May 2012 WELDING JOURNAL • VOLUME 91 NUMBER 5 • MAY 2012 Electroslag Welding of Bridges New Faces in Welding Choosing an Engine Drive Laser Technology Transfer PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING For Info go to www.aws.org/ad-index Fabricator® 252i The latest in a series of 3-in-1 systems Introducing the ALL NEW Multi Process Welding System. MIG. Stick. TIG. All in one machine. With an integrated wire feeder for MIG welding, the Fabricator 252i is the compact welder designed to take on industrial level welding needs in virtually any working environment. When you need reliable and consistent performance, day in and day out, and the power of up to 300 Amps, look to the 252i. For more information, contact your distributor, or go to thermadyne.com/3in1. www.thermadyne.com/3in1 For Info go to www.aws.org/ad-index For Info go to www.aws.org/ad-index May 2012 • Volume 91 • Number 5 CONTENTS AWS Web site www.aws.org Features Departments 24 Narrow Gap Electroslag Is Process of Choice for Welding San Francisco-Oakland Bay Bridge Editorial ............................4 Ironworkers created 10-m-long welds using the ESW process for the suspension bridge’s tower Press Time News ..................6 24 B. Turpin et al. News of the Industry ..............8 33 Welding Research’s New Talent Pool International Update ............12 Five promising young researchers outline their welding Stainless Q&A ....................14 interests Product & Print Spotlight ......18 A. Cullison et al. Conferences ......................54 38 What Do You Need in an Engine-Driven Welding Machine? Coming Events....................56 These tips will help you figure out the features you need in an Certification Schedule ..........58 engine-driven welding machine J. Leisner and J. Gitter RWMA Q&A ......................60 Welding Workbook ..............62 44 Is Small Town America the New Face in Welding? Society News ....................65 A group of high school welding contest winners from America’s smaller and rural communities discuss what drew Tech Topics ......................66 them to the field and what they hope for their careers Errata B2.1:2009................66 38 B. Wehrman Errata D17.1:2010..............66 Addenda: B2.1:2009 ..........66 50 Moving Laser Research from the Lab to Industry The National Laser Centre in South Africa provides state-of- Guide to AWS Services ........88 the-art R&D photonic facilities and promotes the use of lasers Personnel ........................90 in industry through technology transfer Classifieds ........................98 F. Sciammarella Advertiser Index ................100 Welding Research Supplement 133-s Reagent Selection in Austenitic Stainless Steel 44 Solidification Modes Characterization This research compared eight different reagents to determine which produced the best results for microstructural characterization of solidification modes M. A. Valiente Bermejo 140-s Nonlinear Modeling of Dynamic Metal Transfer in Laser-Enhanced GMAW Welding Journal (ISSN 0043-2296) is published Estimating an improved laser recoil pressure force aided monthly by the American Welding Society for $120.00 per year in the United States and posses- development of a modified nonlinear model sions, $160 per year in foreign countries: $7.50 Y. Huang et al. per single issue for domestic AWS members and $10.00 per single issue for nonmembers and 149-s Analysis of Thermal Cycle during Multipass Arc $14.00 single issue for international. American Welding Welding Society is located at 550 NW LeJeune Rd., A new method is proposed to account for convection and Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and addi- radiation heat loss from the plate surface during multipass gas tional mailing offices. POSTMASTER: Send address tungsten arc welding changes to Welding Journal, 550 NW LeJeune Rd., C. S. Pathak et al. Miami, FL 33126-5671. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be 155-s Weldability of Aluminum Alloys with High-Power Diode sent to Bleuchip International, P.O. Box 25542, Laser London, ON N6C 6B2 By controlling the experimental variables, butt joints were Readers of Welding Journal may make copies of produced with higher penetration than previously reported for articles for personal, archival, educational or the conduction regime research purposes, and which are not for sale or resale. Permission is granted to quote from arti- J. M. Sánchez-Amaya et al. cles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. On the cover: The electroslag welding process was used to make 20 welds in 60 days at the base of the single-tower, self-anchored suspension span on the new San Francisco-Oakland Bay Bridge. (Photo courtesy of Electroslag Systems, Technology and Development, Portland, Ore.) WELDING JOURNAL 3 EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding Get the Most Technical Info: Officers President William A. Rice Jr. Come to IIW OKI Bering Vice President Nancy C. Cole We would like to take this opportunity to encourage you to attend the 65th Annual NCC Engineering Assembly of the International Institute of Welding, July 8–13, in Denver, Colo. We Vice President Dean R. Wilson believe this will be your best educational opportunity of the year; you will find no other Kimberly-Clark Global Safety conference anywhere offering a wider range of technical information. The reason for this is that welding experts from all over the world will be sharing their knowledge with the Vice President David J. Landon people who make it to Denver. Vermeer Mfg. Co. The IIW Annual Assembly is a full week of technical presentations combined with Treasurer Robert G. Pali several social activities. This allows you to hear the presentations during the day, and fol- J. P. Nissen Co. low up on the information with the speakers in the evening. It is an outstanding venue for discovering what is going on in welding around the world as well as for developing Executive Director Ray W. Shook the contacts to keep you in touch with the work that interests you in the future. The week American Welding Society consists of three (or more) days of Commission and Committee meetings followed by a two-day conference. The first three days of meetings involve technical presentations on a wide range of subjects. These are based in the Commissions and Committees. Each Directors group has a particular area of technical interest, much like those of the AWS Technical T. Anderson (At Large), ITW Global Welding Tech. Center Committees. The final two days are given over to an International Conference. This J. R. Bray (Dist. 18), Affiliated Machinery, Inc. year’s conference is Welding for Repair and Life Extension of Plants and Infrastructure, and has an international group of invited papers. The conference will open and close J. C. Bruskotter (Past President), Bruskotter Consulting Services with plenary sessions and has two tracks running concurrent sessions in between the ple- G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services nary sessions. T. A. Ferri (Dist. 1), Thermadyne Industries This Annual Assembly offers a unique opportunity to participate in an international D. A. Flood (Dist. 22), Tri Tool, Inc. event without leaving the U.S.A. It gives you an opportunity to evaluate the value of the meetings without the expense in time and money to attend the Annual Assembly when R. A. Harris (Dist. 10), Total Quality Testing it is on another continent. The Assembly was last in the United States in 1997 and on the D. C. Howard (Dist. 7), Concurrent Technologies Corp. North American continent in 2006 in Quebec. In addition, the International Conference J. Jones (Dist. 17), Thermadyne Industries is on a subject of major interest in the United States and will provide the latest informa- W. A. Komlos (Dist. 20), ArcTech, LLC tion on the subject from the world’s experts. If you can’t participate in the entire Annual Assembly, you should at least register to attend the International Conference. R. C. Lanier (Dist. 4), Pitt C.C. Details of the Annual Assembly can be found in the Special Supplement that has T. J. Lienert (At Large), Los Alamos National Laboratory been included with this copy of the Welding Journal. In it, you will find abstracts for the J. Livesay (Dist. 8), Tennessee Technology Center papers to be presented at the International Conference, as well as biographies of the invited M. J. Lucas Jr. (At Large), Belcan Corp. speakers. Further information on the International D. E. Lynnes (Dist. 15), Lynnes Welding Training Institute of Welding and its Annual Assembly can be C. Matricardi (Dist. 5), Welding Solutions, Inc. found in the February 2012 Welding Journal on pages D. L. McQuaid (At Large), DL McQuaid & Associates 28 and 29. The complete program and registration information can be found at www.IIW2012.com. J. L. Mendoza (Past President), Lone Star Welding We would also like to thank the sponsors of the S. P. Moran (At Large), ESAB Welding & Cutting Products Annual Assembly, who are listed in the Supplement. K. A. Phy (Dist. 6), KA Phy Services, Inc. This event would not be possible without their assis- W. R. Polanin (Dist. 13), Illinois Central College tance. The American Council of the IIW is the spon- soring body of this Assembly. The American Council is R. L. Richwine (Dist. 14), Ivy Tech State College the coordinating body for our U.S. members: the D. J. Roland (Dist. 12), Marinette Marine Corp. American Welding Society, the Edison Welding N. Saminich (Dist. 21), Desert Rose H.S. and Career Center Institute, and the Welding Research Council. Without N. S. Shannon (Dist. 19), Carlson Testing of Portland these three organizations paying our IIW dues, none of us could participate in the work of the IIW.