince uses a side-to-side or a drag To determine the best machine set money," he said. If the root opening is too technique; for 6010, he uses whip and tings to achieve a good weld, he will get a tight, the penetration needed may not be pause, drag, or circles. In the overhead scrap piece and play with it, putting it achieved, and this would result in a failed position, for 7018 he uses side-to-side, where he thinks it is going to be. He said joint that would have to be redone. circles, drags it, side to side while holding if he is using a 7018 he will try it out first The techniques Rummel uses to lay at the sides techniques, and for 6010, by 120 A, because every machine (even if down the best bead he can depend on whip and pause or circles. it is the exact same model and 1000 of what process he is performing. "Each Prince thinks the most important traits them came off one assembly line) runs position has its own technique on how to a person needs to be a good welder are differently. weld," he said. For uphill SMAW with an self-confidence and pride in his or her Also, at the AWS Competition hc E7018 electrode, he will go over to the work. noticed the amperage ran a little bit dif right, go over to the left, up, back down, ferent on each manufacturer's machine, across, up, back down, and across. Ryan Rummel so he watched the welders make welds. He believes GTAW is the hardest the amperage that was used, and how process to achieve a consistently good Ryan Rummel (Fig. 3A and B) cur they cleaned off their slag. Rummel said weld. "It takes the most time to do it, rently works as a welder for Transcon, if the amperage is set right, the slag will because your weld travel time is not very Rockdale, Tex. He has been welding for peel off by itself on a 7018, or there will fast, but it is the cleanest welding about 10 years, ever since he was a fresh be little trouble getting it off with a chip process," he said. man in high school. Rummel was the ping hammer; however, if a welder is To overcome obstacles with GTAW, third-place winner at the AWS chipping really hard, the machine is before striking an arc, he will go up to his Professional Welder Competition. either too hot or too cold. weld joint, get his feet placed where he Before Rummel begins to weld, he To him. a quality groove weld in the thinks he will be the most comfortable, does the following: flat position depends on if there is an and do a dry run by holding his wire • First, he looks around the environment open root or backing strap. The open root where his joint is and acting like he is to make sure there is no gasoline or any has to do with the fitup — for example, if going to weld. flammable materials around, like dirty there are two pieces of plate prepared The techniques he uses to get a good rags that could cause a fire. with a groove, there would be about a A- weld in the vertical position is a good • Then, on his weld joint, hc makes sure in. gap between the plate and he would fitup and clean weld joint; in the over he has a good fitup, and that it is clean tackle them on each side so he would be head position, he also suggests a good of any paint, debris, oil, or grease. able to see through a little gap. Whether fitup, clean metal and electrode if per To make a good weld, he makes sure he would perform GTAW, GMAW, or forming SMAW. and proper amperage. his equipment is set properly, including SMAW with an E6010 electrode, he The most important traits a person the amperage and voltage. "That usually would weld from the outside of the plate. needs to be a good welder, according to has the biggest outcome on how your "You push your weld through the back Rummel, are patience and not caring joint's going to look," he said. "Five amps just a little bit, maybe Vd. or Vn of an inch, about getting dirty or hot. up or five amps down can determine if and essentially what you're doing is weld "You don't learn welding overnight," you have a beautiful looking weld." ing on the backside while you're welding he said.^ AUGUST 2005 What if you could find better pay and more job security in welding? w FIND OUT HOW TO BECOME AN AWS CWI OR CWE. ENROLL TODAY AND SAVE OVER $900 ON YOUR BOOKS. AWS Certification can mean better pay, more job secu rity, and the proof that your skills and knowledge label you as one of the industry's elite. We offer five and a half days of intensive seminars that help prepare you to pass the AWS certification tests. Our experienced instructors help you learn the materi al you need to know fast, and show you how to use and understand the latest standards. AWS seminars are an excellent value. You save time and money too, because we supply many of the books you need (a $900 value). There are clinics for D1.1 Code, AP11104 Code, Welding Inspection Technology, and Visual Inspection, followed by the certification exam at the end of the week. By grouping the preparation with the test, you can attend AWS seminars with less time off from the job and less travel expense. When it comes to preparing for an exam that proves you're one of the best, then take it from the people who know it best—AWS. American Welding Society To become an AWS member, call 800-443-9353, ext. 480, or visit our website at www.aws.org FIND THE AWS SEMINAR NEAREST YOU. FOR MORE INFORMATION, CALL 800-443-9353, EXT. 449 MIAMI, FL {EXAM ONLY) 9/15/2005 DENVER, CO 10/8/2005 LONG BEACH, CA 11/12/2005 NEW ORLEANS, LA 9/11-16 9/17/2005 PHOENIX, AZ 10/2-7 10/8/2005 BEAUMONT, TX 11/6-11 11/12/2005 SYRACUSE, NY 9/11-16 9/17/2005 MIAMI, FL (EXAM ONLY) 10/20/2005 PORTLAND, OR 11/6-11 11/12/2005 MINNEAPOLIS, MN 9/18-23 9/24/2005 PITTSBURGH, PA 10/16-21 10/22/2005 LOUISVILLE, KY 11/13-18 11/19/2005 SEATTLE, WA 9/18-23 9/24/2005 TULSA, OK 10/16-21 10/22/2005 SIOUX FALLS, SD 11/13-18 11/19/2005 SAN DIEGO, CA 9/18-23 9/24/2005 SAN ANTONIO, TX 10/16-21 10/22/2005 ST. LOUIS, MO (EXAM ONLY) 12/3/2005 ANCHORAGE, AK (EXAM ONLV) 9/24/2005 CHICAGO, IL 10/23-28 10/29/2005 SAN JUAN, PR 12/4-9 12/10/2005 DALLAS, TX 9/25-30 10/1/2005 ATLANTA, GA 10/23-28 10/29/2005 MIAMI, FL 12/4-9 12/10/2005 DETROIT, Ml 9/25-30 10/1/2005 RENO, NV 10/30-11/4 11/5/2005 COLUMBUS, OH (AT NBBPVI)* 12/5-9 12/10/2005 MILWAUKEE, Wl 9/25-30 10/1/2005 BALTIMORE, MD 10/30-11/4 11/5/2005 CORPUS CHRISTI, TX (EXAM ONLY) 12/17/2005 Circle No. 7 on Reader Info-Card The Fiber Laser A Newcomer for Material Welding and Cutting BY G. VERHAEGHE A new type of laser is attracting interest from the materials processing industry The first reports on the use of lasers for material processing in commercial ap plications were published in the early sev enties. For many years, the C02 laser re mained the only laser of choice when deep penetration keyhole welding was re quired. A significant step forward was made when continuous wave (CW) solid- state lasers, in the form of the lamp- pumped Nd:YAG laser, became commer cially available, covering at least part of the power range of C02 lasers, and intro ducing the benefits and advantages of op tical fiber delivery of the laser beam to Fig. 1 — The 7-kW Yb-fiber laser, comprised the workpiece. More recently, the laser of 200-W single-mode fiber modules, and its industry has seen -improvements in these optical setup at TWI Ltd. existing technologies, with the introduc tion ofthe diffusion-cooled, or slab geom etry, C02 laser and the diode-pumped pier, to form the laser resonator, creating version of the Nd:YAG laser, as well as a long thin laser, which due to the flexibil development of completely new laser ity of the optical fiber (which is simply sources, such as the direct diode laser, the coiled up) can be very compact. Although disc laser, and the fiber laser. Since the ment is the lasing medium. Laser diodes it is possible to use the lasing fiber as the output powers of the fiber laser have ex are used to stimulate the lasing medium beam delivery fiber, with the appropriate ceeded one kilowatt, the materials pro to emit photons, an action known as pump beam shaping and focusing optics at its cessing industry has gained interest in this ing, at a wavelength specific to the rare end, decoupling of the beam delivery fiber new technology as an addition to, or a earth element used as the doping clement. from the lasing fiber is preferred for lasers possible replacement for, the more con Ytterbium is generally used for the high- used for material processing to protect ventional C02 and Nd:YAG lasers cur power fiber lasers currently available for from unwanted back-reflections from the rently used. material processing, and it emits a wave workpiece surface. length approximately the same as Nd: YAG To date, 700-W single-mode fiber laser Fiber Laser Technology lasers, i.e., between 1.060 and 1.085 mi modules are commercially available, with cron. The doped fiber is surrounded by a prototype single-mode Yb-fiber lasers up Fiber lasers (not to be confused with low-refractive-index material that acts as to 1000 W of output power already being fiber-delivered lasers where the fiber is a waveguide for the pumping light and en assessed under laboratory conditions merely an optical delivery mechanism) are sures optimum transfer of this energy to (Ref. 1). The manufacturing route cur solid-state lasers in which an optical fiber the lasing medium. Diffraction gratings rently preferred for achieving multikilo doped with low levels of a rare earth ele are used as rear mirror and output cou- watt output powers suitable for deep pen- G. VERHAEGHE is with TWI Ltd., Granta Park, Great Abington, Cambridge, U.K. AUGUST 2005 Table 1 - Laser Source Comparison co2 Lamp-pumped Diode-pumped Yb Fiber Thin Disc Nd:YAG Nd:YAG (multimode) Yb:YAG Lasing medium Gas mixture Crystalline rod Crystalline rod Doped fiber Crystalline disc Wavelength, micron 10.6 1.06 1.06 1.07 1.03 Beam transmission Mirror, lens Fiber, lens Fiber, lens Fiber, lens Fiber, lens Typical delivery fiber, — 600 400 100-200 150-200 Micron Output powersWkW Up to 15 kW Up to 4 kW Up to 6 kW Up to 20 kW Up to 4 kW Typical beam 3.7 25 12 12 7 quality^). 3.7 12 <12 1.8 4 mm.mrad Maintenance : 0.8-1 2-5 ioo(c) 2-5 interval, kh Power efficiency % 5-8 3-5 10-20 20-30 10-20 Approximate cost per kW, k$ 60 130-150 150-180 130-150 130-150 Footprint of laser large medium medium small medium source Laser mobility low low low high low Notes: (a) Commercially available at the time of writing. (b) The top figures are for the max. available output powers, the bottom figures for the same type of laser but configured for optimum operation at 1 kW. (c) Manufacturer's claim. etration keyhole welding of metals is by angle product of the actual beam to that waist diameter, often also referred to as combining the outputs from a series of expected for a perfect beam (for which the laser spot. The relationship between these commercially available single-mode the shape of propagation is a hyperbola) the ratio of the collimating and focusing units into a single fiber output, as shown (Ref. 2). The beam quality of a solid-state lens focal lengths and the ratio of the in Fig. 1 for the 7-kW fiber laser. Although laser, often referred to as the beam pa beam delivery fiber diameter and the spot this beam-combining technique, propri rameter product (BPP), is generally size, determines, for a given output power, etary to the laser manufacturer, reduces quoted in mm.milliradians, with a low the maximum power density available at the beam quality, the reduction is rela value meaning a high beam quality. Con the workpiece. The stand-off distance, the tively small, with the resulting laser beam fusion sometimes arises as beam quality distance measured between the focusing still having properties suitable for trans can be expressed using either full or half lens and the surface of the material, mission through small-diameter optical beam diameter and divergence angles, but should be large enough to provide a de fibers and for welding. in this paper, beam quality is quoted in gree of confidence that spatter from the terms of half beam diameter and half di welding process will not damage the pro Comparison with vergence angle, in line with the ISO stan cessing optics. The greater the stand-off Existing Laser dard for laser beam propagation (Ref. 3). distance, the greater also the depth of Technology Table 1 provides an overview of the char focus, which is a measure for how diver acteristics of some of the commercially gent the beam remains over a given dis Fiber laser technology seems to allow, available CW laser sources. In this table, tance (Ref. 2). So, a higher beam quality for the first time, the manufacture of scal beam quality is expressed in mm.millira can provide a higher power density at the able lasers, in a compact form, with no ob dians with the C02 laser value appropri beam focus, or a larger stand-off dis vious limit to the power available. Today, ately converted. Figures are given for the tance/greater depth of focus, both of the output power of a fiber laser exceeds maximum output power commercially which influence the welding performance. that of commercially available Nd: YAG available for each laser at the time of writ laser technology, while also offering a bet ing, and, for comparison purposes, an es Power Efficiency ter beam quality. In fact, fiber laser power timate has also been made of the BPP and beam quality are approaching, and in available for each technology at an out The long, thin fiber geometry allows certain cases exceeding, those of CO-> put power of 1 kW. effective cooling and is thus ideal to min lasers. For instance, a 17-kW Yb-fiber But what impact, in practical terms, imize thermal effects due to the pump en laser with a beam parameter product docs beam quality have on welding per ergy. That, and the inherently high gain (BPP) of around 12 mm.mrad was recently formance? A high beam quality means of the fiber laser source, translates to a installed in Europe and a 5-kW system that the beam can be focused into a small- high power-conversion efficiency, which with a BPP of 2 mm.mrad is now available. diameter optical delivery fiber, which is the ratio of optical power available at translates, on the processing side, for a the workpiece to the electrical power con Beam Quality given lens diameter, in a smaller minimum sumed, claimed to be between 20% and beam waist diameter or a larger stand-off 30% (Ref. 4). For the 7-kW system in But what is beam quality? At any point, distance. The laser process head images stalled at TWI, a power-conversion effi the laser beam can be characterized by a the end of the fiber onto the workpiece, ciency of 21% was calculated for an out divergence angle and a beam width, or di by first collimating (i.e., making parallel) put power of 4 and 7 kW, based on the op ameter. The beam quality is defined as the the diverging laser beam exiting from the tical power measured after a four-way op ratio of the beam width and divergence fiber, before focusing to a minimum beam tical switch — Fig. 1. This is significantly WELDING JOURNAL 0.6 - • 7kW at workpiece 0.5 - • 4kW at workpiece Ig o 4 - S 0.3 - Q. £ 0.3 "S \ ^"^ f 0.2 - TI ^^J^---;--~r^~*~~~~-^--^ 0.1 - »-« — -^" "~~^ 0.1 0 - 0 0 1 100 200 300 400 500 200 300 welding speed, in./min welding speed, in./min Fig. 2 — Performance curves for the welding of C-Mn steel using Fig. 3 — Performance cuives for the welding of Al using a Yb- a Yb-fiber laser. fiber laser. Fig. 4 — Zero root opening, square-edge butt joints in 8-mm- (3Ai6-in.-) thick C-Mn steel A Welded with a 4-kWNctYAG at 0.5 m/min (20 In./min); B — 7-kWfiber laser at 1.6 m/min (63 in./min). better than the power conversion effi Because of a simple and compact de tion in Europe, and the first one of those ciency of around 8% and 3% for C02 and sign, the 7-kW Yb-fiber laser was, in con only operational for just over a year, it is lamp-pumped Nd-YAG lasers, respec trast with the requirements for C02 and at this stage impossible to either confirm tively (Table 1). The immediate economic Nd:YAG lasers, installed in only a few or deny this 100,000-hour claim. impact is twofold, in that less power is re hours. This included connecting the laser quired to run the laser and less power is to the chiller, the four-way optical switch Cost of Technology also required to dissipate the heat gener and laser process head, and preparing the ated by the laser. Air cooling, for instance, system for a beam and output power The initial investment cost of any laser is now available for Yb-fiber lasers up to analysis. is high, but this should be viewed together 2 kW, whereas higher output powers re with the productivity advantages the tech quire water cooling. Reliability nology offers, i.e. calculating the running costs of the technology per weld or per Source Design A reliability in the order of 100,000 component. For the fiber laser, this should hours before maintenance/failure of the take into account the use of a smaller As the lasing fibers can be coiled, and laser diode pumps is claimed for the fiber chiller, lower energy consumption ofthe no bulky moving parts are required, the lasers. This is longer than the maintenance laser and chiller, the reduced floorspace, footprint of the fiber laser is significantly interval of conventional solid-state lasers, and low maintenance and service require smaller than conventional laser technol which refers to the time between two con ments. Notwithstanding large variations ogy. The footprint of TWI's 7-kW laser secutive changes of the pumping source, in quoted prices, the authors estimate that source, without chiller, is approximately i.e., flashlamps in case of lamp-pumped in the current competitive market, at the 1 m2 (10.76 sq ft). This is more than four and diode bars in case of diode-pumped time of writing, the cost per kW of Yb- times smaller than that of a commercially Nd:YAG lasers. The 100,000-hour claim fiber laser technology is about the same available 4-kW lamp-pumped Nd:YAG is based on the fact that fiber laser pump as that of a lamp-pumped Nd: YAG laser laser source, and many times smaller, for ing technology uses less-stressed laser source. Because of the fast pace of tech instance, than that of the 10-kW cross- diodes instead of diode stacks (Ref. 4). nological development and increasing axial flow CO-, laser source used at TWI With only a few Yb-fiber lasers with an competition between existing and new in the early 1980s. output power higher than 5 kW in opera laser technologies, it is expected that over- AUGUST 2005 Fig. 5 — Zero root opening, square-edge butt joints in 6.35-mm- (A-in.-) thick 7000-series aluminium alloy. A — Welded with a 3.5-kW Nd;YAG; B and C — 7-kW Yb-fiber laser. Fig. 6 — Lap joints completed in 1.2 to 1.2 mm (AJ in. to VM in.) ultrahigh-strength steel using 4-kW Nd:YAG laser and 4-kW Yb-fiber laser power. all prices per kW of laser output power tained from a series of completely pene and a weld with an aspect ratio of approx could drop further. A limiting factor in trating bead-on-plate runs carried out on imately 1:1. Doubling the power to 7 kW, this price drop, however, is the cost of the steel and aluminum, show the welding per in the case of the Yb-fiber laser, resulted laser diode pumps. formance, i.e., depth of penetration vs. in a much higher power density, allowing speed, of the 7-kW fiber laser for a meas welding speeds of between 2.8 and 4.8 Fiber Laser Welding ured power at the workpiece of 4 and 7 kW m/min (110 and 190 in./min), i.e., a ten- The process setup was similar to that typi to sixteen-fold increase. The resulting Laser beam welding is not uncommon cally used for welding with a 4-kW lamp- welds (Fig. 5B and C) have a much higher in today's manufacturing industry. Steel and pumped Nd:YAG laser, comprising an op aspect ratio, typical for laser welding. A aluminum, for instance, are welded suc tical glass cover slide, an airknife and he stringent weld quality in accordance with cessfully for a range of industrial applica lium shielding for the aluminum welds. BS EN ISO 13919-1 was achieved for all tions. The automotive industry in particu Figure 4 compares the cross sections welds. lar has been instrumental in getting laser of zero root opening, square-edge butt When welding 1.2- to 1.2-mm (%4- to technology onto the shop floor. Whereas joints in 8-mm- (%-in.-) thick C-Mn steel X.j-in.-) thick lap joints in ultrahigh- the high-speed capability is particularly at using 4-kW Nd:YAG (Fig. 4A) and 7-kW strength steel (UHSS) using 4-kW tractive for automotive applications, other Yb-fiber (Fig. 4B) laser power at the Nd:YAG laser power, as measured at the industry sectors also gain benefit from its workpiece. Both were completed using a workpiece, a welding speed of 2.5 m/min single-pass, deep penetration welding ca 600-micron laser spot size focused on the (100 in./min) was achieved for a laser spot pability. Output powers of up to 15 kW are material surface, and at a welding speed size of 600 micron — Fig. 6A. Using a 4- commercially available for C02 lasers, but of 0.5 m/min (20 in./min) and 1.6 m/min kW Yb-fiber laser with a BPP of 5 often the necessary use of mirrors for beam (63 in./min) for the Nd: YAG laser and Yb- mm.mrad resulted in a welding speed of manipulation is considered restrictive in fiber laser, respectively. The differences 4 and 17 m/min (160 and 275 in./min) for applying this technology for flexible manu in power density and heat input clearly af a 450 micron and a 140 micron laser spot facturing. Fiber-delivered solid-state lasers, fects the weld and HAZ region. A strin diameter, respectively. Note the high as on the other hand, offer the required flexi gent weld quality in accordance with BS pect ratio of this last weld, with a width of bility, but, so far, have been limited in out EN ISO 13919-1 was achievable for both the weld (including HAZ) less than 1 mm. put power, i.e., typically less than 4 kW. The lasers used. By choosing a hybrid laser-arc config advent of this new fiber-delivered solid- The cross section in Fig. 5A is one of uration, i.e., combining an arc in the same state laser with higher output powers than a zero root opening, square-edge butt weld pool as that of the laser beam, faster before (and a better beam quality than ex joint, in 6.35-mm- (Vt in.-) thick 7000-se welding speeds, larger depth of penetra isting solid-state lasers), evidently offers ries aluminum alloy using 3.5-kW new welding and cutting opportunities for tion, improved quality and/or improved Nd: YAG laser power at the workpiece fo thin- and thick-section applications. tolerance to joint fitup can be achieved, cused into a 600 micron laser spot size. compared with the individual processes. The low power density, just enough to In other words, the technical benefits of Welding Samples achieve complete joint penetration, re laser beam welding arc retained or en sulted in a slow welding speed of 0.3 hanced while the economy of the process The diagrams shown in Figs. 2 and 3, ob m/min (12 in./min), i.e., high heat input, is improved. Plenty of examples exist in WELDING JOURNAL Fig. 7 — A butt joint completed in 8-mm- (Ai,-in.-) thick X60 pipe steel using 7-kW Yb-fiber laser power in a hybrid configura tion with GMA W. Fig. 9 — A selection of materials cut using a 17 mm.mrad BPP Yb-fiber laser. 4-mm- (Xa- and %-in.-) thick mild steel nical contributions of Paul Hilton, Steve samples (2nd and 4th from the top) were Shi, Pak Chong, and Anthony Elliott. cut using oxygen assist gas, whereas the 0.8- mm (ArAn.) Zn-coated steel (top), the References 3- and 6-mm (A- and 14-in.) austenitic stainless steel (3rd and 6th from top), and 1. Woods, S. 2003. Fiber lasers — the new the 5-mm (M<,-in.) 5000-series aluminum high power, high quality, high efficiency source. alloy (5th from top) were all cut using AILU magazine. The Industrial Laser User, high-pressure inert gas. Issue 33, December, pp. 32, 33. 2. Hilton. P. A. 1998. Fiber optic beam de Concluding Remarks livery for high-power CW Nd:YAG lasers. Con fidential TWI Report 88277/49/98. The manufacture of lasers has become 3. BS EN ISO 11146:1999: Lasers and Laser a highly competitive market, with lasers Related Equipment — Test Methods for Laser Beam Parameters — Beam Widths. Divergence Fig. 8 —A zero root opening, square-edge being introduced in different industry sec Angles and Beam Propagation Factor. butt joint completed in a 12.7-mm- ('A-in.-) tors for a wide range of applications, in cluding cutting, drilling, welding, thick 7000-series aluminium alloy using 4. Shiner, B. 2004. kW fiber lasers for ma marking, and surface engineering. Weld terial processing markets. AILU magazine. The 7-kW Yb-fiber laser power in a hybrid con ing trials at TWI using the latest fiber laser Industrial Laser User, Issue 35, June, p. 23. figuration with GMAW technology confirm that this new type of laser source should now be considered as an alternative to CO? or Nd:YAG lasers the literature demonstrating this concept for the welding of materials such as steel for CO? or Nd:YAG lasers. The welds and aluminium. The initial cutting results shown in Figs. 7 and 8 demonstrate how also show considerable promise for this the 7-kW Yb-fiber laser was used in a hy new technology. Moreover, its compact brid configuration on 8-mm- (M.,-in.-) thick design, easy set-up, and lower power and X60 pipe steel and 12.7-mm- (!4-in.-) thick cooling requirements compared with ex Dear Readers: 7000-series aluminum, respectively. Both isting laser technology, make it ideal for were carried out in the PF position at a on-site welding, for pipeline welding or The Welding Journal encourages shipbuilding, or for remote repair, for in welding speed of 1.8 and 0.9 m/min (70 an exchange of ideas through stance. As the fast-paced development and 35 in./min), respectively. letters to the editor. Please send continues to push up the power levels and improve the beam quality, the range of in your letters to the Welding Journal Fiber Laser Cutting dustrial applications for this new type of Dept., 550 NW LeJeune Rd., laser will undoubtedly expand. It remains Miami, FL 33126. You can also Because the beam quality of these new to be seen however, if this competition be reach us by FAX at (305) 443-7404 lasers is now in the same order of magni tween laser technologies will also result or by sending an e-mail to Kristin tude as C02 lasers, fiber lasers should also in more affordable lasers. • be considered for cutting applications, a Campbell at [email protected]. market currently dominated by C02 lasers. Some of the first cutting results Acknowledgments using a Yb-fiber laser with a BPP of 17 mm.mrad are shown in Fig. 9. The 2- and This article has benefited from the tech AUGUST 2005 Anatoi "•MK if* Weldin 'The heart of any welding tournament is the contestant, all alone in the booth, struggling to do his besf BY HOWARD M. WOODWARD now flurries, gusty winds, and temperatures in the low 20s did not deter the 110 students from S 15 schools in four states, dozens of instructors, guests, and volunteers from traveling to New Castle, Ind., to partici pate in the 27th Annual Mid-West Weld ing Tournament, held March 9-11. Timed with impressive precision, from early morning to evening, wave after wave of five-student teams entered the New Castle Area Vocational School (NCAVS) weld lab and classrooms. They performed their projects and written exams, then ex ited the building and climbed on their buses, leaving just in time for the arriving buses to discharge the next wave of welders who entered the lab to demon strate their knowledge and skills. At times, the hallways were crowded with bustling lines of students in protec tive welding gear and carrying heavy tool Eyes peeled and pencils sharpened, Indiana Section members tackled the serious business boxes moving in and out of the building of judging the entries. Shown are (from left) Bob Richwine, Nick Laskai; Dave Koutz, Oren — resembling a rush hour scene at a busy Soules, District 14 Director Tully Parker, Gaiy Dugger; and Stephen Schmutte. commuter station. The Indiana Section's Role ments of the tournament, and monitored Getting Started ... Again Orchestrating this whirlwind of activ the two-hour-long written examination ity has been for the past six years the re portion of the event —Fig. 2. Empowered by the success of this warding, yet occasionally daunting, task Robert Hobbs and Jerry Walden, year's tournament, Anderson is already taken on by the AWS Indiana Section, NCAVS director and career counselor, re making initial arrangements for the 2006 spearheaded by Mike Anderson (Fig. 1), spectively, generously gave their full sup welding tournament. Section treasurer, and a welding teacher port and backing to the event. Even the He must start once again to commit the at NCAVS. He is the acknowledged mas two invited banquet speakers, Chris Pol schools to schedule their teams, make a termind or "lightning rod," as he puts it, lock, AWS director of education, and roster of people committed to work, pur for the event. Dennis Klingman, The Lincoln Electric chase equipment, negotiate blocks of hotel Anderson was well supported this year Co. (Fig. 3), got caught up into the con rooms for participants who must stay by numerous volunteers, the events' arms, tagious energy of the tournament and overnight, and contact vendors to urge legs, and judging eyes (lead photo). They jumped in to help where they could. There them to sponsor awards and contribute timed and oversaw the four welding seg- was always a lot to do. cash and consumables donations — Fig. 4. HOWARD M. WOODWARD ([email protected]) is Associate Editor of the Welding Journal. WELDING JOURNAL W Fig. 2 — The job of each team's "brainy" Fig. 3 — Robert Hobbs (left), director, New member was to answer the theory questions Castle Area Vocational School, introduced and solve the practical math problems in keynote speaker Christopher Pollock (cen Fig. 1 —Mike Anderson, coordinator of the the written exam portion ofthe tournament. ter), A WS director of education, and Den annual Indiana event. nis Klingman, The Lincoln Electric Co., at the school." The smiles on this year's top the awards-presentation banquet. winners (Figs. 6, 7) said it all. New this year, Anderson provided clip The Rich Legacy of the Tournament the students and faculty from about a boards and digital timers (Fig. 5) to each dozen Indiana and Kentucky schools." booth monitor to assure each contestant "The impressive legacy of our Mid- got the exact amount of time allocated to West Welding Tournament" Anderson The Indiana-Kentucky do his assignment. noted, "took root nearly three decades Welding Classic ago as the brainchild of two veteran weld The Value of Trophies ing instructors, Larry Hensley and James Anderson recalled. "The fledgling con and Volunteering Conway. Hensley," he recalled, "taught test, dubbed The Indiana-Kentucky Weld welding in Jeffersonville, on the Indiana ing Classic, was held in Jeffersonville. The Dozens of engraved glittering individ side of the Ohio River, just across from welding teachers," he said, "ran those ual and team awards, ranging from two to Louisville, Ky. Jim Conway was based here early contests. They designed the projects, six feet tall were presented during the in New Castle (located about 120 miles to set up the workstations, supervised the banquet on the last day. the north). tests, and judged the weldments." Anderson noted that the trophies pro "Together," Anderson added, "the two vide a much-needed morale boost for the men developed an idea for a new type of Surviving the Hard Times students. "Typically," he said, "welding welding competition that would highlight students do not participate in the trophy- more than just the welding skills — some Anderson acknowledged, "The Jeffer winning sports activities at school, and thing that would be more demanding than sonville competitions were often strapped they have had no awards to display in their the VICA welding contests being held at financially during the early years." He school's trophy case in the past. Now, the the time. smiled, and added, "The coveted first- welders have impressive awards to display "Thus, they contacted a number of place team prize was an ornate six-foot- next to the trophies won by their fellow area welding teachers in Indiana and Ken tall traveling trophy. Each year the win students who are active in sports. It makes tucky to convene for a welding contest ning team was required to bring it back a lasting reminder of the event and is a planning meeting. That group then imple for the next year's winners to take home. silent builder ofthe image of welding in mented its initial tournament involving However," Anderson said, "as you might The Bottom Line The oft-quoted wheeze. "Winning is not everything, but it sure beats losing," somehow does not apply to a welding contest. Winning is always great, of course, but the big talking point for being in a welding competition is simply the thrill of being an active part of an ex citing event. The contest itself is just one milestone in each student's welding experience, which began months before with many hours of preparation, practice, and study. Students taking two-year welding courses have two opportunities to participate in Mid-West Welding Tournament. The second time around these students are a year older and a lot wiser about what's expected of them, and their performances reflect that extra experience. Every AWS Indiana Section member said his incentive to work on the tournament was to encourage the young welders to stay with the craft. It's a tough trade to learn, but once mas A Mid-West Welding Tournament tered, can be a constant source of personal satisfaction. All economic indexes predict an competitor experiencing the thrill of alarming shortage of manual welders in the near future — a dire prediction which bodes being an active part of an exciting well for welders and welding engineers just entering the workforce. event. AUGUST 2005 expect, the bulky trophy often got strapped to the top of a school bus or onto the back of a van in order to get it home. After a few years of that kind of mistreat ment, the trophy looked pretty bad, so the traveling trophy idea was scrapped in favor of take-home-for-keeps awards. The Pioneers' Determination "Over the years, the contest had its ups and downs, but," Anderson reflected, "it was Conway who really kept the contests going year after year. Some years," he stated, "Conway took money out of his own pocket to support the awards-pres entation banquet for the event, or even to buy the trophies. The only money sup porting the contest at that time was each team paying an entrance fee of $150. Fig. 4 — It took a long table to hold all of Fig. 5 — The booth monitors used a sepa Later, the team entry fee was raised to the hundreds of prizes donated by the local rate clip board and digital timer for each $200 — the fee we currently charge." vendors and patrons making it possible for contestant to assure each welder was accu Anderson praised Hensley's people every student, a winner or not, to take home rately timed and his work documented. skills. "Larry Hensley's persuasiveness several welding-related items. was undoubtedly the motivating force be hind keeping the welding contests going and a two-hour written theory exam. The Hollers said, "I also work with the 4-H year after year," Anderson said. As for school decides which team member is as program where I teach welding to kids James Conway," he added, "I've known signed to do which segment of the con from the 4-H entry age of 9 through to 18 Jim for 21 years. I am indebted to him as test," Anderson explained. years old. I especially like this welding the man who got me into teaching weld The students assigned to take this tournament because it excites the students ing in the first place. We all owe these men year's written exam were confronted with to work harder and is a positive incentive a great deal for their dedication to the pro a tough ten-part test: safety, welding for them to learn." motion of the image of welding in the In terms, metallurgy, shielded metal arc Indiana Section member Bennie Flynn diana-Kentucky region." welding, oxyacetylene processes, gas tung stated, "This contest is taken very seri The Indiana Section members were in sten arc welding, gas metal and flux core ously by these students. Their determined vited to participate in the Jeffersonville arc welding, shop math problems, weld attitudes reflect on their inspired instruc contests but few could volunteer because ing symbols, and print reading. tors who have obviously impressed them of the long travel distance involved. How "Usually, all ofthe schools attend the with the importance of welding, and how ever, all that changed six years ago when banquet, so this year we had about 140 at welding impacts every aspect of every the venue moved from Jeffersonville to tendees, including Section members, par one's life. the excellent facilities offered at the New ents, and state officials and newspaper re "Understandably, many of the students Castle Area Vocational School. porters, etc." get nervous knowing they arc participat Getting Down to Basics ing in one of the biggest welding tourna Teaching Passions of the Volunteers ments in the country. However, when they "The contest has five areas of compe get inside that booth and drop the hood tition: GTAW, FCAW, GMAW, SMAW, Indiana Section Vice Chair J. R. they are completely alone, competing only The Mid-West Welding Tournament The Volunteers Making it all happen this year at the Mid-West Welding Tournament were the following volunteers. AWS Past President Dick Alley, Kile Byer, Don Davis, Gary Dugger, Bennie Flynn, Rick Granger, Jack Hinbach, J. R. Hollers, Dave Jackson, Ben Jury, David Koutz, Nolan Lai, Nick Laskar, Tom Mauser, Ron Mutterspaugh. John Myers, Gene Poe, Tim Starkey, Gary Tucker, District 14 Director Tully Parker, Gene Poe, Bob Richwine, Stephen Schmutte. Oran Soulcs, Gary Tucker, and Adam Woosley. The Sponsors This year, about $4000 in gifts for the participants were donated by the following 23 local businesses. The AWS Indiana Section, Campbell Hausfield, Flynn Welding, Geiger & Peters, Inc., Hollers Welding. Indiana Oxygcn-Bloom- ington, Indiana Oxygen-Muncie, Indianapolis Welding Supply, Jackson Products, Kleindorfer's Hardware. The Lincoln Electric Co., Linde Gas, Major Tool & Machine, Inc., MacDonald's, Miller Electric Mfg. Co., New Castle Moose, Praxair, Pro Air, Inc., Smiley's Body Shop, Starweld, Sutton & Garten, Teepak LLC, and Wcstfield Steel. WELDING JOURNAL Fig. 6 — The first-place team trophy went to the Pike Central High Fig. 7 — Second-place team honors went to the Kentucky Tech Nel School team featuring (from left) Zach Leinenback, Adam Lutgring, son County team shown (from left) Josh Wiseman, Blake Rogers, Kyle Beiei; Zach Wehi; and Alex Renner. Jeremy Hicks, Ben Jury, and Brian Jones. against themselves. Let the judges' ratings great to see kids with that kind of adult the future of my chosen profession. I have fall where they may, all these students attitude toward hard work. You don't my own business and I also work in the want to do is to leave here knowing they often see that kind dedication in the av field for Indiana University, but volun did their best work. erage student. I do this volunteer work be teering to help the kids is the most re "Personally," Flynn said, "for me, it is cause of those welding students. They are warding to me.* Has the lack of a CWI become an obstacle to your success? The Hobart Institute of Welding Technology can provide the professional training you need to pass the Certified Welding Inspector and Educator exams. While nearly all of our students pass with j^jG? flying colors, those who don't the first time can return within six months free of charge.* We're that confident! Visual Inspection JJOBART INSTITUTE I IOFWELDINGTECHNOUXIYIJ Sep 13-15 ' Nov 8-10 • Mar 14-16 1930-2005 he Nissen Metal iMarkers utilize a specially-formulated paint Arc Welding Inspection & Quality Control to provide permanent marking under almost any conditions. They Sep 26-30 • Nov 14-18 • Jan 16-20 • Jun 5-9 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, Prep for AWS Welding Inspector/Educator Exam fade, or rub off. Oct 10-21 • Dec 5-16 • Feb 13-24 • Mar 20-31 • May 8-19 The markers are available in both an unbreakable plastic bottle and These and other comprehensive Technical Training the standard metal tube. They are available in three point sizes and 12 bright, lead-free, high gloss colors. courses are offered throughout the year- www.nissenmarkers.com Call Today! 1-800-332-9448 Call, Fax, or Write > for Additional Information. or visit us at www.welding.org for more information. *Some restrictions apply; please contact us for details. © 2005 Hobart Institute J.P. Nissen Co. of Welding Technology, Troy. OH. St. of Ohio Reg. No. 70-12-0064HT P.O. Box 339 • Glenside, PA 19038 (215) 886-2025 • Fax: (215) 886-0707 Circle No. 28 on Reader Info-Card Circle No. 31 on Reader Info-Card AUGUST 2005 NAVY JOINING ^SHHQ&w CENTER A MANTECH CENTER OF EXCELLENCE OPERATED BY EWI Collarless Construction Studied for Surface Ship Combatants he Navy Joining Center (NJC) is participating in a project to de Tvelop collarless construction tech niques for U.S. Navy surface shipbuilders in support of DD(X) (Fig. 1) system de sign. The project team combines the weld ing process expertise of Edison Welding Institute (EWI) and the state-of-the-art modeling capabilities of Advanced Com putational and Engineering Services (ACES), Northrop Grumman Ship Sys tems, and Bath Iron Works under the leadership of the Institute for Manufac turing and Sustainment Technology (iMAST). The objective of this project is to de termine an optimal collarless construction method to decrease fabrication costs and weight of the DD(X). Current Navy ship designs feature oversized rectangular openings cut from transverse stiffener webs to allow penetration of the longitu dinal stiffeners. In order to restore the structural integrity of the transverse stiff eners, each opening is filled by a "collar" that is welded to the web of the longitu Fig. 1 —An artist's conception ofthe DD(X) surface ship combatant. dinal stiffener and to the web of the trans verse stiffener. Fabricating and installing these collars element analysis validated by large-scale is labor intensive and costly, as they re physical testing. To date, hydrostatic and quire extensive fitting and welding time. longitudinal compression testing is com Heat from welding also creates distortion plete and results have exceeded the estab and residual stresses that can further in lished pass/fail criteria. Hydrostatic and crease construction costs generated by re longitudinal compression finite element work and repair. A design that does not models have also been successfully vali use collars will reduce fabrication costs dated. The design of fatigue test speci and save weight. mens is complete, and shock test designs In Phase I of the project, the team de are in process. The successful completion veloped a portfolio of innovative collar of these large-scale tests will permit the less designs. A comprehensive series of fi use of collarless construction techniques nite element analyses was then conducted for the DD(X). for the required loading scenarios for lon For more information, contact gitudinal and transverse connections — Fig. 2 — A representative finite element Nancy Porter at (614) 688-5194; Fig. 2. analysis of grillage structure with collarless nancy _porter(a ewi.org. Each connection was also evaluated construction. with regard to ease of production, pro duction time, and cost savings with the goal of down selecting collarless construc oughly evaluate the structural perform The Navy Joining Center tion options that have comparable ance of the baseline Navy collar design 1250 Arthur E. Adams Dr. strength to a baseline collar design. The and the collarless construction design op Columbus, OH 43221 winning alternatives were then carried tions. Planned structural tests include Phone: (614) 688-5010 into Phase II for testing and analysis shock, hydrostatic loading, longitudinal FAX: (614) 688-5001 e-mail: NJCfaewi.org validation. compression, and transverse fatigue. For www: http://www.ewi.oig During Phase II, the project team iden each structural evaluation, detailed test Contact: Larry Brown tified a series of physical tests to thor- plans were developed that featured finite WELDING JOURNAL COMING EVENTS NOTE: A DIAMOND (*) DENOTES AN AWS-SPONSORED EVENT. 4th Int'l Surface Engineering Congress and Exhibition, and 19th • Materials Science & Technology Conference and Exhibition. Int'l Conference on Surface Modification Technologies. Aug. Sept. 25-28, David L. Lawrence Convention Center, Pittsburgh, 1-3, Radisson Riverfront Hotel, St. Paul, Minn. Contact ASM Pa. Held in conjunction with the ASM Heat Treating Society Con Int'l at www.asminternational.org/surface. ference. Contact www.matscitech.org. EPRI Int'l Conference on Maintenance. Aug. 8-10, Jersey City, Metalform Mexico 2005. Sept. 28-30, Monterrey, Mexico. Con N.J. To focus on both nuclear and fossil maintenance issues. Spon tact Graylin Presbury [email protected]. sored by Electric Power Research Institute (EPRI). Contact http:/'/inter, viewcentral. com/reg/epri/2453. 5th Int'l Forum on Aluminum Ships. Oct. 11-13, Zenkyoren Bldg. Tokyo, Japan. All business conducted in English. Contact Standards Engineering Society Annual Conference. Aug. 15, 16, The Society of Naval Architects of Japan, [email protected]. Omni Charlotte Hotel, Charlotte, N.C. Contact H. Glenn Ziegen fuss [email protected] or visit www.ses-standards.org. Expo FABTEC-Canacintra. Oct. 12-14. World Trade Center, Mexico City, Mexico. Contact Grupo MFV Mexico, Schweissen & Schneiden 2005, 16th Int'l Welding Fair. Sept. www.grupomfv.com; [email protected]. 12-17, Essen, Germany. Joining, cutting and surfacing, with Qual ity Testing Int'l, and Structural Bonding Int'l. Sponsored by Messe 15th Korea Machinery Fair (KOMAF 2005). Oct. 26-30, Korea Essen and DVS (German Welding Society). For complete infor Int'l Exhibition Center, Koyang, Korea. For complete informa mation, visit www.schweissenuschneiden.de. tion, visit www.komaf.org. rd 3 China Int'l Coking Technology and Coke Market Congress. ICALEO® 2005, 24th Int'l Congress on Applications of Lasers Sept. 14, 15, Crowne Plaza Park View, Wuzhou, Beijing, China. and Electro-Optics. Oct. 31-Nov. 3, Hyatt Regency, Miami, Fla. Contact www.coke-china.com. Contact the Laser Institute of America at www.laserinstitute.org. EMO Hannover: The World of Machine Tools & Metalworking. Assn. for Manufacturing Excellence National Conference. Oct. Sept. 14-21, Fairgrounds, Hannover, Germany. Contacts: 31-Nov. 4,Westin Copley Place Hotel, Boston, Mass. Cost is www.emo-hannover.de; Hannover Fairs USA, Angela Dessables, $2120, $1995 for AME members. Contact AME (847) 520-3282, at [email protected]. ext. 226; www.ame.org. BEVEL-MILL® Why buy a shop PLATE BEVELERS full of machines? *Super capacity When you can buy 1 that can do the work of many. *Fast-clean bevels up to 1 3/16' *Variable angle *Made in U.S.A. quality |% Jancy Engineering Inc. introduces the RadiusMoster. The RadiusMoster is a patented Several models available belt grinding machine which utilizes advanced technology that allows it to convincingly FREE CATALOG outperform all other general purpose belt grinders. It grinds, notches, sharpens, Call 1-800-886-5418 polishes, deburs and much more. For more information and to view a larger list of Fax 1-810-632-6640 uses visit Jancy.com or call 877-SLUGGER. www.heckind.net JANCY P.O. Box 425 Hartland, Michigan 48353 2735 Hickory Grove Rd. Davenport, IA 52804 • 877-SLUGGER (758-4437) Heck Jancy.com • e-moil: [email protected] INDUSTRIES INC Circle No. 27 on Reader Info-Card Circle No. 30 on Reader Info-Card AUGUST 2005 15th Steelmaking Conference and 5th Ironmaking Conference. Nov. 7-10, Hotel Colonial, San Nicolas, Argentina. Contact Ar gentina Iron and Steel Institute, www.siderurgia.org.ar. Aerospace Testing Expo 2005 North America. Nov. 8-10, Long Beach Convention Center, Long Beach, Calif. For complete in formation, visit www.aerospacetesting-expo.com/northamerica. Rustproof • FABTECH International & The AWS Welding Show. Nov. 13-16, McCormick Place South, Chicago, 111. Contact American Welding Society, (800) 443-9353, ext. 462; www.aws.org. Iron & Steel Interkama Asia. Nov. 28-Dec. 1, Shanghai, China. Sponsored by Deutsche Messe AG. Contact www.interkama-asia.com. NEW 2005 World Steel Bridge Symposium and Workshops. Nov. 29-Dec. 2, Orlando, Fla. Sponsored by National Steel Bridge Al liance and Federal Highway Administration. Contact www.ns- Developed for baweb.org. the galvanizing FabForm 2005. Dec. 6-8, Exhibition Center, Nuremberg, Ger many. Encompasses key sectors of sheet metal forming and fab industry. ricating technologies. Contact www.fabform.de. Motorsports — Manufacturing for Performance. Jan. 23-25, 2006, Indiana Convention Center, Indianapolis, Ind. Contact www.sme.org. METALFORM Regional Trade Show. March 21-23, 2006, Nashville, Tenn. Sponsored by the Precision Metalforming Assn. briteproducts.com Contact www.metalform.com. A Division of Weld-Aid Products The Total Manufacturing Experience. March 27-30, 2006, Los Phone: 1-888-99BRITE • Fax: 313-883-4930 Angeles Convention Center, Los Angeles, Calif. Colocates WESTEC 2006, the SME Summit, Automation & Assembly Con Circle No. 40 on Reader Info-Card ference and Exhibits, Micro-Manufacturing Conference, and the Nano-Manufacturing Conference. Contact Society of Manufac turing Engineers (800) 733-4763; www.sme.org. Pacific Int'l Conference on Applications of Lasers and Optics. May 15-17, 2006, Melbourne, Australia. Contact www.laserinsti- titte.org/conferences. Beijing Essen Welding and Cutting Fair. June 28-July 1, 2006, Intl Exhibition Center, Beijing, China. Contact www.beijing-essen- welding.de. Educational Opportunities Workshop for Friction Stir Welding Technology for Defense Applications. Aug. 17, 18, Edison Welding Institute (EWI), Columbus, Ohio. Organized by The Navy Joining Center, and National Center for Excellence in Metalworking Technology. Contact Connie S. Kotula, EWI, 1250 Arthur E. Adams Dr., Columbus, OH 43221; (614) 688-5156; [email protected]. Blodgett's Welding Design Seminar. Oct. 11-13, Cleveland, Ohio. Contact: The Lincoln Electric Co., 22801 St. Clair Ave., HEAVY DUTY TUNGSTEN GRINDER Cleveland, OH 44117. Tuition is $595. To register contact (216) 383-2240, www. lincolnelectric. com/knowledge/training/seminars. FOR 3/16" - .040" SAFETY: Enclosed diamond wheel grinding area Engineering Effective Team Management and Practice Seminar. WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability Aug. 15-17. Troy, Mich. Designed for managers at all levels, PRODUCTIVITY: Longitudinal diamond grind vour tungsten under 30 seconds including those preparing to take on management responsibilities VALUE: Diamond Bat, grind & cut your tungsten economically for the first time. Fees, including lunch and refreshments, are $1235, $1135 for members of the Society of Automotive DIAMOND GROUND PRODUCTS * Engineers (SAE). Contact SAE Int'l, (877) 606-7323; www.cus- 2550 A/urile Circle, Newbury Park, California 91320 cj- tom erseivice @sae. org. Phune (805) 498-3837 • FAX 1805) 498-9347 Email: [email protected] * Website: www.dianiondgrouiid.coin Circle No. 22 on Reader Info-Card WELDING JOURNAL AWS 2005 Schedule City Exam Prep CWI/CWE CWI/CWE Prep Courses and Exams Course Exam Exam applications must be submitted six weeks before the exam Dallas, Tex. Nov. 14-19 No Test date. For exam information and an application, contact the AWS 9-Year Recertification Course Certification Dept., (800) 443-9353, ext. 273. For exam prep Denver, Colo. Oct. 2-7 Oct. 8 course information, contact the AWS Education Dept., (800) 443- 9353, ext. 229. (API 1104 Clinic also offered) Detroit. Mich. Sept. 25-30 Oct. 1 (API 1104 Clinic also offered) Houston. Tex. Aug. 14-19 Aug. 20 (API 1104 Clinic also offered) City Exam Prep CWI/CWE Long Beach. Calif. Nov. 6-11 Nov. 12 Course Exam (API 1104 Clinic also offered) Louisville. Ky. Nov. 13-18 Nov. 19 Anchorage, Alaska EXAM ONLY Sept. 24 (API 1104 Clinic also offered) Atlanta, Ga. Oct. 23-28 Oct. 29 Memphis. Tenn. Aug. 7-12 Aug. 13 (API 1104 Clinic also offered) (API 1104 Clinic also offered) Baltimore, Md. Oct. 30-Nov. 4 Nov. 5 Miami, Fla. EXAM ONLY Aug. 18 (API 1104 Clinic also offered) Miami, Fla. EXAM ONLY Sept. 15 Beaumont, Tex. Nov. 6-11 Nov. 12 Miami, Fla. EXAM ONLY Oct. 20 (API 1104 Clinic also offered) Miami, Fla. Dec. 4-9 Dec. 10 Charlotte, N.C. Aug. 21-26 Aug. 27 (API 1104 Clinic also offered) (API 1104 Cli: also offered) Milwaukee, Wis. Sept. 25-30 Oct. Chicago, Oct. 23-28 Oct. 29 (API 1104 Clinic also offered) (API 1104 Clinic also offered) Minneapolis, Minn. Sept. 18-23 Sept. 24 Columbus, Ohio Aug. 8-12 Aug. 13 (API 1104 Clinic also offered) (MBBPVI) New Orleans. La. Sept. 11-16 Sept. 17 Columbus, Ohio Dec. 5-9 Dec. 10 (API 1104 Clinic also offered) (MBBPVI) Orlando, Fla. Dec. 5-10 No Test Corpus Christi, Tex. EXAM ONLY Dec. 17 9-Year Recertification Course Dallas, Tex. Sept. 25-30 Oct. 1 Phoenix. Ariz. Oct. 2-7 Oct. 8 (API 1104 Clinic also offered) (API 1104 Clinic also offered) Pittsburgh. Pa. Oct. 16-21 Oct. 22 (API 1104 Clinic also offered) Portland, Ore. Nov. 6-11 Nov. 12 (API 1104 Clinic also offered) Reno, Nev. Oct. 30-Nov. 4 Nov. 5 (API 1104 Clinic also offered) % TRIANGLE Rochester, N.Y. EXAM ONLY Aug. 20 I ^ ENGINEERING, INC. St. Louis, Mo. EXAM ONLY Dec. 3 Salt Lake Citv. Utah Aug. 7-12 Aug. 13 (API 1104 Clinic also offered) Services for the Welding Industry San Antonio. Tex. Oct. 16-21 Oct. 22 (API 1104 Clinic also offered) San Diego, Calif. Aug. 22-27 No Test • Weld engineering and consulting-WPS, PQR 9-Year Recertification Course • Welder training and qualification coupons San Diego, Calif. Sept. 18-23 Sept. 24 (API 1104 Clinic also offered) • Destructive test equipment San Juan. P.R. Dec. 4-9 Dec. 10 (API 1104 Clinic also offered) • Full testing services Seattle, Wash. Sept. 18-23 Sept. 24 (API 1104 Clinic also offered) Sioux Falls. S.Dak. Nov. 13-18 Nov. 19 Sustaining Member (API 1104 Clinic also offered) Syracuse, N.Y. Sept. 11-16 Sept. 17 (API 1104 Clinic also offered) Tulsa, Okla. Oct. 16-21 Oct. 22 (API 1104 Clinic also offered) INTERNATIONAL COURSES Weld Coupon The Mexico training and testing location is DALUS, S.A. de Abrasive Cutter C.V., Monterrey, N.L. Contact: Lorena Garza at [email protected]. DALUS is an AWS-accredited training and P.O. Box 1205, 6 Industrial Way testing facility. It employs the S.E.N.S.E. (Schools Excelling West Hanover, MA 02339 Through Skill Standards Education) programs. (781)878-1500 • (781)878-1374 • Fax(781)878-2547 www.tneng.com Monterrey, Mex. Nov. 7-11 Nov. 12 Circle No. 38 on Reader Info-Card AUGUST 2005 BY HOWARD M. WOODWARD Cincinnati Int rejig ces Kids to a eventy-two kids, including two Cub Scout troops, had the time of their lives learning about and performing welding operations Sat a Cincinnati Section program dedi cated "to introducing kids to the excite ment of welding." Ranging in age from 8 to 18, the boys and girls came from far and wide at tracted by invitations and meeting no tices posted by Section members at local welding supply house counters, and at local schools. Cincinnati Section Chair Eric Johnson invented the idea for a kids welding party right after he at tended the 2004 AWS Leadership Sym AFTER: Alex Prokopchak literally had posium. Johnson said he patterned the her eyes opened to the joys of welding. kids welding night after a 4H youth welding event organized by Larry Heck BEFORE: Len Prokopchak gives his endorn in Columbus, Ohio. daughter, Alex, her first welding lesson. Meeting host Steve Rottman, a welding instructor at J. D. Patton Vo The event required the coordination cational School, opened the evening of the vocational school, instructors, with the basic ground rules and safety and sponsoring businesses. instructions. Welding supplier F&M Mafco do Six instruction booths were set up nated the extra-small-size gloves and for gas metal arc welding, gas tungsten the brightly colored welding caps for the arc welding, and plasma arc cutting, event. each manned by an expert who guided Johnson said, "It was great to see all each youth safely through the learning those kids moving around wearing their experience. red beanies looking just like real Two scout troops joined the event. welders." Johnson was convinced now, Scoutmaster Thorn Ball, a CWI and "Let a kid strike his first arc and he will Nine-year-old Lucas Aschemeier experi ASNT Level III, said, "The kids had a never forget it. These kids will think of enced gas metal arc welding first-hand great time and they could not wait until welding as a creative and very desirable under the sharp eye of Lou Vitucci, a they could weld again." occupation." • Lincoln Electric district sales manager. WELDING JOURNAL Tech Topics Technical tion in a standardized 37-pin connector Committee are proposed. Stakeholders: Any indus OPPORTUNITIES try using arc welding robots. Revised Meetings standard: P. Howe, ext. 309. BSR/AWS D16.3M/D16.3:200X, Ship and Boatbuilding WS technical committee meet Risk Assessment Guide for Robotic Arc ings arc open to the public. If you Welding. D3A Committee Awant to attend a meeting, con AWS D16.3M/D16.3, Risk Assess tact the staff secretary of the commit ment Guide for Robotic Arc Welding, pro The D3A Committee seeks vol tee as listed below at AWS, 550 NW vides recommendations and guidelines unteers to help revise D3.7, Guide LeJeune Rd., Miami, FL 33126; tele for the safe application of robotic arc for Aluminum Hull Welding, and phone (305) 443-9353. welding. Emphasis is placed on confor D3.5, Guide for Steel Hull Welding. Aug. 10, Int'l Standards Activities mance of this process with prevailing in Topics include design, cutting, quali Committee. Columbus, Ohio. General dustry standards for hazard analysis and fication, construction practices, meeting. Staff contact: A. Davis, ext. proper safeguarding. Stakeholders: inspection, and welding processes 466. Any industry using arc welding robots. and equipment. Contact Brian Aug. 11, 12, Technical Activities Revised standard: P. Howe. ext. 309. McGrath, (800) 443-9353, ext. 311, Committee. Columbus, Ohio. General bmcgrath @aws. org. meeting. Staff contact: P. Howe, ext. Standards for Public Review 309. AWS was approved as an accredited stan Aug. 30, D15 Committee on Rail dards-preparing organization by the Ameri road Welding. St. Louis, Mo. Standards can National Standards Institute (ANSI) in preparation. Staff contact: R. Hancock, 1979. AWS rules, as approved by ANSI, re ext. 226. quire that all standards be open to public re Aug. 30, D15A Subcommittee on view for comment during the approval Iron Castings Freight Cars and Their Materials. St. process. The following standards are submit Louis, Mo. Standards preparation. Staff ted for public review. Draft copies may be D11 Committee contact: R. Hancock, ext. 226. obtained from Rosalinda O'Neill, (800/305) Sept. 12-17, Dl Committee on 443-9353, ext. 451, [email protected]. The Dl l Committee seeks vol Structural Welding. Minneapolis, Minn. A2.4:200X, Specification for Standard unteers to help revise Dl 1.2-89, Standards preparation and general Symbols for Welding, Brazing, and Nonde Guide for Welding Iron Castings. meeting. Staff contact: J. Gayler, ext. structive Examination. Revised standard — Experts in the welding of iron cast 472. $82.50. ANSI public review expires 8/23/05. ings as well as users of iron castings Sept. 21, SH4 Subcommittee on La D1.1/D1.1M:2006, Structural Welding are urged to participate in this beling and Safe Practices. Pittsburgh, Code — Steel Revised standard — $200. important work. Contact John Pa. Standards preparation. Staff con ANSI public review expires 8/16/05. Gayler, (800) 443-9353, ext. 472, tact: S. Hedrick, ext. 305. D14J/D143M:200X, Specification for gayler@a ws. org. Welding Earthmoving, Construction, anclAgri- Standards for PINS cultiiral Equipment. Revised standard — Development work has begun on the $61.50. ANSI public review expires 8/23/05. following new or revised standards. D14.7/D14.7M:200X, Recommended Concerned individuals are invited to Practices for Si n facing and Recoi tditioning of contribute to the development of these IndustrialMill Rolls. Newstandard— $32.50. standards. Participation on AWS Tech ANSI public review expires 8/23/05. Inspection nical Committees and Subcommittees D18.3/D 18 JM:200X, Specification for B1 Committee is open to everyone. Contact the staff Welding of Tanks. Vessels, and Other Equip secretary listed with the document for ment in Sanitary (Hygienic) Applications. New- The Bl Committee on Methods complete information. standard — $25. ANSI public review expires of Inspection seeks volunteers to BSR/AWS D16.2/D16.2M:200X, 8/23/05. help revise AWS B 1.10:1999, Guide Guide for Components of Robotic and for the Nondestructive Examination Automatic Arc Welding Installations. Revised Standards Approved by ANSI of Welds, and AWS B 1.11:2000, AWS/NEMA D16.2/D16.2M, Guide A5.l8/A5A8M:2W5,SpecificationforCar- Guide for the Visual Examination of for Components of Robotic and Auto bon Steel Electrodes at id Rods for Gas Shielded Welds. Meetings will be held using matic Arc Welding Installations, provides Arc Welding. Approval date 6/9/05. the Internet, teleconferences, and performance recommendations for A5.29/A5.29M:2005, Specification for e-mail. A face-to-face meeting may evaluating components of a typical ro Low-Alloy Steel Electrodes for Flux Cored Arc be held during the next AWS botic or automatic welding installation. Welding Approval date 6/8/05. Welding Show. Nov. 13-16, 2005, in Emphasis is placed on the role of the D14.4/D14.4M:2005, Specification for Chicago. Contact Brian McGrath, welding interface. A pin arrangement Welded Joints in Machinery and Equipment. (800) 443-9353, ext. 311, bmcgrath and specific pin function for each loca Approval date 6/10/05. • @a ws.org. • M AUGUST 2005 AWS Staffs for the Future at Annual Transition Meeting amian J. Kotecki was installed as AWS president in a cere D mony held June 6 at AWS head quarters in Miami, Fla. Dr. Kotecki and his three vice presi dents will serve a 19-month term, end ing January 1, 2007, to facilitate chang ing the Society's fiscal year to begin Jan uary 1. Kotecki said in his acceptance talk that 41 years ago, within a brief six- month period, he made three life- changing decisions: he married Kate, went to college, and joined the Ameri can Welding Society. He noted they were all excellent decisions, and he looks forward to working with AWS staff and volunteers as their president. Victor Y. Matthews, accompanied by wife, Sally, was formally installed for his Kate Kotecki and Ray Shook unveil President Damian Kotecki's official portrait. first term as a vice president. On hand for the event were vice presidents Gene Lawson and Jerry Uttrachi, and James E. Greer, AWS president 2004-2005. A highlight of the annual transition event is the presentation of the AWS Michael A. Rowland Employee ofthe Year Award. The award recognizes an AWS employee who has demonstrated exceptional service and contributions to the Society. All AWS staff members are invited to nominate a colleague for the honor, which includes an engraved plaque/clock, $1000 cash, a $75 certifi cate for dinner at an area restaurant, and a reserved parking space. AWS Executive Director Ray Shook and James Greer introduced 12-year employee Hidail Nunez as the 2005 Michael A. Rowland Employee ofthe Hidail Nunez (center), Michael A. Rowland AWS Employee ofthe Year, is shown with Year. Shook said, "Nunez, who works A WS Executive Director Ray Shook (left), and Jim Greer, A WS president 2004-2005. in Accounting and Purchasing, is cited for doing an excellent job juggling both to satisfy his customers' needs. job. He has put in extra effort familiar duties. He has done a wonderful job "He has become very knowledgeable izing himself with each product, and has working with his fellow staff members, in this field and is extremely helpful. Al requested samples for staff members to asking questions in order to understand though the added Purchasing responsi view to ensure accuracy before order their needs, looking for new vendors to bilities entail additional effort and ded ing. He always exhibits a great attitude, get better prices and quality, becoming ication in learning and researching, and the service he provides is always very informed, and going the extra mile Hidail Nunez has done an exceptional with a smile."* Nominations Sought for 2006 Prof. Masubuchi Award ominations are sought for the or younger, and may live anywhere in interests and accomplishments, educa 2006 Prof. Koichi Masubuchi the world. The candidate need not be tional background, professional experi N Award, sponsored by the Dept. an American Welding Society member. ence, publications, honors, and 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 to technology of welding, especially marine tions to the advancement of the science five letters of recommendation from re and outer space structures. and technology of materials joining searchers familiar with the candidate. December 1, 2005, is the deadline. through research and development. The resume should include a summary Submit your nomination to Prof. John The candidate must be 40 years old statement of the candidate's research DuPont [email protected].• WELDING JOURNAL isted are the participants in the T. Shirk, Tidewater — 4 D. Zabel, Southeast Nebraska — 18 2004-2005 Campaign. See page 81 H. Shore, Tulsa — 4 M. Anderson, Indiana — 17 Lfor campaign rules and prize list. D. Wright, Kansas City — 4 T. Baldwin, Arrowhead — 17 Call Membership Dept. (800) 443-9353, B. Franklin, Mobile — 3 C. Donnell, Northwest Ohio — 17 ext. 480, for more information. E. Levert, North Texas — 3 J. Fox, Northwest Ohio — 17 Congratulations to the MGM Cam G. Navas, Washington, D.C. — 3 D. Marks, Lehigh Valley — 17 paign winners! T. Neubauer, Sangamon Valley — 3 P. Bedel, Indiana — 16 N. Rampersad, International — 3 D. Newman, Ozark — 16 Most New Individual Members: T. Baldwin, Arrowhead — 2 J. Carey, Boston — 15 Michael Karagoulis, Detroit M. Batchelor, Boston — 2 J. Daugherty, Louisville — 14 Most New Student Members: A. Baughman, Stark Central — 2 J. Davis, Baltimore — 14 Charles Daily, Puget Sound A. Burton, Chicago — 2 B. Lavallee, Northern New York — 14 J. Campbell, Milwaukee — 2 A. Badeaux, Washington, D.C. — 13 Winner's Circle J. Cantlin, Southern Colorado — 2 D. Kowalski, Pittsburgh — 13 AWS Members who have sponsored 20 or J. Carney, Western Michigan — 2 H. Jackson, L.A./lnland Empire — 13 more new Individual Members, per year, K. Carter, Tri-River — 2 D. Schnalzer, Lehigh Valley — 13 since June 1, 1999. C. Daily, Puget Sound — 2 A. Stute, Madison-Beloit — 13 J. Compton, San Fernando Vallev5 M. Darnell, San Antonio — 2 D. Combs, Santa Clara Valley — 12 E. Ezell, Mobile3 M. Davidson, Tulsa — 2 V. Covey, Central Texas — 12 J. Merzthal, Peru2 J. Emmerson, Connecticut — 2 S. Robeson, Cumberland Valley — 12 B. Mikeska, Houston1 K. Erickson, Florida West Coast — 2 R.Collins, New York —11 R. Peaslee, Detroit1 G. Fudala, Philadelphia — 2 L. Davis, New Orleans — 11 W Shreve, Fox Valley1 G. Garner, St. Louis — 2 C. Kipp, Lehigh Valley — 11 G. Taylor, Pascagoula2 P. Harper. Baton Rouge — 2 B. Yarrison, York-Central Pa. — 11 M. Karagoulis, Detroit1 B. Jaskulski, Western Michigan — 2 T. Moore, New Orleans — 10 S. McGill, Northeast Tennessee1 D. Kensrue, Long Bch./Orange Cty. — 2 R. Thomas, Sr., Holston Valley — 10 T. Weaver, Johnstown/Altoona1 J. Krall, Dayton — 2 A. Demarco, New Orleans — 9 G. Woomer, Johnstown/Altoona1 P. Layola, Int'l — 2 W Harris, Pascagoula — 9 R. Wray, Nebraska1 R. Nielsen, Utah — 2 G. Putnam, Green & White Mts. — 9 Superscript denotes the number of times R. Olson, Siouxland. — 2 R. Tupta, Milwaukee — 9 an Individual Member achieved Winner's H. Riviere, South Florida — 2 R. Chase, L.A./lnland Empire — 8 Circle status. Status is awarded at the close R. Robles, Corpus Christi — 2 M. Koehler, Milwaukee — 8 of each membership campaign year. D. Russell, Chattanooga — 2 G. Seese, Pittsburgh — 8 S. Salamon, New Jersey — 2 C. Wesley, Northwestern Pa. — 8 President's Guild W Scarince, Northwest — 2 T. Alberts, Southwest Virginia — 7 A WS Members sponsoring 20 or more new G. Schroeter, Central Nebraska — 2 J. Crosby, Atlanta — 7 Individual Members between June 1, 2004, O. Templet. Baton Rouge — 2 R. Grays, Kern — 7 and May 31, 2005. R. Palovcsik, St. Louis — 7 M. Karagoulis, Detroit — 43 Student Sponsors J. Swoyer, Lehigh Valley — 7 E. Ezell, Mobile — 29 A WS Members sponsoring 3 or more new J. Carney, Western Michigan — 6 J. Compton, San Fernando Valley — 28 A WS Student Members between June 1, M. Hill, Lexington — 6 2004, and May 31, 2005. W Kielhorn, East Texas — 6 President's Roundtable C. Daily, Puget Sound — 105 T. Moffitt, Tulsa — 6 A WS Members sponsoring 11-19 new In G. Euliano, Northwestern Pa. — 78 T. Shirk, Tidewater — 6 dividual Members between June 1, 2004, M. Pointer, Sierra Neveda — 46 M. Tait, L.A./lnland Empire — 6 and May 31, 2005. R. Norris, Maine — 44 D. Vranich, North Florida — 6 G. Taylor, Pascagoula — 16 R. Olson, Siouxland. — 43 J. Boyer, Lancaster — 5 D. Herr, York-Central Pa. — 12 K. Langdon, Johnny Appleseed — 29 C. Bridwell, Ozark — 5 W. Shreve, Fox Valley — 12 D. Harrison, Detroit — 28 R. Ledford, Birmingham —5 H. Hughes, Mahoning Valley — 27 R. Rux, Wyoming — 5 President's Club D. Atteridge, Inland Empire — 25 G. Bish, Atlanta —4 A WS Members sponsoring 6-10 new In D. Ketler, Willamette Valley — 24 P. Carney, Lehigh Valley — 4 dividual Members between June 1, 2004, D. Scott, Peoria — 24 R. Hilty, Pittsburgh — 4 and May 31, 2005. A. Baughman. Stark Central — 22 J. Knapp, Tulsa — 4 J. Bobo, Atlanta — 9 W Campbell, Mid-Ohio — 22 R. Robles, Corpus Christi — 4 J. McCarty, St. Louis — 9 N. Carlson, Idaho/Montana — 22 B. Taves, Puget Sound — 4 R. Culbert, Inland Empire — 8 J. Pelster, Southeast Nebraska — 22 R. Theiss, Houston — 4 T. Buchanan, Mid-Ohio — 21 S. Ulrich, St. Louis — 4 President's Honor Roll P. Childers, Oklahoma City — 21 M. Collins, Charlotte — 3 A WS Members sponsoring 1-5 new Indi J. Sullivan, Mobile — 21 S. Colton, San Diego — 3 vidual Members between June 1, 2004, F. Wernet, Lehigh Valley — 21 S. Gore, Charlotte — 3 and May 31, 2005. A. Reis, Pittsburgh —20 T. Gordon, Sabine — 3 O. Baker, Olympic — 5 T. Geisler, Pittsburgh — 19 J. Hope, Puget Sound — 3 J. Jaeger, Kansas — 5 D. Hatfield, Tulsa— 19 J. Hurry, Washington D.C. — 3 M. Tryon, Utah — 5 S. Siviski, Maine — 19 T. Kienbaum, Colorado — 3 B. Breeden, Santa Clara Valley — 4 R. Boyer, Nevada— 18 J. Morash, Boston — 3 G. Euliano, Northwestern Penn. — 4 W Galvery, Long Bch./Orange Cty.— 18 R. Olesky, Pittsburgh — 3 D. Guthrie, Tulsa — 4 D. Roskiewich, Philadelphia — 18 R. Richwine, Indiana — 3 C. Reeves, Oklahoma City — 4 A. Vidick, Wyoming — 18 J. Sullivan, Holston Valley — 3* AUGUST 2005 SECTION NEWS DISTRICT 1 • • Director: Russ Norris Tl pmBv Phone: (603) 433-0855 r *' ' 1 DISTRICT 1 CONFERENCE MAY 21 Activity: Russ Norris, District 1 direc tor, headed the meeting attended by representatives from the Boston, Cen — tral Massachusetts, Connecticut, Green ' Ik • • • Jfr* • & White Mountains, Maine, and Mon i treal Sections. Tom Ferri, Boston Sec Shown during the Boston Section tour are Tom Ferri (left) accepts his Silver Mem tion, was presented his Silver Member (from left) welder Brian Bates, engineer ber Award from Jim Reid at the District Award for 25 years of membership in Pete Morin, and Tom Ferri. 1 Conference in May. the Society. The event was held at Wa- terville Valley Ski Resort in New Hamp shire. BOSTON MAY 23 Activity: The Section members toured AZZ/CGIT in Westborough, Mass., to study the manufacture of aluminum compressed gas insulated power trans mission bus systems. Both GMA and GTA welding methods were presented in detail. The tour was led by Pete Morin, senior manufacturing engineer, and Brian Bates, lead welder. One ofthe Connecticut Section members CONNECTICUT is shown making a virtual weld at the Billy Bisher took speed metal-cutting hon APRIL 19 state-of-the-art VRSim training facility in ors during the Career Institute of Tech Speaker: Matt Wallace, CEO New Britain, Conn. nology Student Chapter's visit to GTS. Affiliation: VRSim, New Britain, Conn. Topic: Virtual environment welder ing and Testing Institute (WTTI). At training DISTRICT 2 GTS, the students participated in a Activity: Each attendee took the oppor Director: Kenneth R. Stockton speed metal-cutting contest where Billy tunity to enter the virtual welding train Phone: (732) 787-0805 Bisher took top honors at 46 seconds. ing environment to make a virtual weld. Following a tour of WTTI, Allentown, The facility was created by VRSim with Pa., the group proceeded for a power funding from the Office of Naval Re lunch to discuss the day's activities. search via the Navy Joining Center at DISTRICT 3 the Edison Welding Institute. Director: Alan J. Badeaux, Sr. Phone:(301)934-9061 READING MAY 5 GREEN & WHITE MTS. Career Institute of Technology Activity: The Section presented its an APRIL 14 Student Chapter nual Senior Awards plaques to the lead Speaker: Wesley Mekrit ing seniors in each of the vocational MAY 12 Affiliation: Mekrit Sales technical schools in the area. The win Topic: GTA welding Activity: The Student Chapter, Chris Kip, advisor, enjoyed an educational ners were Sean T. Kotyk, Berks County Activity: The program included a hands- Career and Technology Center; Keith on opportunity to get the feel for cold field trip to two companies in the Eas ton, Pa., area, GTS and Welder Train- Martin, Lancaster County Career and wire feed, and sharpening tungsten tips. Technology Center; Anna Shaw, Lan- WELDING JOURNAL Michael Bannester (right) accepts his Chairman's Appreciation Award from Mike Klinkroth at the North Central Florida Program in May. Career Institute of Technology Student Chapter members huddle at WTTI to leant about caster Mennonite High School; Bradley inspection of welds. G. Hess, Lebanon County Career and Technology Center; and Jackson Baez, Reading-Muhlenberg Area Vo-Tech. YORK-CENTRAL PA. APRIL 7 Speakers: Ken Ellis and Scott Shehab Affiliation: CNH Engineering Activity: Special guests at the program were past-AWS President Bill DeLong, AWS President Jim Greer, and District 3 Director Alan Badeaux. The program was held at Four Points Sheraton Hotel. DISTRICT 4 Director: Ted Alberts Phone: (540) 674-3600, ext. 4314 DISTRICT 5 Director: Leonard P. Connor Phone: (954)981-3977 Shown at the York-Central Pennsylvania Section program are (front, from left) Ken Ellis NORTH CENTRAL FLORIDA and Scott Shehab; (standing, from left) Cochair George Bottenfield, A WS President MAY 10 Jim Greer, past-AWS President Bill DeLong, District 3 Director Alan Badeaux, and Activity: The Section members toured Cochair Mike Bunnell. the OFAB facility in Ocala, Fla., to study its laser beam cutting operations. Mike Klinkroth described the various processes, then presented Chairman Michael Bannester with the Section's Certificate of Appreciation Award. SOUTH CAROLINA MAY 19 Activity: The Section once again hosted its annual "Pig Pickin' Social" at Haselden and Co., Inc., in Mt. Pleasant, S.C. Featured were the installation of officers, and the presentation ofthe Life Membership Award to U. G. William son, Jr., for 35 years of membership in the Society. Williamson founded Williamson's Welding and Burning Co. in 1977. On hand for the event were his wife, Carol; daughter. Barbara Ellis; Shown at the South Carolina Section's Pig Pickin' Social are (from left) Nathan Haynes, son and a welder, David; and grandson Carol and U. G. Williamson, Jr., Barbara Ellis, and David Williamson. and a welder, Nathan Haynes. AUGUST 2005 DISTRICT 6 Director: Neal A. Chapman Phone: (315)349-6960 DISTRICT 7 Director: Don Howard Phone: (814)269-2895 DISTRICT 8 Director: Wallace E. Honey Winners in the New Orleans redfish event were (from left) Derrick Gros, Mark Carte, Phone: (256) 332-3366 Craig Collins, Joe Tortomase, and Randy Steverson. NORTHEAST MISSISSIPPI MAY 26 Activity: The Section hosted its instal lation of officers program at Richey's Restaurant in Starkville, Miss. The new slate includes Charles Slayton, chair; Larry Odom and Brent Davis, vice chairs; Wendy Sloan, treasurer; and Robbin Shull, secretary. DISTRICT 9 Director: John Bruskotter Phone:(504)394-0812 Winners in the New Orleans speckled trout class were (from left) Brandon Ledet, Barry NEW ORLEANS Plaisance, Kyle Schellhaas, Randy Steverson, and Dwayne New. MAY 7 Activity: The Section members hosted their 7th Annual Fishing Rodeo to raise money for its welding students' educa DISTRICT 11 tions. The winners in the redfish divi Director: Eftihios Siradakis sion were Derrick Gros, Mark Carte, Phone: (989) 894-4101 Craig Collins, Joe Tortomase, and Randy Steverson. The winners in the NORTHWEST OHIO speckled trout class were Brandon MAY 10 Ledet, Barry Plaisance, Kyle Schell- Speaker: Joe Rutherford, administrator haas, Randy Steverson, and Dwayne Affiliation: Ohio D.O.T. New. The Calcutta class winners were Topic: Construction ofthe 1-280 cable Tim Clement and Kyle Schellhaas. stay bridge spanning the Maumee River Activity: Anthony Stryz and Dennis Humbert, respectively, received their Tim Clement (left) and Kyle Schellhaas Gold and Silver Membership Awards. revel in their victories at the New Orleans District 11 Director Eftihios Siradakis Section's fishing rodeo fund-raiser. DISTRICT 10 presented the District Meritorious Award to Larry Blake and Dick West. Director: Richard A. Harris The Section presented its Distinguished Phone: (440) 338-5921 Service Award to Chair Dick West. Spe cial guests at the dinner were five past NORTHWESTERN PA. chairmen: Terry Lowe, Tom Ball, James MAY 10 Sommers, Harvey Weide, and Anthony Speaker: Robert Hetzendorfer, techni Stryz. The program was held at HJ's cal representative Prime Cut in Toledo, Ohio. Affiliation: The Lincoln Electric Co. Topic: Retrofitting Bay bridges to with stand earthquakes WESTERN MICHIGAN Activity: Chair Chet Wesley presented JUNE 8 the Dalton E. Hamilton CWI of the Activity: The Section hosted its annual Year Section Award to Tom Kostreba. golf outing at Scott Lake Country Club Northwestern Pennsylvania Section Chair AWS Vice President Vic Matthews at in Grand Rapids, Mich. Jim Sovern Chet Wesley (left) chats with speaker tended the program. swapped his winning raffle ticket for a Robert Hetzendoifer at the May program. WELDING JOURNAL Ken Karwowski (left) accepts his Chair man's Appreciation Award from Mark Uttech, vice chair of the Racine/Kenosha Section. Shown at the Northwestern Pennsylvania Section program are (from left) Chair Chet Miller welding helmet, and Tom Krause Wesley, CWI award winner Tom Kostreba and his son, and AWS Vice President Victor went home smiling with a $1000 travel Y. Matthews. voucher. The event attracted 108 golfers. DISTRICT 12 Director: Sean P. Moran Phone: (920) 954-3828 MILWAUKEE MAY 24 Speaker: John Hinrichs, vice president technology and market development Affiliation: Friction Stir Link, Inc. Topic: Back to the future of robotics Activity: This meeting was held at Em bassy Suites in Brookfield, Wis., in con The Racine/Kenosha Section members posed for a group shot during their tour ofthe junction with the AWS Robotic Arc Bucynis Erie mining equipment plant in South Milwaukee, Wis., in March. Welding Conference, chaired by Jeff Noruk. Craig Wentzel was introduced as the incoming chairman. His first of ficial act was to award an appreciation plaque to outgoing Chair John Koze niecki. RACINE/KENOSHA MARCH 16 Activity: The Section members toured Bucyrus Erie mining equipment plant located in South Milwaukee, Wis. Vice Chair Mark Uttech presented a certifi cate of appreciation to Ken Karwowski for his service as chairman. Jim Sovern hugs his Miller welding hel Tom Krause (left) is shown with Kevin DISTRICT 13 met presented by Mike Wind, Western Foster, Western Michigan Section chair, Director: Jesse L. Hunter Michigan Section vice chair. at the golf outing in June. Phone: (309) 359-3063 AUGUST 2005 DISTRICT 14 Director: Tully C. Parker Phone:(618)667-7744 ST. LOUIS APRIL Activity: District 14 Director Tully Parker presented Ed Crane with his Gold Membership Award for 50 years of membership in the Society. Tulsa Section members are all set for the trip to Dallas for the AWS Welding Show April 26. DISTRICT 15 Director: Mace V. Harris Phone: (952) 925-1222 DISTRICT 16 Director: Charles F. Burg Phone:(515)233-1333 KANSAS FEBRUARY 3 Speaker: Wyatt Swaim, consultant Affiliation: The Lincoln Electric Co. Topic: Code welding 4130 tubing Ed Crane (left) accepts his Gold Mem John Knapp (right) presents an apprecia Activity: The program was held at But bership Award from Tully Parker, District tion award to Eddie Harper for his work ler County C. C. 14 director, at a meeting ofthe St. Louis in the SkillsUSA competitions at the Tulsa Section. Section program in May. MARCH 3 Speaker: Steve Denning, consultant Topic: Plasma arc cutting demonstra tion Activity: The meeting was held at Ret- rosystems, Valley Center, Kans. APRIL 7 Speaker: Bruce Crouse, Level III NDE Affiliation: Crowley County CC, in structor Topic: AWS Dl.l, Section 6, reading weld X rays JUNE 2 Activity: Willie Shew, president, guided Tony Schuler (center) led the Tulsa Sec the Section members on a tour of the tion members on a tour of Valmont In Big Dog Motorcycles plant located in Mark Davidson (right) is welcomed as the dustries in May. Chair Mark Davidson Wichita, Kans. Of special interest was incoming chair by outgoing Chair Jay (left) is shown with outgoing Chair Jay the final assembly line and a close-up Rufner at the May Tulsa Section program. Rufner. look at the robotic welding machines used to join the bike frames. Big Dog Motorcycles has been a supporter of the Affiliation: Moraine Valley Community various awards. The schedule for future Section's activities for many years. College, Chicago meetings was discussed. Past AWS Pres Topic: The future job market for welders ident Ernest D. Levert, Sr., attended the Activity: The program was held in program. Spring Creek Barbecue near Dallas, DISTRICT 17 Tex. Director: Oren P. Reich Phone: (254) 867-2203 MAY 17 TULSA Activity: The North Texas Section mem APRIL 26 NORTH TEXAS bers met at Spring Creek Barbeque to Activity: Twenty Section members and APRIL 21 discuss what they learned at the AWS 27 high school welding students took the Speaker: James E. Greer, AWS presi Welding Show. The new slate of officers bus trip to Dallas, Tex., to attend the dent, and welding professor was elected, and nominations noted for AWS Welding Show. WELDING JOURNAL DISTRICT 20 Director: Nancy M. Carlson Phone: (208) 526-6302 IDAHO/MONTANA FEBRUARY 24 Activity: Kyle Kofford arranged the de tails for the area welding competition at Eastern Idaho Technical College in Idaho Falls. The local high schools and agriculture students participated. The vocational technical students oversaw the contests and judged the quality of the workmanship. Shown at the Houston Section program are (from left) Chair Dennis Eck and student scholarship awardees Mike Hicks, Thomas Baily, and John Francis. DISTRICT 21 Director: Jack D. Compton Phone: (661)362-3218 CALIF. CENTRAL COAST APRIL 9 Activity: The Section members hosted a high school welding competition at Allan Hancock College in Santa Maria, Calif. Beginning and advanced welding students from eight local schools par ticipated. The barbecue lunch was pro vided by Praxair. The event was at tended by 120 members and students. High school students strut their stuff at MAY 24 the Idaho/Montana Section welding com Speaker: Matt Johnson, district manager petition in February. Affiliation: Miller Electric Co. Topic: The Miller Chopper built by Houston Section Chair Dennis Eck (left) OCC presents a speaker gift to Tom Janie. Activity: The California Central Coast DISTRICT 18 Section members participated in a Director: John L. Mendoza demonstration of plasma arc equipment Phone: (210)353-3679 used in bike fabrication. Assisting in the program were Rayvell Snowden, a weld HOUSTON ing instructor at Allan Hancock Col MAY 24 lege; Section Chairman Stan Luis, Prax Speaker: Tom Jarvie air territory manager; and Hans Duus, Topic: Crack tip opening displacement a professional blacksmith. This Califor Activity: Chairman Dennis Eck pre nia Central Coast program was held at sented Section-sponsored scholarships Praxair Distributors, Inc., Santa Maria, to students Mike Hicks, Thomas Baily, Calif., for about 100 attendees. and John Francis. Shown are the delegates to the District 21 conference. DISTRICT 22 Director: Kent S. Baucher MAY 24 Phone: (559)276-9311 Activity: The Tulsa Section members DISTRICT 19 toured Valmont Industries in Tulsa, Director: Phil Zammit District Conference Okla.. to study the manufacture of steel Phone: (509) 468-2310, ext. 120 JUNE 3,4 utility poles in diameters up to 120 in. Activity: Representatives from the and 240 ft high. SPOKANE Sacramento, Fresno, Santa Clara, and Tony Schuler, manufacturing man JUNE 8 San Francisco Sections attended the ager, conducted the tour. Welding in Speaker: Phil Zammit, District 19 di conference held in Old Sacramento. On structor John Knapp presented Eddie rector hand were Mike Urioste, Durella Harper, The Lincoln Electric Co., an Affiliation: Brooklyn Iron Works Combs, Lome Grimes, Mike Rabo, Dis appreciation award for his work in ar Topic: Update on AWS national news trict 22 Director Kent Baucher, Dale ranging the Oklahoma 2005 SkillsUSA Activity: The Section hosted its annual Phillips, Kerry Shatell, Dale Flood, weld competitions. Outgoing Chair Jay election of officers. The meeting was Brad Bosworth, Dave Rouegno, Rich Rufner welcomed incoming Chair Mark held at the Oxarc Training Center in Hashimoto, and AWS staff manager of Davidson. Spokane, Wash. safety and health, Steve Hedrick. AUGUST 2005 San Francisco Section WeldFest attendees had a lot to see and do. Shown at the District 22 conference are (from left) Mike Rabo, District 22 Director Kent Baucher, Mike Urioste, Dale Phillips, Durella Combs, Keny Shatell, Lome Grimes, Dale Flood, and Steve Hedrick. Shown at the California Central Coast welding competition are (from left) John Goosman, Rayvell Snowden, Walt Aviko, and Chairman Stan Luis. FRESNO APRIL 27 Activity: The Section hosted its 12th an nual trap shoot outing at Kingsburg Gun Club in Kingsburg, Calif. Each ofthe 42 participants shot two rounds for a total of 50 shots. Ed Brixley took the $100 first place prize, Mark Mathus got $75 Shown at the California Central Coast Section program with the 75th anniversary Miller for his second-place showing, and Blair Chopper are (from left) Matt Johnson, Rayvell Snowden, Stan Luis, and Hans Duus. Redfern and Melanie Jones tied for third. Jones took home the $50 prize after winning the tie-breaker. Jason De- Costa's 'lowest score' earned him the Section's Rubber Chicken award. SACRAMENTO VALLEY MAY 18 Activity: The Section members toured Holt of California, Pleasant Grove plant. Speaker Max Jones, Jr., con ducted the tour ofthe authorized Cater pillar Equipment Dealership's large welding repair facilities. SAN FRANCISCO May 11 Melanie Jones and Blair Redfern battle it out during the tie-breaker for third place in the Activity: The Section sponsored its Fresno Section's trap shoot. WeldFest 2005 at the Laney College welding facilities in Oakland, Calif., for about 110 attendees. Featured were hands-on demonstrations ofthe latest welding technology followed by a bar- beque dinner catered by the college's culinary arts students. The vendors in cluded Aearo, Robert Bosch Tools, Har ris Calorific, Airgas, Bernard, Hyper therm, Ansell, OKI Bering, Bacou-Dal- loz, Scotchman, Lincoln Electric, Al liance Gas Products, 3M Safety Prod ucts, 3M Abrasives, Miller Electric, Ho bart, Smith, Petrogen, Flange Wizard, Members ofthe Sacramento Valley Section are shown during their tour of the Holt of and Garrett's Guide, LLC. California facility in May. WELDING JOURNAL New AWS Supporters New Sustaining Companies Educational Institutions New Affiliate Companies Washington Alloy Co. Blackhawk Technical College American Carriage, Inc. 7010-G Reamcs Rd. 6004 Prairie Rd.. PO Box 5009 1401 Goodrick Rd. Charlotte, NC 28216 Janesville. Wl 53547 Tehachapi, CA 93561 Representative: Joe E. Dearborn Emily Griffith Opportunity School CAPCO Plastics 1250 Welton St. 9231 Billy the Kid Washington Alloy Co., in business Denver, CO 80204 El Paso, TX 79907 for 22 years, is a provider of a broad selection of welding alloys including Klamath Community College H. Wilden & Assoc, Inc. aluminum, carbon steels, stainless 7390 S. Sixth St. 7310 Tilgham St., Ste. 600 steels, and hard surfacing products to Klamath Falls, OR 97603 Allentown, PA 18106 welding distributors in the United States and Canada. It ships products South Arkansas Community College National Tool & Die Welding, Inc. from four warehouses strategically lo 3696 E. Main Rd. 13340 Merriman Rd. cated in Charlotte, N.C, Rancho Cu- El Dorado. AR 71730 Livonia, MI 48150 camonga,Calif., Dayton, Ohio, and Houston, Tex. The company is certi Tennessee Technology Center at R. C. Fabricators, Inc. fied to ISO 9001, 2000 Quality Man Oneida/Huntsville 824 Locust St. agement System. 355 Scott High Dr. Wilmington, DE 19801 Huntsville, TN 37756 Total Facility Solutions, Inc. Membership 1001 Klein Rd., Ste. 400 Counts Piano, TX 75074 Welding Distributor Company Representative: Kimon A. Popores Oconee Welding Supply, Inc. Member As of 601 E. North 1st St. Grades 7/1/05 Total Facility Solutions (TFS), Inc., Seneca, SC 29678 is a wholly owned subsidiary of M +W Sustaining 420 Zander. The company provides self- Supporting 213 perform ultrahigh-purity HVAC me Educational 344 chanical and electrical contracting. Supporting Company Affiliate 305 Also, TFS offers preconstruction pric Welding distributor 52 ing services that provide accurate proj Total corporate members 1,334 ect costs, with MEP system prefabri- Blane-Chase Industrial Construction cation and on-site installations avail & Maintenance, LLC Individual members 43,714 able nationwide. Call Mike Barnes at 3285 Specks Run Rd. Student + transitional members 4,811 (927) 535-7300 for more information. Bunker Hill. WV 25413 Total members 48,525 AWS Foundation Presents Int'l Scholarship Award he American Welding Society to use the knowledge I gain at Montana to help fund the scholarships, visit Foundation, Inc., has named Yue Tech together with the working experi www.aws.org/foundation, or call (800) Tqiu Mao, from Chengdu, China, ence I already have, to become a quali 443-9353, ext. 212. the recipient of the 2005-2006 AWS In fied mechanical and welding engineer." The AWS Foundation, Inc., was es ternational Scholarship. All full-time international students tablished by the American Welding So Ms. Mao is currently pursuing her pursuing undergraduate or graduate ciety on September 13, 1989, to meet master's degree in general engineering, studies in joining sciences are eligible the needs for education and research in with an emphasis on welding, at Mon to apply for one of the AWS Founda the field of welding and related joining tana Tech at the University of Montana. tion, Inc., International Scholarships. technologies. While working as a mechanical en Applicants may be enrolled in any The Foundation is a 501 C, not-for- gineer in China, Ms. Mao decided to at accredited joining science program at profit corporation, managed by a volun tend Montana Tech to further her stud any institution in the world. teer board of trustees with supporting ies in welding engineering. To learn more about the AWS Foun staff located at AWS headquarters in "After graduation," she said. "I plan dation scholarships and opportunities Miami. Fla.* I AUGUST 2005 Member-Get-A-Member Campaign RECRUIT NEW MEMRERS... WIN GREAT PRIZES A simple way to give back to your profession, strengthen AWS and win great prizes is by participating in the 2005-2006 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. Plus, you become part of an exclusive group of AWS Members who get involved. 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. Who better than you to encourage someone to join AWS? AWS MEMBER RENEFITS CHECKLIST: • Annual subscription to the Welding Journal. < Networking opportunities through local Section • A 25% discount on hundreds of first-rate AWS meetings, the AWS Welding Show and an on technical publications and 140+ industry codes. line bulletin board on the AWS website at • Deep discounts on 120+ technical training Did you learn of the Society through an AWS Member? 3 Yes 3 No Type of Business (Check ONE only) A —I Contract construction If "yes." Members name: Member's # (if known): B _l Chemicals & allied products C 3 Petroleum & coal industries * D 3 Primary metal industries ADDRESS NOTE: This address will be used for all Society mail. E _J Fabricated metal products F J Machinery except elect, (incl. gas welding) Company (if applicable) G -J Electrical equip., supplies, electrodes H J Transportation equip. — air, aerospace I 3 Transportation equip. — automotive Address J J Transportation equip. — boats, ships K J Transportation equip. — railroad L J Utilities Address Con't. M _l Welding distributors & retail trade N J Misc. repair services (incl. welding shops) City_ State/Province _Zip/Postal Code. .Country 0 _J Educational Services (univ., libraries, schools) P J Engineering & architectural services (incl. PROFILE DATA NOTE: This data will be used to develop programs and services to assns.) serve you better. Q _J Misc. business services (incl. commercial labs) R _J Government (federal, state, local) 0 Who pays your dues?: J Company J Self-paid @ Sex: J Male J Female S 3 Other Job Classification (Check ONE only) © Education level: J High school diploma J Associate's J Bachelor's J Master's J Doctoral 01 J President, owner, partner, officer 02 _l Manager, director, superintendent (or _ assistant) PAYMENT INFORMATION (Required) 03 J Sales 04 J Purchasing ONE-YEAR AWS INDIVIDUAL MEMBERSHIP ^$80, 05 _J Engineer — welding 20 -J Engineer — design TWO-YEAR AWS INDIVIDUAL MEMBERSHIPt $#<^ $135 21 J Engineer — manufacturing 06 J Engineer — other He* Member? Yes No 10 • Architect designer 12 Ll Metallurgist If m.atlil one-time initiation fee of $12 S 13 3 Research & development 22 J Quality control Add $25 for book selection ($192 value), and save up to 87%tt S .(Optional) 07 J Inspector, tester 08 J Supervisor, foreman (Note: applies to new Individual Members only - Book selections on upper-right corner) 14 _J Technician 09 -I Welder, welding or cutting operator TOTAL PAYMENT S II J Consultant 15 J Educator AWS STUDENT MEMBERSHIP*! NOTE: Dues include $18.70 for Welding Journal 17 3 Librarian subscription and $4.00 for the AWS Foundation. 16 J Student J Domestic (Canada & Mexico incl.) $15 18 J Customer Service • International $4.00 of membership dues goes to support the AWS 19 • Other Foundation Technical Interests (Check all that apply) TOTAL PAYMENT J A J Ferrous metals Payment can be made (in U.S. dollars) by check or money order (international or foreign), B J Aluminum payable to the American Welding Society, or by charge card. C 3 Nonferrous metals except aluminum D _l Advanced materials/lntermetallics • Check • Money Order J Bill Me E J Ceramics F _J High energy beam processes • American Express —I Diners Club _J Carte Blanche _l MasterCard 3 Visa 3 Discover _l Other G J Arc welding H J Brazing and soldering I I I I J Resistance welding J 3 Thermal spray Your Account Number Expiration Date (mm/yy) K J Cutting L _) NDT Signature of Applicant: _ Application Date: M _J Safety and health N 3 Bending and shearing Office Use Only 0 J Roll forming Check # Account # P J Stamping and punching Source Code WJ Date Amount Q J Aerospace fIVo-year Individual .Membership Special Offer applies onlv to new ffS Individual Members. R J Automotive American Welding Society S _l Machinery "Discount Publication Offer applies only to new ATS Individual Members. Select one of ihe four T _J Marine P.O. Box 440367 listed publications lor an additional S2S: Multi-Year Discount: First year is SM. each additional year is U J Piping and tubing Miami, FL 33144-0367 $75. No limit on year. (nol available lo Student Members). tttStudent Member: Any individual who V J Pressure vessels and tanks Telephone (800) 443-9353 attends a recognized college, university, technical, vocational school or high school is eligible. Domestic W J Sheet metal X 3 Structures FAX (305) 443-5647 Members are those students residing in North America (incl. Canada It Mexico). This membership Y 3 Other Visit our website: www.aws.org includes the If elding Jounid magazine. Student Mcmbetships do nol include a discounted publication. Z J Automation Airmail Postage Option: International Members may receive their magazines via Airmail by adding S Identifies funding sources for welding educa Serves as a liaison between Section members and Ross Hancock., [email protected] ....(226) tion, research, and development. Monitors leg AWS headquarters. Informs members about Welding Qualification, Friction Welding, Rail islative and regulatory issues of importance to AWS benefits and activities. road Welding. Joining of Metals and Alloys. the industry. Cynthia Jenney .. [email protected] ....(304) EDUCATION SERVICES Definitions and Symbols, Brazing and Soldering, BRAZING and SOLDERING Managing Director Brazing Filler Metals and Fluxes, Technical Editing. MANUFACTURERS' COMMITTEE Richard J. DePue... [email protected] ....(237) Jeff Weber., [email protected] (246) Brian McGrath . [email protected] (311) Educational Product Development Methods of Inspection, Mechanical Testing of Director Welds, Thermal Spray, Arc Welding and Cut WEMCO — Welding Equipment Christopher Pollock.. [email protected](2\9) ting, Welding in Marine Construction, Piping Manufacturers' Committee, and and Tubing, Titanium and Zirconium Filler WIN — Welding Industry Network Responsible for tracking the effectiveness of Metals, Filter Metals for Naval Vessels. Mary Ellen Mills., [email protected] (444) programs and development of new products and services. Coordinates in-plant seminars and Note: Official interpretations of A WS standards workshops. Administers the S.E.N.S.E. pro may be obtained only by sending a request in writ CONVENTION and EXPOSITIONS gram. Assists Government Liaison Committee ing to the Managing Director, Technical Services. Exhibiting Information (242, 295) with advocacy efforts. Works with Education Oral opinions on AWS standards may be ren Committees to disseminate information on ca dered. However, such opinions represent only the Associate Executive Director/Sales Director reers, national education, and training trends, personal opinions ofthe particular individuals Jeff Weber., [email protected] (246) and schools that offer welding training, certifi giving them. These individuals do not speak on cates or degrees. behalf of A WS, nor do these oral opinions con Director of Convention & Expositions stitute official or unofficial opinions or interpre John Ospina.. [email protected] (462) Conferences and Seminars tations of A WS. in addition, oral opinions are in Director formal and should not be used as a substitute for Organizes the annual AWS Welding Show and Giselle I. Hufsey.. [email protected] (278) an official interpretation. Convention. Regulates space assignments, reg istration materials, and other Expo activities. Responsible for conferences, exhibitions, and seminars on topics ranging from the ba WEB SITE ADMINISTRATION sics to the leading edge of technology. Orga Director nizes CWI, SCWI, and 9-Year Renewal certifi Keith Thompson., [email protected] (414) cation-driven seminars. WELDING JOURNAL TeleWeld Nominees for National Office FAX: (305) 443-5951 nly Sustaining Members, Mem a member ofthe Society, other than a Stu Publications Sales/Orders bers, Honorary Members, Life dent Member, must be frequently avail Global Engineering Documents OMembers, or Retired Members able to the national office, and should be (800) 854-7179 or (303) 397-7956 who have been members for a period of of executive status in business or indus online at www.global.ihs.com at least three years shall be eligible for try with experience in financial affairs. election as a director or national officer. Director-at-Large: To be eligible for Journal Reprints It is the duty ofthe National Nominat election as a director-at-large, an individ Order quality custom reprints from ing Committee to nominate candidates for ual shall previously have held office as Claudia Stachowiak, FosteReprints national office. The committee shall hold chairman of a Section; as chairman or vice telephone (866) 879-9144, ext. 121 an open meeting, preferably at the Annual chairman of a standing, technical or spe e-mail at [email protected] Meeting, at which members may appear to cial committee of the Society; or as Dis present and discuss the eligibility of all can trict director. didates. Interested parties should write a let To be considered a candidate for the po ter stating which office they seek, includ AWS Foundation, Inc. sitions of president, vice president, treas ing a statement of qualifications, their The AWS Foundation is a not-for-profit urer, or director-at-large, the following willingness and ability to serve if nomi corporation established to provide support qualifications and conditions apply: nated and elected, and 20 copies of their for educational and scientific endeavors President: To be eligible to hold the biographical sketch. of the American Welding Society. office of president, an individual must This material should be sent to James Information on gift-giving programs is have served as a vice president for at least E. Greer, Chairman, National Nominat available upon request. one year. ing Committee, American Welding Soci Vice President: To be eligible to hold ety, 550 NW LeJeune Rd., Miami, FL Chairman, Board of Trustees the office of vice president, an individual 33126. Ronald C. Pierce must have served at least one year as a di The next meeting of the National Executive Director rector, other than executive director and Nominating Committee is scheduled for Ray W. Shook secretary. October 2006. The term of office for can Treasurer: To be eligible to hold the didates nominated at this meeting will Managing Director office of treasurer, an individual must be commence January 1, 2008. • Wendy S. Reeve 550 NW LeJeune Rd., Miami, FL33126 (305) 445-6628; (800) 443-9353, ext. 293 e-mail: [email protected] Honorary Meritorious Awards general information: (800) 443-9353, ext. 689 he Honorary-Meritorious Awards Committee makes recommendations for the nom inees presented for Honorary Membership, National Meritorious Certificate, TWilliam Irrgang Memorial, and the George E. Willis Awards. These awards are pre sented during the AWS Exposition and Convention held each spring. The deadline for submissions is July 1 prior to the year of awards presentations. Send candidate materials AWS Mission Statement to Wendy Sue Reeve, Secretary, Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd„ Miami, FL 33126. Descriptions of the awards follow. The mission of the American Welding Society is to advance the science, National Meritorious Certificate International Meritorious Certificate technology, and application of welding Award: This award is given in recognition Award: This award is given in recogni and allied processes, including of the candidate's counsel, loyalty, and de tion of the candidate's significant con joining, brazing, soldering, votion to the affairs of the Society, assis tributions to the worldwide welding in cutting, and thermal spraying. 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 It is the intent of the American half of the Society. awardee is not required to be a member of the American Welding Society. Mul Welding Society to build AWS to the highest quality standards possible. William Irrgang Memorial Award: This tiple awards can be given per year as the award is administered by the American situation dictates. The award consists of The Society welcomes your suggestions. Welding Society and sponsored by The Lin a certificate to be presented at the Please contact any staff member, or coln Electric Co. to honor the late William awards luncheon or at another time as AWS President Damian J. Kotecki Irrgang. It is awarded each year to the in appropriate in conjunction with the as listed on the previous page. dividual who has done the most to enhance AWS President's travel itinerary, and. if the American Welding Society's goal of ad appropriate, a one-year membership in vancing the science and technology of the American Welding Society. welding over the past five-year period. George E. Willis Award: This award is Honorary Membership Award: An administered by the American Welding Honorary Member shall be a person of Society and sponsored by The Lincoln acknowledged eminence in the welding Electric Co. to honor George E. Willis. It profession, or who is accredited with ex is awarded each year to an individual for ceptional accomplishments in the devel promoting the advancement of welding in opment of the welding art, upon whom ternationally by fostering cooperative par the American Welding Society sees fit to ticipation in areas such as technology trans confer an honorary distinction. An Hon fer, standards rationalization, and promo orary Member shall have full rights of tion of industrial goodwill. membership. • AUGUST 2005 AWS Radiographic Interpreter. We're proud to announce the AWS Radiographic Interpreter certification program. Designed for NDE professionals and current AWS Certified Welding Inspectors, this training and certification program :m 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 4 indications and use of acceptance criteria as •&^k^M expressed in the AWS, API and ASME codes. For more information on the course, qualification requirements, certification exams and test locations, please visit our website at www.aws.org/certification/RI f or call 1-800-443-9353 ext 273. • T/UJJJJJJIJ 3buw&t & Carilfjcuilujj ECUJJ D-iJJ-13,TjLfiiiJ- 'X/ibinhHrTXXjXit 1,2005 itenu, Maviidii - U'Siuhnr 3'J-iNJou3Jjiii3f 5,2005 'AuXiun, 'fouis - Uwdinhbf 5-JO, 2005 American Welding Society Founded in 1919 to advance the science, technology and application of welding and allied processes including Circle No. 6 on Reader Info-Card joining, brazing, soldering, cutting and thermal spray. WELDING n .«a WORKBOOK Datasheet 269 Weld Joint Basics A fusion weld from both sides of the part is called a double The weld is categorized by the configuration of the edge shape groove weld. This is often required in large or thick weldments. or butting members. Below is a variety of different groove welds. (A) DOUBLE-SQUARE-GROOVE WELD (E) DOUBLE-U-GROOVE WELO (B) DOUBLE-BEVEL-GROOVE WELD (F) DOUBLE-FLARE-BEVEL-GROOVE WELD (C) DOUBLE-V-GROOVE WELD (G) DOUBLE-FLARE-V-GROOVEWELD (D) DOUBLE-J-GROOVE WELD WITH BACKING Excerpted from AWS A3.0:2001, Standard Welding Terms and Definitions. AUGUST 2005 The essential standard for quality fabrication, Now available in Structural Bundles that save you money too. AWS D1.1, Structural Welding New for 2004: • Contains the latest workmanship standards, inspection - Code—Steel procedures, acceptance criteria Save time and money, and Clarifies requirements that need an engineer's approval, minimizing code-interpretation conflicts maximize reliability and safety, Modifies allowable stress range formulae with the 2004 edition of AWS D1.1. Structural Welding Code—Steel. - Enhances construction integrity safety by requiring additional tests when FCAW and GMAW constant current power supplies Engineers, architects, and are used fabricators depend on this book Reflects advances in technology by the addition of new steels to ensure the integrity of welded to pre-qualified base metal list tructures. ANSI Approved. Adjusts welder qualification essential variables ABLE AS A CD TOO! Adjusts dimensions and tolerances on prequalification joint details Order today. Call us at 800.854.7179 or visit global.ihs.com to get your copy. D1.1/D1.1M:2004, Structural Welding Code—Steel D1.1/D1.1M:2004 CD, Structural Welding Code—Steel Order Code: AWS D1.I/D1.1M. Nonmembers: $360, AWS Members: $270 Order Code: AWS D1.1/D1.1M CD, Nonmembers: $380, AWS Members: $285 D1.1/D1.1M:2004 COMBO, Structural Welding Code—Steel Order Code: AWS D1.1/D1.1M COMBO, Nonmembers: $620, AWS Members: $465 Save $$$ with these AWS Structural Bundles INDIVIDUAL BUNDLE PRICE PRICING 15% OFF MEMBER NONMEMBER Bundle A - Structural Steel/AISC Steel Building Structures AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL S360 S270 AWSA2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 AWS A3.0 2001 STANDARD WELDING TERMS AND DEFINITIONS S128 $96 Bundle Total Order Code: AWS BUNDLE A $532 $399 Bundle B - D1 All Structural Welding Codes AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL $360 $270 AWSD1.2/D1.2M 2003 STRUCTURAL WELDING CODE—ALUMINUM $132 $99 AWSD1.3 1998 STRUCTURAL WELDING CODE—SHEET STEEL $100 $75 AWSD1.4 1998 STRUCTURAL WELDING CODE—REINFORCING STEEL $84 $63 AASHTO/ AWSD1.5M/D1.5 2002 BRIDGE WELDING CODE $188 $141 AWSD1.6 1999 STRUCTURAL WELDING CODE—STAINLESS STEEL $132 $99 Bundle Total Order Code: AWS BUNDLE B $747 $848 $636 Bundle C - AISC Conventional and Complex Steel Building Structures AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL $360 S270 AWSA2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 Bundle Total Order Code: AWS BUNDLE C $496 $372 $424 $318 Bundle D - AISC Simple and Major Steel Bridges AASHTO/ AWSD1.5M/D1.5 2002 BRIDGE WELDING CODE $188 $141 AWSA2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 S102 Bundle Total Order Code: AWS BUNDLED $324 $243 $276 $207 Bundle E - Structural Aluminum AWSD1.2/D1.2M 2003 STRUCTURAL WELDING CODE—ALUMINUM $132 S99 AWSA2.4 1998 STANDARD SYMB0L$ FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 AWS A3.0 2001 STANDARD WELDING TERMS AND DEFINITIONS $128 $96 Bundle Total Order Code: AWS BUNDLE E $396 $297 $336 $252 American Welding Society Visit our Web site www.aws.org for membership information NEW *W-f LITERATURE FOR MORE INFORMATION. CIRCLE NUMBER ON READER INFORMATION CARD. Free Book Details Steel Tub tentGrotips I Documents S SBA5ITubGird- the design of process pipelines and Girder Bridge Design erBookLink.pdf. For a limited time, hard processing equipment who want insights bound copies of the book can be requested into what problems may be encountered from NSBA, 1 E. Wacker Dr., Ste. 3100, and how to solve them. The guide may also Chicago, IL 60601-2000: (312) 670-7011; be ordered from Orbimatic Ltd., 7 Manor FAX (312) 670-5403. Grove Centre, Vicarage Farm Rd., Peterborough PE1 5UH, U.K.; Orbital Welding Detailed in Infofci orbimatic. co. uk. Downloadable Guide Brochure Pictures Metalforming Automation GUIDE TO ORBITAL TIG WELDING Drive and control solutions for metalforming and press automation The colorful 50-page book, Practical Steel Tub Girder Design, released by the National Steel Bridge Alliance (NSBA), a division of the American Institute of Steel Construction, Inc., addresses the en tire bridge design process, including lay out, basic design, and detailing, with guid A well-illustrated, full-color, 24-page ance on construction loading stages. The brochure details drive and control solu first chapter is a rationale for choosing tub tions for metalforming and press au girders and related application issues. The 13-page E-book (PDF) version of tomation. Its focus is on higher profit Later chapters discuss tub geometries, Guide to Orbital TIG Welding can be down with fewer problems by implementing the analysis techniques, diaphragms and brac loaded from the Orbimatic (U.K.) Ltd. Indramat servo motion systems. Illus ing, and miscellaneous details. Included site, www.orbimatlc.co.uk/LitList.htm. The trated are drives for small press feeders are discussions of three sample projects, book begins with the basics of the gas to large 800-hp variable frequency/vec an extensive list of references, an appen tungsten arc welding process and follows tor drives for powering the presses. In dix of computer design tools, and a sec through with troubleshooting pointers. cluded are brushless servo and vector tion on suggested design details. The en Additional information is provided on ma drives from 1/4 to 500 hp (0.2-375 kW). tire book or individual chapters can be terials selection, tube fabrication, weld Numerous applications are discussed in downloaded free as Adobe Acrobat files purging, and postweld treatments. The cluding blanking lines, gantries, press-to- (PDFs). Visit www.aisc.org/Content/Con- guide is written for engineers involved in press transfers, roll feeds, roll forming lines, oscillating shears, stackers/destack- ers, wire, tube, and pipe benders, and zig zag feeds. To download the brochure, go to www.boschrexroth-us.com, then enter Webcode US0210 to access the brochures COR-MET download pages. SPECIALTY CORED WIRE Bosch Rexroth 114 5150 Prairie Slone Pkwy.. Hoffman Estates, IL 60192 AND COATED ELECTRODES (810) 227-3251 FAX: (810) 227-9266 The Brazing Book Is Online www.cor-met.com The free, interactive, updated edition of The Brazing Book is available online where it can be viewed and/or ordered on CD. Written for both novices and pros, it is profusely illustrated and detailed. The M4mm) book's five sections 1) explain how to use brazing properly; 2) display photographs Circle No. 19 on Reader Info-Card AUGUST 2005 WELDHUGGER COVER GAS DISTRIBUTION SYSTEMS of its many applications; 3) present nu merous charts, technical information, brazing products, filler metals, fluxes, etc.; 4) detail the company's brazing services and equipment; and 5) supplies supple mental brazing-related information. Visit www. brazingbook. com. Lucas-Milhaupt, Inc. 115 5656 S. Pennsylvania Ave., Cudahy, WI 53110 Humorous/Educational Oxyfuel Safety Posters Offered LYSIS HUGGER Toll Free: (877) WELDHGR (877) 935-3447 Fax: (480) 940-9366 SMITH Safety Tip 5 Visit our website at: www.weldhugger.com Circle No. 41 on Reader Info-Card leafing pigment and other metallic com NEW PRODUCTS ponents that create a durable, corrosion- — continued from page 21 resistant, satin finish that can withstand up to 1200°F and temperature cycling. It High-Temperature Paint comes in pints, quarts, and gallons. Suit able for applications requiring cycling, it Protects Areas employs rust inhibitors designed to over come the reactions caused by high temper atures and salt-air weathering. This indus trial-grade coating can be applied by brush, spray, or roller. Stainless Steel Coatings, Inc. Ill 835 Sterling Rd./PO Box 1145, So. Lancaster, MA 01561 Can you see the 37 (or m Satoy Rote: Know and toHow aH safety rules and qractos Welding Machine Includes tohlMttHJ, healing and cuttiin operations. Inverter Arc Control Technology "Can you see the 37 safety violations shown here?" queries the Safety Tips #5 The PowCon® Arc Stud™ 625 stud poster, one of six in the company's oxy welding machine features inverter arc con fuel safety poster series. The colorful dis trol technology for arc stud performance plays challenge employees to study the and lightweight portability. It weighs 75 lb. cartoons and in turn sharpen their sense The output range is 500 to 1000 A, and it of awareness to the hazards of the work has a rated output of 1000 A/32 V at a 7%/4 place. The set of six posters in the Safety studs per minute duty cycle. Stud diame Tips Series cost $18, or they may be or ters range from % to % in., and welding a dered as part of a complete safety train %-in. stud requires 950 A and takes % s. ing package, including a video and testing The machine measures 17 in. high, 12M in. materials. Call (800) 843-7912 for details. wide, and 24 in. deep. Other technologies Smith Equipment Co. 116 STEEL-IT® high-temp metallic blend 2601 Lockheed Ave.. Watertown. SD 57201-5636 #7156 paint features a 316L stainless steel — continued on page 91 WELDING JOURNAL PERSONNEL Airgas South 1975, most recently served as plant director of its L.P.'s ALNET distributor manager. network and business development team Names President for specialty gases. Previously, he was director of specialty gases business Airgas, Inc., Rad Perfect Fit Glove Revamps development. nor, Pa., has ap Its Senior Management pointed Jay Sulli Team van as president of Edison Welding Institute the Airgas South re Perfect Fit Glove Co. LLC, Buffalo, Selects President and CEO gion, one of its 13 N.Y., has announced a new senior man regional companies. agement team led by Greg Wall, vice pres The Edison Welding Institute board of Previously, Sullivan ident and general manager; and Matt trustees has selected Henry J. Cialone as served as chief fi Reid, senior product manager. Reporting president and chief executive officer of nancial officer for to Reid are Product Managers Bill the Columbus. Ohio, organization. Jay Sullivan Airgas South. He Soellner, Man- Beth Villalobos, and Mary Cialone will replace Don Caudy who has succeeds Mike La-Vigne. Don Mueller was named to the been serving as interim president since Rohde who was re new position of demand planning man January. Cialone previously served Bat cently named senior vice president of dis ager, and Adam Liu was appointed to pur telle Memorial Institute as vice president, tribution operation for Airgas, Inc. chasing manager. commercial energy business. Bosch Power Tools New President Appointed to August Mack Appoints President Head J. W. Harris Environmental Promotes Three Bosch Power Tools, Mt. Prospect, 111., Lincoln Electric a division ofthe Robert Bosch Tool Corp., Holdings, Inc., August Mack Environmental, Inc., In has appointed Frank Carroll to president. Cleveland. Ohio, dianapolis, Ind., has promoted Joe Bosch Power Tools North America. Car has appointed David Stephens to project manager, and Mor roll has served the company in various J. Nangle as presi gan Saltsgiver and Laura Himes to staff managerial positions for 17 years. dent of J. W. Harris Co., Inc., a recently Wall Colmonoy Fills acquired manufac SARU SILVER ALLOY General Manager Post turer of brazing and PRIVATE LIMITED soldering alloys. David J. Nangle Pioneer & Largest Manufacturer in India Wall Colmonoy, Nangle will continue exporting to 22 countries worldwide Madison Heights, as president of two Mich., has pro other Lincoln subsidiaries, Harris moted Daniel Naz Calorific, Inc., and Welding, Cutting Tools zarett to general & Accessories, Inc. manager of its alloy manufacturing facil Air Liquide Names Director ity in Los Lunas, N.Mex. Nazzarett, Air Liquide America L.P., Houston, an employee since Tex., has appointed Richard Murphy as Daniel Nazzarett HARTLOTE UND FLUSSMITTEL Silver Brazing Alloys (Silver Solder) DO YOUR OWN TESTING Silver Copper Phos. Brazing Alloys Copper Brazing Alloys Brazing Fluxes (Powder s. paste) Bend Testers - Bend Specimen Cutting H- Fixtures - Coupons -Tensile Testers Visit our website for all sizes and Available in the form of Rods (Bare & Flux Coated), models available Wires, Foils, Strips, Preforms, Granules, Anodes to any desired specifications. See us at Schweissen & Schneiden 2005 Hall # 7 Stand # 7-312 3, Sam Nagar, Sardhana Road, Meerut - 250001, FischER ENqiNEERJNq COMPANY U.P. (India) Tel: +91-121-2555433, 2555932, 2555291 Fax: +91-121-2555515 E-mail: [email protected] www.fischerengr.com • (937)754-1750 Web: http://www.sarusilver.com Circle No. 26 on Reader Info-Card Circle No. 35 on Reader Info-Card •• AUGUST 2005 managers. Stephens and Saltsgiver have TRUMPF Promotes Two to ager, Midwest re worked on ground water remediation Product Managers gion, nondestructive projects. Himes has specialized in subsur testing. Most re face investigations and construction. cently, Mazur was a TRUMPF Inc., Farmington, Conn., technical sales and has promoted James Rogowski to prod project manager Alley Joins Barckhoff uct manager of its laser cutting and au with Quality Inspec tomation groups, and Mike Morissette to Welding Management tion Services, Inc., product manager of the punching and Buffalo, N.Y. Barckhoff Weld bending groups in North America. Ro ing Management, gowski will continue to manage the sales Stephen Mazur Minneapolis, Minn., of automation systems. Morissette will has named Richard continue to manage the sales of high L. Alley [AWS] as a speed punching machines. senior sales execu tive. Alley, who Obituary served as AWS pres ident 1989-1990, Northrop Grumman Elects and later served as Ship Systems President Richard L. Alley an associate execu Eddie C. Cady tive director for the Northrop Grum Society, has an extensive background in man, Los Angeles, Eddie C. Cady, 81, died June 19 follow many areas of the welding industry. Calif., has elected ing a long illness. A Philip Teel corpo long-time member Sales Vice President rate vice president of the AWS Tulsa and president of its Named at Machinery & Section, he per ship systems sector. formed as its secre Welder Corp. Teel succeeds Philip tary for 25 years. He A. Dur, who intends Gail Beyer II has also was treasurer at to retire at the end joined Machinery & Lawnwood Free Philip Teel of the year. Dur will Welder Corp., West Will Baptist Church. serve until his re Allis, Wis., as vice During World War tirement as corporate vice president as president-sales. II, he served in the sisting the CEO. Beyer, with 24 years Eddie C. Cady U.S. Navy. Follow in the welding supply ing discharge from and distribution Kodak Names NDT the Navy, he worked business, most re Manager for CE Natco for 43 years until his retire cently served as ment. He is survived by his wife, Lorene, a branch manager Eastman Kodak Co., Rochester, N.Y., a daughter, a son, four grandchildren, one Gail Beyer II with Airgas. has named Stephen Mazur as area man- great-grandson, and two sisters. source to the primary voltage applied NEW PRODUCTS (480/575 VAC, three-phase). Also, it of — continued from page 91 fers Wind Tunnel Technology™ that pro tects electrical components and PC boards from contamination. Miller Electric Mfg. Co. 112 PO Box 100, Liehonia, GA 30058 Torches Come in Medium- and Heavy-Duty Toolbox Outfits The company's Dual Guard oxyfuel cutting torches are offered in medium- and heavy-duty toolbox outfits, which fea ture a rugged, high-impact plastic with steel latches and can safely transport oxy clude a cutting torch, cutting tip, oxygen fuel equipment. The Combination Outfit regulator, and fuel gas regulators. The features a torch that can cut 6 to 8 in. and medium-duty toolbox outfits for both incorporated into the machine's design in weld Vi- to 1-in. material. The Hand (or types of torches come with two cutting clude the Fan-On-Demand™ cooling sys Straight) Torch Outfit features a torch that tips, and the heavy-duty toolbox outfits tem that operates only when needed, re cuts 12 to 24 in. The Combination Outfits feature three cutting tips. Accessories are ducing noise, energy use, and the amount come with a torch handle, cutting attach included in both toolbox outfits. of contaminates pulled through the ma ment, oxygen regulator, and fuel gas reg chine, along with an Auto-Link® circuit, ulator, along with cutting, welding, and Smith Equipment 113 2601 Lockheed Ave.. Watertown, SD 57201-5636 which automatically links the power heating tips. The Hand Torch Outfits in WELDING JOURNAL ESSEN RED HOT t Plasma and Laser Consumables JOKISCH Anti-Spatter Centricut, a worldwide supplier of plasma CENTRICUT and laser consumable parts, invites you to Forget grinding! JOKISCH LB-100 Anti- visit the Hypertherm booth at Essen to see Spatter is a non-toxic liquid that stops Centricut's latest products. The new SILVER- spatter every time while leaving no LINE® electrode is now available for residues that may affect painting or Kjellberg, Esab, Komatsu, and many other plating. JOKISCH produces no pinholes plasma systems. The SilverLine technology or porosity. Excellent for stainless steel, ESAB provides unprecedented cut quality and oxides are easily removed, as well as INNERIOGIC ::•-' parts life. Stop by to see all the Centricut being spatter free. Designed for robotic KJEUBERB product lines including laser parts for welding applications. Amada, Bystronic, Cincinnati, Mazak, THERMAL DYNAMICS Mitsubishi, and Trumpf. Also visit us at WHITNEY www.centricut.com. Centricut is a subsidiary Intercon Enterprises, Inc. of Hypertherm. 1125 Fir Ave. Centricut, LLC Blaine, WA 98230 Circle No. 200 Two Technology Dr. (800) 665-6655 West Lebanon, NH 03784 Circle No. 204 or (604) 946-6066 ESSEN BOOTH (603) 298-7849 FAX: (604) 946-5340 HALL 11, STAND 11-322 FAX: (603) 298-5938 SEE US AT ESSEN BOOTH www.intercononline.com E-mail: [email protected] HALL 8.1, STAND 8-209 E-mail: [email protected] The Turbo-Sharp III™ The Translight is the ideal helmet for the welder, whose first love was a car. CK Worldwide, Inc., introduces the For over 80 years, Jackson Products has S^A Turbo-Sharp III™ portable tungsten provided workers with superior protection. r^HliW. grinder. This system is an enclosed tung- We strive to improve workplace safety with £ i^^^ sten electrode grinder, which minimizes our innovative personal protective equip ^^B i^^ grinding dust exposure to both the user ment. Our sleek, lightweight welding hel ^^H V and the environment. Tungsten electrode mets come in a variety of racy colors and _^^R diameters from 0.040 to 0.25 in. can be with a variety of auto-darkening filter ground with various tip angles from 10 options for the European welder. Visit our to 70 deg. The grinder features a double sided, diamond coated grinding stand to test drive our revolutionary welding products and arc protection. wheel providing a maximum number of grinds. The Turbo-Sharp III™ For ordering information or details about our custom branding program, comes in a convenient metal carrying case, which includes the grinder, contact Jackson Products in the UK at: pen style electrode holder, vacuum system attachment, 12.5 ft power Jackson Products, Ltd. cord and tools to change grinding discs, tungsten diameters, and tip Circle No. 205 angles. Unit 2, the Washington Centre Halesowen Rd., Netherton, Circle No. 201 CK Worldwide, Inc. West Midlands, DY2 9RE, UK 3501 C St. NE SEE US AT ESSEN 44 (0)1384 240001 ESSEN BOOTH Auburn, WA 98002 BOOTH HALL 5, [email protected] or in the USA HALL 7, STAND 7-316 (253) 854-5820 STAND 210 at: (800) 253-7281 FAX: (253) 939-1746 [email protected] New Welding Alloys for Forge World's Broadest Selections _COR-MET_ Die Upgrade and Repair of Welding Positioners SPECIALTY CORED WIRES COATED ELECTRODES Cor-met will offer new welding alloys for Koike Aronson designs and manufac forge die upgrade and repair as well as tures one of the world's broadest information on equipment for applica selections of welding positioners, tion of these alloys. Alloys for hard- from 8 kg and up. We offer Tilt Turn facing that include chrome carbides, Positioners (150MT); Turning Rolls titanium carbides, tungsten carbides, (1200MT); Manipulator (11M x 11M) and vanadium carbides will be present and specially designed systems, ed. Our line of nickel-base cored wires sized to your requirements. Koike will also be shown as well as our cobalt Aronson is also the only company in overlay materials. Final preparation for gear elevatedthe industry whose machines are positioner to be shipped to China. serviced by the craftsmen who build Cor-Met, Inc. them. 12500 E. Grand River Koike Aronson, Inc./Ransome Brighton, Ml 48116 Circle No. 206 Circle No. 202 (800) 848-2719 Arcade, NY USA FAX: (810) 227-9266 800-252-5232 SEE US AT ESSEN BOOTH SEE US AT ESSEN BOOTH www.cor-met.com HALL 8, STAND 8-118 HALL 10, STAND 10-204 New Full-Color SUPERFLASH Compressed New Power Source for Gas Equipment 2005 Catalog Orbital Welding Our new 2005 catalog is just off the press. Long Magnatech's new Tubemaster Model 514 known for quality flashback arrestors, IBEDA, Inc., brings the benefits of all-digital design to SUPERFLASH Compressed Gas Equipment precision orbital tube welding. Division now has added high quality lines of custom Autoprogramming allows inexperienced pre-heating burners for pre-heating, compressed users to automatically generate parame gas manifolds, oxygen and nitrogen liquid to gas ters, eliminating the learning curve. This filling systems. This catalog is loaded with colorful 200-A power source, with 110-230 VAC pictures plus specification and application data for autoranging input, has a stainless steel more than 400 products. For more information enclosure, and incorporates both sealed call us toll free 888-327-7306 in the U.S. keypad and color LCD for rugged jobsite usage. The Model 514 incorporates QC/QC monitoring, and operates Heads with wire feed capability. IBEDA, Inc., SUPERFLASH Compressed Gas Equip Div. Magnatech PO Box 260 31379 Lorain Rd. Circle No. 207 Circle No. 203 East Granby, CT 06026-0260 North Olmsted, OH 44070 SEE US AT ESSEN 001-440-716-9960 (860) 653-2573 FAX: (860) 653-0486 BOOTH HALL 6, FAX: 001-440-716-9963 SEE US AT ESSEN BOOTH E-Mail: [email protected] 92 STAND 6-404 E-mail: [email protected] HALL B/8, STAND B/8-118 www.magnatech-lp.com ESSEN RED HOT f DryRod Welding Electrode BDI Exhibits TOUGH GUNs® for Stabilizing Ovens Today's Welding Professionals. Offering a complete line of DryRod Browne Dreyfus International will exclusively Welding Electrode Stabilizing present the TOUGH GUN® line from DryRod Welding Electrode Tregaskiss Welding Products, including the Stabilizing ovens for holding and latest GMAW innovations such as the reconditioning welding electrodes, enhanced cooling system of the TOUGH bulk flux and wire. Available in GUN® I.C.E. torch and the ultimate Sure portable versions (shown) and larger shop ovens. The Safetube is a Start contact tip. Also featured will be WTC watertight, durable container that protects electrodes from dust, water, brand GTAW and Plasma Arc Cutting torches and air. See our complete line. of BDI Europa. Phoenix International, Inc. Tregaskiss, BDI, LTD Circle No. 208 8711 West Port Ave. 305 Madison Ave., Ste. 420 Milwaukee, Wl 53224 New York, NY 10165 SEE US AT ESSEN BOOTH (414) 973-3400 (212) 867-7700 HALL 8, STAND 8-118 FAX: (414) 973-3210 Circle No. 212 FAX: (212) 867-7820 www.phx-international.com SEE US AT ESSEN BOOTH www.bdi-ltd.com HALL 7, STAND 7-514 Titan Welding Helmets Wear-Resistant Alloy Balanced, ergonomically crafted and lightweight, RTECH Consumables the Sellstrom Titan™ line of welding helmets have Stop by and visit our booth in Hall 6, been thoughtfully engineered to maximize per Stand 225 at the Essen Welding Fair this formance and enable welders to work more effi September, or contact us for more infor ciently and comfortably. The shell is made of a mation. We make high-quality wear-resist durable, incredibly heat resistant material with ant consumables (rods, electrodes, contours that not only look fantastic, but actually wires, and powders) and specialize in redirect spatter safely away from the cover plate. cobalt and nickel HARDFACING and Unique bezel assembly makes it even easier to WEAR-RESISTANT alloys. They are capa change or add impact plates, filter plates, and ble of maintaining their hardness at tem auto-darkening filters. Meets ANSI Z87.1 stan peratures of up to 1500°F (800°C) and dards and are CUL certified to meet CAN/CSA have applications in multiple industries Z94.3 standards. Made in the USA. from automotive to aerospace. Circle No. 209 Sellstrom Manufacturing Co. One Sellstrom Dr. Weartech International SEE US AT ESSEN Palatine, IL 60067 13032 Park St. BOOTH HALL US (847) 358-2000 Circle No. 213 Santa Fe Springs, CA 90670 Pavilion, STAND 7- FAX (847) 358-8564 (562) 698-7847 21L E-mail: [email protected] SEE US AT ESSEN BOOTH FAX: (562) 945-5664 http://www.sellstrom.com HALL 6, STAND 225 www.weartech.net EZ ARC WELDING SYTEMS Aquasol Purge Paper and Products Make Purging GENTEC offers affordable solutions Effortless E'Z'ARC SYSTEMS to workstation design. The EZ ARC Welding Pcsithnets Turning Roltf product line includes complete weld In just three simple steps, you're ready to ing workstations that accommodate weld. a wide variety of part configurations. 1. Clean pipe with EZ Wipes™ multipur Components attach to a base rail pose, saturated cleaning wipes. system fixture parts for optimum 2. Form and tape dam with Aquasol® results on a repetitive basis. Water-Soluble Paper and Tape. Automation may be achieved using 3. Cover root gap with EZ Zone™ Tape, optional Sequencer. The product line the only purge gas retaining tape with an also includes welding Positioners adhesive-free center zone, ensuring a and Turning Rolls. contaminant-free weld. Genstar Technologies Co., Inc. Aquasol Corp. Circle No. 214 1576 Sweet Home Rd. C 4525 Edison Ave. 0 . Chino, CA 91710 Amherst, NY 14228 (909) 606-2726 SEE US AT ESSEN BOOTH (716) 654-8888 HALL 7, STAND 316F Circle No. 210 www.genstartech.com e-mail: [email protected] www.aquasolcorporation.com New Laser Manifold Increases CUTMASTER™ 1 Series Power and Performance Of Plasma Cutting Systems Cutting Machines Rexarc's Laser Manifold uses proprietary Thermal Dynamics® has introduced a Zero Drop™ technology to increase the new family of CUTMASTER® ISeries air power and performance of cutting plasma cutting systems, featuring the machines. The Laser maintains continu company's revolutionary lTorch' plas ous downstream pressure and flow from high-pressure cradle banks or ma torch and patent-pending ATC liquid cans — even when switching from supply to reserve. Without a (Advanced Torch Connector) quick dis drop in pressure, your cuts are clean, waste is minimized, and finishing connect. All ISeries machines take time is reduced. The Laser handles your most demanding applications, advantage of the lTorch start (non-HF) capability that eliminates electron running all day, delivering up to 7,500 ft3/h at 450 psig without costly ic interference. Each system is suitable for cutting materials including alu downtime or optic contamination. Request a free brochure or see the minum, stainless steel, and mild steel in applications ranging from con "Lasers On Steroids" video online. struction to fabrication to manufacturing. Circle No. 211 Thermal Dynamics Rexarc International, Inc. Circle No. 215 A Thermadyne Co. 35 E. 3rd St./PO Box 7 16052 Swingley Ridge Rd., Ste. 300 SEE US AT ESSEN BOOTH West Alexandria, OH 43851 St. Louis, MO 63017 HALL 7, STAND N (937) 839-4604 SEE US AT ESSEN BOOTH (636) 728-3000 go www.rexarc.com HALL 2, STAND 311 www.thermal-dynamics.com CLASSIFIEDS ll_?*__ll_ CAREER OPPORTUNITIES STAFF ENGINEER/COMMITTEE ADMINISTRATOR CWI/NDT Bridge Weld Inspector MACTEC Engineering & Consulting Inc. INTERNATIONAL STANDARDS DEVELOPMENT - MIAMI, FL Salary $70,000 - $80,000 Join a high-achieving inspectors/technicians Principal duties include management of ISO technical com Interested parties should send a and engineers team providing QA inspec mittees that develop International Standards for the welding resume and salary range along with tion and consulting services to State of industry worldwide, U.S. Technical Advisory Groups (TAGs) a cover letter outlining interest to California DOT for a multi-year new and to ISO committees that develop U.S. positions on draft ISO retrofit bridge construction program. This standards, and AWS Technical Committees that develop American Welding Society is a lifetime opportunity in working on U.S. national welding standards. Involves approximately unique high-profile bridge structures. 550 N.W. LeJeune Rd. 20% travel, some international. Miami, Fl 33126 MACTEC inspectors perform QA services in fabrication facilities (domestic and inter Attn.: Andrew Davis Requires a University degree, preferably in engineering or national) and at bridge sites. Technical Services equivalent (experience in welding or manufacturing desir Requirements include AWS Certified [email protected] able), standards development experience, especially ISO Inspector, Level II UT (Flaw Detection), procedures (either as a committee member or from a stan bridge and construction experience, valid AWS -An Equal Opportunity Employer dards development organization), excellent verbal and writ driver's license, Residence or relocation to Visit our Website at www.aws.org ten English skills. Must be computer literate, proficient in MS California, and travel. Windows/PC environment and have good e-mail and inter net skills (for web-based standards development). 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SUPPLEMENT TO THE WELDING JOURNAL, AUGUST 2005 (WRT^ Sponsored by the American Welding Society and the Welding Research Council Vj \\)J Determination of Optimal Welding Conditions with a Controlled Random Search Procedure A controlled random search procedure can determine the near-optimal settings of welding process parameters within a large search space with a relatively small number of experiments BY D. KIM, M. KANG, AND S. RHEE ABSTRACT. This study proposes a However, costly and time-consuming ex 2-12). Several studies have employed re method for determining the near-optimal periments are required in order to deter gression analysis in order to induce a lin settings of welding process parameters mine the optimum welding process para ear model between the welding process using a controlled random search (CRS) meters due to the complex and nonlinear parameters and weld bead geometry para wherein the near-optimal settings of the nature of the welding process. Therefore, meters (Refs. 3-5). Other studies have welding process parameters are deter a more efficient method is needed to de used neural networks to develop nonlin mined through experiments. The method termine the optimum welding parameters. ear models of the welding process (Refs. suggested in this study is used to deter The general procedure that could be 6-8), while other studies (Refs. 9,10) have mine the welding process parameters by used to determine the optimum weld pa used the Taguchi method to find robust which the desired weld bead geometry is rameters is response surface methodology welding conditions. All of these tech formed in gas metal arc (GMA) welding. (RSM). Response surface methodology is niques can be used effectively when the In this method, the output variables (front a group of statistical and mathematical application process is near the optimum bead height, back bead width, and pene techniques useful in modeling, improving, conditions or over a stable operating re tration) are determined by the input vari and optimizing processes. The general gion in which an arc can be struck and ables (wire feed rate, welding voltage, and procedure of RSM for process optimiza melt-through does not occur (Ref. 13). welding speed). The number of levels for tion is as follows (Ref. 1): Hence, preliminary experiments to help each input variable and the total search 1) Conduct screening experiments. move the experimental region near the points were determined to be 10 and 1000, 2) Move the experimental region near optimal point and provide a stable operat respectively. the optimal point. The best condition ing region must be performed in order to from this step is called "the near-optimal apply regression modeling, neural net Introduction condition." work modeling, and the Taguchi method 3) Develop a model within a relatively to the arc welding process. There are sev Bead geometry in the arc welding small region around the optimal point. eral ways for determining the near-opti process is an important factor in deter 4) Determine the optimal settings for mal welding conditions: mining the mechanical characteristics of process parameters that maximize or min Determination of the near-optimal the weld. Bead geometry variables, such as imize the objective function. welding conditions through a simple ex bead width, bead height, and penetration Many studies have been conducted on periment is possible based upon a full fac depth, are greatly influenced by welding screening experiments, modeling, and op torial experiment without inducing a process parameters including welding cur timization of welding processes (Refs. model for the welding process. Neverthe rent, welding voltage, shielding gas, and less, the number of experiments necessary contact tube-to-work distance (CTWD). exponentially increases as the number and The selection of the appropriate welding level of input variables increase. It is thus process parameters is required in order to impractical to apply the method in the ini KEYWORDS obtain the desired weld bead geometry, tial stages of determining the welding which greatly influences weld quality. process parameters. The method of steep Arc Welding est assent based upon derivatives (Ref. 14) Controlled Random Search can lose the direction of the search when D. KIM is with Joining & Coating Technol Optimization melt-through or other nonlinear phenom ogy, Shipbuilding & Plant R&D Institute, Weld Bead Geometry Samsung Heavy Industries Co., Geoje-si, ena appear within the search range of the Weld Quality Korea. M. KANG is with Advanced Welding welding process parameters. Welding Process Parameter & Joining Research Team, KITECH In- The genetic algorithm, which is a cheon, Korea. S. RHEE is with the Depart global algorithm, can overcome the prob ment of Mechanical Engineering, Hanyang University, Seoul, Korea. lems associated with full factorial experi- WELDING JOURNAL fltSlt-Ittllitlllll s I'i'i =11JI! M :1=M=fcl WT The search can be performed within processes wherein the objective function value is quantitative or qualitative when an order can be established since the search is conducted according to the order of the objective function values. 5) While many optimization methods use the de terministic transition rule, the CRS algo rithm instead uses the stochastic transition rule. The process of finding a minimal point using CRS is as follows: Controlled random search randomly generates a preset N number of search points called the candidate solutions within the search region of V, and conse quently begins the search. The objective function of each search point is obtained, and the location information of each F2g. 7 — IFeM bead geometty. search point and the objective function value are stored in array A. A new search point P is then selected based upon the set of candidate solutions in each of the next Table — 1 Search Range for Welding Parameters and Number of Levels iterations. The objective function value of point P is calculated when the search point Parameter Range Number of levels P exists within the search range V. The ob Wire feed rate 11.3-23.0 (cm/s) 10 jective function value calculated at point P Welding voltage 18-27(V) 10 (fP) is compared with the objective func Welding speed 2-22 (mm/s) 10 tion value at point M (fM) as the maximum objective function value of the N number of points stored in array A. lifP AUGUST 2005 :I=W=M:M! modified algorithm, Rt is always the point L. which has the least function value, and n points are randomly chosen from N-l points. Hence, L can never be the pole of the simplex. In this study, the modified CRS is used in order to determine the optimal condi tions for the welding process. The opti mization process ofthe modified CRS can be summarized as follows: Step 1. Define the upper and lower bounds. Step 2. Choose random N points over V; evaluate the objective function at each point; store the positions and function val ues in an array A. Step 3. Find the point M with the great est function value fa, and the point L with 0 2 mm the least function value fL. Step 4. Choose random n distinct points R2 ..., /J„+/excluding L. Let Rt =L, and de termine the centroid G of points Rl Rn. Compute the next trial point . Step 5. If P is within V, then evaluate fP f^Bm^^^ and go to Step 6; else, return to Step 4. Step 6. Hfp < fM, then replace M by P in A and go to Step 7; else, return to Step 4. Step 7. If the stop criterion is satisfied when the value of the objective function is less than a predefined small number, then stop; otherwise return to Step 3. I 1 1 0 2 mm Experimental Procedure The base metal to be welded was mild 8 steel with a thickness of 4.0 mm. The joint type was a square groove, and the root opening was fixed at 1.2 mm. The electrode wire was an AWS classification ER 70S-6 with a diameter of 1.0 mm. The electrode i j 0 polarity was direct current electrode posi 2 mm 2 mm tive. Contact tube-to-work distance was 20 mm. The shielding gas used in the experi ment was 80%Ar + 20%CO2, and the flow rate was 20 L/min. The power source used in the welding process was a machine with a constant voltage characteristic. The search range of each welding parameter was as fol lows: The search range of the wire feed rate was 11.3 —23.0 (cm/s), the search range of the welding voltage was 18 ~ 27 V, and the search range of the welding speed was 2 ~ 11 mm/s. Welding was performed under each welding condition determined through CRS, and the front bead height, back bead width, and penetration were con Fig. 2 — Cross sections of welds made with various combinations (Table 2) of process vari sequently measured. A copper backing bar ables produced (in/from) the initial candidate solutions. was used with the distance between the base metal and the copper backing bar set at 1 back bead width, and penetration affecting obtained through the experiment. In the op mm. the weld quality, as shown in Fig. 1. timization problem, Hd = 1.5 mm, Wd = 4.0 mm, Pd = 5.0 mm arc selected as the desired w 2 2 2 Results and Discussion /= (Hd-Hp + (Wd~ ) + (Pd-P) ( ) bead geometiy. Obtaining the desired bead geometry thus implies finding the welding The purpose of this optimization prob where Hd. Wd. and Pd are the desired front parameters minimizing/. lem was to obtain a complete penetration bead height, back bead width, and penetra The determination ofthe search region weld. The following objective function was tion, while H W, and P are the front bead is one of the important steps of the overall formulated by using the front bead height. height, back bead width, and penetration the optimization procedure. One of the WELDING JOURNAL :l=W=fil:W: macro cross sections of the weld formed under each welding condition. The weld ing conditions of experiment number 8 produced the most satisfactory welding quality, and the welding conditions of ex periment number 9 produced the worst quality welds among the initial ten welding conditions. The back bead is not formed 0 2 mm under the welding conditions of experi ments number 1, 3-7, 9, and 10. On the other hand, under the conditions of exper iments 2 and 8, the back bead is generated, 14 melt-through is prevented by the backing bar, and the penetration is limited. ^ In the next stage, welding condition M with the greatest objective function value fu and welding condition L with the least objective function value fL arc deter mined through the results of the experi 0 2 mm ments on the initial candidate solutions. Three welding conditions are then ran *\ domly selected from the nine welding conditions excluding L to comprise a 15 16 three-dimensional simplex, and the next search point P is determined by L and the three selected conditions through equa tion P = 2G -Rn+i. In this equation, Rn + ] is the welding conditions selected last, while G is the centroid of all of the points ex I i cluding Rn + 1. The search is performed 0 2 mm •i with point M excluded from the candidate ySI solution set and point P included in the set - when the search point P exists within the search range and the objective function ——• —-•—•-" points are necessitated to find the optimal value fp is smaller than/ . ••••• • : M 17 ••'• ,• .'...;,. .;.,'• • •• WM process parameters through the full facto In this study, the welding conditions of rial experiment under the conditions experiment number 9 correspond with stated in Table 1. Any method that re point M, and the objective function value quires such a large number of search (ftf) under these conditions is 32.0. In ad points is considered unrealistic due to the dition, the welding conditions of experi great number of experiments required. ment number 8 correspond with point L, I I I The process of determining the opti and the objective function value (fL) under 0 2 mm mal welding process parameters using these conditions is 0.4. The three welding CRS is as follows: In the first stage of the conditions randomly selected to comprise CRS search process, a set of random can the simplex are the welding conditions of didate solutions (N) are generated. As the Fig. 3 — Cross sections of welds made with experiments 2, 6, and 5, and thus the sim value of N increases, the number of ex plex is comprised of the welding condi various combinations (Table 3) of process periments increases. Thus, the conver variables produced at each iteration. tions of experiments numbers 8. 2. 6, and gence of the algorithm may be slow (Ref. 5. The welding conditions of experiment 21). The appropriate choice of N is a mat number 5 become the pole ofthe simplex, ter of experience. In this study, the search and centroid G is calculated from the was performed with ten initial candidate welding conditions of experiments num choice methods is based on previous solutions — Table 2. bers 8, 2, and 6. The welding conditions, works or welding books. It is difficult to Welding was conducted three times which become the next search point ob get all the information on input parame under each welding condition determined tained from Equation 1, are comprised of ters from previous works or welding through the CRS algorithm. Three sam a wire feed rate of 13.9 cm/s, welding volt books. However, the combination of pre ples were cut from each welding condition age of 24 V, and welding speed at 7 mm/s. vious works, welding books, and welding and the transverse face of the weldment The front bead height, back bead width, engineer's experience can give useful in was ground and macroetched. Then, the and penetration obtained after welding formation on the search region. In this front bead height, back bead width, and under these conditions are 1.4,0.0, and 2.2 paper, the search region was determined penetration acquired from each welding mm, respectively, and the objective func based on a previous work (Ref. 22) and au condition were measured and the mean of tion value fp is 23.9. Since/F is smaller than thors' experience. The search range of the each value was applied to Equation 2 in fM, experiment number 8, which corre process parameters and the number of order to calculate the objective function sponds with M, is eliminated from the can levels to find the welding process parame value. The ten welding conditions and the didate solution set, and the welding con ters that minimize Equation 2 are as experiment results under each condition dition of point P is included instead. are shown in Table 2. Fiaure 2 shows the shown in Table 1. Hence, 1000 search This process is repeated until satisfac- AUGUST 2005 ;l=W=fJ;Wi tory weld quality (f" 0.1 ) is obtained. In tee that the optimal weld this study, satisfactory weld quality is ob ing condition obtained by tained in the 8th iteration, and only 17 ex the CRS algorithm is the periments are necessitated since the near global minimum because optimal condition is found in the 8th iter the global minimum de ation. The welding process parameters pends on the number of and experiment results from the 2nd to 8th initial random candidate iteration are shown in Table 3. Figure 3 solutions, complexity of shows the macro cross section of the weld the objective functions under each welding condition. The final and methodology in which candidate solutions are comprised of the the individual candidate welding conditions of experiment and solution is chosen. Since numbers 2, 3, 7, 8, and 12-17. Figure 4 the specific rates of con shows the average objective function value vergence differ according obtained from the candidate solutions for to the initial candidate so each iteration. Figure 4 demonstrates that lutions and stochastic se the averages of the objective function val lection mechanism, an ues of the 10 candidate solutions decrease other run may require as the iteration increases. many iterations. The welding conditions determined in th It should be noted that the 8 iteration as the optimal welding the obtained welding con Fig. 4 — Results ofthe controlled random search procedure. conditions are a wire feed rate of 16.5 ditions are valid only when cm/s, welding voltage of 22 V, and welding the welding input parame speed at 5 mm/s. The front bead height, ters being considered are back bead width, and penetration ob within the limits of those tained under these conditions are 1.3, 3.9, investigated. and 5.0 mm, respectively. The results ob The CRS algorithm explained above is rithm does not give models between input tained through the study are satisfactory variables and output variables. Therefore, th effective in finding near-optimal condi with the optimal condition found in the 8 tions; however, the convergence perfor in order to overcome these problems a com iteration despite the slight disparity with mance after reaching near-optimal condi bination of regression or neural network the weld geometry values initially estab tions diminishes drastically. Thus, modeling and optimization algorithm was lished. The CRS algorithm is a global op continuing experiments with the CRS algo used around the near optimal conditions to timization algorithm similar to the genetic rithm after finding the near-optimal condi develop welding process models and to op algorithm. However, this does not guaran tions are ineffective. Also, the CRS algo- timize weld bead geometry. Table 2 — Res jits ofthe Initial Candidate Solutions Experiment Feed Rate Voltage Speed Height Width Penetration Objective Number (cm/s) (V) (mm/s) (mm) (mm) (mm) Function 1 20.4 19 8 2.0 0.0 1.5 28.5 2 19.1 24 5 1.2 4.6 5.0 0.5 3 16.5 21 7 1.7 o.o 3.7 17.7 4 13.9 18 9 0.5 0.0 1.5 29.3 5 17.8 19 3 3.2 0.0 2.2 26.7 6 12.6 21 6 1.8 11.(1 2.5 22.3 7 11.3 23 6 1.5 11.11 2.0 23.8 8 15.2 20 4 2.0 3.6 5.(1 0.4 9 21.7 20 9 1.4 0.0 1.0 32.0 10 16.5 21 7 2.1 0.0 3.0 20.4 Table 3 — Results of the Next Iterations Experiment Feed Rate Voltage Speed Height Width Penetration Objectibe Number (cm/s) (V) (mm/s) (mm) (mm) (mm) Function 11 13.9 24 7 1.4 0.0 2.2 23.9 12 11.3 22 4 1.8 1.6 4.3 6.3 13 15.2 24 4 1.5 3.0 5.0 1.(1 14 21.7 22 5 2.1 5.1 5.0 1.6 15 17.8 22 4 2.2 4.8 5.0 1.1 Id 13.9 21 6 1.9 (Ml 3.0 20.2 17 16.5 22 5 1.3 3.9 5.0 0.1 WELDING JOURNAL fl.,T"> :J=W=M:M Conclusion J. 1993. The effects of process variables on the 13. Subramaniam, S., White, D. R., Jones, J. weld deposit area of submerged arc welding E.. and Lyons, D. W. 1999. Experimental ap The CRS method is proposed in this process. Welding Journal 72( 1): 11-s to 18-s. proach to selection of pulsing parameters in study as a method of determining the 5. Gunaraj, V. and Murugan, N. 1999. Ap pulsed GMAW. Welding Journal 78(5): 166-s to welding conditions that produce the de plication of response surface methodology for 172-s. sired weld geometry. The objective func predicting weld quality in submerged arc weld 14. Rao, S. S. 1996. Engineering Optimiza tion does not have to be differentiable ing of pipes. Journal of Materials Processing tion. John Wiley & Sons. Inc. when conducting optimization through Technology 88: 266-275. 15. Kim. D„ and Rhee, S. 2001. Optimiza CRS. In addition, the CRS algorithm is 6. Andersen, K., Cook. G. E., Karsai, G.. tion of arc welding parameters using a genetic relatively easy to program. The welding and Ramaswamy, K. 1990. Artificial neural net algorithm. Welding Journal 80(7): 184-s to 189- process parameters, which generate a works applied to arc welding process modeling s. complete penetration weld, are deter and control. IEEE Trans, on Industiy Applica 16. Kim. D., and Rhee. S. 2004. Optimiza mined through the CRS. The input vari tions 26(5): 824-830. tion of a gas metal arc welding process using the ables are the wire feed rate, welding volt 7. Li. P.. Fang. M. T. C. and Lucas. J. 1997. desirability function and the genetic algorithm. age, and welding speed, while the output Modeling of submerged arc weld beads using Proceedings ofthe Institute of Mechanical Engi variables are the front bead height, back self-adaptive offset neural network. Journal of neering, Part B — Journal of Engineering Manu bead width, and penetration of the bead Materials Processing Technology 71: 288-298. facture, 218, pp. 35-41. geometry. The welding conditions, which 8. Meng. T. K.. and Butler. C. 1997. Solving 17. Goldberg. D. E. 1989. Genetic Algo produce the desired output variables, can multiple response optimization problems using rithms in Search. Optimization, and Machine be determined through systematic experi adaptive neural networks. International Journal Learning, Addison-Wesley. ments even in systems considerably diffi of Advanced Manufacturing Technology 13: 18. Grcfenstette. J. J. 1986. Optimization of cult to model, such as the welding process, 666-675. control parameters for genetic algorithms. through the CRS method. 9. McConnell. I. A., and McPherson, N. A. IEEE Trans, on Syst. Man Cybem 16(1): 1997. The application of statistical process de 122-128. References sign to a FCAW process. Welding Journal 19. Steinberg. D. M.. and Hunter, W. G. 76(10): 412-s to 416-s. 1984. Experimental design: review and com 1. Myers. R. H., and Montgomery. D. II. 10. Tarng. Y. S.. and Yang. W. H. 1998. Op ment. Technometrics 26(2): 71-97. 1995. Response Surface Methodology, John timization of the weld bead geometry in gas 20. Price. W L. 1977. A controlled random Wiley & Sons, Inc., pp. 9-12. tungsten arc welding by the Taguchi method. In search procedure for global optimization. The 2. O'Brien. R. L. (Editor) 1991. Welding ternational Journal of Advanced Manufacturing Computer Journal 20(4): 367-370. Handbook. 8th Ed.. Vol. 2. Welding process, Technology 14: 549-554. 21. Price. W L. 1983. Global optimization by Miami. Fla.: American Welding Society, pp. 11. Gicen, R. 2004. How to optimize mild controlled random search. Journal of Optimiza 110-155. steel GMAW. Weldingjoumal 83(12): 30-32. tion Theoiy and Applications 74(3): 333-348. 3. Konkol, P. J., and Koons. G. F. 1978. Op 12. Murugananth. M.. Babu. S. S., and 22. Nakamura. M. 1972. Technical points of timization of parameters for two-wire AC-AC David. S. A. 2004. Optimization of shielded manual operation for C02 semi-automatic arc submerged arc welding. We/ding Journal 57( 12): metal arc welding metal composition for welding. Journal of JWS 41(7): 1041-1055. 367-s to 374-s. Charpy toughness. Welding Journal 83( 10): 267- 4. Yana. L. J.. Chandel. R. S.. and Bibby. M. s to 276-s. CAN WE TALK? The Welding Journal staff encourages an exchange of ideas with you. our readers. If you'd like to ask a question, share an idea or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with the right person. Publisher/Editor Managing Editor Peer Review Coordinator Andrew Cullison Zaida Chavez Doreen Kubish [email protected], Extension 249 [email protected], Extension 265 [email protected], Extension 275 Article Submissions Design and Production Peer Review of Research Papers Senior Editor Advertising Sales Director Welding Journal Dept. Mary Ruth Johnsen Rob Saltzstein 550 N.W. LeJeune Rd. [email protected], Extension 238 [email protected], Extension 243 Miami. FL 33126 Feature Articles Advertising Sales (800) 443-9353 FAX (305) 443-7404 Associate Editor Advertising Production Coordinator Howard Woodward Frank Wilson [email protected], Extension 244 fivilsontciaws.oig. Extension 465 Society News Advertising Production Personnel Advertising Sales & Promotion Coordinator Assistant Editor Lea Garrigan Badwy Kristin Campbell [email protected], Extension 220 kcampbell(aaws.org, Extension 257 Production and Promotion New Products News of the Industry AUGUST 2005 Constraints-Based Modeling Enables Successful Development of a Welding Electrode Specification for Critical Navy Applications A novel modeling approach substantially reduces risk in developing a high- performance welding electrode specification for critical U.S. Navy applications BY K. SAMPATH ABSTRACT. An innovative constraints- low-alloy (HSLA) type steels with a mini temperature controls during welding to based modeling approach was used to suc mum yield strength of 80 or 100 ksi are reduce the occurrence of HAC in the weld cessfully specify the chemical composition used extensively in U.S. Navy ship and HAZ. These additional operations in range for advanced consumable elec submarine construction (Ref. 1). Com crease fabrication cost, produce consider trodes intended for gas metal arc welding mercial applications for these high- able production delays, and increase (GMAW) of high-strength steels for criti performance steels include off-highway welder discomfort. It is estimated that cal U.S. Navy applications. Initially, vari vehicles, bridges, pressure vessels, storage elimination or substantial reduction in ous U.S. Navy requirements for advanced vessels, etc. temperature control during welding could consumable electrodes were converted The HY steels were developed in the save about $10 million in the construction into a set of constraints that related chem 1960s and exhibit a tempered martensitic of an aircraft carrier and $15 million in the ical composition of steels to certain met microstructure. The HY-80 and HY-100 construction of a submarine in material, allurgical characteristics with appropriate steels are characterized by a high carbon labor, and lost productivity, irrespective of numerical ranges. The metallurgical char content (Ref. 2) ranging from about 0.12 the type of arc welding processes used. acteristics and their numerical ranges, in to 0.20 wt-% (percent by weight). Hydro Currently, various U.S. shipyards em turn, were used to identify critical ele gen-assisted cracking (HAC) in the weld ploy the GMAW process as the preferred ments for compositional control, and to heat-affected zone (HAZ) is a serious fabrication process for constructing sev specify the compositional ranges for the issue in the welding of these high-strength eral ship structures, and primarily use Ar- individual alloy elements. Subsequently, a structural steels with a high carbon 5%CO as weld shielding gas. AWS A5.28, 23 factorial design of experiments was z content. Specification for Eow-Alloy Steel Electrodes used to develop a batch of welding elec These steels show a high potential to and Rods for Gas Shielded Arc Welding trodes, and limited experiments were car form twinned martensite and solid-state (Ref. 3), recommends ER-100S and ER- ried out to evaluate the performance of cracking in the HAZ when the following 120S welding consumables for joining the welding electrodes. Results showed HY-80 and HY-100 steels. Table 1 speci that two of the eight electrodes met or ex conditions are simultaneously present: 1) ceeded ER-100S requirements, while one a source of dissolved hydrogen; 2) high fies the chemical composition range and of the eight electrodes met or exceeded residual tensile stress distribution; 3) a mechanical property requirements for ER-120S requirements. Additional weld temperature range that did not allow sig ER-100S and ER-120S GMAW consum evaluations performed over a much wider nificant solid-state diffusion of atomic hy able electrodes. These electrodes often welding operational envelope using one of drogen from the steel; and 4) a time delay exhibit a carbon content in excess of 0.05 the eight electrodes provided weldments following welding that allowed atomic hy wt-%. Consequently, these welding con with acceptable weld mechanical proper drogen to accumulate at internal "flaws" sumables also require significant preheat ties for ER-100S over the entire range of in the steel, thereby leading to HAC. The to reduce the occurrence of HAC in the welding conditions. Thus, use of the con HY steels require the application of pre weld metal (Ref. 4). straints-based modeling approach greatly heat, interpass, and occasionally post soak High-strength low-alloy steels were de reduced the risks inherent in developing veloped in the 1980s in an effort to reduce electrode specification, while allowing fabrication costs (Ref. 1). In contrast to one to meet or exceed U.S. Navy require KEYWORDS the HY steels, the HSLA-80 and HSLA- ments at minimal cost and schedule, 100 steels (Ref. 5) have a lower carbon thereby validating the exceptional utility Hydrogen-Assisted Cracking content (0.07 wt-% maximum) and exhibit of this novel modeling approach. (HAC) a ferritic and a bainitic microstructure, re Gas Metal Arc Welding (GMAW) spectively. Unlike the martensitic mi HSLA-80 and HSLA-100 Steels crostructure. the ferritic and bainitic mi Background HY-80 and HY-100 Steels crostructures exhibit little or no Carbon Equivalent Number susceptibility to HAC. Because of their High yield (HY) and high-strength (CEN) low susceptibility to HAC, HSLA-80 and Charpy V-Notch (CVN) HSLA-100 steels require much less strin K. SAMPATH is a Technology/Business Consul ER-100S and ER-120S Electrodes gent preheating controls compared to the tant in Johnstown, Pa. Constraints-Based Modeling corresponding grade of HY steels, thereby offering a huge potential for low-cost fab- WELDING JOURNAL Table 1 — Chemi:a l Composition Ranges Objectives trodes, while improving their weldability and Mechanical Property Requirements in terms of excellent resistance to HAC. The present work describes an innova The above metallurgical characteris AWS A5.28 tive constraints-based modeling approach tics and their numerical ranges, in turn, Specificat ion that proved quite efficient in developing a were used to identify critical elements for specification for consumable, bare, solid- compositional control, and to specify ap Element ER 100S ER 120S wire electrodes for GMAW of HSLA-80 propriate compositional ranges for the in 3 Carbon 0.08 0.10 and HSLA-100 steels that met or ex dividual alloy elements. Subsequently, a 2 Manganese 1.25-1.80 1.40-1.80 ceeded the above U.S. Navy require factorial design of experiments was used Silicon 0.20-0.55 0.25-0.60 ments. to develop a batch of welding electrodes. Phosphorus 0.010 0.010 A U.S. General Accounting Office re Limited experiments were used to eval Sulfur 0.010 0.010 port (Ref. 7) has quoted that "only 39% of uate the performance of these advanced Nickel 1.40-2.10 2.0-2.80 welding electrodes. Results showed that Chromium 0.30 0.60 (U.S. Government) specification parame two of the eight electrodes met or ex Molybdenum 0.25-0.55 0.30-0.65 ters were supported by historical data and Vanadium 0.05 0.03 less than 5% of the parameters were sup ceeded ER-100S mechanical property re Titanium 0.10 0.10 ported by test data," thereby strongly en quirements, while one of the eight elec Zirconium 0.10 0.10 dorsing a need for strengthening the spec trodes met or exceeded ER-120S Aluminum 0.10 0.10 ification development and approval mechanical property requirements. Sub Copper 0.25 0.25 process. In this context, the constraints- sequently, one of the eight welding elec Other Elements, Tota 0.50 0.50 based modeling effort was also aimed at trodes was evaluated over a much wider Iron Balance Balance directly strengthening this vital process. range of welding conditions. Results over Mechanical Propc rty whelmingly supported the underlying Constraints-Based Modeling metallurgical principles. Tensile Strength 100 120 The use of the constraints-based mod (ksi) The constraints-based modeling ap eling approach greatly reduced the risks Yield Strength 88 105 proach uses the following two key inherent to developing the electrode spec (ksi) principles: ification, while allowing one to meet or ex Elongation (%) 16 14 ceed U.S. Navy requirements at minimal Minimum CVN — — 1) Consolidate prior and perceived knowl at 0°F (ft-lb) edge into a coherent set of mutually in cost and schedule, thereby validating the Minimum CVN 50 50 clusive constraints that meet specific re exceptional utility of this novel modeling at -60°F (ft-lb) quirements: and approach. 2) Use the set of constraints to formulate controlled experiments that would limit Model Development the experimental space, while reducing rication of very large structures. inherent risks, thereby allowing one to The primary emphasis of the modeling However, HSLA-80 and HSLA-100 reach beyond the consolidated knowl effort was to ensure excellent weldability. steels are currently fabricated with ER- edge in developing novel, low-cost, low- For the purpose of this work, weldability 100S and ER-120S solid wire electrodes risk solutions to overcome persistent was defined as the ability to re-create or used for GMAW of HY-80 and HY-100 materials (processing and fabrication) retain high-performance base metal mi steels. Since the currently available ER- issues. crostructure that showed a minimal sus ceptibility to HAC. As the HSLA-80 and 100S and ER-120S solid wire electrodes Under this modeling approach, ini HSLA-100 steels have a low carbon con require preheat and interpass controls, tially the various U.S. Navy requirements for ER-100S and ER-120S electrodes (i.e.. tent (0.07 wt-% maximum), exhibit a fer and post soak temperature control for ER- minimize the need for preheat and inter ritic and bainitic microstructure, respec 120S, their use precludes the full eco pass temperature controls, while eliminat tively, and show a minimal susceptibility to nomic advantages of HSLA steels (Ref. 6). ing sensitivity to HAC, improve welding HAC. one could expect that weld metals For the foregoing reasons, there is an eco operational envelope to allow wide varia with similar characteristics, including de nomic need for developing advanced con tions in weld cooling rate and welding pro sired microstructures, would offer excel sumable, bare, solid-wire electrodes for ductivity, and increase one's ability to lent weldability. Based on this premise, GMAW of HSLA-80 and HSLA-100 achieve acceptable variations in weld me the various U.S. Navy requirements were steels. chanical properties despite wide varia converted into a set of mutually inclusive As the prime user, the U.S. Navy has tions in weld cooling rate) were converted constraints that enabled one to identify identified that the candidate advanced into specific constraints that could be re and define appropriate chemical composi GMAW consumables for high-strength lated to the chemical composition of steels tion ranges for providing high- steels should exhibit the following charac through a set of mutually inclusive consti performance weld metals with a predomi teristics: 1) eliminate or substantially re tutive equations with appropriate numer nantly ferritic or bainitic microstructure duce the need for preheat controls; 2) ical ranges. Each of these constitutive and minimal susceptibility to HAC. show adequate resistance to HAC; 3) equations obtained from prior art under A composition having the features of meet or exceed the mechanical property scores one or more metallurgical charac the constraints-based model is comprised requirements ofthe existing ER-100S and teristics. The respective numerical ranges of iron (Fe) and specific amounts (in per ER-120S electrodes; 4) allow welding over for the selected metallurgical characteris cent by weight) of carbon (C), manganese a broad operational envelope in terms of tics were also obtained from an analysis of (Mn), nickel (Ni), chromium (Cr), molyb plate thickness, welding position, and prior art. Specific numerical ranges were denum (Mo), silicon (Si), copper (Cu), weld energy input; and 5) show minimal decided based on the possibility to achieve vanadium (V), niobium (Nb), and boron variation in weld mechanical properties a desirable range of mechanical properties (B) that concurrently satisfy the following (especially yield strength) when welded (tensile strength, low-temperature tough three equations: ness) for both ER-100S and ER-120S elec over a broad operational envelope. B50 (°C) = 770 - (270 x C) - (90 x Mn) AUGUST 2005 Table 2 — Chemical Composition of Bare Wire GMAW Electrodes No. Mn Cr V Mo Cu 11 B O II 1 0.027 1.51 0.001 0.0019 0.34 0.02 2.52 0.52 0.001 0.001 0.033 0.001 69 6 2.11 2 0.028 1.49 0.001 0.0018 0.37 0.01 2.38 0.99 0.001 0.001 0.031 0.001 47 9 1.51 3 0.028 1.54 0.001 0.0018 0.34 0.01 3.78 0.52 0.001 0.001 0.028 0.001 52 10 2.13 4 0.029 1.5 0.001 0.0018 0.35 0.01 3.73 0.98 0.002 0.001 0.03 0.001 78 6 1.46 5 0.03 1.82 0.001 0.0020 0.34 0.01 2.37 0.52 0.003 0.001 0.029 0.001 76 6 1.63 6 0.029 1.82 0.001 0.0021 0.35 0.01 238 0.98 0.003 0.001 0.029 0.001 66 7 1.15 7 0.026 1.82 0.001 0.0022 0.35 0.01 3.77 0.51 0.002 0.001 0.027 0.001 64 6 1.79 8 0.03 1.8 0.001 0.0019 0.33 0.01 3.72 0.99 0.003 0.001 0.025 0.0003 82 4 1.23 Chemical composition (# 1 through 8) is expressed in wt-%. Balance is essentially Fe. Chemical composition determined from vacuum induction melt (VIM) billets. N, O, and H contents determined from hare solid wire electrodes. N and O contents are expressed in parts per million (ppm). H content is expressed in mL/100 g of Fc. Bare wire size is 0.0625 in. diameter. - (37 x Ni) - (70 x Cr) - (83 x Mo) (1) strength, low-temperature toughness, and mally from austenite through a displacive resistance to HAC of ER-100S and ER- reaction involving a limited diffusion of where the calculated value of B50 is 400° to 120S electrodes, the desired range for Ms carbon (Ref. 12), while in certain other sit 500°C; temperature is approximately 400° to uations the bainite may nucleate and grow Ms (°C) = 561 - (474 x C) - (33 x Mn)- 450°C. into austenite exclusively through diffu (17xNi)-(17xCr)-(21 xMo) (2) The third equation relates the chemi sion control. When the bainite transfor cal composition to the carbon equivalent mation occurs athermally, the quantity of where the calculated value of Ms is 400° to number (CEN), which is often used to dis bainite formed at a given temperature be 450°C; tinguish the high-strength structural steels tween Bs and BF temperatures can be es CEN = C+A(C) x {Si/24+Mn/6+Cu/15 that may require preheating during weld timated from the ratio of the difference +Ni/20+(Cr+Mo+V+Nb)/5+5B) (3) fabrication (Ref. 11). The desired value between Bs temperature and the transfor for CEN of structural steels that may elim mation temperature over 120°C, the latter where A(C)=0.75 + 0.25 tanh [20 x (C- inate or substantially reduce the need for being the difference between Bs and BF 0.12)], and where the calculated value of preheat and interpass temperature con temperatures. In HSLA-100 steel, CEN is 0.28 to 0.41. trols ranges from 0.28 to 0.41. wherein the maximum carbon content is The first equation relates the chemical limited to 0.07 wt-%, prior work (Ref. 13) composition to the B50 temperature, i.e., High-Performance Steel Weld Metal has shown the bainite transformation to the temperature at which 50% bainite occur athermally. Differential thermal transformation occurs (Ref. 8). Bainite Bainitic steels exhibit high tensile analysis studies performed on experimen refers to a crystalline structure of consid strength (in 135 to 170 ksi range) and good tal low-carbon, low-alloy bainitic weld erable toughness, combining high strength impact toughness at low temperature metals (Ref. 14) have also shown clear ev with high ductility. Bainite is a transfor (Refs. 9, 10). The carbon content of these idence for formation of bainite between mation product of austenite. Lowering the steels typically ranges from 0.08 up to 0.17 Bs and BF temperatures. For the limited transformation temperature allows one to wt-%. These steels contain alloy additions, purpose of this modeling effort, the bai refine the grain size of the transformation which retard the high-temperature trans nite transformation in low-carbon, low- product, leading to simultaneous in formation of austenite to pro-eutectoid or alloy steel weld metal was perceived to be creases in both tensile strength and ductil blocky ferrite, and facilitate the transfor athermal, so one could use the constitutive ity. Based on prior art (Refs. 9,10), a range mation to lower bainite at the corre relationship between chemical composi of 400° to 500°C for the B50 temperature sponding bainite-start Bs temperature tion and B50 temperature. allowed one to match the tensile strength (the temperature at which bainite trans Furthermore, the higher strength range for ER-100S and ER-120S formation occurs). While bainite forms bainitic steels exhibit a B50 temperature in electrodes. only from austenite, the bainite transfor the range of 420° to 550°C and. in this The second equation relates the chemi mation occurs between the Bs and BF tem range, the strength of these steels in peratures (Refs. 9, 10), and for the limited cal composition to the Ms temperature, creases linearly with a decrease in B50 tem i.e., the temperature at which martensite purpose ofthe current modeling work, the perature (Refs. 9, 10). This relationship transformation starts (Ref. 8). Martensite author perceived this transformation to be provides an additional means to predict refers to a very hard but brittle structure of athermal (i.e., insensitive to cooling rate). strength. In other words, percent bainite formed is iron and carbon that has a higher suscepti The Ms temperature of these steels is bility to HAC. Martensite is also a trans dependent primarily on the transforma often well below their corresponding B tion temperature between B and B . For 50 formation product of austenite. In other s F temperature. Considering that both bai example, B temperature indicates the words, both bainite and martensite form 5() nite and martensite are products of temperature at which 50% bainite trans only from austenite. One could manipulate austenite, one could readily recognize that formation occurs. The B temperature is this characteristic to design the chemical 5u a high-strength steel will be free from composition of a high-performance steel. midway between the Bs temperature and the B temperature. The B temperature martensite when the Ms temperature of For example, a careful lowering of the Ms F F is normally 120°C below the B tempera the steel is below its BF temperature. temperature below the B50 temperature of s Specifically, when the Ms temperature is a steel would allow one to achieve a large ture, and 60°C below the B5U temperature. at least 30°C below the B50 temperature, volume fraction of bainite than martensite The bainite transformation is known to then more than 75% of the weld metal in the resultant microstructure. show dual characteristics, i.e., under cer would likely contain bainite. Imposition of Based on the ranges for tensile tain conditions, the bainite forms ather- this additional constraint to reduce the WELDING JOURNAL I * IIIIII 11II Mi % lllll II I I 11 lllll UMil Minimize the Need for Preheat drogen, and eventual transformation of a hydrogen-enriched austenite could poten Interestingly enough, the tially lead to HAC, it is desirable to limit preheat, interpass, and post excessive increases in nickel content to soak temperature controls nec preclude the occurrence of retained essary to minimize the suscep austenite. tibility of structural steels to Consolidation of this prior knowledge HAC can be also related to the identifies that low-carbon welding elec chemical composition of the trodes based on a Fe-C-Mn-Ni-Mo system steels through the CEN equa with a CEN ranging from 0.28 to 0.41 (Ref. tion (Ref. 8). The CEN is ex 15) may meet or exceed U.S. Navy needs. pressed as a function of carbon Calculated Weld Cooling Rate at 10CO°F(f/s) (C), manganese (Mn), nickel Low-Temperature Toughness Fig. 1 — Variation of weld metal yield strength with calculated (Ni), chromium (Cr), molybde weld cooling rate. num (Mo), silicon (Si), copper Besides microstructural control to (Cu), vanadium (V), niobium achieve mechanical property goals, one (Nb), and boron (B) content, in should also consider the effects of inclu volume fraction of martensite in weld weight percent. In general, as the value of sions on achieving minimum low-temper metal to less than 25% can be expected to CEN increases, so does the need for in ature toughness requirements. Depend provide a weld metal with a predominantly creasing the level of preheat, when using a ing on both morphology and size bainitic microstructure with the necessary low-hydrogen fusion welding practice. distribution, oxide and nitride inclusions strength, toughness, and resistance to One could use the CEN equation to as in steel weld metals often decrease weld- HAC characteristics. Accordingly, a steel sess the relative effects of different alloy metal ductility and in certain extreme sit with an Ms temperature 30° to 50°C below elements on the need for preheat. Evi uations may also lead to the occurrence of its B50 temperature will have very little dently carbon content has the greatest ef incomplete fusion type weld defects. martensite, and may exhibit only a limited fect on the CEN. When considering weld Therefore, it is desirable to minimize the susceptibility to HAC. As HAC occurs pri metal, a substantial reduction in the car combined oxygen and nitrogen content, marily in the presence of a martensitic mi bon content of the welding consumable is preferably below 550 ppm (Refs. 15, 16). crostructure, the above constraint pro necessary to obtain significant reduction The gas content can be controlled initially vides an additional means to ensure in preheat levels. To further reduce the through producing melts for wire elec against HAC. CEN and the sensitivity of weld metals to trodes using vacuum induction melting Interestingly, the Bs, BF, and B5() tem preheat controls, it is desirable to limit the practices and subsequently through the peratures as well as the Ms and MF tem levels of elements with the highest coeffi application of suitable welding conditions, peratures are all related to the chemical cients in the CEN equation (e.g., boron, e.g., a principally inert gas atmosphere, composition of the steel (Ref. 8). Consol chromium, molybdenum, vanadium, nio despite the presence of adverse humidity idation of this prior knowledge identifies bium) and increase the levels of elements conditions at shipyards. that low-carbon, low-alloy welding elec with the lowest coefficients in the CEN Thus, a consolidation of the above trodes designed to provide weld metal equation (e.g., silicon, nickel, copper, and prior knowledge shows the immense use characterized by a B50 temperature in the manganese). ofthe new constraints-based modeling ap range of 400° to 500°C, and an Ms tem Since copper and silicon contribute rel proach for specifying the chemical com perature well below their corresponding atively little to strengthening, and exces position of solid wire electrodes for GMA B50 temperature, would exhibit high sive additions may promote fusion zone welding of HSLA steels as it relates to the strength and acceptable Charpy V-notch solidification cracking (especially should U.S. Navy requirements (weld operational (CVN) impact toughness. Furthermore, the weld metal undergo primary austenitic envelope, and weld strength and tough the athermal nature of the bainite trans type solidification), it is preferable that a ness properties) with the following metal formation, in this instance as perceived by substantial reduction in carbon content is lurgical criteria: B50 temperature (the the author, is likely to permit the use of a compensated with appropriate increases temperature at which 50% bainite trans wide operational envelope, i.e., large in nickel and manganese contents to formation occurs), Ms temperature (the changes in weld heat input conditions may achieve adequate strength and toughness temperature at which martensite transfor still produce weld metal microstructure without impairing the sensitivity to pre mation starts), and combined oxygen and with acceptable variations in weld heat. Excessive increases in nickel content nitrogen content. Concurrently, this ap mechanical properties. could be expected to stabilize austenite. proach also relates the need to eliminate As austenite has a higher solubility for hy- or reduce preheat, interpass, and post soak temperature controls with the CEN of the weld metal. Table 3 — Calculated Metallurgical Characteristics of Bare Wire Welding Electrodes Mutually Inclusive No. B50 Temperature Ms Temperature Carbon Equivalent Combined (O+N) Using the constraints-based modeling CC) (°C) Number (CEN) Content (ppm) approach, the following metallurgical cri 1 489 444 0.29 75 teria (Ref. 17) for weld metal were em 2 457 437 0.33 56 ployed in specifying the chemical compo 3 440 422 0.32 62 sition of solid wire electrodes to meet the 4 407 414 0.36 84 strength and toughness requirements of 5 467 435 0.31 82 ER-100S and ER-120S electrodes, as well 6 428 426 0.36 73 7 417 414 0.34 70 as exhibit a reduced sensitivity to preheat: 8 379 403 0.39 86 1) A B50 temperature ranging from 400° to 500°C; AUGUST 2005 mill! 3J 1 1 | 11 1II11!19! SvIqW^jTTPi 1 • 1 -r*J —r^TlW i Table 4 — GMAW Schedules for Demonstration Weldments Weld Voltage Current Weld Travel Rate Energy Input Preheat/Intcrpass Measured Weld Cooling Rate Series (Volts) (Amps) (in./min) (kj/in.) Temperature (°F) at 1000°F(°F/s) A 27 310 9 55 60/125 42^14 B 2S 340 5 11(1 60/125 23-24 C 28 340 5 11(1 275/300 10.8-11.5 Root Pass 25 280 12 35 60/125 or 275/300 Table 5 — Mechanical Property Test Results of GMA Welds Room-Temperature All-Weld Tensile Test CVN Impact Test (ft-lb) Weld No. Yield Strength Ultimate Tensile Elongation Reduction At-60°F At0°F (ksi) Strength (ksi) (%) in Area (%) ER100S 100 min — — 50 min — ER120S — 120 min — — 50 min — IA 88.6 102.5 24.0 72.2 44.8 107.4 IB 87.5 99.2 24.5 72.5 73.0 111.6 IC 81.8 96.3 26.5 71.6 51.5 90.8 2A 108.4 116.2 21.4 70.4 60.7 98.6 2B 95.1 108.6 23.5 69.2 26.2* 72.8 2C 88.5 107.4 24.5 71.0 25.2* 66.2 3A 105.7 114.6 22.0 68.9 74.6 102.0 3B 92.6 105.1 23.5 70.9 73.2 112.0 3C 88.3 102.8 24.3 70.6 49.0 95.0 4A 118.3 127.6 20.5 66.7 48.4 74.0 4B 104.4 118.1 22.0 66.4 68.6 90.8 4C 102.2 120.7 21.5 67.4 47.4 89.2 5A 93.8 103.9 23.0 70.2 68.4 108.2 5B 85.6 100.4 25.8 71.0 51.6 98.8 5C 80.2 98.2 24.8 70.3 45.7 100.0 6A 113.3 122.4 21.5 66.8 52.7 76.4 6B 98.5 113.6 23.0 68.4 46.3 90.6 6C 95.9 112.0 24.3 68.6 38.2 99.6 7A 107.2 116.7 20.5 67.4 69.2 89.4 713 96.2 109.6 23.0 69.3 88.4 109.4 7C 88.3 108.0 24.8 69.1 67.8 107.4 XA 121.2 132.8 20.8 64.9 54.8 75.4 SB 107.3 125.2 21.5 65.5 62.4 95.8 8C 108.2 122.2 23.5 66.4 54.2 86.4 Tensile test results represent an average of 2 tests; CVN impact test results repi'esent an average of 5 tests. * Visual examination of fractured surfaces showed weld defects. 2) An Ms temperature less than the cor and Ms temperatures, and thereby carbon (at about 0.03 wt-%) compositions responding B5() temperature; achieve adequate strength and toughness were based on a 2? factorial design, with 3) A CEN ranging from 0.28 to 0.41; and in the weld metal without impairing its one low and another high level for man 4) A combined oxygen and nitrogen sensitivity to preheat. In contrast, substi ganese (approximately 1.5 and 1.8 wt-%), content, preferably below 550 ppm. tuting molybdenum in the place of carbon nickel (approximately 2.5 and 3.8 wt-%), The above criteria for weld metal is likely to provide only a minimal de and molybdenum (approximately 0.5 and chemical composition were then satisfied crease in CEN, while substantial additions 1.0 wt-%) and contained other elements in a mutually inclusive fashion through a of molybdenum to reduce CEN may not such as silicon, phosphorus, and sulfur at judicious specification of the chemical allow one to meet the B50 and Ms tem some nominal values. As both HSLA-80 composition of the solid wire electrodes. peratures criteria. The interplay of spe and HSLA-100 steels exhibit a higher For example, in specifying the chemi cific elements in simultaneously control nickel content than manganese content cal composition of the welding electrode ling the calculated B50 temperature, Ms (Ref. 5), the wire formulations used a and the dependent weld metal, one could temperature, and CEN within desirable higher nickel content, and a relatively remove chromium and significantly re ranges can be easily ascertained using an lower manganese content in order to min duce the carbon content in the wire elec appropriate computer algorithm. imize difficulties that could possibly occur trode (much below the 0.07 wt-% maxi due to base metal dilution effects. The mum specified for HSLA-100 steel), and Experimental Evaluation compositions also included approximately thereby reduce the CEN, and substantially 0.03 wt-% titanium as a deoxidizer, grain minimize the need for preheat controls. Electrode Design refiner, and "nitrogen getter," and thus at These losses in alloy content could be tempted to control the amount of oxygen compensated with appropriate increases Based on the above considerations, a and nitrogen in the weld metal. Prior in in nickel and manganese content of the batch of eight solid wire electrodes was vestigation using experimental flux-cored wire electrode to meet the criteria for B50 prepared (Refs. 17, 18). These eight low- wire electrodes has shown the beneficial WELDING dOURNAL effect of titanium addition in controlling marginal increase in wear loss in the draw ditions closely simulated typical shipyard weld metal nitrogen content (Ref. 16). Ti ing dies, compared to conventional high- fabrication conditions. These included tanium addition also served to refine the strength steel wire electrodes. An 80% protective shielding of the weld metal weld metal grains. yield was obtained from the starting quan using a principally inert shielding gas (Ar- 3 The actual chemical compositions of tity to the final finish quantity. The solid 5% C02) at 35 ft /h flow rate, and 'A to 1 the solid wire electrodes were also ad wire electrodes showed acceptable cast in. stickout. The stringer bead, multipass justed using appropriate delta quantities and pitch (helix). Table 3 shows the calcu welding technique used 10-15-deg torch (Ref. 19) to compensate for the loss of al lated metallurgical characteristics of the lag angle to effectively tie in the weld loying elements (particularly manganese) solid wire electrodes based primarily on passes and to produce a desirable overlap across the arc column. In GMAW, the melt composition. between individual weld beads. Consistent delta quantities of alloy elements vary with with acceptable cast and pitch, all of the alloy element, shielding gas type, flow Demonstration Weldments experimental wires showed good feeding rate, and weld energy input. For example, behavior and minimal weld spatter, which when Ar-5% C02 is used as a shielding Using each of the eight experimental resulted in excellent bead characteristics. gas, the delta quantity for carbon is +0.01 wire electrodes, a set of three demonstra The cooling rate at 1000°F of each of the wt-%, i.e., one would commonly observe a tion weldments was produced in 1-in.- demonstration weldments was measured 0.01 wt-% pickup in the carbon content of thick HSLA-100 steel plate using a by plunging a Pt/Pt-Rh thermocouple into the weld metal relative to that of the weld stringer bead, multipass GMAW tech the trailing edge of the weld pool of a fill ing electrode. Likewise, under similar nique. The three weldments were desig pass at plate midthickness. welding conditions, the delta quantity for nated series A, B, and C (Table 4). The manganese is -0.2 wt-%, i.e., one would GMAW procedure employed a single- V Weld Testing commonly observe a 0.2 wt-% decrease in joint preparation with a 45-deg included the manganese content of the weld metal angle, a 1^-in. root opening with a /4-in.- Following the completion of welding relative to that of the welding electrode. thick strip permanent backing bar, and and a radiographic examination of the Table 2 shows the melt chemical composi 0.0625-in.-diameter solid wire electrodes. demonstration weldments, room-temper tion of the solid wire electrodes. The weld test assemblies typically mea ature all-weld-metal tensile tests, and Ingots were produced using the vac sured 1x36x36 in. in size. The weldments weld metal CVN impact tests (at -60° and uum induction melting (VIM) practice as were produced in the flat position and 0°F) were performed in the as-welded it allowed a strict control over hydrogen, with nominal restraint. condition, per MIL-STD-248 using ap oxygen, and nitrogen content of the melt. The same set of welding parameters propriate test specimens. The test results, Careful selection of raw materials and vac was used to produce both the root passes which included yield strength (YS), ulti uum processing were employed to control and the fill passes in the A-series welds (55 mate tensile strength (UTS), the percent residual elements such as sulfur and phos kJ/in. energy input). The root passes of the elongation at failure (EL), the percent re phorous. The VIM ingots were subse B- and C-series welds were produced duction of area at failure (RA), and CVN quently hot rolled and drawn into 0.0625- using 35 kJ/in. energy input, while 110 impact results at -60° and 0°F, are sum in.-diameter solid wire electrodes. The kJ/in. energy input was used to produce marized in Table 5. wire drawing operation encountered a the fill passes. In general, the GMAW con- The test results showed the weld met als produced using solid wire electrodes #7 and #8 to meet or exceed the me Table 6 — Calculated Metallurgical Characteristics of GMA Weld Metals chanical property requirements of ER- 100S, and match/undermatch the yield Weld BjQ Temperature Ms Temperature Carbon Equivalent Combined (O+N) strength of HSLA-100 steel, and No. (°C) (°C) Number (CEN) Content (ppm) match/overmatch the yield strength of HSLA-80 steel. Additionally, weld metal produced using the wire electrode #8 was 1A-1C 501-502 444-446 0.28-0.29 211-229 2A-2C 462-480 433-438 0.33-0.34 182-211 found to meet or exceed the mechanical 3A-3C 446-461 421-423 0.33-0.34 216-228 property requirements of ER-120S, and 4A-4C 417-^137 410-415 0.37-0.38 211-226 match/undermatch the yield strength of 5A-5C 487^191 439^142 0.29-0.30 187-196 HSLA-100 steel, and overmatch the yield 0.36-0.37 130-195 6A-6C 430-453 421^t27 strength of HSLA-80 steel, under all three 7A-7C 422-432 411-413 0.35 190-203 8A-8C 404-410 403-408 0.38-0.41 192-221 welding conditions. Table 7 -— GMAW Schedules for Additional Evaluation Weld Base Plate Energy Input Welding Meta .1 Preheat Interpass Calculated Weld Cooling No. (kJ/in.) Position Transl er Temperature (°F) Temperature (°F) Rate at 1000°F (°F/s) 1 HSLA-100 30 Flat Spra i 125 125 95 2 HSLA-100 45 Flat Spra; Y 150 150 57 3 HY-100 45 Flat Spra;y 150 150 57 4 HSLA-100 55 Flat Spra' y 60 125 47 5 HSLA-100 11(1 Flat Spra;Y 60 125 11 6 HSLA-100 110 Uphill Pulse d 300 300 7 7 HSLA-100 11(1 Flat Spra;Y 275 300 5 8 HY-100 110 Flat Spra; Y 300 300 5 AUGUST 2005 Table 8 — Mechanical Property Test Results of Additional GMA Welds Room-Temperature All-Weld Tensile Test CVN Impact Test (ft-lb) Weld No. Base Plate Weld Cooling Rate Yield Strenath Ultimate Tensile Elongation Reduction At-60°F at 1000°F (°F/s) (ksi) Strength (ksi) (%) in Area (%) ER-100S HY-100/HY-80 100.0 50 min 1 HSLA-100 95 114.0 119.2 19.2 63 86 124 2 HSLA-100 57 108.2 114.8 21.3 68 74 90 3 HY-100 57 109.2 116.2 22.3 67 76 96 4 HSLA-100 47 105.7 114.6 22.0 69 75 102 5 HSLA-100 II 92.6 105.1 23.5 71 73 112 6 HSLA-100 7 87.0 109.0 24.3 72 125 146 7 HSLA-100 5 88.3 102.8 24.3 71 49 95 8 HY-100 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. Model Validation Table 9 — Proposed Revisions to AWS A5.28 Specification Details of weld metal chemical compo sitions are presented in U.S. Patent Chemical Composition 5,744,782 (Ref. 20). Table 6 shows the nu merical ranges for the calculated metal ER 100S ER 120S lurgical characteristics of the above GMA weld metals. The results revealed several Element Current Proposed Current Proposed general trends. First, yield strength of the weld metals increased with CEN. Second, Carbon 0.08 0.08 0.10 0.08 Manganese 1.25-1.80 1.0-2.0 for a given B temperature, welds pro 1.0-2.0 1.40-1.80 50 Phosphorus 0.010 0.010 0.010 0.010 duced using higher cooling rates showed a Silicon 0.20-0.55 0.20-0.55 0.25-0.60 0.20-0.60 higher strength. Third, for a given Ms tem Sulfur 0.010 0.010 0.010 0.010 perature, welds produced using higher Nickel 1.40-2.10 2.0-1.0 2.0-2.80 2.0-4.0 cooling rates showed a higher strength. Chromium 0.30 0.30 0.60 0.30 Fourth, at a given CEN, the CVN impact Molybdenum 0.25-0.55 0.30-1.0 0.30-0.65 0.50-1.0 toughness increased with increasing weld Vanadium 0.05 0.05 0.03 0.05 cooling rates. The above trends were con Titanium 0.10 0.10 0.10 0.10 sistent with the known effects of higher Zirconium 0.10 0.10 0.10 0.10 weld cooling rate in refining weld metal Aluminum 0.10 0.10 0.10 0.10 Copper 0.25 0.25 0.25 0.25 grain size, and the effects of refined grain Other Elements, Total 0.50 0.50 0.50 0.50 size in simultaneously improving both Iron Balance Balance Balance Balance yield strength and low-temperature im pact toughness. Fifth, a comparison ofthe Mechanical Property effects of oxygen content and nitrogen content of the weld metals on the CVN ER 100S ER 120S impact toughness at 0° and -60°F indi cated the beneficial effects of minimal Tensile/Impact Property Current Proposed Current Proposed amounts of oxygen and nitrogen in im Yield Strength (ksi) 88 82-120 105 105-122 proving weld metal CVN impact Minimum Tensile Strength (ksi) 100 100 120 120 toughness. Minimum Tensile Elongation (%) 16 Id 14 15 Minimum CVN a 0°F (ft-lb) — 80 — 80 Additional Evaluation Minimum CVN a -60°F (ft-lb) 50 50 50 50 Following the above initial evaluation, welding electrode #3 was used for addi tional evaluation. A set of eight GMA weldments was produced in 1-in.-thick chanical property tests. weld metals with yield strengths that un HSLA-100 and HY-100 steel plates using Figure 1 shows the variation in weld dermatched the yield strength of the base a wide range of shipyard fabrication con metal yield strength with calculated weld material. The weld metal toughness was ditions. Table 7 shows the GMAW sched cooling rate. The trend line showed the exceptionally good in all cases, although ule employed for producing weldments following statistical relationship, at a r2 weld #7, produced at very high energy for these additional evaluations. Table 7 value of 0.99: input and with HSLA-100 plate, narrowly also shows the calculated weld cooling Yield strength (in ksi) = 75 x (Calcu missed the minimum CVN impact tough rates that ranged from 95° to 5°F/s. The lated weld cooling rate at lOOOT/s)009 ness requirement at -60°F. Weld #8 pro weld cooling rates were calculated using At low weld energy input conditions or duced under identical welding conditions, the procedure outlined in Ref. 21. As be high weld cooling rates, welding electrode but with HY-100 plate instead of HSLA- fore, following welding, both room- #3 provided weld metals with yield 100 plate, showed exceptional CVN im temperature all weld tensile and CVN im strengths that overmatched the yield pact toughness properties at -60°F, possi pact at 0° and -60°F weld mechanical strength of the base material. The same bly underscoring the influence of base property tests were performed. Table 8 electrode, at high weld energy input con metal dilution and epitaxial growth effects shows the results of the weld metal mc- ditions or low weld cooling rates, provided on weld metal mechanical properties. The WELDING dOURNAL : i i i i i 1111 inmiimm ational envelope reflecting a broad range weld microstructure development, and re tion: p. 406. of shipyard welding conditions showed ac sultant weld mechanical properties of low- 13. Wilson, A. D. International Steel Group ceptable variation in weld mechanical alloy high-strength steel weld metals. Table (formerly Lukens Steel Company). Coatesville. properties, meeting or exceeding specific 9 shows the proposed revisions to the Pa. U.S. Navy requirements. chemical composition ranges of the AWS 14. Blackburn. J. M. U.S. Navy, Navy Yard. A5.28 Specification. Some ofthe mechan Washington, D.C. Conclusions ical property ranges proposed in Table 9 15. Green, R. S., Sampath, K., Devletian, J. are derived from MIL-E-23765/2E(SH) H., Singh, D., Howden, D. G., and Zhang, L. 1. A constraints-based modeling ap specification (Ref. 22). 1993. Filler wire development for GMA weld proach was used to successfully specify the ing of HSLA-100 steel. International Trends in chemical composition of new, advanced Acknowledgments Welding Science and Technology. Eds. S. A. solid wire electrodes for GMAW of David and J. M. Vitek. Materials Park. Ohio: HSLA-80 and HSLA-100 steels. The author is pleased to acknowledge ASM International, pp. 359-364. 2. The metallurgical characteristics of Paul W Holsberg, Charles L. Null, 16. Wong. R. J., and Hayes, M. D. 1990. The the GMA weld metals and the corre Howard A. Kuhn. and Richard S. Green Metallurgy: Welding & Qualification of Microal sponding all-weld-metal mechanical prop for their encouragement and support. loyed (HSLA) Steel Weldments. Miami. Fla.: erty test values confirmed the validity and American Welding Society, pp. 450-489. utility of the constraints-based modeling References 17. Sampath. K., Green, R. S., Civis, D. A., approach in specifying the chemical com Williams, B. E., and Konkol. P. J. 1995. Metal position of new, advanced solid wire 1. Montemarano. T. W. Sack, B. P., Gudas. lurgical model speeds development of GMA electrodes. J. P.. Vassilaros, M. G., and Vanderveldt, H. H. welding wire for HSLA steel. Welding Journal 1986. High strength low alloy steels in naval 3. The metallurgical criteria related the 74(12): 69-76. construction. Journal of Ship Production 2(3): strength and toughness requirements of 18. Sampath. K., Green, R. S., Civis. D. A., 145-162. weld metals with the chemical composi Dong, H., and Konkol, P. J. 1995. Evaluation of tion of the wire electrodes. 2. MIL-S-16216K (SH), Steel Plate, Alloy, new high performance electrodes for GMA Structural, High Yield Strength (HY-80 and HY- 4. The metallurgical criteria also re welding of HSLA-100 steel. High Peifonnance 100). June 1987. lated the need to eliminate or substantially Stntctural Steels. Ed. R. Asfahani. Materials reduce preheat, interpass, and post soak 3. A5.28, Specification for Low-Alloy Steel Park, Ohio: ASM International, pp. 179-188. Electrodes and Rods for Gas Shielded Arc Weld temperature controls with the chemical 19. Oldland, P. T. Ramsay. C. W, Matlock, ing. 2005. Miami. Fla.: American Welding composition. D. K.. and Olsen, D. L. 1989. Significant fea Society. 5. Solid wire electrodes and welding tures of high-strength steel weld metal mi conditions that provided weld metal char 4. Holsberg, P. W.. Gudas. J. P.. and Caplan, crostructures. Welding Journal 68(4): 158-s to acterized by 1) a CEN ranging from 0.33 I. L. 1990. Navy's welding research picks up 168-s. steam. Advanced Materials & Processes 138(1): to 0.41; 2) a B temperature ranging from 20. Sampath, K., and Green, R. S. April 5t) 45-49. 404° to 461°C; 3) an M temperature less 1998. U.S. Patent: 5,744,782, Advanced Con s 5. MIL-S-24645A (SH), Steel Plate. Sheet or than the B temperature; and 4) minimal sumable Electrodes for Gas Metal Arc (GMA) 50 Coil, Age-Hardening Alloy, Structural, High Yield oxygen and nitrogen content exhibited su Welding of High Strength Low Alloy (HSLA) Strength (HSLA-80 and HSLA-100). January perior weld mechanical properties, in Steels. 1990. cluding excellent low temperature tough 21. Jhaveri, P., Moffatt, W. G., and Adams, 6. Holsberg, P. W, and Wong, R. J. 1990. ness when welding HSLA-100 and Jr. C. M. 1962. The effect of plate thickness and Welding of HSLA-100 for naval applications. HY-100 steels over a range of weld energy radiation on heat flow in welding and cutting. Weldability of Materials. Eds. R. A. Patterson input and preheat, and interpass temper Welding Journal 41(1): 12-sto 16-s. and K. W. Mahin. Materials Park. Ohio: ASM 22. MIL-E-23765/2E (SH), "Electrodes and ature controls. International, pp. 219-239. 6. The constraints-based modeling ap Rods — Welding, Bare, Solid, or Alloy Cored; 7. Navy Ships: Lessons of Prior Programs proach allowed a better control of materi and Fluxes, Low Alloy Steel." April 1994. May Reduce New Attack Submarine Cost In als specification development for high- creases and Delays. GAO/NSIAD-95-4, United strength steel welding electrodes, and States General Accounting Office GAO Report strengthened the understanding ofthe ef to Congressional Requesters. October 1994. fects of weld metal chemical composition p. 7. on processing (welding operational enve 8. Steven. W, and Haynes, A. G. 1956. The lope), microstructure development, and temperature of formation of martensite and mechanical properties. bainite in low-alloy steels. Journal of the Iron An Important and Steel Institute 183(8): 349-359. Future Work 9. Irvine. K. J., and Pickering. F B. 1957. Event Low-carbon bainitic steels. Journal of the Iron Based on the above work, and the re and Steel Institute 184(12): 292-309. on Its Way? sults of other recent work performed 10. Leslie, W. C. 1981. The Physical Metal under the auspices of U.S. Navy and com lurgy of Steels. Tokyo. Japan: McGraw-Hill In Send information on upcoming mercial electrode manufacturers, the AWS ternational Book Company. McGraw-Hill, Ko- events to the Welding Journal A5 Filler Metal Committee may like to re gakusha, Inc., pp. 201-205. Dept., 550 NW LeJeune Rd., vise the chemical composition ranges spec 11. Yurioka, N., Suzuki. H.. Ohshita, S., and Miami, FL 33126. Items can ified in A5.28, Specification for Low-Alloy Saito, S. 1983. Determination of necessary pre Steel Electrodes for Gas Shielded Arc Weld also be sent via FAX to (305) heating temperature in steel welding. Welding 443-7404 or by e-mail to ing, to reflect these latest advances in the Journal 62(6): 147s-153s. woodward@aws. org. understanding of the relationships among 12. Bhadeshia, H. K. D. H. 2001. Bainite in chemical composition, welding conditions. Steels. Institute of Materials. U. K.. 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TYPE OF BUSINESS 6. Sales V. ANNUAL DOLLAR VOLUME 21 55 89 123 157 191 225 259 293 NOTE: 1. Construction 7. Purchasing 1. Under $1 Million ?? 56 90 124 156 192 226 260 294 2. Primary Metal Products 3. Education 2. $1 Million to 5 Million ?3 57 91 125 159 193 227 261 295 To speed the processing 3. Fabricated Metal Products 9. Other 3. Over $5 Million 24 58 92 126 160 194 228 262 296 4. Transportation PR 59 93 127 161 195 229 263 297 of your inquiry, please 5. Petrochemical III. PURCHASING AUTHORITY VI. THIS INQUIRY IS FOR 26 50 94 128 162 196 230 264 298 6. Misc. Repair Services 1. Recommend 1. Immediate Purchase 27 51 95 -pg 163 197 231 265 299 provide ALL the information 7. Educational Services 2. Specify 2. Future Project ?R 62 96 130 164 '98 232 266 300 requested on the card. 8. Utilities 3. Approve 3. General Information 29 63 97 131 165 199 233 267 301 9. Other nn 64 98 132 166 700 234 268 302 This will make it easier IV. NUMBER OF EMPLOYEES 31 65 99 133 167 201 235 269 303 II. JOB FUNCTION/TITLE 1. Under 3? 66 100 134 168 202 236 270 304 for the companies to follow 1. Corp. Management 2. 50 to 99 33 67 101 135 169 203 237 271 2. Plant Mgmt. 3. 100 to 499 34 68 102 136 170 204 238 272 up on your request as soon 3. Engineer 4. 500 to 999 4. Welding or Cutting Oper. 5. 1000 to 2499 Please mail: as possible. 5. Quality Control 6. 2500 to more • 305- List of AWS publications -1306- Information on AWS Membership iW if ll • %/0 M r*w_ ^^ ABIROB TM A I LED O R 5 Robotic welding...meet the new kid. ABIROB™ modular designed 500 and 360 ampere torches allow the user to quickly change the swan- neck or cable assembly while maintaining tool center point (TCP), assuring accurate repeatability and con tinuous precision welding. The keyed torch mount ing-arm duplicates TCP with complete torch change. From eria to end, ABIROB torches are second to none with aluminum-armored swannecks for crash protection, internal air blast for anti-spatter applica tions, and heavy-duty cable support springs at front and rear to prolong cable life. Direct mounts allow ABIROB torches to connect with all major wire feed models. Stand aside boys; the nev/ kid's in town. Welding and cutting brought to the point. ABICOR 8 6 BINZEL Circle No. 1 on Reader Info-Card ww. abicor user, WANT TO INCREASE YOUR TRAVEL SPEEDS BY UP TO 1 00O/ Lincoln How! SM Lincoln Electric's exclusive fflfl Cf GITI /W/G welding process can increase travel speeds by up to 100%, compared to automatic single-wire MIG welding. Ask the Experts at Lincoln if Tandem MIG welding can improve your productivity and keep you ahead of the competition. Equipment Howls LINCOLN I www.lincolnelectric.com/askhou> "1 ELECTRIC THE WELDING EXPERTS. Circle No. 33 on Reader Info-Card