Electroslag Welding of Bridges

May 2012

EDN ORA OUE9 UBR5•MY2012 MAY • 5 NUMBER 91 VOLUME • JOURNAL WELDING Electroslag Welding of Bridges

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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

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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. Finally, T. A. Siewert (At Large), NIST we would like to thank the members of the Organizing H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc. Committee as well as the staff of the American R. P. Wilcox (Dist. 11), ACH Co. Welding Society who have done all of the work to make this event possible. M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute D. Wright (Dist. 16), Zephyr Products, Inc.

Thomas M. Mustaleski (top) and Damian J. Kotecki Co-chairs, 2012 IIW Planning Committee; past presidents, AWS

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For Info go to www.aws.org/ad-index PRESS TIME NEWS

Publisher Andrew Cullison Energy Department Announces $180 Million for Initiative to Deploy U.S. Offshore Wind Projects Editorial Editorial Director Andrew Cullison Energy Secretary Steven Chu recently announced the start of an initiative to capture Editor Mary Ruth Johnsen the potential of wind energy off American coasts. As part of a planned six-year $180 Associate Editor Howard M. Woodward million initiative, an initial $20 million will be available this year as the first step in sup- Associate Editor Kristin Campbell Melissa Gomez porting up to four offshore wind energy installations across the United States. Peer Review Coordinator America’s offshore wind resources, estimated at more than 4000 gigawatts, will help Publisher Emeritus Jeff Weber the United States meet its energy, environmental, and economic challenges and provide energy to coastal cities. Design and Production The department will focus this latest research and demonstration initiative on tech- Managing Editor Zaida Chavez nologies that will achieve large cost reductions. These will help address key challenges Senior Production Coordinator Brenda Flores associated with installing utility-scale offshore wind turbines, connecting offshore tur- Manager of International Periodicals and bines to the power grid, and navigating new permitting and approval processes. Electronic Media Carlos Guzman Advertising Future Naval Force May Sail with the Strength of Titanium National Sales Director Rob Saltzstein Advertising Sales Representative Lea Paneca A U.S. Office of Naval Research (ONR)-funded project will produce a full-size ship Senior Advertising Production Manager Frank Wilson hull section made entirely with marine-grade titanium using a welding technique that could help bring titanium into future Navy ship construction. Subscriptions The team building this section recently completed the industry’s longest friction stir Subscriptions Representative Sylvia Ferreira titanium-alloy welds and aims to complete the ship hull section this summer. Friction- [email protected] stir welds more than 17 ft long joined the titanium-alloy plates for the section’s deck. If constructed in titanium, Navy ships would have lighter weight for the same size, al- American Welding Society lowing for a bigger payload, and virtually no corrosion. However, titanium costs up to 550 NW LeJeune Rd., Miami, FL 33126 nine times more than steel and is technically difficult and expensive to manufacture into (305) 443-9353 or (800) 443-9353 marine vessel hulls. Publications, Expositions, Marketing Committee Researchers at the University of New Orleans School of Naval Architecture and Tex- D. L. Doench, Chair tron Marine and Land Systems are demonstrating the feasibility of manufacturing tita- Hobart Brothers Co. nium ship hull structures. Using lower-cost marine-grades of titanium, they fabricated a S. Bartholomew, Vice Chair 20-ft-long main deck panel composed of six titanium plates, joined together by friction ESAB Welding & Cutting Prod. stir welding, as part of technology studies for an experimental naval vessel. J. D. Weber, Secretary The researchers used new titanium friction stir welding methods by Florida-based American Welding Society Keystone Synergistic Enterprises, Inc., with funding from the ONR and Air Force. The T. Birky, Lincoln Electric Co. processes were transferred to the National Center for Advanced Manufacturing. D. Brown, Weiler Brush To fabricate the ship hull structure, more than 70 ft of welded linear joints were made J. Deckrow, Hypertherm at a high linear speed, indicating reduced manufacturing time; showed good weld pene- D. DeCorte, RoMan Mfg. tration, indicating a secure connection; and had no distortion of the titanium adjoining J. R. Franklin, Sellstrom Mfg. Co. F. H. Kasnick, Praxair the weld. Experts attribute the success to an effective pin tool design, process parame- D. Levin, Airgas ters that emphasized pin tool life, and exact duplication of the process steps. E. C. Lipphardt, Consultant R. Madden, Hypertherm Airgas Acquires Nordan Smith D. Marquard, IBEDA Superflash J. Mueller, Thermadyne Industries Airgas, Inc., Radnor, Pa., acquired the assets and operations of Industrial Welding J. F. Saenger Jr., Consultant Supplies of Hattiesburg, LLC, doing business as Nordan Smith, Hattiesburg, Miss. S. Smith, Weld-Aid Products The acquired business, with 17 locations throughout Mississippi, Arkansas, and Ala- N. C. Cole, Ex Off., NCC Engineering bama, generates annual revenues in excess of $30 million. After a transitional time, six J. N. DuPont, Ex Off., Lehigh University L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems of the acquired locations will be integrated into the mid-South region of Airgas USA, S. P. Moran, Ex Off., ESAB Welding & Cutting Prod. LLC, and eleven will be integrated into the South region. E. Norman, Ex Off., Southwest Area Career Center R. G. Pali, Ex Off., J. P. Nissen Co. RoboVent Joins List of Manufacturers Located in Minnesota R. Ranc, Ex Off., Superior Products W. A. Rice, Ex Off., OKI Bering RoboVent, a U.S. manufacturer of ventilation and filtration equipment, has opened R. W. Shook, Ex Off., American Welding Society a suburban Minneapolis office. Proximity to various industries, including defense con- D. Wilson, Ex Off., Kimberly-Clark Global Safety tractors, marine manufacturing, food processing, composites manufacturing, and a few Copyright © 2012 by American Welding Society in both printed and elec- others, prompted the company to open its 8th location in North America. tronic formats. The Society is not responsible for any statement made or “As our product offerings expand beyond our traditional customers in automotive opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not in- and transportation, we identified a few geographical markets where RoboVent can make tended for use without independent, substantiating investigation on the an important contribution to the success of key manufacturing segments. Minnesota part of potential users. and the neighboring states was one of them, so we’re very happy to be here,” said Jim Reid, president of the RoboVent Solutions Group.◆

MEMBER 6 MAY 2012 For Info go to www.aws.org/ad-index NEWS OF THE INDUSTRY

Koike Fabricates 130-Ton Weld Positioner for Chinese Nuclear Reactor

Koike Aronson, Inc./Ransome, Arcade, N.Y., has created its largest weld positioner with a 130-ton model for Harbin Electric Corp., Qinhuangdao City, China. The $1.5 million device will be used to weld and clad component parts for a new nuclear reactor in that region. It can hold, rotate, and tilt 550,000 lb. “We will be shipping the machine by the third week in April,” said Koike President and CEO Jerry Leary. In addition, the company has plans to expand its headquarters with a $3.5 million addition. The initial expansion will be 40,000 sq ft with the potential to go to 100,000 sq ft. “We are in the process of obtaining the necessary permits and contractor quotes for this latest expansion. We hope to start it by mid year,” Leary added. Currently, the company has 140 employees but several openings still need to be filled. As of press time, the following positions were available: mechanical designer/engineer; electrical engineer; water jet/laser cutting machine specialist; field service technician; second shifts for a CNC machinist, mechanical builder, welder/fitter, and spray painter; plus a part-time parts picker. For more details, go to www.koike.com, and click on the U.S. map. Also, in related company news, Turner Motor- sports, Mooresville, N.C., recently announced the addition of Koike to the sponsorship lineup for the 2012 NASCAR Camping World Truck Series program. The cutting equipment and positioning machinery manufacturer will adorn the hood and sides The 130-ton weld positioner created by Koike for Harbin Electric in China of the No. 31 Chevy Silverado driven by James will be used to weld and clad component parts for a new nuclear reactor. Buescher during the 2012 campaign. It was expected to be shipped in mid-April.

AWS Energy Conference Comes to Welding Code — Reinforced Steel, and D1.6, Structural Welding San Diego in June Code — Stainless Steel, rules for nuclear fabrication; • Jack Schroeder, an ESAB automation sales manager, wind- tower fabrication and patented isolated cold electrode process; The American Welding Society (AWS)-sponsored conference • Ian Harris, Edison Welding Institute, plasma gas metal on Welding in the Energy Industries will be held June 12 and 13 arc/hybrid arc welding and high brightness laser welds; at the Courtyard San Diego Old Town in San Diego, Calif. Listed • Bruce Thompson, Edison Welding Institute, friction stir are the speakers’ names, positions, and presentation topics. welding, including tool material innovations; • Richard Campbell, the first engineer from the welding field • Matthew Yarmuch, Alberta Innovates — Technology Fu- to be named a Bechtel fellow, the use of several technologies, in- tures, an overview of the tar sands in Alberta and the role mod- cluding gas metal arc welding surface tension transfer; ern welding technologies play in their development; • Michael Ludwig, segment manager, shipbuilding and power • John Babich, ArcelorMittal’s steel plate operation, the avail- generation for Fronius USA, high deposition cladding methods ability of roll-bonded C276 clad for coal-fired power plant FGD for energy applications; equipment and stacks; • Kevin Beardsley, a pipeline expert from Lincoln Electric, • Ben Pletcher, Chicago Bridge & Iron, welding 9% nickel the company’s entry into laser welding to produce claddings; LNG storage tanks; • Bill Newell, vice president of Euroweld, preheat — misun- • Michael Blakely, Dynamic Materials, how explosion weld- derstood, often overlooked and sometimes misapplied; ing is used to provide plate for use in many industries; • Shane Findlan, chief welding engineer at the Shaw Group, • Larry Paul, ThyssenKrupp VDM, weld overlay options for the use of D1.1, Structural Welding Code — Steel, D1.4, Structural fossil fired boilers; and

8 MAY 2012 • Randall Dooley, Kennametal’s Conforma Clad, unusual so- Last November, 18 students started a 10-week shipfitter boot lutions to problems in the power-generation industry. camp developed by the Gulf States Shipbuilders Consortium For additional information, visit www.aws.org/conferences/ (GSSC) to prepare them for entry-level employment in the mar- 2012energy.html. itime industry. Before an invitation was extended to participate, candidates completed prequalification activities. Gulf States Shipbuilders Consortium Boot On March 1, the 12 individuals who completed the pilot program participated in a graduation ceremony hosted by Missis- Camp Students Graduate into Jobs sippi Gulf Coast Community College (MGCCC) at its Advanced Manufacturing and Technology Center in Gulfport, Miss. A job fair followed the event giving graduates an opportunity to interview with representatives from area shipyards, including Bollinger Shipyards, Ingalls Shipbuilding, Trinity Yachts, and VT Halter Marine. All 12 graduates were offered employment. GSSC’s Shipfitter Boot Camps are part of a larger project — funded through a U.S. Department of Commerce Katrina Grant — to develop a standardized, performance-based shipfitting curriculum with a portable skill certificate that is recognized by its members along the Gulf Coast and can be used by high schools, colleges, shipyards, and skilled trade providers to train individuals on core shipfitting skills. “Because this curriculum was designed by industry for industry, it assures that the participants are coming out of the training ready to begin entry-level jobs in shipbuilding and metal fabrication,” said Mark Landry, MGCCC workforce director in Jack- son and George counties.

After completing the 10-week shipfitter boot camp by the Gulf States Alcoa Wins Navy Contract to Develop Shipbuilders Consortium, all 12 graduates were offered employ- Advanced Welding Techniques ment. Shown above, student Joshua Chiles grinds a plate edge in preparation for welding. He will also attach a 10 in. × 10 ft plate to Alcoa, New York, N.Y., has won a $2.1 million U.S. Navy con- the edge. (Photo courtesy of Mississippi Gulf Coast Community tract to develop advanced welding techniques designed to reduce College.) manufacturing costs on aluminum-intensive ships.

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WELDING JOURNAL 9 Under the program, developed through a collaboration with Alcoa’s Government Affairs team and researchers at the Alcoa Technical Center in New Kensington, Pa., the company will adapt high-deposition gas metal arc welding technology to marine structures, enabling the Navy to reduce the cost of shipbuilding. Total projected savings for the Navy could be as much as $200 million under current shipbuilding plans. The process will be applied to the Navy’s Littoral Combat Ship and could be transferred to the Navy’s Joint High Speed Vessel and other aluminum-intensive ships.

Jet Edge Featured on Modern Marvels and DIGGERS Jet Edge R&D Engineer Michael Wheeler holds a Modern Mar- The History Channel’s Modern Marvels show highlighted Jet vels logo. The show’s ‘Under Pressure’ episode explores the science Edge waterjets and Michael Waltrip Racing (MWR) in its recent behind creating an extreme ultrahigh-pressure waterjet. (Photo cour- episode, “Under Pressure.” Considering that few things could be tesy of Jet Edge.) under more pressure than a 90,000 lb/in.2 industrial waterjet cutting machine and a NASCAR® team racing to get ready for the terjet cutting system. To distress the part and encourage faster next green flag, the show’s production crew traveled to MWR’s rusting, its test lab crew ran a fan-tipped waterjet head over the shop in Cornelius, N.C., to shoot the episode. It explores the sci- finished part to rough up the surface, then raised the water level ence behind creating an extreme ultrahigh-pressure waterjet that in the tank and let the part soak overnight under water on top of can cut parts from virtually any material, and explains how the metal slats. The part was sprinkled with sidewalk salt and left on shop uses its Jet Edge X-Stream waterjet cutting machine to cut the slats for a day to continue rusting. Within two days, the com- more than 1000 parts for each of its race cars. The episode has pany had a part that looked like it had been in the ground for interviews with Michael Wheeler, Jet Edge’s R&D engineer; Nick years waiting for DIGGERS to find it. Hughes, MWR’s technical director; and Jeremy Vanderleest, MWR’s waterjet operator. In addition, National Geographic TV’s new show DIGGERS Caterpillar to Expand South Carolina — focusing on the treasure hunting adventures of Tim Saylor Facility, More Than 80 New Jobs Expected and George Wyant — features a metal logo of its name made by Jet Edge shown at the start of each episode. The ¼-in.-steel logo Caterpillar, Inc., is planning a $20 million expansion to its was cut with a 90 ksi X-Stream-powered High Rail Gantry wa- manufacturing facility in Sumter, S.C., bringing the total foot-

For info go to www.aws.org/ad-index 10 MAY 2012 print to approximately 275,000 sq ft once complete. When the expansion is operational and at full capacity, it is anticipated the company will add more than 80 jobs over a two-year period. Work is scheduled to be completed by the fourth quarter of 2012. Hir- ing is expected to begin in the third quarter of 2012. Positions will be posted on www.jointeamcaterpillar.com. The facility produces small hydraulic cylinders used in a variety of Cat® products. The extra capacity will bring the production of large hydraulic cylinders from the company’s Joliet, Ill., facility to Sumter. Once the expansion is completed, the Sumter facility will be the primary source for small and large hydraulic cylinders for North and South America. RathGibson to Be Acquired by Precision Castparts Corp.

RathGibson, Janesville, Wis., a manufacturer of welded, welded and drawn, and seamless stainless steel, nickel, and specialty alloy tubing, agreed to be acquired by Precision Castparts Corp., a manufacturer of complex metal components and prod- Photographed are Philip “Biff” Keidel Jr. (left), president of Robert ucts. The takeover is pending regulatory approvals. Wooler, and William R. Jones, CEO of Solar Manufacturing. Mark G. Essig, CEO of RathGibson, stated that operating as Manufacturing, Souderton, Pa. The custom-built product fea- part of Precision will allow the company to accelerate growth tures a SolarVac 3000 control system, operator interface, and plans and offer a more complete product capability. In addition, temperature programmer/control. The horizontal front-loading he thanked the current ownership group, led by Wayzata Part- furnace has a 36 in. wide × 36 in. high × 48 in. deep work zone ners, for guiding the company through its recent restructuring. and 3500-lb load capacity. With a maximum operating temperature of 2500°F, the Class 2 furnace has a temperature uniformity Robert Wooler Increases Capacity with of ±10°F per AMS 2750-D standards. With the addition, Robert Vacuum Furnace from Solar Manufacturing Wooler can offer furnace availability and capacity especially for austenitic, martensitic, and precipitation hardening stainless Robert Wooler, Dresher, Pa., a commercial heat-treating com- steels. The total installed investment, inclusive of utilities and pany, recently commissioned a new vacuum furnace from Solar upgrades, was $600,000.◆

For info go to www.aws.org/ad-index WELDING JOURNAL 11 INTERNATIONAL UPDATE

Damen Develops Single Weld Nozzle Spinning Method

The Eskom Academy of Learning Welding School will help to al- Damen’s nozzle spinning machine produces a single weld joint leviate the shortage of qualified welding professionals in South on the inner side of the propeller nozzle. Africa. Many South African companies in the construction and steel sectors have to import welders from countries such as Korea, Damen Marine Components recently developed a propeller Argentina, and the Phillipines. (Image: photo.machinestogo.net.) nozzle production method based on a single weld joint on the inner side of the nozzle. This makes the process more efficient cated that the school will train at least 700 young people as welders and environmentally friendly. The new machine, which has been over the next seven years. installed at the company’s facility in Gdansk, Poland, can pro- “There is a massive shortage of welding professionals in South duce nozzles with an inside diameter from 1000 mm to 4.5 m. Africa,” said Etienne Nell, SAIW manager of training services. The machine utilizes an automated system and can handle “One of the reasons for this is that the training of welding ap- stainless steel, duplex steel, and special steel alloys. prentices no longer gets priority.” Under the traditional system, the inside of the nozzle is con- At the opening of the school, Minister of Public Enterprises structed from several small welded parts. The new method requires Malusi Gigaba said it is important for state institutions to de- less welding and grinding, and results in a smoother surface. velop skills in house. “The welders will be able to work not only Damen Marine Components is based in Hardinxveld, The for Eskom, but will also be of use to the broader South African Netherlands, and is part of the Damen Shipyards Group. economy,” he said. Once the trainees finish the course, which includes a theory Australian Firm Sets Up Keyhole GTAW component as well as on-the-job training at power stations, they Demo Facility will receive a dual qualification that will be recognized not only in South Africa, but internationally as the certificate is accred- Keyhole TIG (K-TIG) Ltd. recently ited by the International Institute of Welding. installed a $150,000 demonstration unit at its Salisbury, Australia, of- Fronius Opens UK Welding Business fices. The unit was set up to show how keyhole gas tungsten arc welding (GTAW) can weld thick-gauge materials, including stainless steel and titanium, in less time than is possible with standard GTAW. The system includes a welding torch, controller unit, underfloor power supply, and rigging to hold and rotate large pipes while they are K-TIG CEO Gordon Kay being welded. The patent-protected technology was originally developed by CSIRO, but now is wholly owned by K-TIG. “With this, we can do a weld in three minutes that would nor- The Fronius UK team. The company has opened a 3800-sq-m mally take as long as six hours,” said K-TIG CEO Gordon Kay. facility in Milton Keynes. Besides the demonstration unit, the company is also preparing to launch a series of videos that show how companies can achieve Fronius International GmbH recently opened a subsidiary of its required welds, he added. welding business in the United Kingdom. Located in Milton Keynes, Fronius U.K. Ltd.’s 3800-sq-m facility houses the tech support team, New Welding School Opens in South Africa a repair center, warehouse, and training area. The company offers solutions for gas metal arc welding, gas The Eskom Academy of Learning Welding School recently tungsten arc welding, electrodes, laser beam welding, plasma, re- opened in Midrand, South Africa. The school is a partnership be- sistance spot welding, and automation. By the end of the year, three tween the South African Institute of Welding (SAIW) and public sales and service teams will work out of the head office and an ad- electric utility company Eskom. Brian Dames, Eskom CEO, indi- ditional team will be based in Scotland.♦

WELDING JOURNAL 12 Capacity Precision Strength

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For Info go to www.aws.org/ad-index STAINLESS Q&A BY DAMIAN J. KOTECKI

Q: We prepared an all-weld-metal tensile shop, to the tensile testing stage, low ten- test specimen from a lot of E312-16 sile elongation is observed even if the weld austenitic stainless steel electrodes in metal is very low in diffusible hydrogen. order to qualify the lot. The AWS A5.4 Low hydrogen is not zero hydrogen. This standard (Ref. 1) requires 22% elongation diffusible hydrogen will diffuse out of the in the tensile test, but we only observed low-alloy weld metal in a few days at room 10%. The ferrite content measured be- temperature, or more quickly at slightly el- tween 55 and 60 FN, which seems normal. evated temperatures. Accordingly, the Why should we get such a low elongation AWS A5.5 standard (Ref. 2) permits aging result, and what can we do about it? of low-alloy-steel weld metal tensile test specimens at 90° to 105°C (200° to 220°F ) A: First, let me observe that 312 weld for up to 48 h before tensile testing in Fig. 1 — Tensile specimen fracture face of metal, contrary to popular belief and many order to reveal the weld metal’s inherent 2553-type duplex stainless steel weld metal handbooks, is not austenitic stainless steel. tensile ductility. exhibiting evidence of hydrogen damage. Metallurgically, 312 weld metal is duplex Unlike the situation with low-alloy- This specimen fractured at 13% elongation. stainless steel. It solidifies as 100% ferrite steel weld metal, however, aging of the Hydrogen damage, often called a “fisheye,” and only forms austenite during cooling tensile specimen at room temperature or is visible as the bright flat area near the top after solidification, just as do the other du- at slightly elevated temperatures will not edge of the specimen. plex stainless steel weld metals like 2209, allow escape of diffusible hydrogen from 2553, 2593, 2594, and 2595, all of which duplex stainless steel weld metal within typically produce weld metal of 30 to 60 your lifetime. This is because the austenite 100° to 125°C [210° to 260°F]) until use. FN. The only significant difference be- that first forms during cooling from solid- Exposed electrodes need to be rebaked to tween 312 and the other duplex stainless ification temperature invariably forms dry them. steel weld metals is that the other duplex along the original ferrite grain boundaries. Follow up: The inquirer advised that he stainless steel weld metals rely almost en- All of the ferrite is encapsulated within did indeed find a fisheye on his failed ten- tirely on nitrogen to promote the forma- austenite envelopes that are virtually im- sile specimen fracture surface. He then re- tion of austenite in the solid state, while permeable to diffusible hydrogen at ambi- baked the exposed electrodes at 350°C 312 relies mainly on carbon, with some as- ent temperature or even at temperatures (660°F), and welded a new test plate. This sistance from nitrogen, to promote forma- well above the aging temperature permit- time the tensile test produced 21% elon- tion of austenite. Typically, 312 weld metal ted by the AWS A5.5 standard. Tempera- gation, slightly less than the 22% elonga- contains about 0.10% C and 0.08% N, tures high enough to remove the hydrogen tion requirement of the AWS A5.4 stan- while the other duplex stainless steel weld in a reasonable time frame (e.g., 450° to dard, but much better than the 10% elon- metals typically contain 0.03% C, or less, 650°C [840° to 1200°F]) will embrittle the gation reported for as-exposed electrodes. I advised him to rebake at a still higher and 0.15% N or more. Since 312 is mainly duplex stainless steel weld metal by for- ◆ used for joining difficult-to-weld low-alloy mation of alpha prime and/or sigma phase. temperature, closer to 450°C (840°F). steels, the high carbon content has no ef- When low-alloy-steel weld metal ten- References fect on corrosion resistance of the joint. sile test specimens fail elongation require- In addition to the carbon and nitrogen ments due to diffusible hydrogen rem- 1. A5.4/A5.4M:2006, Specification for mentioned above, 312 typically contains nants, the fracture surface often exhibits Stainless Steel Electrodes for Shielded Metal 29% Cr and 9% Ni. According to the local brittle areas commonly called Arc Welding. American Welding Society. WRC-1992 Diagram, such a composition “fisheyes.” Fisheyes are clear evidence of Miami, Fla. is predicted to contain about 55 to 60 FN, diffusible hydrogen damage. Next, I note 2. A5.5/A5.5M:2006, Specification for just about what you found. So everything that many duplex stainless steel weld met- Low-Alloy Steel Electrodes for Shielded about your lot of electrodes seems to be als, including 312, exhibit tensile strengths Metal Arc Welding. American Welding So- normal. However, there is another factor above 110 ksi (760 MPa), not unlike ciety. Miami, Fla. to consider — diffusible hydrogen. Dif- E11018M weld metal. And, when the du- 3. Kotecki, D. J. 1989. Heat treatment fusible hydrogen has no effect on plex stainless steel weld metal fails with of duplex stainless steel weld metals. Weld- austenitic stainless steel weld metals, but it low tensile elongation, it often exhibits ing Journal 68(11): 431-s to 441-s. has a pronounced effect on duplex stain- fisheyes. An example of a tensile specimen less steel weld metals, similar to, but not fracture containing a fisheye from my own the same as, the effect it has on low-alloy- experience with duplex stainless steels DAMIAN J. KOTECKI is president, steel weld metals. (Ref. 3) is shown in Fig. 1. Damian Kotecki Welding Consultants, Inc. In low-alloy-steel weld metals, dif- I suspect that your electrodes had He is treasurer of the IIW and a member of fusible hydrogen can produce delayed picked up enough coating moisture to pro- the A5D Subcommittee on Stainless Steel cracking, as is well known. However, less duce the hydrogen damage that accounted Filler Metals, D1K Subcommittee on Stain- well known is that levels of diffusible hy- for your low tensile elongation. Duplex less Steel Structural Welding; and WRC drogen below that which will produce de- stainless steel electrodes need to be Subcommittee on Welding Stainless Steels layed cracking in low-alloy-steel weld treated like low-hydrogen electrodes for and Nickel-Base Alloys. He is a past chair of metal can result in low tensile elongation, low-alloy steels. This means they need to the A5 Committee on Filler Metals and Al- just as you have observed in your 312 weld be baked at a high temperature such as lied Materials, and served as AWS president metal. A common experience is that, when 450°C (840°F) during manufacture. Then (2005–2006). Send questions to damian@ low-alloy-steel weld metal, such as that they need to be protected from moisture damiankotecki.com, or Damian Kotecki, from E11018M electrodes, is rushed from pickup by storing in sealed containers or in c/o Welding Journal Dept., 550 NW LeJeune the welding stage, through the machine an oven at elevated temperature (e.g., at Rd., Miami, FL 33126.

14 MAY 2012 For Info go to www.aws.org/ad-index Friends and Colleagues:

The American Welding Society established the honor of Counselor to recognize individual members for a career of distinguished organizational leadership that has enhanced the image and impact of the welding industry. Election as a Counselor shall be based on an individual’s career of outstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership in the welding industry by one or more of the following:

• Leadership of or within an organization that has made a substantial contribution to the welding industry. The individual’s organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities.

• Leadership of or within an organization that has made a substantial contribution to training and vocational education in the welding industry. The individual’s organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employee in industry activities.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this issue of the Welding Journal. The deadline for submission is July 1, 2012. The committee looks forward to receiving these nominations for 2013 consideration.

Sincerely,

Alfred F. Fleury Chair, Counselor Selection Committee Nomination of AWS Counselor

I. HISTORY AND BACKGROUND In 1999, the American Welding Society established the honor of Counselor to recognize individual members for a career of distinguished organizational leadership that has enhanced the image and impact of the welding industry. Election as a Counselor shall be based on an individual’s career of outstanding accomplishment. To be eligible for appointment, an individual shall have demonstrated his or her leadership in the welding industry by one or more of the following: • Leadership of or within an organization that has made a substantial contribution to the welding industry. (The individual’s organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA, NSRP SP7 or other similar groups.) • Leadership of or within an organization that has made substantial contribution to training and vocational education in the welding industry. (The individual’s organization shall have shown an ongoing commitment to the industry, as evidenced by support of partici pation of its employees in industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA, NSRP SP7 or other similar groups.) II. RULES A. Candidates for Counselor shall have at least 10 years of membership in AWS. B. Each candidate for Counselor shall be nominated by at least five members of the Society. C. Nominations shall be submitted on the official form available from AWS headquarters. D. Nominations must be submitted to AWS headquarters no later than July 1 of the year prior to that in which the award is to be presented. E. Nominations shall remain valid for three years. F. All information on nominees will be held in strict confidence. G. Candidates who have been elected as Fellows of AWS shall not be eligible for election as Counselors. Candidates may not be nominated for both of these awards at the same time. III. NUMBER OF COUNSELORS TO BE SELECTED Maximum of 10 Counselors selected each year.

Return completed Counselor nomination package to:

Wendy S. Reeve American Welding Society Senior Manager Award Programs and Administrative Support 550 N.W. LeJeune Road Miami, FL 33126 Telephone: 800-443-9353, extension 293 SUBMISSION DEADLINE: July 1, 2012 (please type or print in black ink) CLASS OF 2013 COUNSELOR NOMINATION FORM

DATE______NAME OF CANDIDATE______

AWS MEMBER NO.______YEARS OF AWS MEMBERSHIP______

HOME ADDRESS______

CITY______STATE______ZIP CODE______PHONE______

PRESENT COMPANY/INSTITUTION AFFILIATION______

TITLE/POSITION______

BUSINESS ADDRESS______

CITY______STATE______ZIP CODE______PHONE______

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION______

MAJOR & MINOR______

DEGREES OR CERTIFICATES/YEAR______

LICENSED PROFESSIONAL ENGINEER: YES______NO______STATE______

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE______

POSITION______YEARS______

COMPANY/CITY/STATE______

POSITION______YEARS______

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

______

______IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT** The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All information and support material provided by the candidate’s Counselor Proposer, Nominating Members and peers are considered.

SUBMITTED BY: PROPOSER______AWS Member No.______The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the candidate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.

NOMINATING MEMBER:______Print Name______AWS Member No.______NOMINATING MEMBER:______Print Name______AWS Member No.______NOMINATING MEMBER:______Print Name______AWS Member No.______NOMINATING MEMBER:______Print Name______AWS Member No.______SUBMISSION DEADLINE JULY 1, 2012 For Info go to www.aws.org/ad-index PRODUCT & PRINT SPOTLIGHT

Power Source Designed to Work Well with Difficult SMAW Electrodes in Structural Steel Applications

The Big Blue® 450 Duo CST, a dual-operator diesel engine-driven welding generator, features two CST 280 SMA/GTA inverters and 12,000 W of continuous three- phase power in a single unit. Powered by Mitsubishi’s S4L2 4-cylinder diesel engine, it allows two welders to work off the same machine with two separate welding outputs. Also, the machine is suitable for SMA electrodes in structural steel and fabrication applications, such as E6010, and GTA for pipe fabrication and maintenance applications. The Tier 4i-compliant machine operates at 1800 rev/min. It contains an easy process selector for SMA and GTA applications. SMA welders can further tailor welding output by selecting the type of electrode and whether to weld in a “stiff” (more dig/arc force) or “soft” setting (lower dig/arc force). The system has Adaptive Hot Start™ for SMAW applications that increases the output amperage at the start of a weld to help prevent the electrode from sticking and creating an inclusion. Lift-Arc™ technology improves GTA arc starts without the use of high frequency. In addition, the machine offers the following: a three-phase, rotating-field generator that requires less fuel and horsepower to operate; built-in thermal overload protection prevents damage if the duty cycle is exceeded or if airflow is blocked; an engine designed to run more than 10,000 h before its first major overhaul; and meter maintenance display that reports hours, oil change intervals, high coolant temperature/low oil shutdowns, and a low fuel shutdown.

Miller Electric Mfg. Co. www.millerwelds.com (800) 426-4553

Welding Helmet Features Saw Useful for Cutting Four Sensors Structural Steel

The WeldSkill® autodarkening welding helmet contains four sensors, can be used in weld and grind modes, and will darken when GTA welding even at 5 A. It has a 3.86 × 1.69 in. viewing area, weighs 16 oz, and uses solar power. When switching from light to dark, the helmet darkens in 33 microseconds. When switching from dark to light, users can select from three switching speeds — short (0.25 to 0.35 s), medium (0.35 to 0.50 s), and long (0.50 to 0.80 s). The four-sensor helmet passes all of the 49 tests required under the ANSI year warranty, the helmet comes in car- Z87.1-2010 standards. The sensitivity and bon fiber, patriot eagle, chopper rider, or delay knobs are placed on the outside of skull and fire styles. the helmet shell. When setting the helmet down, a recessed lens design prevents the Tweco® The K20RS, 20-in. abrasive saw is de- faceplate from touching the table, pro- www.tweco.com signed to cut structural steel and wide tecting it from scratches. Backed by a two- (800) 231-9353 parts. It can be operated chop style for

18 MAY 2012 cutoff or radial style for long parts. The sawhead moves lengthwise for wide cuts and locks in place for chop action. Also, the product features a 1-in. spindle arbor; 2500 rev/min spindle speed; 15-hp, 3- phase motor; and foot-operated chain vise. Capacities are 6 × 18 in. for structural, I-beams, and shapes.

Kalamazoo Industries, Inc. www.kalamazooind.com (800) 592-2050

Complete Oxyacetylene Welding Course on DVD

The Oxyacetylene Welding, Brazing, and Cutting DV30.0 skill course, suitable for training on the job and in educational institutions, is presented on four DVDs. The three-hour-long program is divided into 31 topics, detailing a variety of fillet welds, lap joints, square groove welds, square and bevel cuts, single V-groove welds, fillet braze welds, square groove welds, butt joints, flat and vertical position-up, and edge bead welds, and hardfacing operations. The course includes the DVDs, one instructor guide, and 50 copies each of four written tests. The complete course lists for $995. For more information, visit the Web site shown, then type DV30 in the search window.

Hobart Institute of Welding Technology For info go to www.aws.org/ad-index www.welding.org (800) 332-9448 Casters and Wheel Products Illustrated

Welders... Positioners... Generators... Specialty Equipment.

Available in hard copy and online, the 117-page, full-color 2012 catalog features a number of additions to the product line, including the Trans-form LT wheel, and L and G series of lighter-duty casters, En- core® economy line of caster and wheel reddarc.com 1-866-733-3272

For info go to www.aws.org/ad-index WELDING JOURNAL 19 products, an expanded replacement-parts grinding dusts; weld smoke; fumes and section, plus additional information, spec- odors; and oil mists. It includes the ifications, and product photographs. Call patented E-Z Arm® extractor arm, plus the number shown to order a hard copy an all-aluminum motor designed and built or visit the Web site shown, click the re- by the company along with its patented sources button, then click literature on the Vibra-Pulse® filter cleaning system. The scroll-down menu to download the PDF. PCH-1 model is available with a 0.5-, 1.0-, or 1.5-hp motor capable of air flow Colson Caster Corp. rates up to 800 ft3/min. The PCH-2 model www.colsoncaster.com is offered with a 1.0-, 1.5-, or 3.0-hp motor (800) 643-5515 capable of air flow rates up to 1200 ft3/min.

Dust Collector Comes with Airflow Systems, Inc. Extractor Arm www.airflowsystems.com (214) 503-8008

Orbital Welding Detailed in Free Handbook

The free, 56-page, full-color Orbital Welding Handbook explains and illustrates the process from the basics to specific ap- 3 1 The 5 ⁄4- × 8 ⁄4-in. handbook is available in plications. Detailed are the GTAW English, French, or German. Complete process, types of electrodes, filler metals, the form on the Web site to receive up to shielding gases, calculating heat input, three copies in the mail. hardware components, programmable power sources, orbital welding heads, wire Polysoude S.A.S. feeders, remote control pendants, weld www.polysoude.com cycle programming, real-time data acqui- (661) 702-0141 The PCH series of portable dust col- sition, tube-to-tube fusion welding, calcu- lection systems are suitable for chemical, lation of weld parameter values, joint and Software Contains 3-D pharmaceutical, and food processing electrode preparation, narrow gap and hot Simulation Package dusts and powders; buffing, polishing, and wire GTAW, welding recessed tubes, etc.

An updated version of the company’s Wincaps III offline programming software saves development time by allowing a robot to be programmed on an offline computer. It also enables remote monitoring of workcell operations via real-time I/O status indicators and control logs. The product’s 3-D simulation package allows users to lay out an entire automation workcell in a virtual environment. This version employs more of the robot’s na- tive command language; gives a more accurate cycle-time representation; and allows users to record the simulation session and save it as an AVI file. The Easy Teach feature lets users move the robot to a particular point by clicking on the surface of the virtual model.

Denso www.densorobotics.com (888) 476-2689 For info go to www.aws.org/ad-index 20 MAY 2012 Remote Field Probes tion. To download the PDF, visit the Web with capacities of 165 to 400 tons and with Featured in Brochure site, click the support button, the PDF li- or without a manipulator. brary button, then scroll down to the document desired. Cole-Tuve, Inc. www.coletuve.com Olympus NDT, Inc. (877) 989-0700 www.olympus-ims.com (781) 419-3900 Industrial Reels Pictured in Catalog Shearing/Flanging Machine Works on Steel, Aluminum

The eight-page, full-color Advances in Model EFM, a combination shear- 1 RFT Tube Testing Solutions brochure illus- ing/flanging machine, offers up to ⁄4 × 118 trates and explains the differences be- in. capacity in steel and aluminum and up 5 tween remote field testing (RFT) models, to ⁄32 in. in stainless steel for flat and the near-field technique using eddy cur- crowned, round and elliptical, and double rent technology, software improvements D heads and bottoms as well as other non- and details of CARTO™ software, probe symmetrical shapes. As optional accessory adapters, reverse probe adapters, acces- equipment for the larger flanging ma- The 56-page, full-color Hose, Cord & sories, foot switch, and ordering informa- chines, dishing machines are available Cable Reels catalog highlights the com-

For info go to www.aws.org/ad-index WELDING JOURNAL 21 pany’s complete lines of products featur- aluminum. The list price is 83 euros (ap- ing a user-friendly index and easily navi- proximately $111), plus shipping. To view gated layout. Described is the EZ-Coil® the table of contents or to order, visit the safety reel line. A hard copy may be re- Web site, then enter welding processes in quested by phone or e-mail at info@ the search window. coxreels.com. The PDF may be viewed or downloaded from the Web site shown. Research and Markets www.researchandmarkets.com Coxreels® (800) 526-8630 www.coxreels.com (800) 269-7335 Blaster Eliminates Need for Lower Screw Auger Welding Processes Handbook Updated

The 280-page Welding Processes Hand- book is described as a concise, authoritative, and practical introduction to welding and its applications for both students and engineers. This substantially revised and extended second edition reflects the latest developments in the main welding technologies and their applications. It reviews the gas welding processes and dis- cusses the fundamentals of arc welding, including arc physics and power sources. Also detailed are resistance and laser- beam welding and their applications for The redesigned 72T table blaster has cutting, hardfacing, soldering, and braz- a wraparound door for easy access and ing. Included are a discussion of mecha- eliminates the need for a lower screw nization, safety, residual stress and distor- auger. The air intake allows for an appli- tion, welding design, costs, and quality as- cation of more than 2800 ft3/min. Several 1 surance, as well as the welding of steel and wear liners are available, including a ⁄2-

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index 22 MAY 2012 in.-thick cast chrome/moly, replaceable liner. Most applications are covered by the standard offering, but it can also be fitted with a rotary scalping drum, auxiliary abrasive hoppers, peening packages, and various horsepower options. Custom sizes and wheel configurations are offered to accommodate application requirements. All company cartridge-style dust collectors are sold with NFPA-required helmet attachment system for face shields ManuManufacturingfacturing deflagration panels as standard. and welding helmets. Each of the cap’s nine shades of solid-color resin gives a Viking Blast & Wash Systems Flux Cored www.vikingcorporation.com permanent, no-chip, no-peel finish. (800) 835-1096 Honeywell Safety Products www.fibre-metal.com WeldingWelding WireWire Hat Handles Hard Knocks (800) 430-4110 without Developing Cracks Water Cooler Filter COBALTCOBALTLT The Fibre-Metal® Roughneck® P2A Intended for GMAW, GTAW hard hat offers a smooth, round design and matte finish for workers on construc- The 2012 Torch Saver water cooler fil- NICKELNICKEL tion and heavy-industry job sites. Con- ter, designed to filter the coolant in weld- structed of a proprietary injection-molded ing water coolers, is for applications such fiberglass compound, it offers impact and as GMAW, GTAW, automatic, robotic, crack resistance; handles hard knocks and laser welding. Both screen and 25 mi- HARDFACEHARDFACE without developing nicks and cracks; and cron filters are available. These extend meets ANSI-Z89.1-2009 impact resist- coolant life and reduce the amount of con- ance tests at temperatures up to 370°F. It taminants in the water cooling system. is offered with three headgear options — STAINLESSSTTAAINLESS the Fibre-Metal nonslip/nonstrip ratchet, BRW Technologies SwingStrap™, or TabLok™. It also comes www.brwtechnologies.com with the Quick-Lok® or Speedy® loop (864) 941-7212 ALLOYALLOY STEELSTEEL

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WELDING JOURNAL 23 Narrow Gap Electroslag Is Process of Choice for Welding San Francisco- Oakland Bay Bridge

24 MAY 2012 Building a span on a critical time schedule while ensuring high- quality, 10-m-long welds in heavy stock was possible using an ESW process

he California Department of Transportation (Caltrans) is build- Ting a new East Span of the San Francisco-Oakland Bay Bridge connecting Oakland to Yerba Buena Island. The new span consists of three parts: a concrete viaduct section called the Skyway; a steel, single-tower self-anchored suspension span (SAS) bridge; and a cast- in-place concrete transition section. The 1.2-mile-long Skyway originates on the Oakland side near the toll plaza. It forms the east portion of the bridge and is attached to the SAS bridge’s east- ern terminus (Ref. 1). The Skyway was completed in 2007 as reported in Roads and Bridges (Ref. 2). The SAS bridge is located between the Skyway on the east and the Yerba Buena Island transition on the west. The bridge has a single suspension tower. This single-tower design is unique in that the BY BOB TURPIN, main suspension cable of the SAS is not DAN DANKS, anchored to an adjoining land mass but JOHN CALLAGHAN, AND to the suspended roadway itself. The SAS WILLIAM WOOD roadway is 470 m (1542 ft) long. The existing tunnels through Yerba BOB TURPIN and DAN DANKS Buena Island will be retained for the new ([email protected]) are with bridge, which is located just north of the Electroslag Systems, Technology and existing bridge. The bridge will have in- Development, Portland, Ore.; dependent east- and westbound road- JOHN CALLAGHAN is with American ways with five lanes each and one ap- Bridge/Fluor Enterprises, Inc., A Joint Venture (ABFJV); and WILLIAM E. pended bike path cantilevered off the WOOD is a professor at Portland State south side of the eastbound road deck. University, Portland, Ore. The bike path requires a complementary counterweight be hung off the westbound road deck.

WELDING JOURNAL 25 Fig. 1 — Electroslag weld locations in base between tower legs. Center four arrows indicate two separate welds per arrow.

The single, four-legged suspension tower is located approximately 30 m (98 ft) from the east edge of Yerba Buena Is- land. Its 6.4-m- (21-ft-) thick concrete foundation is supported by 13 concrete- filled piles, 2.4 m (8 ft) in diameter. Each pile is driven through the Bay mud and anchored into bedrock to a depth of 59.7 m (196 ft). The tower is 160 m (525 ft) American Bridge/Fluor Joint Venture one entrant angle at 90 deg and the sec- high. It was erected using a series of (ABFJV) (Ref. 1). ond angle at 90, 120, or 150 deg — Figs. strand jack lifts that placed successive leg 1–3. pieces on top of the previous ones. The The Tower Base Welds The narrow gap improved electroslag four tower legs and tower base plate are welding (ESW-NG) process was used to joined by shear plate sections and stiff- Twenty vertical welds, 10 m (32.8 ft) weld the shear plate sections and stiff- ener plates to form a monolithic steel long, on A-709 Grade 345 steel were re- ener plates to the tower legs because of structure for the first ten m (33 ft) of the quired to complete the assembly of the its ability to produce single-pass vertical tower. four tower legs to form the monolithic welds on heavy-section structural steel The first lift of the individual legs, not base. Plate in or adjacent to the weld without a preheating requirement. Ac- including the connecting shear plates, joints were between 45 and 100 mm thick. cess within the tower base was limited weighs 1052 mT (1159 tons) each. Above Five weld configurations were required and the preheating requirement with any that, the four separate legs are joined at that included two transition joints (60 to other welding process would have been regular intervals with energy-absorbing 80 mm, 80 to 100 mm), and three T-joints prohibitive from the standpoint of safety seismic links that will act as protective to join 60-mm plate to the tower leg with and economy. In addition, these welds shear members during an earthquake. The old bridge, built by American Bridge Co. between 1936 and 1938, was significantly damaged by the 1989 Loma Prieta earthquake. It will be removed after the new bridge is commissioned. The new SAS structure, scheduled to open in late 2013, is being built by the

Fig. 2 — Upper approximately seven meters of an 80- to 100-mm transition weld (between arrows).

26 MAY 2012 Fig. 3 — Cross sections of the five different weld joint configurations and corre- sponding cooling shoes: Detail A, 120- deg T (shoes 3 and 4); Detail B, 150-deg T (shoes 3 and 5); Detail C, 60 to 80 mm transition (shoes 1 and 2); Detail D, 90- deg T (shoe 3); Detail E, 80- to 100-mm transition (shoes 1 and 2).

Fig. 4 — ABFJV, Caltrans, Portland State University, Smith Emery, and EST&D personnel witness procedure qualification record (PQR) welds in Portland.

had to be made in a very short amount Project Plan ment appropriate for the long welds. The of time and FCAW-G, SMAW, and proof-of-process utilized exact replicas FCAW-S do not offer the deposition The project was divided into three pri- of the welds in the 600-mm-high format. rates necessary to meet the schedule re- mary tasks: development of equipment With the successful completion of the quirements. and process, proof of process, and actual shorter welds, 2.4-m- (8-ft) high dupli- The ESW process is better known for welding on the bridge tower. cates of the exact weld joints were made. shop welding applications, and there is The development stage included such Six total of the 2.4-m welds were used to no record of ESW-NG being used to things as adapting existing equipment to demonstrate the process to the bridge make welds longer than 6½ m (21 ft) , ei- the specific requirements of the tower, owner, qualify the weld procedure, and ther on-site or in a fab shop. Therefore, designing and fabricating special compo- train the Ironworker gang in the ESW in addition to the normal D1.5 (Ref. 3) nents like shoe clamps and consumable process — Fig. 4. The last step of the procedure qualification, it was necessary guide holder, and devising the procedure proof-of-process phase was welding the to demonstrate the field-ready ESW-NG for fabricating the required 11-m-long full-size mock-up (10 m high) of the 80- process to Caltrans. Prior to conducting consumable electrode guides. to 100-mm transition weld in the ABFJV welds on the actual tower, a full-scale The development task started with yard in Oakland. mock-up was welded and inspected in the 600-mm- (2 ft-) high plate welds in the Once the bridge owner was satisfied Oakland ABFJV yard using the produc- Electroslag Sytems, Technology and De- with the results of the full-sized mock- tion equipment. The mock-up joint was velopment (EST&D) shop. The welding up, the last task consisted of moving the a 10-m-long, 80- to 100-mm transition parameters required to produce weld equipment out to the tower located in the weld. The joint restraint was designed to metal properties were developed in this San Francisco Bay and making the 20 simulate the actual tower conditions. task along with the evolution of equip- tower welds in situ and in short order.

WELDING JOURNAL 27 Table 1 — PQR Weld Properties (Average Sample Set)

Weld Yield Strength Ultimate Strength % Elong. % R.A. Charpy Impact Bend kPa; (psi) kPa;(psi) (in 2 in.) 0°F, J (ft-lb)

60 – 70 mm 457, 815 (66,400) 612,944 (88,900) 26.5 67.0 45.4 (33.5) No cracks 80–100 mm 499,180 (72,650) 660,518 (95,800) 24.2 67.2 35.3 (26.0) No cracks 90-deg T 496,423 (72,000) 613,633 (89,000) 27.7 69.0 37.3 (27.5) No cracks 120-deg T 501,938 (72,800) 620,528 (90,000) 25.0 60.0 43.5 (32.1) No cracks 150-deg T 497,112 (72,100) 614,426 (89,115) 27.7 69.0 41.4 (30.5) No cracks

Equipment built into all systems to minimize the trode speed (two channels), water flow chance of a weld stopping inadvertently. rate (two channels), and water return Consumable Guide. The 10-m weld Cooling System. The cooling system temperature (two channels). The weld length presented special challenges es- also required special adaptation. Two voltage and amperage traces were used pecially with respect to the consumable water chillers, one active and one in to monitor and control the slag pool guide. The electrode feed equipment ready standby, were moved to the tower depth and flux feed rate. The recorder needed to be capable of pushing the 2.4- work area. They were connected to a system, sampling at a rate of 10 Hz, made 3 mm- ( ⁄32-in.-) diameter wire through the water-distribution manifold that serviced permanent records of all development entire length of the 11-m guide. The six independent copper cooling shoes, and tower welds. guide, made from very low-carbon steel, three for each side of the weld — Fig. 5. Cooling Shoe Retaining System. A also had to survive carrying 1200 A of As the weld progressed upward, the three means to clamp the cooling shoes against current. As the weld progressed and the cooling shoes per side were leap-frogged the joint was required for the entire 10- guide was consumed, the electrical resist- in unison ahead of the molten slag and m height. The system that was devised in- ance changed requiring adjustments to weld pools. Only two shoes were actually cluded a universal square tube strong- the welding voltage during the 4.5-h-long needed per side with the leap-frogging back that was welded to the tower ap- welds. The guide is certified and becomes technique but a third shoe was included proximately 460 mm (18 in.) from the part of the weld. for redundancy. The water chillers main- joint surface. A custom-designed and Welding Machine Power and Elec- tained the water temperature within 5°C fabricated spring-loaded clamp was then trode Drive. Two EST&D ESW con- (10°F) of a predetermined setpoint. inserted between the cooling shoe and trollers were required to regulate two Weld Data Collection and Recording. the strongback. The system allowed for Lincoln DC-1000 power supplies, and Special records were required by the movement between the shoes, strong- two NA5 wire-drive motors were adapted bridge owner. A data-collection system back, and plates to accommodate move- to the consumable guide clamping and was cooperatively designed and assem- ments due to thermal changes and plate positioning system. Independent wire- bled by VGO Engineering and Inte- fitup variations. speed monitors were set up as backups grated Welding Systems. Among the pa- Proof of Process. Development of the for the welding machine controller indi- rameters measured and recorded were welding procedure was done on 600-mm- cators. Several layers of redundancy were welding voltage, welding amperage, elec- (24-in.-) high welds. Mechanical testing

Fig. 5 — Cooling water manifold serv- icing six independent cooling shoes, three on either side of the weld.

28 MAY 2012 6A 6B

Fig. 6 — Cross sections. A — 150-deg T; B — 80–100-mm transition electroslag weld (ESW).

Fig. 7 — Full-sized mock-up weld conducted in ABFJV yard prior to making the actual welds on the bridge tower.

Fig. 8 — An ABFJV ironworker is shown working in the tight area for a tower weld.

WELDING JOURNAL 29 9 Fig. 9 — (Top) Typical weld start configuration with access-hole plugged, starting block and consumable guide in place, and insulators placed between guide and plates.

Fig. 10 — (Bottom) An ABFJV ironworker is shown finishing the weld start shown in Fig. 9 after access-hole plug removal.

was conducted on welds per AWS D1.5 and included chemical composition, yield and ultimate tensile strengths, Charpy 10 impact toughness in the base and weld metal, percent reduction of area, and percent elongation (Table 1). Most of the testing was conducted by IMR KHA in Portland with support of the Materi- als Science Department at Portland State University. After the proper welding parameters were established, 2.4-m- (8-ft-) high welds of the five bridge weld configurations were made in the shop to test the equipment and provide training for the Ironworker gang. A total of six 2.4- m welds were made and witnessed by the bridge owner. Those welds were used for the procedure qualification welds (PQRs) and were 100% ultrasonic (UT) inspected. Transition welds were 100% radiographed (RT) and all PQR welds were sectioned for a full suite of mechanical property testing per D1.5. Cross sections of all PQRs were also extracted and etched — Fig. 6. After the PQRs were cooling shoes (three per side). Each weld access-hole at the base of the weld. The established on the 2.4-m welds, the weld- required approximately 91 kg (200 lb) of weld starting block was designed to fit 3 ing equipment was transported to the 2.4-mm ( ⁄32-in.) electrode that conformed within the access-hole and met the D1.5 ABFJV site on the Bay in Oakland where to the AWS D1.5 code and 68 kg (150 lb) requirements for ESW-NG run-on — the full-sized mock-up 80- to 100-mm of consumable guide material. Fig. 9. Finish work required the plugs and weld was conducted in the ABFJV yard Each 11-m-long consumable guide weld starts be removed so that only sound — Fig. 7. had to be withdrawn from a water-tight weld metal remained — Fig. 10. storage container and carefully lowered Welding on the Tower into the joint opening. The container was Results kept at the site attached to the side of the Among the components that were re- tower. The two-wire consumable guides All 20 ten-m welds were successfully 1 quired for the tower welds were four sets were 6 mm ( ⁄4 in.) thick and between 63 completed in 60 days — Fig. 11. At the of access ladders (two per each side of the mm (2.5 in.) and 88 mm (3.5 in.) wide. time of this writing, the welds had been weld), lightweight movable ladder plat- Nominal weld travel speed (rate of rise) 100% UT inspected. Required repair forms (tree stands), cooling shoe strong- was 37 mm (1.5 in.) per minute, and each work has been detailed but the welding backs, consumable guide positioning and weld took about 4.5 h to complete. Ac- crews are working on other locations on clamping system, two-wire electrode- cess to the weld joints was limited and the bridge so repairs have not been com- drive system, cooling water manifold, ad- often a challenge for many of the welds pleted. The areas requiring repair are equate welding cable to conduct the nom- — Fig. 8. less than 5% of the total 200 m of weld. inal 35-V, 1200-A welding energy, and six Each weld joint was designed with an Most locations that require repair were

30 MAY 2012 11A Fig. 11 — Approximately 460 mm (18 in.) of typical transition electroslag welds: A — 80 to 100 mm; B — 60 to 80 mm.

11B

the result of a momentary low slag pool level caused by slag loss or variations in References the plate fit-up that caused a shallower Acknowledgments slag pool. One weld, No. 19, was inter- The authors gratefully acknowledge rupted due to an unexplained loss of pri- 1. mary power to the welding machine K&K Fabrication, Integrated Welding www.baybridgeinfo.org Systems, VGO Engineering, Portland power supplies. That weld was immedi- 2. Zeyher, A. 2007. All the ately reprepped, restarted and completed State University, Hobart Brothers, Smith Emery, IMR KHA Portland, the ABFJV state’s horses. Roads and the same day. Ultrasonic examinations Bridges (45)5: 26–30. of the restart area showed no indications Ironworker Gang from the International Association of Bridge, Structural, Orna- www.roadsbridges.com/ of any kind. . The extraordinary length of the tower mental, and Reinforcing Ironworkers all-states-horses (Local 377 San Francisco and Local 378 base welds presented several challenges. 3. AASHTO/AWS Alternatives such as FCAW-G, SMAW, Oakland), Caltrans and the American Bridge Fluor Joint Venture for their in- D1.5M/D1.5:2010, Bridge and FCAW-S would have been more chal- . 2010. Miami, lenging for the welders, would have had valuable support and professionalism Welding Code during this unique project. Fla. American Welding higher repair rates and would have taken Society. pp. 1.3.3. impossibly longer. The ESW process proved to be safe, reliable, and efficient.♦

WELDING JOURNAL 31 Know an individual, company, educator, or educational facility that exemplifies what welding is all about?

Nominate them for the

The Image of WWeldingelding AwardsAAwwards Program recognizesrecogn outstanding achievement in the following categories: Individual Distributor (you or other individual) (welding products) Section Educator (A (AWSWS local chapter) (welding teacher at an institution, facilityfacility,, etc.) Large Business Educational Facility (200 or more employees) (any ororganizationganization that conducts welding education or training) Small Business (less than 200 employees) Media (open to industry and business publications)

Entry deadline is July 31, 2012 For more information and to submit a nomination form online, visit www.aws.org/awards/image.html or call 800-443-9353.

An Association of Welding Manufacturers Welding Research’s New Talent Pool

BY ANDREW CULLISON, Here’s a look at five up-and-coming MARY RUTH JOHNSEN, HOWARD WOODWARD, AND researchers who are making their mark KRISTIN CAMPBELL ANDREW CULLISON in welding ([email protected]) is publisher, MARY RUTH JOHNSEN ([email protected]) is editor, and HOWARD WOODWARD ([email protected]) and KRISTIN CAMPBELL ([email protected]) are associate editors of the Welding Journal.

There’s a lot of talk these days about the average age of welders and the shortage that’s expected as the welders from the Baby Boomer generation retire. But the fact is that the welding industry in all its facets employs a mature workforce, welding research being no exception. So who are the people seeking the answers to today’s welding questions? The Welding Journal asked five well-respected welding researchers/educators to recommend some of their promising students or former students. Profiles of five individuals follow.

Caleb Roepke, PhD Colorado School of Mines

When Dr. Stephen Liu of Colorado structures like bridges, ships, and School of Mines, Golden, Col., was asked pipelines. Welding fit the bill. “I got ex- to name an up-and-coming talent in the cited about how the welding field draws welding industry, he said, “I have just the on those scientific disciplines in a very right person — Caleb Roepke.” practical and hands-on way,” he said. “Conscientious and thorough, he blos- “Welding spans a wide spectrum of engi- somed in his graduate studies, working in neering and science, from heavy construc- the field of hybrid laser arc welding. With tion to the latest in welding equipment growth and increasing maturity, Caleb’s and consumables to the study of metal- role as a senior PhD student and leader lurgy,” continued Roepke. “There are fas- was clearly noticeable. He helped his jun- cinating opportunities whether you are in ior colleagues and he shared my load by the fabrication yard or a research lab.” giving them solid advice on research and He started his undergraduate work at experimentation. Caleb is an excellent LeTourneau University, Longview, Tex., speaker, well organized, clear and con- under the direction of Prof. Yoni Adonyi, Caleb Roepke in the hybrid laser arc cise. I would definitely rate him as one of earning a bachelor of science in engineer- welding lab at the Colorado School of the top research students with whom I ing with a concentration on materials join- Mines during his graduate student have had the good fortune to work. He ing. He went on to study for his PhD at days. will serve and lead the welding industry the Colorado School of Mines under the well in the coming years,” said Liu. tutelage of Prof. Liu. “I did most of my It began in high school for Caleb graduate work on hybrid laser arc weld- Roepke when he became interested in ing. The interaction of a laser beam and physics and chemistry and started think- a welding arc is something we are just being about a career in engineering. But it ginning to understand,” said Roepke. wasn’t an interest in an engineering field “Hybrid laser arc is a welding process that that focused on just one discipline. He has moved out of the research lab and is wanted a multidiscipline field of engineer- starting to be considered for more indus- ing that could be applied to building large trial applications. It was fun to be part of

WELDING JOURNAL 33 that even in a small way,” he noted. By the Welding is proving to be filled with opments in processes that can provide im- time he had earned his PhD in metallur- challenges and opportunities, and he sees provements to safety, weld integrity, pro- gical and materials engineering in 2010, it as a profession full of possibilities. ductivity, and reducing costs.” he had invested nine years in studying “From welder to scientist, skilled individ- For those who may be contemplating welding, and it was time to put that knowl- uals in this field are in high demand. There entering the welding profession, he has edge to work. is room to advance your career within the some good advice. “Push yourself in both For the last year and a half, Roepke field as you develop your skills; there are directions of the welding career spectrum. has been employed by ExxonMobil De- always more responsibilities and chal- Put on a helmet and strike an arc, gain velopment Co., Houston, Tex., as a mate- lenges waiting to be taken on. The expe- some hands-on experience with welding rials specialist. It is a job that gives him rience gained in the welding field is also processes. Take a class and spend some the variety he enjoys. “I support new con- highly valuable outside of it in areas like time studying the science and metallurgy struction projects around the world,” he nondestructive testing, quality, materials of welding (the research supplement in said. “I get to help solve challenges re- manufacturing, project management, and the Welding Journal is a great place to lated not only to welding and metallurgy engineering design,” he said. start). A wide range of technical experi- but also materials selection, nondestruc- One of his driving ambitions now is to ences will help you learn quickly where tive testing, corrosion control, fracture become an expert in welding processes your interests lie, and the experiences mechanics, and even nonmetallics like and metallurgy as they relate to the oil and gained through the process will be invalu- coatings and insulation. I really enjoy the gas industry. “I am very interested in weld- able no matter where you decide to start variety of challenges that I get to take on.” ing processes. There is a lot of new devel- your career in the welding profession.”

Rick Noecker, PhD Lehigh University

Eleven years ago, Rick Noecker He chose to study at Lehigh again in thought the time had come to determine part because the college’s professors, in- his next career step. Although honored to cluding Dr. Arnold Marder, associate di- serve in the U.S. Air Force, he faced a dif- rector of the Energy Research Center ficult decision — should he remain in the (ERC), and DuPont, also associated with military or pursue his passion for science the ERC, made a positive impact on him. and engineering? He chose the latter, “Taking on a military veteran who had viewing graduate school as a once-in-a- not performed engineering or research lifetime opportunity to compete in the for five years was a big risk. When I en- “intellectual Olympics” required to earn tered graduate school, I didn’t know if I a doctoral degree. could make the transition to civilian life Originally from Reading, Pa., Noecker and academia. Professor DuPont was in- started his college education in the 1990s strumental in that transition and was a through the Air Force ROTC program at tremendous help to my family,” Noecker Lehigh University, Bethlehem, Pa. said. In 1996, he graduated from Lehigh cum Noecker earned a master of science Dr. Rick Noecker, pictured onboard an laude with a bachelor of science degree in degree in 2004. His thesis focused on un- offshore pipelay vessel, prepares to materials science and engineering, and derstanding the solidification cracking enter a confined space where he will that same year earned a commission in the tendency of steel-copper alloys. The end perform a visual inspection of the inter- Air Force. He served for five years, as an application, the tool and die industry, was nal bead for a double joint girth weld. aircraft maintenance and munitions offi- interested in tailoring the cooling capac- Last October, Noecker supported in- cer, and also received the Air Force Insti- ity of their dies by selectively depositing stallation of the Papua New Guinea tute of Technology’s full scholarship for a materials with higher thermal conductiv- Liquefied Natural Gas project’s off- master’s degree, which he declined. ity, such as copper, onto H-13 tool steel. shore pipeline. Noecker first became interested in Noecker’s effort toward a PhD, ac- welding while looking at graduate school complished in 2007, focused on problems programs in 2001. Dr. John DuPont, a the Navy Nuclear Propulsion Program professor of materials science and engi- (NNPP) experienced with a high- neering at Lehigh, presented a compelling chromium, nickel-based welding consum- case that welding involves many aspects able prone to ductility dip cracking. This of metallurgy and materials science. started as a consulting project Noecker Noecker wanted to learn more about the performed with DuPont as he finished his practical application of phase transforma- master’s, then grew into dissertation re- tions, material characterization, struc- search after receiving a NNPP graduate ture-property relationships, failure analy- fellowship in 2004. sis, fracture mechanics, and alloy DuPont selected his former student as development. a profile candidate for this article partly

34 MAY 2012 because of his outstanding work ethic. reviews to qualifying new technology for “Overview of Joining Challenges in the “Many times during his graduate stud- application on upstream projects. Oil and Gas Industry in Support of Large ies, I would propose new experiments to In addition, Noecker is a materials Capital Projects.” He received the prove our theories. Rick would never view project coordinator for two capital proj- William Sparagen Memorial Certificate these as ‘extra work,’ but would instead ects, and serves as the primary resource Award, also in 2010, for a paper published become excited about the potential for for materials and corrosion related issues. in the Welding Journal Research Supple- learning something new and validating “The one word to describe my role is ment, “Metallurgical Investigation into our proposed ideas,” DuPont said. adventure,” Noecker said, noting the Ductility Dip Cracking in Ni-Based Al- Noecker’s tough choice of deciding pace, business impact, and satisfaction. loys: Part I,” written with DuPont. what path to follow has paid off. Cur- “Welding and fabrication issues often- As for future positions, Noecker antic- rently, he is the lead engineer of the fab- times have a significant execution risk for ipates an assignment to a different Exxon- rication group within the materials and our projects. If we can’t quickly solve the Mobil company or an international as- corrosion group of the ExxonMobil De- problem, the company can stand to lose signment supporting a project team and velopment Co., Houston, Tex. millions of dollars and/or be delayed.” hopes to be a supervisor for the career de- “I am responsible for the daily and He is grateful for his colleagues; access velopment of assigned personnel and weekly work effort of the eight engineers to researchers at the Upstream Research meeting business objectives of their group. in my group...at any given time, there are Co. and Corporate Strategic Research DuPont believes Noecker’s excellent lead- more than 100 projects in the ExxonMo- Center in Clinton, N.J.; working world- ership qualities will propel him into a high- bil portfolio that we may provide welding wide; and his motivators, wife Heather level management position. and fabrication support,” Noecker said. and sons Erick, Joshua, and Thad. “The satisfaction of solving a problem, Services range from specifying com- His array of professional honors in- and working with others of like mind, but pany welding and fabrication require- cludes an invitation to present at the Ma- different ideas and perspectives, has kept ments to engineering contractors and terials Science and Technology Confer- me interested in the industry,” Noecker weld procedure qualification document ence in 2010 based on an article, added.

Jeremy Caron, PhD The Ohio State University

Jeremy Caron’s first introduction to duced Residual Stresses.” It was produced welding was in an undergraduate welding in collaboration with associates from the engineering class taught by Dr. Randy BAM Institute in Berlin, Germany, where Bowers at the University of Windsor in he spent time as a visiting researcher dur- Canada, where he received his bachelor’s ing the period he was working on his PhD. degree in mechanical engineering and his Caron’s dissertation project not only master’s in engineering materials. fit his welding metallurgy interests, but His interest in welding grew during his the knowledge he gained through that master’s research project, which involved project has proved useful for his work with testing of developmental resistance spot his current employer. A year and a half welding electrodes in an automotive as- ago, after graduating from OSU, Caron sembly plant. Because he was intrigued joined the Research and Technology by metallurgy and welding, he pursued an Group at Haynes International, Inc., opportunity to join the Welding and Join- Kokomo, Ind., as a staff engineer and ing Metallurgy Group at The Ohio State welding metallurgist. The company devel- Dr. Jeremy Caron is now involved with University. There, under the supervision ops and manufactures high-performance, the welding of corrosion-resistant and of Professors John Lippold and S. Suresh nickel- and cobalt-based alloys. high-temperature nickel- and cobalt- Babu, his dissertation research focused “While the main focus of my work (at based alloys as a staff engineer and on a weldability evaluation of a new high- Haynes) involves weldability testing and welding metallurgist for Haynes Inter- strength, blast-resistant steel for naval welding metallurgy studies, I am involved national. He was a co-recipient of the applications. in other research areas as well,” Caron ex- 2011 AWS Warren F. Savage Memorial Lippold recommended Caron be pro- plained. “I have enjoyed learning more Award. filed for this article because he was a co- about metal production and manufactur- recipient of the 2011 AWS Warren F. Sav- ing processes. It is satisfying to frequently age Memorial Award for the best welding apply engineering and metallurgical prin- metallurgy paper published that year in ciples learned in school to my daily work.” the Welding Journal, and because he has Among the discoveries he has made published a number of other papers in since leaving academia has been how to top-rated journals as well. Caron’s award- manage many different projects and al- winning paper is titled “Effect of Contin- loys simultaneously. In addition, “each uous Cooling Transformation Variations and every alloy has specific property dif- on Numerical Calculation of Welding-In- ferences and it can be challenging to un-

WELDING JOURNAL 35 derstand these sometimes subtle differ- goals of our research.” main actively involved in the metallurgi- ences,” he said. “It is also challenging to As far as his career aspirations, Caron cal and welding communities throughout develop new alloys that will have commer- sees himself at Haynes for the foreseeable my career.” cial significance, which is one of the main future and knows that he intends “to re-

Vahid Firouzdor, PhD University of Wisconsin, Madison

There are those who consider welding is of high demand for special applications and joining as mature technologies and and is indicated as a high priority in ma- so they may think there’s nothing new to terials joining technology these days. research. Dr. Vahid Firouzdor is not “I tried to weld Al to Mg and Al to Cu. among them. We ended up achieving strong dissimilar “Welding and joining technology is not welds that are as strong as similar welds an old research topic,” he said. “It’s ex- between two similar pieces of the weaker tremely important and there are a lot of material,” Firouzdor said. “We also engineering and scientific gaps that need showed that FSW cannot be considered to be filled. No engineered product can as a pure solid-state welding process and be developed without joining and by grow- liquation can happen in the case of dis- ing the industry and moving to more high- similar metal welding like Al to Mg welds, technology products, the joining technol- which causes a lot of problems like crack- ogy to make these products needs to be ing and severe intermetallic formation.” updated, too. Therefore, the science and For this work, Firouzdor received the technology of welding and joining can play 2010 AWS Charles H. Jennings Memorial Thus far in his research career, Dr. a very important role in the creation Award. In recommending Firouzdor for Vahid Firouzdor’s main interests have of the next generation of high-tech this article, Dr. Kou cited that paper and been joining of dissimilar metals with industries.” mentioned Firouzdor has published other the friction stir welding process and de- Firouzdor earned degrees in Materi- excellent papers on FSW of dissimilar velopment of diffusion barrier coatings. als Science and Engineering from Sharif metals. Thus far, Firouzdor has published University of Technology, Tehran, Iran. 14 journal papers and has five more under His concentration for his B.Sc. was mate- submission. He also won the AWS Inter- rials characterization and for his M.Sc., it national Student Scholarship Award in was welding engineering. To enter the 2009 and 2010, and received an AWS Dis- master’s program, he took the nationwide trict Scholarship Award in 2010. entrance exam and placed second among Following graduation, Firouzdor took 2300 materials science and engineering a position in the Department of Engi- graduates. neering Physics and Nuclear Engineering “I did my thesis with Prof. A. H. at the university. There he worked to de- Kokabi, the most famous welding profes- velop diffusion barrier coatings for miti- sor in Iran, and Prof. A. Simchi,” Firouz- gation of fuel-cladding chemical interac- dor recalled. “I worked on bi-metal com- tions using the electrophoretic deposition ponents, i.e., tool steel/stainless steel technique. “The most challenging part of joints by co-sintering of powder-injected this project again comes back to bonding molded components.” and joining, where we want to join the After graduating, he worked for a year nanoparticles together by proper sinter- as a welding engineer in Iran’s railroad ing and, more importantly, join the coat- industry, but he knew he wanted to con- ing material to the substrate by diffusion tinue his education and he had decided bonding.” he really enjoyed welding. So he applied Firouzdor recently accepted a position to the doctoral program at University of as a materials engineer in the etch depart- Wisconsin-Madison and was accepted by ment of Applied Materials, Inc., Santa Prof. Sindo Kou. Clara, Calif. There he is finding the proj- “I really wanted to do research in a ects being assigned to him are relating new, challenging topic in welding engi- back to his experiences in welding and neering and Prof. Kou suggested a PhD coating technology. “According to our thesis topic on joining of dissimilar mate- company’s goals, we are trying to turn ‘in- rials by the friction stir welding (FSW) novations into industry’ and my role is to process,” he recalled. “Joining of dissimi- participate in the materials science sec- lar materials is rather challenging due to tion of it, which is a very important and dissimilarities in materials’ properties. It challenging part.”

36 MAY 2012 Weijie Zhang Graduate Student, University of Kentucky

Yu Ming Zhang, a professor in the De- pare, he first read many publications dis- partment of Electrical and Computer En- cussing various methods of sensing the gineering at the University of Kentucky, weld pool. Only a few papers described a recommended that one of his students, method that actually measured the weld Weijie Zhang, pursue his doctoral thesis pool surface accurately, hindered because in the area of welding. Weijie graduated of the dynamic nature of the weld pool from Harbin Institute of Technology and the severe interference caused by the (China) with a master’s degree in electri- welding arc. Weijie’s system is further cal engineering. Zhang noted he was very complicated by the monitoring system motivated and demonstrated a desire to mounted in a helmet that will be in con- make a difference as a new PhD student. tinuous movement as the welder works. As a result, he chose Weijie to be the Currently, he has a general idea how to major researcher for a new welding resolve these problems, but he plans to research project funded by a grant from the solve them in the next several months. National Science Foundation. Next, he’ll be concerned with making Weijie admitted he knew nothing the system more accurate, cost-efficient, Doctoral student Weijie Zhang, who about welding prior to meeting Dr. and flexible. Fortunately, he has Dr. holds a research assistantship at the Zhang, but his enthusiasm for welding has Zhang’s expertise to lean on occasionally. University of Kentucky, is working on a grown because of his advisor’s influence. Weijie said that something good happens project to build a machine-human co- He noted that Zhang acts as though doing every time they disuss his work. In addi- operative control system to assist his job (research) is fun for him every day, tion, Weijie’s colleagues in the lab help lesser-skilled manual welders to per- and his confidence and passion have af- each other a lot. The students have dif- form like higher-skilled welders. fected Weijie and his other students. ferent areas of expertise so they often can Weijie’s project is to build a machine- offer enlightening insights on problems human cooperative control system to as- to cause each other to think more sist lesser-skilled manual welders to per- creatively. form like higher-skilled welders. The mo- Now that he has some experience in tivation for this project is based on the welding research, Weijie is looking for- fact there are too few skilled welders avail- ward to what the future holds. He does- able in the workplace. n’t consider himself a “social” guy. He Skilled welders adjust their welding re- prefers his life’s work interface more with sponses based on observations of the weld machines than people. So, he has set his pool. This project will use both a control ultimate goal to do college research. But, system to monitor the welding process first, he wants to work in industry for a combined with a method to “predict” the while after obtaining his doctorate. He welder’s reaction to the weld pool changes wants to get to know first-hand the needs then make any necessary adjustments. in industry that might be benefited by Determining this relationship between welding research. Then, after two or three the weld pool appearance and a skilled years, he will seek a position in a college welder’s response is another major task. to start his research work in welding. When the welder does not react to the Weijie understands that welding re- weld pool changes correctly, i.e., moves search has been going on for a long time, too slow, misjudges the arc length, etc., and it is difficult to develop a brand-new the machine must correct for the errors process or a sensing/control technology as a skilled welder would. that no one has yet devised. So, he thinks Weijie is designing a flexible monitor- it would be much wiser to find a challenge ing system that will measure the weld pool in the welding industry that has not been surface in real time. Dr. Zhang and Wei- completely investigated. Also, it would be jie have devised a detector based on a reg- more meaningful and fun to tackle a prac- ular helmet fitted with a camera, imaging tical problem than develop something plane, etc. While the welder wears the hel- that has little application in industry. met, the system will continuously moni- Weijie’s advice for an aspiring post- tor the weld pool surface. graduate student is to maintain a passion Weijie considers the design of the hel- about your chosen field, have fun with it, met the most interesting part for him, and be audacious and aggressively creative, how to make it work as planned will be and since welding research demands a lot the most difficult. of experiments, don’t be afraid of getting He said accurately measuring the weld your hands dirty.◆ pool was his next big challenge. To pre-

WELDING JOURNAL 37 BY JOHN LEISNER What Do You Need AND JOE GITTER JOHN LEISNER and JOE GITTER are in an Engine-Driven product managers, Miller Electric Mfg. Co., Appleton, Wis., Welding Machine? www.millerwelds.com.

Apex welder Barry Neal welds a column of ¾-in. A36 structural steel at Seattle University. The company selects 5 300-A engine-driven welding machines to run the ⁄64-in. wire it needs to get to the production speeds it needs.

eld together by thousands of variables to take into consideration when structural welding are shielded metal arc pounds of weld metal, today’s selecting an engine-driven welding (SMA) and flux cored arc (FCA) weld- Hstructural steel buildings are machine/generator for structural appli- ing. Both are self shielded and offer less built under the guidelines of AWS Codes cations. chance of contamination compared to a D1.1–D1.9. These codes dictate specific solid wire with a shielding gas (wind welding processes and techniques for Process Versatility Is Key blows away the shielding gas in outdoor everything from moment frames to floor applications). Shielded metal arc weld- decks and handrails, but there are The two most common processes in ing has the simplest equipment, the low-

38 MAY 2012 Here are some of the things you need to consider before purchasing an engine-driven welding machine/generator for structural steel applications

est cost, and is relatively easy to use. Flux “We need a 300-A machine to run the generators can easily be turned into a 5 cored arc welding is advantageous in ⁄64-in. wire that gets us to production multioperator system by running another high-volume applications as it is more ef- speeds and allows us to be competitive,” welding machine off of the machine’s ficient and has higher deposition rates, said Kevin Callahan, project manager, generator power. although it requires a wire feeder — Fig. Apex Steel, Redmond, Wash. (see lead 1. The wire feeder requires a constant photo). “A 200-A machine isn’t going to Power Generation/Air current (CC) or constant voltage (CV) do it.” welding machine. A CV welding machine Another option for structural steel Capabilities is required with wires designed to meet erectors is multioperator systems. The specific codes/requirements, such as benefit of a multioperator system exists Engine drives offer power generation AWS D1.8. Such wires are not designed in its ability to provide two high-quality capabilities ranging from 5000 to 27,000 to run with a CC machine. welding arcs from one engine-driven W. Choosing the right one depends on Most structural steel contractors unit. This allows you to get the work of the tools you run and if you need to si- choose a machine that performs SMAW, two machines done with one (two oper- multaneously weld and run other tools. FCAW, gas metal arc welding (GMAW), ators use one machine). In addition to Knowing the wattage needed to run tools gas tungsten arc welding (GTAW), and the equipment cost savings of one ma- such as grinders (1800 W), cut-off saws carbon arc gouging, and is even compat- chine compared to two, multioperator (up to 2400 W), air compressors (8200 ible with spool guns for GMAW of alu- systems can use more than 50% less fuel starting W), and plasma arc cutting ma- minum (for use on handrails and other than two single-operator units with com- chines (10,000 to 12,000 W) will help you internal/finishing components) — Fig. 2. parable engine power. It’s also easier to pick the right unit — Fig. 3. Machines ranging from 250 to 300 A pro- transport, and produces less noise and “When you only have to move a sin- vide more than enough power to meet fewer emissions compared to two sepa- gle unit from job to job, you have obvi- the demands of most structural electrode rate machines. It’s important to note that ous cost savings in labor and fuel,” said diameters and codes. many standard engine-driven welding Steve Price, president, Coastal Steel,

Fig. 1 — Coastal Steel Field Superintendent Chad Hummel welds a diagonal moment brace using the FCAW process. Flux cored arc is pre- ferred for wire welding in the field for its high deposition rates and self shielding.

WELDING JOURNAL 39 Fig. 2 — While many of the construction welding applications today rely on the shielded metal arc welding (SMAW) process, most structural steel contractors select multiprocess machines that can handle nearly every need, such as the FCAW process shown here.

Tacoma, Wash. “The less you have on duced penetration, an unacceptable com- “We’ll pull a 12/3 power cord off its site, the less cluttered things are, and the promise in structural steel welding. generator to run the shear wrench,” ex- less equipment you have to secure at “If you’ve got a guy welding, and an- plained Chad Hummel, field superin- night to prevent theft. Having this one other crafter comes along and plugs in a tendent, Coastal Steel. “And while one unit makes obsolete the other individual vacuum, it will mess with his arc,” Cala- guy is doing that, you can run a pneu- pieces of equipment. And it doesn’t take han said. “It’s an advantage not having matic button punch and weld at the same any more fuel to run than just a stand- to worry about that.” time. All of that can go on if you have a alone welding machine.” unit centrally located and enough air Another factor to consider when Air Capabilities hose and welding lead to reach.” choosing a welding generator is whether “There’s no longer a need for a com- it has enough generator power to sustain Manufacturers now build air compressor and a welding machine,” said both a welding arc and power tools. Some pressors into welding generators to cre- Price, “thereby saving the cost of trans- models currently feature independent ate a powerful three-in-one tool espe- porting two machines and the fuel to run welding and generator power, while oth- cially useful to structural steel welders. those two machines. It uses virtually the ers offer enough generator power so that Contractors can now weld, and run power same fuel while both operations (com- interference is not a concern. Interfer- and air tools simultaneously off one cen- pressor and welding machine) are ence with the welding arc leads to re- tral unit. working.”

40 MAY 2012 EPA Tier 4 Final Changes for Diesel Engine-Driven Welding Machines/Generators

Tier 4 Final (T4F) emissions regulations go into (more than 25 hp) was only $2000–$3000, many con- effect Jan. 1, 2013, for machines used in the United tractors would pay that premium just to have that extra States and Canada with engines in the 25- to 75-hp power when needed. In examining structural steel range, including engine-driven welding machines/gen- welding applications, most welding machines rarely erators. The U.S. Environmental Protection Agency’s exceed 350 A, and the majority of welding applica- (EPA) T4F regulations significantly reduce the par- tions are performed at 250 A or less. If you occasion- ticulate emissions of diesel engines. This typically really have the need to run high amperages, whether to quires major engine changes and exhaust aftertreat- run much larger electrodes or to perform carbon arc ment devices, dramatically increasing costs. All en- gouging, you may be able to buy one or two 500-A ma- gine manufacturers must supply T4F-compliant en- chines for those less-common applications while buy- gines as of Jan. 1, 2013. There will be some carryover ing 350-A machines for the rest of your fleet. This associated with the normal delivery lead time that will strategy could potentially save you thousands of dol- stretch into early 2013, which means that some Tier 4 lars in equipment purchase costs, while also adding Interim (T4i) engines exceeding 25 hp will still be machines that are smaller, more fuel-efficient, and available for sale after the deadline. T4F regulations offer a lower total cost of ownership. do not apply to previously purchased equipment, and Another way to get more out of a smaller machine these regulations only apply to the United States and is to change processes. The majority of construction Canada. welding applications today rely on the shielded metal How will diesel engine-driven welding arc welding (SMAW) process. Contractors buy 400- machine/generators with more than 25 hp to 500-A machines to handle large-diameter SMAW change? The greatest change will come in terms of electrodes, but they might be able to achieve the same price. T4F diesel engine-driven welding results by switching to the flux cored arc welding machines/generators greater than 25 hp could in- (FCAW) process while transitioning to a machine with crease in price by as much as 50% due to engine and less than 25 hp at 350 A. This requires the added cost installation cost increases. Machines may also get of a wire feeder, but that cost is more than accounted physically larger due to exhaust aftertreatment de- for in the lower price of the engine-drive compared vices added to the engine. These devices get larger as to a T4F machine. The FCAW process provides higher horsepower increases. The new aftertreatment de- deposition rates at an amperage that is easily attained vices also give off additional heat, which requires with machines less than 25 hp. It also produces less proper machine design to manage airflow while still waste as you use all of the wire, compared to SMAW being optimized for installation on trucks. where you regularly discard stubs and spend time What are manufacturers doing to address switching electrodes in and out. T4F? While the regulations affect engines with 25 to Dual-operator systems are also an effective option 75 hp, some manufacturers have gone to great lengths to help lower costs. While some machines fall under to improve machines with engines under 25 hp, pro- the T4F restrictions, they allow two operators to work viding the performance and output many contractors off of one system (and in some cases, up to six welders need at a much lower price point than the new T4F with the addition of inverters running off the ma- designs will allow. These improvements include max- chine’s generator power). This can reduce fuel use by imizing power output and improving fuel efficiency. more than 50% compared to two single-operator units Similar changes are being implemented on machines with comparable engine power, and lower total cost greater than 25 hp to help offset the impact of in- of ownership to counteract the price increases caused creased prices when they hit the market, but it begs by T4F. the question: Do you NEED to buy a fleet of 500-A T4F: An opportunity to assess your equip- machines (greater than 25 hp) when a fleet of 300–400 ment choices. While some will be discouraged by A machines (less than 25 hp) may handle a great ma- the inevitable price increases that come along with jority of your applications? T4F over 25 hp, this is a great opportunity to exam- Can I use a machine with lower horse- ine your welding processes and determine if you may power? When you examine most construction weld- be able to get by with equipment that falls below 25 ing applications, you will find that contractors have hp and is not affected by EPA T4F regulations. Man- been buying machines with more horsepower and am- ufacturers will also be working hard to improve effi- perage than they need because greater output was ciencies (fuel efficiency, reduced maintenance, added available at a reasonable price. If the difference in a performance, and productivity) to offset the cost in- 350-A machine (less than 25 hp) and a 500-A machine creases.

WELDING JOURNAL 41 Fig. 3 — Three-in-one machines (welding machine/generator/air compressor) provide greater versatility by allowing contractors to run pneumatic tools as well as the standard welding and generator functionality.

Fuel Considerations

What type of fuel do you need? The most popular engine drives are available in gasoline, diesel, and even LP models. Gas engines offer a lower product cost, reduced weight, and a smaller size while diesel engines use 20 to 35% less fuel, have longer engine lives, and are required on some sites (see the sidebar on how Tier 4 Final (T4F) regulations will affect diesel engine drives). New electronic fuel- injected (EFI) gas welding generators further reduce fuel use by as much as 27% — a major benefit as many contractors are prohibited from storing fuel on site. Extended runtimes allow for these contractors to spend less time worrying about fueling up machines, and the ability to use less fuel helps drive down costs. “It’s not just the price of the fuel,” explained Callahan. “It’s the time it takes to get it. It’s a killer. It could easily be an hour for my superintendent to take the cans and go to the gas station and fill them up. If we can improve the fuel economy of our machines, the less time we’ll spend filling them up. It’s a huge time savings.” a single-story building or a ten-story high work trucks. rise? Will a machine on a trailer or run- Noise may also be a concern depend- Additional Factors: Size ning gear suffice, or do you need to add ing on where you work. New machines and Sound lifting points for a crane/hoist? Machines are being introduced that run up to 70% being introduced now are noticeably quieter than older machines, which can Consider portability before you lighter, and often provide a smaller foot- help when working in urban areas and choose a machine — are you working on print to take up less space on site and on near schools and hospitals.◆

42 MAY 2012 For Info go to www.aws.org/ad-index Is Small Town America the New Face in Welding?

Several high school students from rural BY BILL WEHRMAN areas enrolled in welding and agricultural BILL WEHRMAN is the marketing communications manager for Thermadyne mechanics programs are looking forward Industries (www.thermadyne.com), St. to their bright futures Louis, Mo.

f the Built with Class student contest Later this spring, the company will an- exposed to welding at a much earlier age results are any indication, many of nounce details for its 2012 Built with Class than their urban counterparts. Ithe new faces in welding are coming contest. from America’s smaller and rural Donating to the Local Fire Dept. communities. Growing up around Of the eight winning schools selected, Welding “When I was about 10 years old, I only two were located in towns with a walked into my dad’s shop at home, population of more than 16,000, and The National FFA Organization’s grabbed a piece of metal out of the scrap none larger than 93,000. “Agricultural Mechanics” career devel- bin, threw a hood over my head, and Sponsored by Thermadyne, St. Louis, opment program emphasizes welding, started running some beads,” said Colby Mo., the contest was launched last year and many of the Built with Class winners Siptak, a senior at Bellville High School, to encourage and support students en- participate in this program. Bellville, Tex. tering the welding industry. Beginning Overall, the necessity of welding on a While practicing various skills, Siptak students were asked to write an essay on farm or ranch means rural students are discovered he could build items to do- why they were interested in learning about welding. Intermediate to advanced students, working in groups of two to five, could submit a team welding project plan. While the contest required the plan only, all team winners completed their projects (visit www.thermadyne.com/builtwith- class/gallery.html). Winners in the beginning category received $250, while team winners received $500 each. In addition, their high schools received a Thermal® Arc Fabricator® 181i multiprocess welding system. This machine is one of the company’s “3-in- 1” welding machines, which can be used for shielded metal arc, gas metal arc, and gas tungsten arc welding. These inverter- based, integrated systems feature a DC, constant current-constant voltage welding output and were developed with technical and training institutions in mind.

Fig. 1 — Kyle Supak is shown with the log splitter that won a team award for Bellville High School.

44 MAY 2012 Fig. 2 — Ashlin Rosamond of Sulphur Springs High School took a welding class to help express her artistic ability. This Praying Cowboy coffee table com- bines welding, plasma cutting, and woodworking.

He welded odds and ends for people. I got into welding my freshman year, fell in love with it, and didn’t want to get out,” Supak explained. Mounts, who already works for a heavy-equipment repair company, said, “On the ranch we live on, I’ve always worked around farm equipment. I’m always doing a lot of repair or construction nate to the fire department for their auc- Kyle Supak and Blake Mounts plus in- on pens or hog traps.” tions, then they could use the money structor Jacob Diezi IV, won a team cat- raised to buy necessary materials. egory award — Fig. 1. They built a log Making a Unique Coffee Table splitter with a 20-ton hydraulic press that Building a Log Splitter they lend to the community. While Ashlin Rosamond, a junior at “I grew up around welding. My uncle Sulphur Springs High School, Sulphur Colby Siptak, along with classmates owned a welding shop here in Bellville. Springs, Tex., also participates in an agricultural mechanics program, she had never been around welding until she took a class. She joined because, “I like to express my artistic ability, and I thought it would be neat to express that in a mechanical way.” Rosamond, along with partner Jesse Brown and instructor Dan Froneberger, created a metal and wood coffee table featuring a praying cowboy design that she considers her brand — Fig. 2. Rosa- mond’s next project maintains that West- ern theme; she is currently fabricating a BBQ smoker shaped like a Colt .45 revolver.

Benefits of a Rural Upbringing

Growing up in a rural area — “a place as boonie as you can imagine,” according to one winner — has its advantages. “There’s no other welding type of shop, so anybody who needs anything fixed, they bring it to the school,” said Joel Keevert, a senior at Swiss Hills Ca- reer Center, Woodfield, Ohio — Fig. 3. His instructor Tom Rouse added, “It varies from farmers bringing in trailers and plows to a 13-ton skimmer pump for a government forestry project.”

Fig. 3 — Joel Keevert of Swiss Hills Ca- reer Center, shown along with instructor Tom Rouse, plans to find an apprenticeship with one of the skilled trade unions after graduation.

WELDING JOURNAL 45 An Early Introduction to them for time. We have to get students Preparing for Welding Welding interested in welding, and a catalog isn’t and Real-World Challenges going to do it” — Fig. 4. For students not exposed to welding on the farm or through family members, Welding Class = Working In addition to reading, math, blue- creating the next generation of welders Creatively with Your Hands print reading, operating mills, lathes, requires reaching out to them as early as forklift trucks, and other equipment re- Joel Keevert, mentioned earlier in the eighth grade. lated to metal fabricating, welding in- article, confirms the sentiment about par- structors seem especially committed to Emphasize Exciting Career ents who do not know that much about preparing students for the real world. Paths welding. Only when he brought items “I like to think that they learn a little home did they start to grasp the basic bit about respecting each other and team- “We need to send our students the idea. “After I told them a little bit about work,” said Coy Hall, an instructor at message that welding offers many differ- it, they really got into it,” he said. Clark County Area Technical College, ent career paths,” said Nicki Howard, di- Keevert wrote that he first explored Winchester, Ky. “A lot of times, it’s not rector of secondary education at Canton welding during his sophomore year. “I how good of a welder you are, but the South High School, Canton, Ohio. went on a tour of the lab and got to try employability skills that you bring to an She added that the typical pattern in my hand at welding steel. Although my interview, such as punctuality and pre- secondary education has been to wait first bead didn’t look that good, I knew paredness. Honesty and trustworthiness until students are juniors or seniors and this was what I wanted to do. I like to do are important, too. I tell my students that say, “Okay, now pick a job. That’s too things with my hands, and I like to be able if something breaks, there’s no sense in late. Students need to think about that to step back and show people what I have trying to hide it. Come to me, and we can in advance. If they choose a technical ed- done. Not everyone can sit in a class all probably fix it.” ucation path, they need the opportunity day. I am a person who has to be doing It is important students work toward to apply what they learn (while still in something creative. For me, I could their daily goals. “But if you’re not work- school).” spend all day in my booth welding on the ing,” said Hall, “I’m right on your hip. same plate over and over again.” I’m going to treat you like a boss will treat Invest Time in Guiding Students Many students admit they find class- you. I expect work to get done on time.” rooms dry and boring, and their grades Also, new faces in welding need to Canton South High School winner tend to decline as a result. Put them in a think beyond themselves and recognize Dentale White wrote in her essay that welding class, however, and their focus every individual has the opportunity to during a freshman year tour of the sharpens exponentially. Instead of fidg- contribute to — or detract from — the school’s technical annex, “I first remem- eting, they have the discipline to spend reputation of their school’s welding or ber going into the wood-shop room hours under the hood trying to make the agricultural mechanics program. Postsec- thinking it was the coolest room ever.” next bead better than the last. Using ondary institutions and local employers Then she entered the welding lab. welding as an anchor point, instructors know which schools consistently produce “There were flames flying everywhere! It can then pull through the other academic the most desirable prospects and which looked like fireworks! It was like noth- disciplines. do not. ing I had ever seen before…at that point, the wood-shop room was no longer the coolest room ever.” In addition, instructor Art Baughman believes: “Kids often want to do what their parents did, and a lot of them are not aware of welding. That’s where Den- tale has been a real ambassador because she’s talking-up welding when we promote the program. Kids are going to listen to her more than me. We also need more industry people willing to let kids job shadow, coordinate plant field trips, or come in and talk to students. We’re not asking them for money, we’re asking

Fig. 4 — Instructor Art Baughman of Canton South High School said student Dentale White makes a great ambassador by helping the school promote the benefits of its welding program. “Kids are going to listen to her more than me,” he said.

46 MAY 2012 Fig. 5 — Aimee Bowman signed up for instructor Coy Hall’s welding class at Clark County Area Technical College specifically to set an example for other young women. “Doing something that is male dominated is perfectly okay,” she said.

Young Women Among the New Faces in Welding

Of the 13 winning entrants in the Built with Class contest, five were determined young women. Coy Hall’s student, 15- year-old Aimee Bowman, pulled no punches in her essay — Fig. 5. “I could sit here and think of a million reasons why I chose to take a welding class. I’m sure most of those reasons would sound better than the real reason. I am currently taking welding classes to show girls who are younger than I am that ally cool projects and do them well. My White said. “My mother always told me doing something that is male dominated mom was really happy. She’s into agri- to do what I wanted and don’t let anyone is perfectly okay.” culture, so she’s got me teaching her how stop me. I didn’t come down to the weld- Bowman feels that welding gives her to weld.” ing lab to be noticed or stand out. I came a sense of power and confidence. “Yes, Dentale White also received encour- to work. People may think because I’m a I’m a girl, but I can do the same things agement from her mother. girl I get a lot handed to me…but I don’t. as guys can do. Some women may be “A lot of people were surprised to see I work just as hard if not harder than most scared that they will be ridiculed…I want that this is what I wanted to go into,” boys. Me being the only girl in my class to try and make welding a more gender- friendly occupation.”

Making Parents Appreciate and Understand the Trade

Becoming a top-notch welder is hard enough for anyone, but young women also have to deal with classmates who sometimes act like little boys instead of young men. “The boys give you a hard time every now and then, maybe saying, ‘Oh, that’s not going to be good.’ But you show them wrong by turning out something really great,” said Ashlin Rosamond. At first, Rosamond’s father did not understand why she took welding classes, “But now that he sees what I’ve made, he’s happy. He sees that I can make re-

Fig. 6 — “I would much rather say I built or repaired a piece of equipment on my own vs. saying that someone else did the job for me,” said Kristi Hallmark, shown here with instructor John Griffith of Alto High School.

WELDING JOURNAL 47 made me a lot stronger mentally and Ashlin Rosamond also wants to be- Kyle Supak plans to trade in his gas physically. I had to earn respect in this come a teacher, in this case an agricul- metal arc welding gun for a brazing and class just like anyone else.” tural instructor, after attending Angela soldering kit. “I actually have a full ride Sixteen-year-old Kristi Hallmark of State University. to go to an air-conditioning and heating Alto High School, Alto, Tex., believes that Instructor Tom Rouse, a former iron- class and electrical class,” he said. The welding can give anyone the personal sat- worker, recently brought in a union rep- program he is referring to is at Blinn Col- isfaction of being independent — Fig. 6. resentative to speak to the class. Joel lege, Brenham, Tex. After he completes “So many people in today’s time have Keevert was impressed and feels fairly that, he is thinking about attending TSTC forgotten how to perform tasks on their sure that becoming an apprentice with a to earn welding certifications, and if he own, and they have become overly de- skilled trade union is in his future. Be- achieves a few, “I always have something pendent on others to repair and build cause his high school is located in the else to fall back on.” things. It may be my pride that’s getting Marcellus Shale Formation and the as- Instructor Coy Hall said Aimee Bow- to me, but I would much rather say I built sociated natural gas “fracking” boom, the man has multiple options as well. While or repaired a piece of equipment on my need for pipe welders should be boom- she plans to continue his welding class, own vs. saying that someone else did the ing when he graduates. That apprentice- he feels that her health sciences classes job for me,” Hallmark said. ship just might be with the United hold a greater attraction, which he has Association. no problem with her pursuing. Next Steps Ahead Two of the students from Bellville also In the rural area where Bowman lives, see hydrocarbons in their future. Colby there are only a few large employers. Built with Class winners such as Den- Siptak plans to attend Texas State Tech- Whatever their chosen career path, Hall tale White “make their own edge. They nical College (TSTC) in Waco to obtain advises these new faces in welding to be go above and beyond,” according to in- his degree and become a pipeline welder. willing to “travel wherever the work is. structor Art Baughman. White intends Blake Mounts wants to attend a four-year If you’re going to spend all this time on to pursue a mechanical engineering de- college and become a petrochemical in- technical education, you have to get out gree at the University of Akron. Baugh- spector. “That involves welding 24/7 be- there and use it. If you can, get out of man hopes that she eventually comes cause you have to be able to find what’s your comfort zone and experience the back to Canton South as a teacher be- wrong with tanks and vessels, and then world.”◆ cause of her patience when working with you have to be able to tell the welders other students. how to fix it.”

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48 MAY 2012 For Info go to www.aws.org/ad-index Moving Laser Research from the Lab to Industry

A small research group has made an impact on BY FEDERICO SCIAMMARELLA FEDERICO SCIAMMARELLA the South African economy by transferring ([email protected]) is compe- laser-based technology to companies tency area manager, Laser Materials Processing, Council for Sci- throughout industry entific & Industrial Research (CSIR), National Laser Centre, Pretoria, South Africa.

small group in South Africa has, despite obstacles, done a tremen- Adous amount of quality research and has had a great impact on the nation’s manufacturing industry. This article highlights some of the work done and shows some examples of how the South African manufacturing industry has benefited from their support. The next time you are looking for an experienced partner in laser materials processing or want to get experience in laser materials processing, think South Africa and the Na- tional Laser Centre (NLC). The National Laser Centre became part of the Council for Scientific & Industrial Research (CSIR) in 2003. The NLC serves a dual purpose. First, it acts as a national asset by doing the following: • Playing an enabling role in the academic environment • Providing state-of-the-art R&D photonic facilities • Promoting the use of lasers in industry.

Lead photo — Laser metal deposition of continuous caster roll.

50 MAY 2012 Fig. 1 — Transverse section of a TiAl weld.

Secondly, it also offers contract R&D, particular alloys made it almost impossi- has found its way into as a result of good in which it does development of laser- ble to produce crack-free welds. The TiAl weldability and good mechanical prop- based processes and provides systems alloys are of interest because of their high erties such as high strength and tough- and services for industry. The NLC has ratio of modulus and strength to density ness. This process has already produced three main branches: Laser Physics and at elevated temperatures (a key compo- a large number of components (i.e., fuel Technology (LPT), Higher Education In- nent for the aerospace and automotive rails, engine mounts, engine brackets, stitutions (HEI), and Laser Materials industries). As detailed in the work, V- and suspension parts) for the industries Processing (LMP). This article concen- groove weld plates were preheated with mentioned. trates on the LMP group. For more in- an ohmic resistance heating device up to A comprehensive welding analysis formation about it and the other groups, 900°C; the system developed at LMP also (Ref. 2) was done on F357, a hypo-eutec- visit www.csir.co.za/laser. enabled controlled cooling. This ap- tic Al-7%Si-0.6%Mg alloy, without beryl- The key objective for LMP is to opti- proach enabled production of a crack- lium. It is well known that welding Al al- mize the competitiveness of the South free weld. Figure 1 shows a cross section loys, particularly those that are cast, African manufacturing industry through taken from one of the welds. While the poses significant challenges. The goal targeted research aimed at figure does not show the complete-joint- was to establish a baseline of operating • Development penetration welds that were achieved in parameters in which an Nd:YAG laser • Dissemination the research — important because fa- could be used to successfully perform au- • Implementation tigue is an issue in aerospace — it does togenous welds in butt joints on the of appropriate laser-enabled manufac- show the good metallurgical structure CSIR’s rheo-cast semi-solid metal plates, turing processes to meet the current and that was also achieved. which were either left as-cast or in a T4 future needs of the South African man- While this work yielded good initial or T6 condition. Some of the main con- ufacturing industry. Therefore, most of results, future research will be conducted cerns were porosity and the variation of the research conducted is tied to indus- to establish an optimized process and/or mechanical properties due to precipitate try. Following are some examples of the postweld heat treatment that homoge- dissolution in the weld and overaging in group’s work. The first few deal with the nizes the microstructure in the weld and the heat-affected zone (HAZ). Figure 2 aerospace industry, an area that has base material in an attempt to eliminate shows a cross section of one of the welds α tremendous potential for growing the the 2 saturated region at the weld inter- obtained. South African economy. Other examples face that causes higher hardness values. Autogenous deep penetration include solutions for the steel-making in- It is important to maintain a consistent Nd:YAG laser welding of SSM rheo-cast dustry and ongoing work in the area of microstructure in the welded conditions F357 aluminium was investigated with a additive manufacturing of titanium aero- to avoid any fatigue issue. range of parameters in order to create space components. All this work has been defect-free welds. These parameters in- published and references are provided cluded laser beam spot configuration, for further information. Deep-Penetration Nd:YAG laser beam spot intensity distributions, Laser Welding of Rheo-Cast center-to-center spot separation dis- Laser Powder Welding of TiAl F357 Al Alloys tances, and shielding gas combinations Alloys and flow rates, along with various purg- This work was done in conjunction ing gases. Because laser welding facili- One project dealt with laser powder with Material Science & Manufacturing, tates high cooling rates, it is possible welding of titanium aluminide alloys another unit within the CSIR. That group to produce weld joints through deep- (TiAl). The work itself (Ref. 1) led to a possesses the capability for rheo-casting penetration laser welding of age-hard- successful process development in which of Al alloys. The interest in aluminum enable Al-Si-Mg alloys, with mechanical crack-free welds were produced. This Alloy F357 is due to the fact that it has properties matching those of the T6 tem- work had been extensively researched in been used for semi-solid processing for per condition. The key advantage is that the past, and traditional methods com- more than 30 years and has various mar- it is possible to do this without a post- bined with the sensitive nature of these kets (i.e., automotive and aerospace) it weld solid-solution heat treatment. The

WELDING JOURNAL 51 Fig. 2 — Stereo microstructure of the bead geometry of an F357 laser butt-joint weld.

Weld interface

resulting mechanical properties of SSM lized because it had the capability to con- tion properties. The addition of various rheo-cast F357 aluminium welded in the trol the heat input and solidification elements will be investigated such as the T4 condition and only artificially aged process. Although martensitic stainless addition of N and Ti. Optimization of after welding (T4+ condition) compares steels currently provide one of the most postweld heat treatment parameters will very well with the T6 base material cost-effective routes for these applica- also be investigated so that the required properties. tions, the laser based process has another mechanical properties are maintained, Transmission electron microscopy advantage over traditional methods be- as this plays a key role particularly in the (TEM) was utilized to analyze the cause it offers access to a wider variety steel-making industry. Currently, there strengthening mechanisms obtained dur- of advanced and improved alloys. This is are rollers that have undergone this laser ing laser welding as well as the different due to the fact that it is not limited to the metal deposition process that are in use heat treatments. The TEM analysis was range of commercially available welding in a plant here in South Africa. The cur- consistent with the expected precipita- consumables, but can also utilize alloy rent lifetime for rollers that are repaired tion-hardening processes in Al-Si-Mg al- powders and mixtures of these powders. conventionally is around 150,000 tons. loys. The quench sensitivity of SSM rheo- This was the focus of the research and is The ones that underwent the laser metal cast F357 aluminium alloy is low enough detailed quite well in Ref. 3. The goal was deposition process developed at the Na- to obtain an increase in strength values to develop new alloy combinations capa- tional Laser Centre will, at a minimum, during laser welding, and no postweld ble of producing clad layers with supe- double that lifetime. This is based on pe- heat treatment is necessary to obtain T6 rior properties to that of the traditional riodic checks of these rollers, which cur- mechanical properties according to per- martensitic stainless steels. rently have not shown any signs of wear. formance specifications. This research was innovative because it combined the nonequilibrium microstructures that can result from rapid Additive Manufacturing of Ti Laser Metal Deposition of solidification via laser processing and Aerospace Components Low-Carbon Martensitic new alloy compositions developed by the Stainless Steel LMP group. An example is the develop- The race has been on for some time ment of modified low-C martensitic in the area of additive manufacturing. This project has been in progress for stainless steels with molybdenum. Laser This is particularly true in the aerospace a number of years and is still ongoing. It cladding of these alloys resulted in fully field. Despite having to be very conser- is related to the refurbishment of contin- martensitic microstructures with no delta vative on what it can put on aircraft, the uous casting rolls that are used in the ferrite. The presence of delta ferrite re- industry is always an early adapter of steelmaking industry (see lead photo). sults in sensitization at the ferrite grain technology. The NLC has been working One of the most cost-effective refurbish- boundaries that decreases corrosion and with Aerosud, a South African aerospace ment processes for continuous casting oxidation resistance. In this instance, the company, on the development of an ad- rolls involves cladding with martensitic novelty lies in the combination of rapid ditive manufacturing system to produce stainless steels. When cladding via con- solidification with a desirable phase com- large aerospace components (~ 6.5 × 2 ventional methods, there are a number position that results in improved corro- × 2 ft) specifically from Ti alloys. With of issues that can arise, such as large vari- sion and oxidation resistance. the second-largest reserve of titanium ations in chemical composition and met- The future scope of research will con- ore in the world, South Africa exports a allurgical structures, which results in pre- tinue with additional alloy modification lot of raw material. However, it then must mature and unpredictable failure of the required to further improve corrosion purchase a finished product (i.e., billet, cladding. A laser-based approach was uti- properties, wear resistance, and oxida- sheet). This obviously makes the supply

52 MAY 2012 chain very long and costly, and increases the industry’s buy-to-fly ratio. In conjunction with the Material Science & Manufacturing group, which is producing Ti powder through a novel and inex- pensive process, the NLC will design a system that will enable Aerosud to make these components, which will be used by the Boeings and Airbuses of the world. There are many challenges to face for this system to come on-line, but by some- time next year, an operational model will be available and presented to South Africa and the world as a one of a kind. There have been many projects ongoing at LMP: from laser welding of marag- ing steel rocket motor casings to in-situ welding/repairing of stainless steel water tanks that were leaking. Despite being a small group, the Laser Materials Pro- cessing group has made an impact on the South African economy. In fact, the LMP group has, on average, over the past three years supported 20 short technology feasibility studies per year for a variety of companies. At present, it is estimated that more than 60% of these studies have resulted in the adoption of a laser-based technology solution by the company involved. The group hopes to continue growing and making a difference by creating valuable jobs as well as wealth.◆ For info go to www.aws.org/ad-index

References

1. Smal, C., Meacock, C., and Rossouw, H. 2010. Laser powder welding of Ti52Al46.8Cr1SiO2 titanium aluminide alloy at elevated temperature. High Temperature Materials Processing Vol. 1-2, pp.157–160. 2. Theron, M. 2010. Quench- ing and tempering effects on rheo- cast F357 aluminium alloy during Nd:YAG laser welding. MsC thesis. University of Cape Town, South Africa. 3. Van Rooyen, C. 2008. Mi- crostructural development during laser cladding of low-CC martensitic stainless steel. Welding in the World, Vol. 52, No. 3/4, pp. 22–29.

For info go to www.aws.org/ad-index WELDING JOURNAL 53 CONFERENCES

The Energy Boom: The 15th Aluminum Welding Conference will also provide several opportunities to network informally with speakers and Get on the Bandwagon other participants, as well as an exhibition showcasing products June 12, 13 and services of interest to the aluminum welding industry. San Diego, Calif. Aluminum lends itself to a wide variety of industrial applications because of its light weight, high strength-to-weight ratio, The demands for new and improved welding technology from corrosion resistance, and other attributes. However, because its the expanding energy markets are starting to pay off in the devel- chemical and physical properties are different from those of steel, opment of superior hybrid welding processes, new filler metals, and welding of aluminum requires special processes, techniques, and a host of cladding procedures. These technologies are showing up expertise. in nuclear power plants, in coal-fired utilities, and especially in new 1700-mile-long pipelines designed to bring oil and natural gas to FABTECH 2012 American markets. On the agenda are talks on Lincoln Electric’s new laser hot wire cladding process and the ICE process from ESAB November 12–14 in Sweden that is intended for wind-power fabrication. Other top- Las Vegas, Nev. ics will include the successes of the new P87 filler metal, the variety of applications for explosion welding, and, from Edison Welding North America’s largest metal forming, fabricating, welding, Institute, a close look at the less-expensive plasma/GMA hybrid and finishing event heads to the Las Vegas Convention Center. welding process. If your job requires you to look for new ways to work smarter, operate leaner, and boost productivity, then you and your team 15th Annual Aluminum Welding need to attend FABTECH. Make plans now to attend your industry’s main event and you’ll find the products, resources, and Conference, September 18, 19 ideas to strengthen your business and achieve your manufactur- Seattle, Wash. ing goals. Following are conferences being offered at the Show. A panel of distinguished aluminum industry experts will Activity Picks up in Underwater Welding survey the state of the art in aluminum welding technology and practice. November 12 Installations in the Gulf of Mexico in particular are increasing and the divers in those areas are making sure that everything is okay in all of the welds connected to the offshore platforms. Uwe Aschemeier will be on hand to discuss the performance of wet welding electrodes as well as tell you about some underwater repair work. Covering the Many Aspects in Health and Safety, November 13

As industry awaits the next ruling on fumes from manganese, companies have their work cut out for them in such areas as the control of radiation, ventilation, welder comfort and visibility, plasma cutting, and the light from lasers. There is much to keep tabs on. This conference will focus on many of the solutions. What Are Some of the New Wrinkles in Nondestructive Testing? November 14

Such processes as alternating current field measurement (ACFM), time of flight diffraction (TOFD), computed radiogra- phy, and the many types of phased array methods are moving more and more into critical inspection lines. This conference will also provide information on the new technologies that are also being approved for use in the demanding work under the ASME Code.◆

For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext. 264, or e- mail [email protected]. You can also visit the Conference De- partment Web site at www.aws.org/conferences for upcoming conferences and registration information. For info go to www.aws.org/ad-index

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Scan this code to watch an exciting preview of FABTECH.ABTECH.F Followlow us:us:Fol Cosponsors: COMING EVENTS NOTE: A DIAMOND ( ♦) DENOTES AN AWS-SPONSORED EVENT. ♦AWS Weldmex. May 2–4. Mexico City, Mexico. Sponsored by the June 26–28. Loews Vanderbilt Hotel, Nashville, Tenn. Sponsored American Welding Society, the event will focus on welding and by Tube & Pipe Association, Int’l; UK-based Int’l Tube Associa- cutting products, including thermal spray, metal finishing, and tion; and Fabricators & Manufacturers Association, Int’l; safety equipment. The show will co-locate with Metalform Mex- www.pipetubeconf.com/nashville. ico and FABTECH Mexico. www.weldmex.com. ♦ 65th Annual Assembly of the International Institute of Welding SME Annual Conf. June 3–5, Cleveland Marriott Downtown (IIW). July 8–13. Hyatt Regency Hotel Denver and Colorado Con- Hotel, Cleveland, Ohio. Sponsored by the Society of Manufac- vention Center, Denver, Colo. Sponsored by the American Welding turing Engineers. www.sme.org/conference. Society, Edison Welding Institute, and Welding Research Council. Featured will be a conference on Welding for Repair and Life Ex- 17th Beijing-Essen Welding and Cutting Fair. June 4–7. New tension of Plants and Infrastructure. For complete information, visit China Int’l Exhibition Centre, Beijing, China. www.cmes.org/ www.iiw2012.com. essen/en/index.htm. Review of Progress in Quantitative Nondestructive Evaluation North American Manufacturing Research Conf. (NAMRC). June (QNDE). July 15–20. Hyatt Regency Tech Center, Denver, Colo. 4–8, University of Notre Dame, South Bend, Ind. Sponsored by Contact [email protected] or www.qndeprograms.org. the Society of Manufacturing Engineers. www.sme.org/namrc. Educational Opportunities Alloys in Power Plant Technology. June 12, 13. ABBA Berlin Hotel. Berlin, Germany. Sponsored by VDI, Association of Ger- Fundamentals of Brazing. Sept. 25–27, Wyndham Hotel San Jose, man Engineers. www.vdi.de/materialsinpowerplants. San Jose, Calif. Lucas Milhaupt®, a Handy & Harman Co. (800) 558-3856; www.lucasmilhaupt.com/en-US/training/upcomingtrain- Global Petroleum Show. June 12–14. Stampede Park, Calgary, ingeventsdetail/29. Alb., Canada. http://globalpetroleumshow.com. Machine Safeguarding Seminars. Rockford Systems, Inc.; (800) 922-7533; visit www.rockfordsystems.com. ♦The Energy Boom: Get on the Bandwagon. June 12, 13, San Diego, Calif. Sponsored by the American Welding Society. NACE Int’l Training and Certification Courses. National Assoc. www.aws.org/conferences. of Corrosion Engineers; (281) 228-6223; www.nace.org. Optimizing Operations through Continuous Improvement Conf. Online Education Courses. Topics include Introduction to Die

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For info go to www.aws.org/ad-index 56 MAY 2012 Casting ($99), Metal Melting and Handling ($99), Product Design ($59), Energy Training ($19), Dross Training ($19), Managing Dust Hazards ($19), Safety (free). North American Die Casting Assn., www.diecasting.org/education/online; or call (847) 808-3161. Robotics Operator Training. Presented by ABB University at 13 locations nationwide. For course titles and locations: www.abb.us/abbuniversity; (800) 435-7365, opt. 2, opt. 4.

Servo-Robot Training Seminars. Two-day laser-vision seminars held throughout the year at Servo-Robot, Inc., near Montreal, Canada. Seminars include tutorials and hands-on practical training. For seminar schedule and costs, e-mail request to info@ser- vorobot.com.

TIP TIG Manual and Automated Plate and Pipe Welding Workshops. Held the third Thursday of every month. 1901 Kitty Hawk Ave., Bldg. 68, Philadelphia Naval Shipyard, Philadelphia, Pa.; (215) 389-7700; www.tiptigusa.com. Tool and Die Welding Courses. Troy, Ohio. Hobart Institute of Welding Technology; (800) 332-9448; www.welding.org.

Unitek Miyachi Corp. Training Services. Personalized training services on resistance and laser beam welding and laser mark- ing; (626) 303-5676; www.unitekmiyachi.com.

Vibration Training Short Courses. Presented at locations nationwide, customer’s site, and by correspondence. Vibration Institute; www.vibinst.org.

Victor Training Seminars. Programs for gas apparatus and service repair technicians, end users, and sales personnel; www.vic- torequip.com. For info go to www.aws.org/ad-index TECHNICALTECHNICAL TTRAININGRAINING TheThThe Hobart InInstitute Institute off WeldinWeldingg TechnoTechnologylogy offersofffeers our comprehensivecomprehensive Technical TrainiTraininginng coursescourses through tththehe yyear!ear! UpcUpcomingoming star start-dates:t-dates: Prep forfor AWSAWS CertifiedCertifified WWeldingelding SuSupervisorpervisor EExamxam NovNov 1212 Prep forfor AWSAWS WeldingWelding Inspector/EducatorInspector/Educator EExamxam MayMayay 1144 : JuJunn 1188 : JuJull 2233 : SSepep 1100 : OcOctt 2222 : DeDecc 3 VisualVisual InspectionInspection SepSep 5 : NovNov 1919 WeldingWelding fforor tthehe NNonon WelWelderder JunJun 4 : AugAug 2727 : SepSep 2424 ArcArc WeldingWelding InspectionInspection & QQualityuality CControlontrol MayMayay 7 : JuJunn 1111 : Ju Jull 1166 : OcOctt 8 : NoNovv 2266 WeldingWelding InsInstructortructor CCourseourse JulJul 9 LiquidLiquid PenetrPenetrantant & MagnMagneticetic PartiParticlecle InspectionInspection AugAug 1133 : NovNov 5 1-800-332-94481-800-332-9448 oror visitvisit uuss aatt www.welding.orgwww.w.weldiding.orgrg forfor moremore information.infnformation. © 22012012 HHobartobartrt InstituteInstitutute ooff WWeldingelding Technology,Technology, Troy,Troy, OHOH St.St. ofof OhioOhio Reg.Reg. No.No. 70-12-0064HT70-12-0064HT

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index WELDING JOURNAL 57 CERTIFICATION SCHEDULE

Certification Seminars, Code Clinics, and Examinations

Certified Welding Inspector (CWI) 9–Year Recertification Seminar for CWI/SCWI LOCATION SEMINAR DATES EXAM DATE For current CWIs and SCWIs needing to meet education Long Beach, CA Exam only May 26 requirements without taking the exam. The exam can be taken Spokane, WA June 3–8 June 9 at any site listed under Certified Welding Inspector. Oklahoma City, OK June 3–8 June 9 LOCATION SEMINAR DATES EXAM DATE Birmingham, AL June 3–8 June 9 Pittsburgh, PA June 4–9 No exam Hartford, CT June 10–15 June 16 San Diego, CA July 9–14 No exam Pittsburgh, PA June 10–15 June 16 Miami, FL July 16–21 No exam Beaumont, TX June 10–15 June 16 Orlando, FL Aug. 20–25 No exam Corpus Christi, TX Exam only July 7 Denver, CO Sept. 10–15 No exam New Orleans, LA July 8–13 July 14 Dallas, TX Oct. 15–20 No exam Phoenix, AZ July 8–13 July 14 New Orleans, LA Oct. 29–Nov. 3 No exam Memphis, TN July 8–13 July 14 Miami, FL July 8–13 July 14 Certified Welding Supervisor (CWS) Orlando, FL July 15–20 July 21 LOCATION SEMINAR DATES EXAM DATE Milwaukee, WI July 15–20 July 21 Minneapolis, MN July 16–20 July 21 Los Angeles, CA July 15–20 July 21 Miami, FL Sept. 10–14 Sept. 15 Sacramento, CA July 15–20 July 21 Norfolk, VA Oct. 15–19 Oct. 20 Louisville, KY July 15–20 July 21 CWS exams are also given at all CWI exam sites. Kansas City, MO July 22–27 July 28 Certified Radiographic Interpreter (CRI) Cleveland, OH July 22–27 July 28 LOCATION SEMINAR DATES EXAM DATE Denver, CO July 29–Aug. 3 Aug. 4 Miami, FL June 4–8 June 9 Philadelphia, PA July 29–Aug. 3 Aug. 4 Dallas, TX July 16–20 July 21 San Diego, CA Aug. 5–10 Aug. 11 Chicago, IL Sept. 10–14 Sept. 15 Chicago, IL Aug. 5–10 Aug. 11 Pittsburgh, PA Oct. 15–19 Oct. 20 Miami, FL Aug. 5–10 Aug. 11 The CRI certification can be a stand-alone credential or can Baton Rouge, LA Aug. 5–10 Aug. 11 exempt you from your next 9-Year Recertification. Bakersfield, CA Aug. 12–17 Aug. 18 Charlotte, NC Aug. 12–17 Aug. 18 Certified Welding Sales Representative (CWSR) Rochester, NY Exam only Aug. 18 CWSR exams will be given at CWI exam sites. San Antonio, TX Aug. 12–17 Aug. 18 Certified Welding Educator (CWE) Miami, FL Exam only Aug. 18 Seminar and exam are given at all sites listed under Certified Portland, ME Aug. 19–24 Aug. 25 Welding Inspector. Seminar attendees will not attend the Code Minneapolis, MN Aug. 19–24 Aug. 25 Clinic portion of the seminar (usually the first two days). Salt Lake City, UT Aug. 19–24 Aug. 25 Pittsburgh, PA Aug. 19–24 Aug. 25 Certified Robotic Arc Welding (CRAW) Seattle, WA Aug. 19–24 Aug. 25 WEEKS OF, FOLLOWED BY LOCATION AND PHONE NUMBER Corpus Christi, TX Exam only Sept. 8 Houston, TX Sept. 9–14 Sept. 15 May 11, Aug. 10, Nov. 9 at St. Louis, MO Sept. 9–14 Sept. 15 ABB, Inc., Auburn Hills, MI; (248) 391–8421 New Orleans, LA Sept. 9–14 Sept. 15 May 21, Aug. 20, Dec. 3 at Miami, FL Sept. 9–14 Sept. 15 Genesis-Systems Group, Davenport, IA; (563) 445-5688 Anchorage, AK Exam only Sept. 22 Oct. 22, Oct. 26 at Lincoln Electric Co., Cleveland, OH; (216) 383-8542 Miami, FL Exam only Oct. 18 July 9, Oct. 15 at Tulsa, OK Oct. 14–19 Oct. 20 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800 Long Beach, CA Oct. 14–19 Oct. 20 May 7, July 9, Sept. 10, Nov. 5 at Newark, NJ Oct. 14–19 Oct. 20 Wolf Robotics, Fort Collins, CO; (970) 225-7736 Nashville, TN Oct. 14–19 Oct. 20 On request at: Portland, OR Oct. 21–26 Oct. 27 MATC, Milwaukee, WI; (414) 297-6996 Roanoke, VA Oct. 21–26 Oct. 27 Detroit, MI Oct. 21–26 Oct. 27 Certified Welding Engineer (CWEng) and Senior Certified Cleveland, OH Oct. 21–26 Oct. 27 Welding Inspector (SCWI) Exams can be taken at any site listed under Certified Welding Inspector. No preparatory seminar is offered. International CWI Courses and Exams Schedules Please visit www.aws.org/certification/inter_contact.html.

IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to confirm your course status before making travel plans. For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.

58 MAY 2012 The most authoritative reference on welding in the world.

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www.awspubs.com 1-888-935-3464 RWMA Q&A BY BOB WHITE JR.

Q: How do I pick out a welding machine cylinder has been picked. Otherwise, the ering in the rest of the plant, and the to do resistance welding to military spec- welding machine might only be able to power company can shut you down. So, if ifications (Mil Specs)? weld 0.025 to 0.025 aluminum but not you are welding heavy aluminum, a three- properly weld 0.016 to 0.016. phase welding machine is the better A: This is a question that we receive all Now that the required weld current choice. the time. The biggest problem is that when and weld pressures are known, we are 6. When considering purchase of a someone buys a welding machine to do ready to pick out the right welding ma- large welding machine, it is important to Mil Spec welding they don’t know the right chine. Following is an example for weld- first check to be sure your plant has elec- questions to ask to properly select the cor- ing aluminum 0.016 to 0.016 up to 0.125 tric service large enough to handle the rect machine. There are plenty of weld- to 0.125, and stainless steel 0.010 to 0.010 high currents. Many times a company will ing machines out there that can make the up to 0.125 to 0.125. buy a welding machine just to find out that weld, but will not be able to produce the 1. Weld pressures for these materials it can’t be used because there is not consistency that a Mil Spec welding ma- will be a maximum of 4500 lb with forg- enough power available. Even though you chine requires. ing for some aluminum alloys, and 200 lb have 800-A service in your plant, that The first thing you want to figure out for the thinnest stainless steel. doesn’t mean you have 800 A available for is what types of materials (alloys) you will 2. Select the maximum throat depth the welding machine. Typically, for a 480- want to weld. This is important because needed to handle your largest part. Throat V, three-phase welding machine, you will some alloys require mechanical forging of depth is the measurement from the weld- need 100 A for each 100 kVA of welding the weld nugget during a weld sequence. ing electrode to the back of the welding machine size, and for a 240-V, three-phase Next, what thickness combinations are machine throat (maximum depth). welding machine you will need 200 A for you going to weld, and will there be only 3. Forging is required for welding alu- each 100 kVA of welding machine size. two layers or will you weld five or even minum. When forging, you want to make Check with your power company if there more layers in the same stack-up? Also, sure the welding machine can reach forge is any doubt about service availability be- what will be the maximum total thickness force within 6–12 milliseconds. If forging fore installing a new welding machine. of the material stack-up? You need to is installed on a standard welding machine 7. The next main question will be know all of this in order to select the with a standard air cylinder, reaching whether you should choose a rocker arm proper size welding machine. forge force can take up to two to three cy- style or press welding machine style. Ei- Once the materials and thicknesses are cles. With this time delay, your weld will ther will work just fine for Mil Spec weld- addressed, we need to size the welding be inconsistent, contain internal cracks or ing, and if designed properly, both should machine. What pressure (electrode force) voids, and you will not be able to qualify have the same amount of machine and will be needed to make both the thickest your welding machine on a class A weld. arm deflection. Therefore, this choice and the thinnest weld? When this is estab- 4. The maximum weld current needed should depend on the configuration of lished, we need to see what weld currents to weld 0.125 to 0.125 aluminum will be the parts you will be welding. However, and duty cycle the welding machine must around 50,000 A. when welding weld nuts or other compo- be able to achieve. Duty cycle require- 5. Do you need single phase or three nents with projections the press welding ments will be quite different for a spot phase? It is possible to do Mil Spec alu- machine style is the only practical choice. welding machine as opposed to a seam minum and stainless steel welds on a sin- Now that you have the answers to most welding machine. gle-phase machine; however, when weld- of your questions about selecting the One of the biggest problems is the re- ing aluminum you need very high current. proper welding machine, it is time to find quirement to weld 0.125 to 0.125 alu- This high weld current on single-phase a company to supply that machine. Be sure minum and then weld 0.016 to 0.016 alu- welding machines will produce very high the company you select understands Mil minum to a class A weld on the same ma- primary current on your power lines, and Spec welding and can help with the quali- chine. When this happens, you have to your power factor will drop to 60 or 70. fication of the welding machine after in- make sure that the right size and type air Both of these conditions can cause flick- stallation. Many times a supplier understands commercial welding but is not con- versant with Mil Spec welding. Your ultimate ability to produce parts successfully welded to Mil Specs depends on both selection of the proper welding machine and working with a knowledgeable and qualified welding machine manufacturer or distributor.◆

BOB WHITE JR. is president of Janda Company, Inc., Corona, Calif. Janda Com- pany, Inc., is a member of the RWMA, a standing committee of the American Weld- ing Society. Send your comments and questions to Bob White Jr. at bobjr@jan- dawelders.com, or mail to Bob White Jr., c/o Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126.

For info go to www.aws.org/ad-index 60 MAY 2012 AWS Conference on The Energy Boom: Get on the Bandwagon

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Hosted by: WELDING WORKBOOK Datasheet 332 Melt-Through and Root Surface Profiles

Melt-through is visible root reinforcement in a joint welded site the side from which welding was done. The root surface is from one side. Examples of melt-through are shown in Fig. shown in Fig. 1E, F.◆ 1A–D. The root surface is the exposed surface of a weld oppo-

Fig. 1 — Examples of melt-through and root surface profiles.

Excerpted from AWS A3.0M/A3.0:2010, Standard Welding Terms and Definitions.

62 MAY 2012

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BY HOWARD M. WOODWARD [email protected] WEMCO and RWMA Hold Joint Annual Event

Two AWS standing committees, WEMCO, an association of welding manufacturers, and the Resistance Welding Manufacturing Alliance (RWMA) held their third annual colocated meetings Feb. 23–25, at the Miramonte Resort & Spa, in Indian Wells, Calif. During WEMCO’s passing-the-baton ceremony on Feb. 24, the following officers were announced for 2012: Bob Ranc, senior vice president of Superior Products, was named chair; Nigel Scotchmer, president of Huys Industries, Ltd., was named first vice chair; and Dave Sullivan, national sales manager of 3M Co., was named second vice chair. The RWMA reelected its 2011 officers for an additional one-year term, ending Dec. 31, 2012: Wade Burnette, chairman; Mark Gramelspacher, first vice chair; Ed The RWMA officers reelected for a one-year term are (from left) Ed Langhenry, Roger Hirsch, Langhenry, second vice chair; and Roger Mark Gramelspacher, and Chair Wade Burnette. Hirsch, RWMA’s 2009–2010 chair, member of the executive committee. Burnette is vice president, sales, at NSRW, Inc.; Gramelspacher is president of CMW, Inc.; Langhenry is senior vice president, sales, at Watteredge, Inc.; and Hirsch is president of Unitrol Electronics, Inc. WEMCO past chairs were recognized at the event, including Jeff Deckrow (Hy- pertherm, Inc.), Bob Roth (RoMan Mfg., Inc.), Dean Wilson (Kimberly-Clark Pro- fessional), Jim Horvath (Thermadyne), Dennis Brown (Weiler Corp.), and Hector Villarreal (Weldcoa). With social media being recognized as one of the most effective methods to en- gage customers and receive measurable results, both organizations agreed to focus on how businesses connect and market using this digital tool. The speakers included Gord Hotchkiss, WEMCO past chairs are (from left) Jeff Deckrow, Bob Roth, Dean Wilson, Jim Horvath, CSO of Mediative based in British Colum- Dennis Brown, and Hector Villarreal. bia, Canada, and author of The Buyer Sphere Project: How Business Buys from which also includes Abicor Binzel, Astaras stitute for Trend Research (ITR), who pre- Business in a Digital Marketplace; Alf Welding Accessories, Kemper System, and sented his annual economic forecast. Schmidt, CEO, IBG Group, Cologne, Thermacut — all WEMCO members. The fourth WEMCO and RWMA Germany; and Nelson Squires, vice presi- Squires discussed Air Products’ pres- colocated annual meeting is tentatively dent, North America gas, for Air Products ence in the social media arena, and how scheduled for Florida, dates and venue to and Chemicals in Allentown, Pa. he plans to expand it in the future. be announced. For complete information Schmidt described general market per- Another highlight of the meetings was about WEMCO and RWMA member- spectives worldwide and for the welding the entertaining talk by renowned econo- ship, activities, and upcoming meetings, sector from his company’s perspective, mist Alan Beaulieu, president of the In- call (800) 443-9353, ext. 239.

WELDING JOURNAL 65 Tech Topics

Errata B2.1/B2.1M:2009-ADD1 New Standards Projects by ANSI, require that all standards be Specification for Welding Procedure and Development work has begun on the open to public review for comment dur- Performance Qualification following two revised standards. Affected ing the approval process. The above stan- The following errata, in addition to pre- individuals are invited to contribute to this dards are submitted for public review with viously announced corrections (see work. Contact Efram Abrams, ext. 307, the expiration dates shown. Draft copies www.aws.org), have been identified and will for complete information. Participation may be obtained from Rosalinda O’Neill, be incorporated into the next reprint. on AWS Technical Committees and Sub- ext. 451, [email protected]. Page 63. Figures B.5B, Guided Bend committees is open to all persons. Fixture-BottomType-Noteb — Correct C1.4M/C1.4:20XX, Specification for Technical Committee Meetings “For M-26, M-81, and M-83 materials, two Resistance Welding of Carbon and Low- All AWS technical committee meet- macroetch specimens shall be used in lieu Alloy Steels. This specification provides ings are open to the public. To attend a of guided bend testing (see also Figures the shear strength and weld button diam- meeting, call the staff secretary, (305) 443- B.5B and B.5C).” To: “For M-26, M-81, eter requirements for carbon and low- 9353, at the extension shown. and M-83 materials, two macroetch speci- alloy steel sheet resistance and projection May 9–11, A2B Subcommittee on Def- mens shall be used in lieu of guided bend welds. Stakeholders: Resistance welding initions. Gatlinburg, Tenn. S. Borrero, ext. testing (see also Figures B.5A and B.5C).” community. 334. Page 64. Figures B.5C, Guided Bend C4.6M:2006 (ISO 9013:2002 IDT) May 9, 10, A2C Subcommittee on Sym- b Fixture-Wrap-Around-Note — Correct (R20XX), Thermal Cutting — Classifica- bols. Gatlinburg, Tenn. S. Borrero, ext. “For M-26, M-81, and M-83 materials, two tion of Thermal Cuts — Geometric Prod- 334. macroetch specimens shall be used in lieu uct Specification and Quality Tolerances. May 10, A2 Committee on Definitions of guided bend testing. See also Figures This is the U.S. national adoption of ISO and Symbols. Gatlinburg, Tenn. S. Bor- B.5B and B.5C.” To: “For M-26, M-81, and 9013:2002, Thermal cutting — Classifica- rero, ext. 334. M-83 materials, two macroetch specimens tion of thermal cuts — Geometric product May 14, C6D Subcommittee on Fric- shall be used in lieu of guided bend test- specification and quality tolerances. It in- tion Stir Welding. Huntsville, Ala. B. Mc- ing (see also Figures B.5A and B.5B).” cludes three annexes, criteria for describ- Grath, ext. 311. ing oxygen-cut surfaces, a photographic May 15, C1 Committee on Resistance Errata D17.1/D17.1M:2010 surface roughness guide, and reference Welding. Livonia, Mich. E. Abrams, ext. Specification for Fusion Welding for documents. Stakeholders: Oxyfuel gas 307. Aerospace Applications welding and cutting community. May 15, D8 Committee on Automotive The following errata have been identi- Welding. Livonia, Mich. E. Abrams, ext. fied and will be incorporated into the next Standards for Public Review 307. reprinting of this document. May 15, J1 Committee on Resistance Page 35. Table 7.1, Acceptance Criteria A5.4/A5.4M:20XX, Specification for b Stainless Steel Electrodes for Shielded Metal Welding Equipment. Livonia, Mich. E. in (mm), Discoloration — Titanium, Abrams, ext. 307. Green, Class B. Correct “Acceptancea” to Arc Welding. Revised. $29.50. 5/14/12. A5.34/A5.34M:20XX, Specification for May 22, D15C Subcommittee on Track Acceptancec” Nickel-Alloy Electrodes for Flux Cored Arc Welding. Kansas City, Mo. S. Borrero, ext. Page 35. Table 7.1, Acceptance Criteria Welding. Revised. $26.50. 5/21/12. 334. in (mm), Discolorationb — Titanium, A9.5:20XX, Guide for Verification and May 22, D17D Subcommittee on Re- Green, Class C. Correct “Acceptancea” to c Validation in Computation Weld Mechan- sistance Welding. Cape Canaveral, Fla. A. Acceptance ” ics. New. $35. 4/23/12. Diaz, ext. 304. B5.1:20XX, Specification for the Quali- May 22, D17J Subcommittee on Fric- Addenda B2.1/B2.1M:2009 fication of Welding Inspectors. Revised. tion Stir Welding for Aerospace. Cape The following Addenda have been $25. 5/7/12. Canaveral, Fla. A. Diaz, ext. 304. identified and will be incorporated into the C4.5M:20XX, Uniform Designation May 22, D17K Subcommittee on Fu- next reprinting of this document. System for Oxyfuel Nozzles. Revised. $25. sion Welding. Cape Canaveral, Fla. A. AWS Standard: B2.1/B2.1M:2009, Specifi- 5/21/12. Diaz, ext. 304. cation for Welding Procedure and Perform- C4.6M:2006 (ISO 9013:2002 IDT) May 23, D15 Committee on Railroad ance Qualification (R20XX), Thermal Cutting — Classifica- Welding. Kansas City, Mo. S. Borrero, ext. Addenda No.: ADD1 tion of Thermal Cuts — Geometric Prod- 334. Subject: Annex D, Normative, Base Metal uct Specification and Quality Tolerances. May 23, D15A Subcommittee on Grouping Reaffirmed. $25. 5/21/12. Freight Cars and Locomotives. Kansas Page 73, D1 Base Metal Specifications: AWS was approved as an accredited City, Mo. S. Borrero, ext. 334. Remove “AISI” standards-preparing organization by the May 23, D17 Committee on Welding Page 73, D1 Base Metal Specifications. American National Standards Institute in the Aircraft and Aerospace Industries. Add “Table D.3 List base metal specifica- (ANSI) in 1979. AWS rules, as approved Cape Canaveral, Fla. A. Diaz, ext. 304. tions for iron castings in accordance with AWS D11.2 groups” Page 74-135, Table D.1, List of Base How to Order Journal Article Reprints and AWS Documents Metal Specifications. New base metals have To order custom reprints of Welding tact Edalia Suarez, [email protected], or been added and corrections have been made Journal articles in quantities of 100 or Ruben Lara, [email protected]. to Table D.1. more, or electronic posting of articles, To order AWS standards, books, and Page 136-258, Table D.2, M-Number contact Rhonda Brown, Foster Printing other publications, contact World Engi- Listing of Base Metals. New base metals Services, [email protected]; neering Xchange, www.awspubs.com; have been added and corrections have been (866) 879-9144, ext. 194; www.market- call toll-free in the United States (888) made to Table D.2. ingreprints.com. To order individual 935-3464; elsewhere call (305) 826-6192; copies of Welding Journal articles, con- or FAX (305) 826-6195.

66 MAY 2012 A5 Recognizes Its Veteran Volunteers

Damian Kotecki (left), an AWS past president, presents the A5 Committee Chair Harry Wehr (right) presents a ten-year 20-year anniversary pin to Harry Wehr, chair, A5 Committee service pin to Rick Sutherlin, chair, A5K Subcommittee on Ti- on Filler Metals and Allied Materials. tanium and Zirconium Filler Metals.

Welding Handbook Committee Seeks Copper, Lead, and Zinc Welding Pros Persons with experience in welding copper, lead, and zinc are Working on the Welding Handbook Committee provides an sought to help revise two chapters of Welding Handbook, Vol. 5, opportunity to share your expertise with your peers. Materials and Applications: Chapter 3, Copper and Copper Al- For complete information, contact Annette O’Brien, secre- loys; and Chapter 5, Lead and Zinc. tary, [email protected]; (800/305) 443-9353, ext. 303.

Opportunities to Contribute to AWS Welding Standards and Codes Robotic and Automatic Welding of Welds in Piping and Tubing. Contact B. for Thermal Spray Feedstock — Solid and The D16 Committee on Robotic and McGrath, [email protected]; ext. 311. Composite Wire and Ceramic Rods. Automatic Welding seeks general interest Magnesium Alloy Filler Metals Surfacing Industrial Mill Rolls and educators to help revise: A5L Subcommittee on Magnesium D14H Subcommittee on Surfacing and D16.1M/D16.1, Specification for Robotic Alloy Filler Metals to assist in the updat- Reconditioning of Industrial Mill Rolls Arc Welding Safety; D16.2M/D16.2, Guide ing of AWS A5.19-92 (R2006), Specifica- to revise AWS D14.7, Recommended Prac- for Components of Robotic and Automatic tion for Magnesium Alloy Welding Elec- tices for Surfacing and Reconditioning of Arc Welding Installations; D16.4M/D16.4, trodes and Rods. Contact Rakesh Gupta, Industrial Mill Rolls. Contact Matt Rubin, Specification for the Qualification of Ro- [email protected], ext. 301. [email protected], ext. 215. botic Arc Welding Personnel. Brian Mc- Soldering; Joining Nickel Alloys Automotive Welding Grath, [email protected]; ext. 311. The B2E Subcommittee on Soldering The D8 Committee on Automotive Soldering; Joining Nickel Alloys Qualifications; G2C Subcommittee on Welding seeks members to help prepare The B2E Subcommittee on Soldering Nickel Alloys to review B2.3/B2.3M, Spec- standards on all aspects of welding in the Qualifications; G2C Subcommittee on ification for Soldering Procedures and Per- automotive industry. Nickel Alloys to review B2.3/B2.3M, Spec- formance Qualification. Alex Diaz, The next meeting of the D8 Commit- ification for Soldering Procedures and Per- [email protected]; ext. 304. tee will be held during the week of the formance Qualification. Contact Steve Thermal Spray Great Designs in Steel 2012 conference Hedrick, [email protected]; ext. 305. C2 Committee on Thermal Spraying and exhibition (May 16), Laurel Manor Local Heat Treating of Pipe Work to update C2.16, Guide for Thermal Spray Conference Center, Livonia, Mich. Con- The D10P Subcommittee for Local Operator Qualification; C2.21, Specifica- tact Efram Abrams, [email protected]; Heat Treating of Pipe to revise D10.10, tion for Thermal Spray Equipment Accept- ext. 307. To submit an online application Recommended Practices for Local Heating ance Inspection; and C2.25, Specification visit www.aws.org/171T.

Nominate Your Candidate for the M.I.T. Prof. Masubuchi Award November 5, 2012, is the deadline for research and development. of Ocean Engineering at Massachusetts submitting nominations for the 2013 Prof. Nominations should include a descrip- Institute of Technology (M.I.T.), this Koichi Masubuchi Award. tion of the candidate’s experience, list of award includes a $5000 honorarium. This award is presented each year to publications, honors, and awards, and at E-mail your nomination package one person, 40 years old or younger, who least three letters of recommendation to Todd A. Palmer, assistant professor, has made significant contributions to the from fellow researchers. The Pennsylvania State University, advancement of materials joining through This award is sponsored by the Dept. [email protected].

WELDING JOURNAL 67 Member-Get-A-Member Campaign

Listed below are the members participating in the 2011–2012 Member-Get-A-Mem- Cottrell Receives Student Chapter Award ber Campaign. Standings are as of March 20, 2012. For rules and prize list, see page 81 of this Welding Journal, or visit www.aws.org/ mgm. Call the AWS Membership Dept. at (800) 443-9353, ext. 480, with any questions about your member-proposer status.

Winners’ Circle Listed are the sponsors of 20 or more Indi- vidual Members per year, since June 1, 1999. The superscript denotes the number of years the member has earned Winners’ Circle status. E. Ezell, Mobile8 J. Compton, San Fernando Valley7 J. Merzthal, Peru2 G. Taylor, Pascagoula2 L. Taylor, Pascagoula2 B. Chin, Auburn1 S. Esders, Detroit1 M. Haggard, Inland Empire1 Austin Cottrell (right), with the AWS Whitmer Career & Technology Center Student Chapter, M. Karagoulis, Detroit1 receives the Student Chapter Member Award from Advisor Craig Donnell, Northwest Ohio 1 S. McGill, NE Tennessee Section, District 11. See notice on page 69. B. Mikeska, Houston1 W. Shreve, Fox Valley1 Student Member Sponsors T. Geisler, Pittsburgh — 9 T. Weaver, Johnstown/Altoona1 M. Pelegrino, Chicago — 90 C. Kipp, Lehigh Valley — 9 G. Woomer, Johnstown/Altoona1 G. Bish, Atlanta — 50 J. Kline, Northern New York — 9 R. Wray, Nebraska1 D. Saunders, Lakeshore — 43 G. Smith, Lehigh Valley — 8 N. Baughman, Stark Central — 37 C. Hobson, Olympic — 7 President’s Guild A. Alvarez, Houston — 35 J. McCarty, St. Louis — 7 Sponsored 20 or more new members R. Belluzzi, New York — 34 D. Zabel, SE Nebraska — 7 E. Ezell, Mobile — 23 M. Box, Mobile — 34 J. Boyer, Lancaster — 6 R. Hammond, Birmingham — 33 M. D’Andrea, Kern — 6 President’s Roundtable T. Palmer, Atlanta — 33 R. Ledford Jr., Birmingham — 6 Sponsored 9–19 new members H. Hughes, Mahoning Valley — 28 S. Poe, Central Michigan — 6 M. Pelegrino, Chicago — 18 D. Berger, New Orleans — 27 T. Shirk, Tidewater — 6 R. Holdren, Columbus — 9 M. Anderson, Indiana — 24 S. Colton, Arizona — 5 S. Siviski, Maine — 24 J. Ginther, Pittsburgh — 5 President’s Club W. England, W. Michigan — 23 T. Moore, New Orleans — 5 Sponsored 3–8 new members M. Boggs, Stark Central — 22 W. Wilson, New Orleans — 5 J. Walker, Blackhawk — 6 T. Palmer, Atlanta — 22 B. Amos, Mobile — 4 D. Biddle, Milwaukee — 5 G. Gammill, NE Mississippi — 21 A. Badeaux, Washington, D.C. — 4 T. Palmer, Atlanta — 5 B. Scherer, Cincinnati — 21 J. Crocker, N. Texas — 4 J. Vincent, Kansas City — 4 R. Huston, Olympic — 20 A. Reis, Pittsburgh — 4 D. Wright, Kansas City — 4 J. Lopez-Padilla, Cuautitlan Izcalli — 20 H. Rendon, Rio Grande Valley — 4 G. Bish, Atlanta — 3 R. Richwine, Indiana — 20 J. Saterland, Spokane — 4 B. Goerg, Fox Valley — 3 J. Theberge, Boston — 20 J. Smith, Greater Huntsville — 4 D. Hale, East Texas — 3 C. Daily, Puget Sound — 19 P. Deslatte, New Orleans — 3 J. Mehta, San Francisco — 3 J. Fox, NW Ohio — 19 A. Holt, St. Louis — 3 J. Miller, Oklahoma City — 3 A. Baughman, Stark Central — 17 J. Meyer, San Francisco — 3 G. Mulee, South Carolina — 3 J. Bruskotter, New Orleans — 17 G. Seese, Johnstown-Altoona — 3 P. Phelps, Western Carolina — 3 J. Ciaramitaro, N. Central Florida — 17 W. Davis, Syracuse — 17 President’s Honor Roll J. Dawson, Pittsburgh — 17 Sponsored 2 new members C. Donnell, NW Ohio — 17 T. Baber, San Fernando Valley R. Evans, Siouxland — 17 T. Baldwin, Atlanta S. Robeson, Cumberland Valley — 17 M. Boggs, Stark Central R. Wahrman, Triangle — 17 AWS Member Counts R. Jones, Houston — 16 O. Burrion, S. Florida April 1, 2012 P. Carney, Philadelphia S. Miner, San Francisco — 16 J. Compton, San Fernando Valley E. Norman, Ozark — 16 G. Fehrman, Philadelphia J. Gable, El Paso — 15 Grades J. Gordy, Houston J. Daugherty, Louisville — 14 Sustaining ...... 532 G. Holl, Lexington D. Pickering, Central Arkansas — 14 Supporting...... 329 G. Jacobson, Cumberland Valley B. Wenzel, Sacramento — 14 Educational ...... 596 J. Lopez-Padilla, Cuautitlan Izcalli H. Browne, New Jersey — 14 Affiliate...... 481 M. Haggard, Inland Empire — 12 J. Mueller, Ozark Welding Distributor...... 58 G. Sanford, Houston R. Hutchinson, Long Bch/Or. Cty — 11 H. Suthar, Charlotte J. Johnson, Madison-Beloit — 11 Total Corporate ...... 1,996 M. Wheeler, Cleveland D. Schnalzer, Lehigh Valley — 11 Individual ...... 58,805 T. White, Pittsburgh E. Ramsey, Johnstown-Altoona — 10 Student + Transitional ...... 11,688 C. Whitesell, Tulsa R. Simpson, Charlotte — 10 Total Members...... 70,493

68 MAY 2012 New International Agent Established in Spain

Shown from left (standing) are Donald Llopis, Pablo Bernardo, Álvaro Sáez, Miguel Jorge, Ramón Ochoa, Roberto Lacave, instructor Ángela Lázaro Martin, Borja Sáiz, Mario Berceruelo, and José Sardinero; (front) Pedro Noguera and Ramon Ochoa.

The American Welding Society recently established Sol y Sol (Soluciones Industri- ales y Soldadura 2008, S.L.) as a new In- ternational Agent based in Toledo, Spain. The agent held its first training seminar and CWI certification examination based on D1.1/D1.1M:2010, Structural Welding Code — Steel. The exam was held Feb. 6. Sol y Sol is owned by Ángela Lázaro Martin, an AWS Certified Welding Inspec- tor, and one of Spain’s few female CWIs. She also conducts the D1.1 training seminars. The AWS representative overseeing the examination was Donald Llopis, senior coordinator, international business. Sol y Sol already has finalized plans for its second training seminar for June and the next CWI certification exam is sched- Shown are (from left) instructor Ángela Lázaro Martin, Roberto Lacave, Carmen Diaz, uled for June 25. Manuel Soria, Álvaro Sáez, Pedro Noguera, José Sardinero, and Ramon Ochoa.

Student Chapter Member Awards Presented

Jordan Hostetter, AWS Columbiana club, student teacher, and guidance aide. gram, and helped to coordinate the LSCC County Career and Technical Center Stu- White is an active volunteer in the local welding seminar, and will participate in dent Chapter, has been selected by Stu- YMCA Soup Kitchens, and the Adopt a the June AWS CWI seminar as the Birm- dent Chapter Advisor Huck Hughes, Ma- Family and Meals on Wheels programs. ingham Section representative. honing Valley Section, District 10, to re- Austin Cottrell, AWS Whitmer Career The AWS Board of Directors estab- ceive the AWS Student Chapter Member & Technology Center Student Chapter, lished the Student Chapter Member Award. Hostetter, a leader in his welding has been selected by Advisor Craig Don- Award to recognize AWS Student Mem- class, has served as both the Chapter’s nell, Northwest Ohio Section, District 11, bers whose Student Chapter activities treasurer and chairman. He actively par- to receive this award. Cottrell maintained have produced outstanding school, com- ticipates in the community as a volunteer a 3.9 GPA in the welding program, won munity, or industry achievements. This for Toys for Tots and the local food drive, this year’s local SkillsUSA welding com- award also provides an opportunity for and has helped to weld a new handrail for petition, placed third in the regionals, and Student Chapter advisors, Section offi- a local church. participated at the SkillsUSA State com- cers, and District directors to recognize Dentale White, AWS Canton South petition. See photo on page 68. outstanding students affiliated with Stu- High School Student Chapter, has been James B. Scott, Lawson State Commu- dent Chapters, as well as to enhance the selected by Advisor Art Baughman, Stark nity College Student Chapter, has been image of welding in their communities. Central Section in District 10, to receive selected by Advisor Roy Ledford Jr., Birm- To qualify for this award, the student this award. White has served the Chapter ingham Section. Scott has served as Chap- must be an active member of an AWS Stu- as both secretary and chairman. Her aca- ter chair, has a 4.0 GPA, and has com- dent Chapter. Download the application demic achievements include Student of pleted several welding procedure qualifi- at www.aws.org/sections/awards/student_ the Month (career technology). She is a cations. He was named the Outstanding chapter.pdf, or call the Membership Dept. varsity cheerleader, member of the SADD Student in theWelding Technology Pro- at (800) 443-9353, ext. 260.

WELDING JOURNAL 69 New AWS Supporters

Sustaining Members Flame Spray Technologies, Inc. NTR Custom Metals LLC dba 4881 Kendrick St. SE Pete’s Custom Metals, 1400 Railroad St. CENSOLSA Grand Rapids, MI 49512 PO Box 791, Fremont, NE 68026 PO Box 025331, SJO 10294 Miami, FL 33102 Global Tungsten & Powders Corp. PC Constructora Representative: Antonio Tous 1 Hawes St., Towanda, PA 18848 Carlos Tosi y Primera www.censolsa.com Cuenca Azuay, Ecuador CENSOLSA is a full-service welding dis- H.C. Starck North American Trading, LLC tributor that represents the top brands in 45 Industrial Pl., Newton, MA 02461 Petrohab LLC welding, soldering, equipment, and acces- 4930 Dacoma, Ste. E, Houston, TX 77092 sories. With almost 40 years in the business, Lineage Alloys, Inc. the company services the entire country from 1901 Ellis School Rd., Baytown, TX 77521 Specialty Fabrication and Powder Coating its main location in San José, Costa Rica. 455 Allegheny Blvd., PO Box 790 Meso Coat, Inc. Franklin, PA 16323 Lapeer Industries, Inc. 24112 Rockwell Dr., Euclid, OH 44117 290 McCormick Dr. StairCrafters Inc. Lapeer, MI 48446 Metallisation Ltd. 105 Beacon Hill Ct., Easley, SC 29640 Representative: Ryan Lenarcic Pear Tree Ln. www.lapeerind.com Dudley, W. Midlands DY2 OXH, UK Welding Distributors Lapeer Industries is a leading provider of services to the defense and aerospace Nation Coating Systems, Inc. Depke Gases & Welding Supplies industries. It specializes in design, machin- 501 Shotwell Dr., Franklin, OH 45005 628 E. Williams St., Danville, IL 61832 ing, and fabrication, to provide top-quality products with on-time delivery. It is ISO Nigen Industries, LLC Educational Institutions 9001:2008 certified, and its Pontiac loca- 13938 Chrisman Rd., Houston, TX 77039 tion is AS9100 B registered. Blue Ridge Technical Center N. American Hoganas High Alloys LLC 280 Luray Ave., Front Royal, VA 22630 Polymet Corp. 101 Bridge St., Johnstown, PA 15902 10073 Commerce Park Dr. Columbia Basin Job Corps CCC Cincinnati, OH 45246 Plasma Coatings 6739 24th Ave., Bldg. 2402 Representative: Bill Mosier 1440 13th Ave., Union Grove, WI 53182 Moses Lake, WA 98837 www.polymet.us Polymet Corp. is a leading manufacturer Progressive Surface, Inc. Columbus State C. C. of high-performance wire for hardfacing, 4695 Danvers Dr. SE 550 E. Spring St., Columbus, OH 43215 welding, and thermal spraying. The com- Grand Rapids, MI 49512 pany stocks a complete line of solid and Cranfield University cored wires for immediate delivery. The PTR-Precision Technologies, Inc. Kings Norton Library products have most all aerospace and com- 120 Post Rd. Info & Library Services mercial approvals. It promises to provide Enfield, CT 06082 Bedfordshire, MK43 0AL, UK the highest level of quality, service, and technical innovation. Thermach, Inc. Cumberland Perry Area Vo-Tech School W8921 State Hwy. 96 110 Old Willow Mill Rd. Supporting Companies Hortonville, WI 54944 Mechanicsburg, PA 17050

Advanced Material Services, Inc. Thermion, Inc. Delta Technical College 7291 Wheatland Meadow Ct. PO Box 780 113 Market Ridge Dr. West Chester, OH 45069 Silverdale, WA 98383 Ridgeland, MS 39157

Alcoa Howmet St. Louis Metallizing Co. Hampton Roads Skills Center 555 Benston Rd., Whitehall, MI 49461 4123 Sarpy Ave. 925 48th St., Newport News, VA 23607 St. Louis, MO 63110 ArcMelt Co. L.C. Hollenstein Career and Technology Center 4734 Earth City Express Way Superior Shot Peening, Inc. 5501 Marine Creek Pkwy. Bridgeton, MO 63044 13930 Luthe Rd., Houston, TX 77039 Ft. Worth, TX 76179

Atlas Machine and Supply, Inc. Affiliate Companies Iowa Valley C. C. District 7000 Global Dr., Louisville, KY 40258 3702 S. Center St. Bay State Surface Technology, Inc. Arc Training & Consultation Services Marshalltown, IA 50158 201 Washington St., Auburn, MA 01501 110 Northwood Ave., West Seneca NY 14224 Northeast C. C. Carpenter Powder Products, Inc. 801 E. Benjamin Ave. 600 Mayer St., Bridgeville, PA 15017 DMS Machining & Fabrication Norfolk, NE 68701 PO Box 477, 10 Transport Dr. Cascadura Industrial SA Barre, VT 05641 Poplar Bluff Technical Career Center Rua Jose Maria Hannickel 3203 Oak Grove Rd. 150- 3rd Andar, Sorolaba Eagle Technology Group Poplar Bluff, MO 63901 Saõ Paulo 18 047 760, Brazil 11575 W. Theodore Trecker Way Milwaukee, WI 53214 Zeppelin Industrial Services Co., Ltd. Curtiss-Wright Surface Technologies PO Box 1495, Al Jubail 31961, Saudi Arabia 12 Thompson Rd., Gish Fabrication & Machine LLC East Windsor, CT 06088 344 S Weaver, Hesston, KS 67062 Exline Inc. MK Custom Fabrication LLC 3256 E. Country Club Rd. 7912 S Depew St. # D, Littleton, CO 80128 Salina, KS 67401

70 MAY 2012 SECTIONSECTIONNEWSNEWS

Shown are some of the attendees having a good time at the welders’ night event hosted annually by the Central Mass./Rhode Island Section. District 1 Thomas Ferri, director (508) 527-1884 [email protected] CENTRAL MASS./R.I. FEBRUARY 16 Activity: The Section held its annual welders’ night event at the Greater New Bedford Regional Technical High School for more than 100 attendees. Representa- tives from Miller Electric, Thermadyne, Shown at the Green & White Mountains Sec- ESAB, and Pferd Abrasives demonstrated tion presentation to Thermadyne engineers some of their latest products. Local dis- are (from left) Nakhleh Hussary, Darrin tributers New Bedford Welding Supply MacKenzie, and Geoff Putnam. and Total Welding Supply offered hands- on demonstrations. Chair Paul Mendez re- senting five District 1 Sections. Jim Reid Chair Paul Mendez (right) receives his Mer- ceived the Section Meritorious Service of Reid Consulting discussed welding P91 itorious Service Award from Vice Chair Award. high-strength chromium steel used for pip- Brendon Pequita at the Central Mass./Rhode ing during the morning classroom session. Island Section program. The welding exercises were held in the af- GREEN & WHITE MTS. ternoon. The event was held at Thermal FEBRUARY 5 Dynamics in West Lebanon, N.H. Activity: The Section members presented an appreciation plaque to the engineers MARCH 8 from Thermal Dynamics Corp. who sup- Activity: The Green & White Mountains plied, cut, and prepared much of the ma- Section members toured Mack Molding in terials used for the welding contests lead- Arlington, Vt., to study a variety of ma- ing up to the World Skills competitions chining and fabricating operations includ- held in London, UK. The engineers in- ing a 3200-W laser cutting system. cluded Nakhleh Hussary, Darrin MacKen- zie, Chris Conway, and Chris Polermo. Geoff Putnam, an AWS Skills Competi- MAINE tion Committee member and technical MARCH 16 specialist at Thermadyne, presented the Activity: The Section members facilitated plaque. The event was held at Thermal Dy- the state SkillsUSA welding competition. namics Corp. in West Lebanon, N.H. The event was held at United Technology Center in Bangor, Maine. The judges in- FEBRUARY 18 cluded Josh Richardson, Warren Swan, Activity: The Green & White Mountains Ron Guimond, Jesse Crosby, Tony Ayotte, Jennifer Eastley and Jim Kein are shown at Section hosted a lecture and hands-on Ed Lepage, Joel Stanley, Pat Kien, and the February 18 Green & White Mountains training program for 45 attendees repre- Tom Ferri, District 1 director. Section event. WELDING JOURNAL 71 Shown at the Green & White Mountains Section tour March 8 are (from left) Ernie Plumb, Jennifer Eastley, Phil Witteman, Gary Buckley, Rich Maddaloni, Ray Henderson, John Steel, Chris Glaski, John Shultz, David Hoffman, Mike Devens, District 1 Director Tom Ferri, and Rich Fuller.

The Maine Section members who judged the state SkillsUSA welding competition are (from left) Josh Richardson, Warren Swan, Ron Gui- mond, Jesse Crosby, Tony Ayotte, Ed Lepage, and Joel Stanley. (Photo taken by Tom Ferri, District 1 director.)

Shown at the Long Island Section meeting are (from left) John Broderick, Jesse Provler, Chair Brian Cassady, Ray O’Leary, District 2 Direc- tor Harland Thompson, and welding instructor Paul Iannotta.

Don Smith (left) and speaker Bob Waite are Awardee James Dolan (left) is shown with Paul Lenox greets speaker Nagesh Goel at shown at the January New Jersey Section Harland Thompson, District 2 director, at the February New Jersey Section program. event. the New Jersey Section program in January.

72 MAY 2012 Shown at the Reading Section program are (from left) Merilyn McLaughlin, Paul Levengood, speaker Chris Dolan, David Hibshman, Joe Young, and speaker Ken Freed. District 2 Harland W. Thompson, director (631) 546-2903 [email protected] LONG ISLAND MARCH 16 Activity: The Section members attended a meeting with the welding instructors and administration personnel at J. M. Barry Career & Technical Center in Westbury, N.Y. The meeting, held annually, allows the welding professionals to review and comment on the welding curriculum presented by the Center and make adjustments to better prepare students for jobs following graduation. Welding students from five schools participated in the Reading Section contest. NEW JERSEY JANUARY 17 Speaker: Bob Waite Topic: Welding in China Activity: James Dolan received the Dis- trict Director’s Award from Harland Thompson, District 2 director. The program was held at Snuffy’s Pantagis Ren- aissance Restaurant in Scotch Plains, N.J.

FEBRUARY 21 Speaker: Nagesh Goel Affiliation: AEIS, LLC Topic: Basic nondestructive evaluation Activity: This New Jersey Section program Shown at the Atlanta Section event are (from left) Secretary Rene Engeron, District 5 Direc- was held at Snuffy’s Pantagis Renaissance tor Carl Matricardi, Chair David Ennis, and presenter John Butler. Restaurant in Scotch Plains, N.J. Activity: The Section held its past chairmen’s recognition program at Reading- District 4 District 3 Muhlenberg Career and Technology Cen- Roy C. Lanier, director Michael Wiswesser, director ter in Reading, Pa. Past chairs attending (252) 321-4285 (610) 820-9551 the event included Merilyn McLaughlin, [email protected] [email protected] Paul Levengood, David Hibshman, and Joe Young. District 5 READING MARCH 17 Carl Matricardi, director FEBRUARY 22 Activity: The Reading Section hosted a (770) 979-6344 Speakers: Chris Dolan, welding applica- welding contest for five schools, each rep- [email protected] tion specialist; Ken Freed, business man- resented by three student welders. Each ager participant received welding gloves, chip- ATLANTA Affiliation: Arcos Industries ping hammers, wire brushes, welding caps, MARCH 8 Topic: Welding applications today ear protection, and safety glasses. Speaker: John Butler, night supervisor

WELDING JOURNAL 73 The Atlanta Section members toured Steel Inc., LLC, in March.

The Pittsburgh Section attendees are shown at the February program.

Robert Brewington (left) is shown with Alan Shissler (center) presents scholarships Northern New York Secretary Dave Parker speaker Bill Myers at the Florida West Coast to Todd Holland (left) and Timothy Getting (left) presents a speaker gift to Kenneth Phy, Section meeting. at the Florida West Coast Section program. District 6 director.

Participants at the Pittsburgh Section stu- Clinton Cunningham (left) and David Sil- dents’ day program were (from left) Kelly Pittsburgh Section Chair Brad King (right) verman earned top scores in the Pittsburgh Scott, Kerry Sabo, and John Foley. is shown with speaker Kyle Williams. Section postsecondary welding contest.

74 MAY 2012 Sequoyah High School Student Chapter contestants are shown during the Chattanooga Section’s welding competition in February. Affiliation: Steel Inc., LLC Topic: Steel Inc.’s operations Activity: The Atlanta Section members toured the facility to study various jobs in progress involving submerged arc welding and air carbon arc gouging.

COLUMBIA JANUARY 12 Speaker: Carl Matricardi, District 5 director; president Affiliation: Welding Solutions, Inc. Topic: The 2002 billboard collapse Activity: Students from the local high schools and Aiken, S.C., Student Chapter Recognized at the Pittsburgh Section program in March were the students who earned welder attended this program. The meeting was certifications during the December weld-offs. held in Lexington, S.C. Topic: Welding for storage of spent nuclear Speaker: Kyle Williams, welding technol- fuel ogist FLORIDA WEST COAST Activity: The program was held at Shaker Affiliation: Alcoa Technology Center MARCH 3 Ridge Country Club in Latham, N.Y. Topic: Aluminum discontinuities. Their Activity: The Section hosted its 20th an- causes and cures nual golf tournament to raise funds for its Activity: The meeting was held at Spring- scholarship program. The event was held District 7 field Grille in Mars, Pa. at Walden Lakes Golf and Country Club Don Howard, director in Plant City, Fla. Alan Shissler, educa- (814) 269-2895 MARCH 2 tion and scholarship chairman, presented [email protected] Activity: The Pittsburgh Section held its three scholarships. Todd Holland, Timo- 31st annual students’ day program at Com- thy Getting, and Maeve Garvin, welding COLUMBUS munity College of Allegheny County in students at Pinellas Technical Education JANUARY 25 Pittsburgh, Pa. Recognized were the 12 Center, each received $500. Speaker: John Laurence Busch, historian students who became certified welders Topic: Steam engine technology during the weld-off competition held last MARCH 14 Activity: This was a joint meeting with December. Kelly Scott from Manpower Speaker: Bill Myers, welding engineer members of the local chapters of SWE, and Kerry Sabo from Sky-Oxygen gave Affiliation: Dresser Industries, ret. ASME, ASM International, AIAA, and talks on how to prepare for jobs in the oil Topic: Electron beam welding of industrial NACE. This meeting was hosted by ASME and gas industry. John Foley represented compressor impellers at La Scala Restaurant in Columbus, Ohio. Local 154 Boilermakers, a sponsor of the Activity: The program was held at Fron- event. tier Steak House in Tampa, Fla. FEBRUARY 23 Speaker: Michael Dunn, director Affiliation: Gas Turbine Lab at OSU TRI-STATE District 6 Topic: Jet engines and erupting volcanoes MARCH 5 Kenneth Phy, director Activity: This was a joint meeting with Speaker: R. Carlisle Smith, professor (315) 218-5297 members of the local chapters of SWE, Affiliation: Bridgemont Community and [email protected] ASME, ASM International, AIAA, and Technical College NACE, held at La Scala Restaurant in Topic: Welding for Marcellus Shale proj- NORTHERN NEW YORK Columbus, Ohio. ect MARCH 6 Activity: Braving a snowstorm, 27 mem- Speaker: Kenneth Phy, District 6 director, bers and guests met at Bridgemont Com- project manager, spent fuel, Nine Mile PITTSBURGH munity and Technical College in South Point Nuclear Generating Station FEBRUARY 21 Charleston, W.Va.

WELDING JOURNAL 75 The NE Mississippi Section members are shown during their January tour.

Lawson State C. C. Student Chapter members are shown at the February seminar hosted by the Birmingham Section. ondary Division: Jeff Lankford, Jerry Thomas, and Kyle Gunther.

NE MISSISSIPPI JANUARY 19 Activity: The Section members toured the Holley Performance Products facility in Aberdeen, Miss. Tavares Irions received the Section Meritorious Award. District 9 Tavares Irions (right) receives the Section George Fairbanks Jr., director (225) 473-6362 Meritorious Award from Gary Gammill, NE ﬁ[email protected] Sequoyah High School Student Chapter par- Mississippi Section treasurer. ticipants in the welding contest are (from left) Colton Jones, instructor Chris Renfro, District 9 Director Award and Dustin Luthringer. District 8 Announced Joe Livesay, director George Fairbanks, District 9 director, (931) 484-7502, ext. 143 has nominated John Tabony, Baton Rouge [email protected] Section, for this award. The District Director Award provides CHATTANOOGA a means for District directors to recognize Sequoyah High School individuals who have contributed their Student Chapter time and effort to the affairs of their local Section and/or District. FEBRUARY 18 Activity: The Section held its annual welding competition at Sequoyah High School in Soddy Daisy, Tenn., for 50 students from BIRMINGHAM local high schools, Chattanooga State Uni- Lawson State C. C. versity, and Plumbers and Steamfitters Student Chapter Local Union 43. Earning the highest scores FEBRUARY 22 Jeff Lankford took first place, postsecondary High School Division: Dustin Luthringer, Activity: The Section and Student Chap- division, in the Chattanooga Section event. Dylan Wilson, and Colton Jones; Postsec- ter members attended a welding seminar

76 MAY 2012 Attendees are shown at the ESAB-sponsored New Orleans Section event held Feb. 28.

Mobile Section Chair Brenda Amos is shown with speaker Branden Muehlbrandt. Shown at the New Orleans Section February 2 meeting are from left (standing) Matthew Blackwell, Ricky Duet, Chair Aldo Duron, Travis Moore, Bruce Hallila, Jimmy Goodson, and Al Theriot; (front) Chris Fernandez, Catherine Chifici, and D. J. Berger.

Tim Howard (left) and Tony Hopper received plaques for their companies’ support of Mobile Section SkillsUSA activities. with hands-on training on the latest welding technology. Participating were ESAB, Shown at the Mobile Section program in January are (from left) Jackie Morris, Chair Brenda Lincoln Electric, Miller Electric, Airgas Amos, Ron Pierce, and speaker Sam Gentry. Welding Supply, Profax/Lenco, Atlas Welding Supply, Bosch Tools, and Harris MARCH 19 Equipment. The event was held at Local Activity: The Mobile Section members 372 Plumbers and Pipefitters in Dun- participated in the SkillsUSA district weld- canville, Ala. Bob Kimbrell made a pres- ing competitions hosted by the T. L. entation at the program. Faulkner Career and Technical Center. Taking the top five top welding honors were Austin Tolbert, Jonathan Ellison, MOBILE Matt Orr, John Rohm, and Taylor JANUARY 12 Goudreault. Speaker: Sam Gentry, executive director Affiliation: AWS Foundation, Inc. Shown at the Mobile Section event are the Topic: The AWS scholarship programs NEW ORLEANS top three welders in the SkillsUSA competi- Activity: The program was held at Saucy FEBRUARY 2 tion (from left) Austin Tolbert, Jonathan El- Q Restaurant in Mobile, Ala. Activity: The Section held an executive lison, and Matt Orr. committee meeting. Attending were Chair FEBRUARY 9 Aldo Duron, Travis Moore, Bruce Hallila, Affiliation: ESAB Speaker: Branden Muehlbrandt Jimmy Goodson, Al Theriot, Chris Fer- Topic: Twenty basic welding questions Affiliation: SkillsUSA nandez, D. J. Berger, Mathew Blackwell, Activity: Students Mathew Blackwell and Topic: Update on SkillsUSA Ricky Duet, and Catherine Chifici. The Catherine Chifici made presentations fo- Activity: Tony Hopper, representing Mar- meeting was held at New Orleans Pipe cusing on urging students to reach out to itime Training, and Tim Howard from Trades in Metairie, La. bring another student to a New Orleans WESCO Gas & Welding Supply, received Section meeting. The evening was spon- appreciation plaques for their company’s FEBRUARY 28 sored by ESAB in the Landmark Hotel support of the SkillsUSA program. Speaker: Jim Kovach, consultant Grand Ballroom in Metairie, La. WELDING JOURNAL 77 Topic: Automating welding operations Activity: The program was held at The Commons at Franklin, Pa.

MAHONING VALLEY MARCH 13 Activity: The Section held its meeting at Plumbers & Pipefitters Union #376 in Boardman, Ohio. Marty Loney and Don Jessop presented talks and demonstrations of pipe welding then guided the at- Shown at the Drake Well Section program are (from left) Gary Riddle, Don Adams, Ward tendees on a tour of the facilities. District Kiser, Dan Bubenheim, speaker Joel Weber, Travis Crate, Rolf Laemmer, Dave Cook, Joseph Director 10 Richard Harris presented the Crate, and Skaler Shotts. Section CWI of the Year Award to Mike Gromada; Section Meritorious Award to Mike Sampson, and the District Meritori- ous Award to Kenny Jones. Jones also received his Silver Member Certificate for 25 years of service to the Society. Attend- ing were members of the Columbiana County Career Center Student Chapter.

Shown at the Mahoning Valley program are (from left) District 10 Director Richard Harris, District 11 Mike Sampson, Kenny Jones, and presenter Marty Loney. Robert P. Wilcox, director (734) 721-8272 [email protected]

DETROIT MARCH 8 Speaker: Pat Gilmore, business development director Affiliation: RoboVent Topic: Air quality requirements for production welding in Michigan Activity: Following the talk, the group Shown at the Detroit Section event are (from left) Beth Dunkin, Chair Don Maatz, Glen toured the company’s new facility for Knight, Tim Cesarz, and Ray Roberts. demonstrations of its latest fume and oil- mist extraction equipment. The Section Appreciation Award was presented to Tim Cesarz. John Bohr received the Section Distinguished Service Award; Mike Palko and Ray Roberts received District 11 Mer- itorious Awards; and Glen Knight received the Dalton E. Hamilton Memorial CWI of the Year Award. Beth Dunkin accepted the Section Industry Sponsor Award on behalf of ATI Industrial Automation, Inc.

NORTHWEST OHIO FEBRUARY 28 Activity: The Section members met at the International Brotherhood of Boilermak- ers Local 85 in Rossford, Ohio. Paul Mc- Welding instructor Don Jessop (right) dis- Pat Gilmore (right) receives a speaker gift Grew, apprenticeship training director, cusses pipe welding for students during the from Tom Sparschu at the Detroit Section discussed the training program and con- Mahoning Valley tour. meeting. ducted a tour of the training facilities.

DRAKE WELL District 10 MARCH 13 District 12 Richard A. Harris, director Speaker: Joel Weber, technical sales Daniel J. Roland, director (440) 338-5921 Affiliation: AMET, Intelligent Welding (715) 735-9341, ext. 6421 [email protected] Systems daniel.roland@us.ﬁncantieri.com

78 MAY 2012 Shown at the Chicago Section program are from left (front) Chair Craig Tichelar, AWS Vice President Nancy Cole, and Bob Zimny; (back) George Novac, Eric Krauss, Jeff Stanczak, Eric Purkey, Marty Vondra, past AWS President Jim Greer, and Pete Host.

Theresa Wiles, outgoing Lakeshore Section Life Member David Ramseur (right) is James Peot (right) receives his Silver Mem- chair, and present Chair John Zielonka were shown with John Zielonka, Lakeshore Sec- ber Award from Lakeshore Section Chair recognized at the March meeting. tion chair. John Zielonka. LAKESHORE on the company and the welding process MARCH 8 by Vice President John Hinrichs and De- Activity: For its ladies’ and past chairmen’s sign Engineer Dan Rawson. Discussed night program, the Section members were welding of the all-aluminum deck toured the Von Stiehl Winery in Algoma, houses for the Navy’s Littoral combat ships Wis. The dinner and meeting were held at USS Freedom and USS Fort Worth, and Moxie’s in Casco, Wis. David Ramseur re- other projects. A tour of the facility fol- ceived his Life Member Certificate for 35 lowed the talks. years of membership in the Society. James Peot received the Silver Member Certifi- cate for 25 years of service to the Society. Theresa Wiles was celebrated for her serv- District 13 ices as chair for the past year. W. Richard Polanin, director Friction stir welding presenters at the Mil- (309) 694-5404 waukee Section event were (from left) Jerry [email protected] MILWAUKEE Opichka, John Hinrichs, and Scott Gillis. FEBRUARY 15 CHICAGO Activity: The Section hosted a hands-on MARCH 14 night at the Oak Creek Campus of Mil- Speaker: Nancy Cole, AWS vice president waukee Area Technical College for 75 par- Affiliation: NCC Engineering, owner ticipants. The highlight of the evening was Topic: Brazing and soldering processes demonstrations of friction stir welding pre- Activity: The program was held at sented by Jerry Opichka, John Hinrichs, Palermo’s Restaurant in Chicago, Ill. and Scott Gillis from Friction Stir Link, Inc. Other attractions were the Lincoln VRTEX® virtual reality arc welding J.A.K. trainer, and interactive displays from MARCH 8 ESAB and Miller Electric. Activity: The Section held its officer meeting in Kankakee, Ill. Secretary Zach Awad, MARCH 15 welding program director at Kankakee Presenters John Hinrichs (left) and Dan Activity: The Section members visited Community College, discussed its welding Rawson are shown at the Milwaukee Sec- Friction Stir Link, Inc., for presentations program. Other topics were the Section’s tion tour.

WELDING JOURNAL 79 The Indiana Section members are shown during their tour of Andretti Motorsports February 22.

The St. Louis Section members toured Sheet Metal Workers Local 36 in February.

Shown at the Indiana Section welding contest are (from left) Clynton Conley, Kyle Hutche- son, Chair Gary Dugger, Scott Mumms, Tony Brosio, Alex Pedico, and Brett Roll. Shown at the J.A.K. Section meeting are (from left) Vice Chair Mike Spangler, Zach Awad, and Chair Mark Stevenson.

participation in other projects, including an upcoming welding contest, increasing student memberships and students’ in- volvement with the J.A.K. Section’s events.

St. Louis Section awardees are (from left) Rick Suria, John Woods, Keith Otten, Chad May- den, Todd Studebaker, Cole Williamson, and Victor Shorkey. District 14 Robert L. Richwine, director (765) 378-5378 [email protected] INDIANA FEBRUARY 11 Activity: The Section judged and organized the regional SkillsUSA welding contests in Indianapolis, Ind. The state quali- fiers were Clynton Conley, Kyle Hutche- son, Scott Mumms, Alex Pedico, and Brett Participants in the St. Louis Section seminar included (from left) Jerry Simpson, Don Mc- Roll. The judges were District 14 Director Fall, David Beers, Bobbie Scholin, Ray Moore, Ed Kasper, and Billy Crow. Bob Richwine, Chair Gary Tucker, Bennie 80 MAY 2012

SPECIAL OFFER FOR NEW AWS INDIVIDUAL MEMBERS – TWO YEARS FOR $135 (a $25 savings) PLUS... Get a popular welding publication for only $35 ($192 value) AWS MEMBERSHIP APPLICATION BOOK/CD-ROM SELECTION 4 Easy Ways to Join or Renew: (Pay Only $35... up to a $192 value) + Mail this form, along with your payment, to AWS NOTE: Only New Individual Members are eligible for this selection. Be sure to add $35 to your total payment. ( Call the Membership Department at (800) 443-9353, ext. 480 ONLY ONE SELECTION PLEASE. 2 Fax this completed form to (305) 443-5647 q Jefferson’s Welding Encyclopedia (CD-ROM only) : Join or renew on our website q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Mr. q Ms. q Mrs. q Dr. Please print • Duplicate this page as needed q Welding Handbook (9th Ed., Vol. 4) q Welding Handbook (9th Ed., Vol. 3) Last Name______q Welding Handbook (9th Ed., Vol. 2) q Welding Handbook (9th Ed., Vol. 1) First Name______M.I.______For more book choices visit www.aws.org/membership Title______Birthdate ______Learn more about each publication at www.awspubs.com Were you ever an AWS Member? q YES q NO If “YES,” give year_____and Member # ______q New Member q Renewal A free local Section Membership is included Primary Phone ( )______Secondary Phone ( ) ______with all AWS Memberships. Section Affiliation Preference (if known): FAX ( )______E-Mail ______Type of Business Did you learn of the Society through an AWS Member? r Yes r No (Check ONE only) A q Contract construction If “yes,” Member’s name:______Member’s # (if known): ______B q Chemicals & allied products C q Petroleum & coal industries From time to time, AWS sends out informational emails about programs we offer, new Member benefits, savings opportunities and D q Primary metal industries changes to our website. If you would prefer not to receive these emails, please check here r E q Fabricated metal products F q Machinery except elect. (incl. gas welding) ADDRESS NOTE: This address will be used for all Society mail. G q Electrical equip., supplies, electrodes H q Transportation equip. — air, aerospace Company (if applicable) ______I q Transportation equip. — automotive J q Transportation equip. — boats, ships K q Transportation equip. — railroad Address ______L q Utilities M q Welding distributors & retail trade Address Con’t. ______N q Misc. repair services (incl. welding shops) O q Educational Services (univ., libraries, schools) P q Engineering & architectural services (incl. City______State/Province______Zip/Postal Code ______Country ______assns.) q NOTE: This data will be used to develop programs and services to Q Misc. business services (incl. commercial labs) PROFILE DATA R q Government (federal, state, local) serve you better. S q Other u q q v q q Who pays your dues?: Company Self-paid Sex: Male Female Job Classification (Check ONE only) w Education level: q High school diploma q Associate’s q Bachelor’s q Master’s q Doctoral 01 q President, owner, partner, officer 02 q Manager, director, superintendent (or PAYMENT INFORMATION (Required) assistant) 03 q Sales 04 q Purchasing ONE-YEAR AWS INDIVIDUAL MEMBERSHIP ...... $80 05 q Engineer — welding SAVE $25 q (New Members Only) 20 Engineer — design TWO-YEAR AWS INDIVIDUAL MEMBERSHIP† ...... $160 $135 21 q Engineer — manufacturing 06 q Engineer — other New Member? ___Yes ___No If yes, add one-time initiation fee of $12 ...... $______10 q Architect designer

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Shown at the Kansas City November program are (from left) Grant Von Lunen, Richard Blaisdell, District 16 Director David Landon, and Jason Miles.

Presenter Howard Rinne (left) is shown with Mike Vincent, Kansas City Section chair, at the January program.

Flynn, Tony Brosio, Gary Dugger, Robert Holland, and Beau McHaffey.

FEBRUARY 22 Activity: The Indiana Section members, with the cooperation of The Lincoln Elec- tric Co., enjoyed a tour of the Andretti Mo- The Kansas City Section members are shown at the November program. torsports garage in Indianapolis. The presenter was Bennie Flynn, Section vice chair.

ST. LOUIS DECEMBER 2 Activity: The Section held its annual holi- day awards-presentation event at Royal Orleans Banquet Center in St. Louis, Mo. Rick Suria and John Woods received Sec- Kansas City Section and ASQ members are shown during their tour of SPX Cooling Tech- tion Meritorious Awards. Keith Otten re- nologies in January. ceived the Section Educator Award. The Section Private Sector Instructor Award KANSAS CITY went to Chad Mayden. The Dalton E. District 15 Hamilton District CWI of the Year Award David Lynnes, director NOVEMBER 10 Kyle Dunning Isaac Somo- was presented to Todd Studebaker and the (701) 365-0606 Speakers: and gie Section CWI Award went to Cole [email protected] Williamson. The District 14 Director Affiliation: University of Missouri Bridge award was presented to Victor Shorkey. Te a m District 16 Topic: The history and challenges of the bridge building competition FEBRUARY 23 Dennis Wright, director David Lan- Activity: The St. Louis Section hosted a (913) 782-0635 Activity: District 16 Director don safety and metal-preparation seminar at [email protected] presented the District Educator of the Grant Von Lunen Sheet Metal Workers Local 36 Training Year Award to , the Dis- Richard Blais- Center in St. Louis, Mo. The presenters KANSAS trict Meritorious Award to dell included Ray Moore from Jackson Safety MARCH 15 , and the District CWI of the Year Jason Miles Products; Bobbie Scholin from Kimberly- Speaker: Clint Eastwood, CWI, territory Award to . The program was Clark; and Don McFall from J. Walter manager held at the University of Missouri in Abrasives. Local 36 representatives Ed Affiliation: ESAB Kansas City, Mo. Kasper and Billy Crow conducted the Topic: The true cost of welding members and guests on a tour of the new Activity: The program was held at Lamp- JANUARY 12 training facility. ton Welding Supply in Wichita, Kan. Activity: The Kansas City Section mem-

WELDING JOURNAL 83 Attendees are shown at the Kansas City tour in March. AWS President Bill Rice (left) presents the Silver Member award to Barry Breeden at the North Texas Section program.

Mike Vincent (left), Kansas City Section chair, is shown with Dennis Wright, District Keith Theesen (left) is shown with Cary 16 director, at the March program. Reeves, Oklahoma City Section chair.

The North Texas Section presented Paul Stanglin with the District 17 Educator and Section Meritorious Awards.

Celebrating the Boy Scouts Welding Badge release at the North Texas Section program are (from left) Dwight Grayson, AWS President Bill Rice, past AWS President Ernest Levert, and Jay Jones, District 17 director. Awardees at the Oklahoma City Section program included (from left) Kenneth Poarch, Johnny Day, and speaker John Marx. District 17 J. Jones, director (940) 368-3130 [email protected] NORTH TEXAS FEBRUARY 28 Speaker: Bill Rice, AWS president, CEO The Alaska Section members are shown at the February program. Affiliation: OKI Bering Supply Topic: Update on AWS activities bers met with members of the local chap- Kan. Tom Breen, a CWI and CWE, gave a Activity: District 17 Director J. Jones, ter of ASQ to tour the SPX Cooling Tech- presentation on weld defects and the qual- scout master and past AWS President nologies facility in Olathe, Kan. Howard ity levels expected on parts produced at Ernest Levert, and Dwight Grayson, a Rinne discussed the company’s history the company. Laroux Gillespie, SME scout master, celebrated the establishment then conducted the tour for 55 attendees. chair, discussed the future of manufactur- of the Boy Scouts of America Welding ing in America. Following the talks, the Merit Badge. Barry Breeden received his MARCH 8 group toured the shop. District 16 Direc- AWS Silver Member Certificate for 25 Activity: The Kansas City Section mem- tor Dennis Wright presented Chair Mike years of service. Paul Stanglin received the bers met with members of the local SME Vincent the District Director Certificate District Educator and the Section Merito- Chapter to visit Webco Mfg. Co. in Olathe, Award. rious Awards.

84 MAY 2012 Portland Section members got a safety briefing before touring Gunderson Corp. in February.

Steve Prost (left), British Columbia Section chair, receives the District Director award from Neil Shannon, District 19 director.

Welding students posed during the Puget Sound Section program in March.

OKLAHOMA CITY Activity: District 19 Director presented FEBRUARY 16 Chair Steve Prost the District Director Speaker: John Marx, SCWI Certificate Award. The program was held Affiliation:The Inspection Group at UA Piping Industry College of British Topic: Nondestructive examination Columbia in Delta, B.C. Activity: John Marx and Kenneth Poarch Speaker Scott Stanley (left) is shown with received their Lifetime Member Certifi- Steve Prost, chair, British Columbia Section. cates for 35 years of service to the Society. OLYMPIC Keith Theesen received the Section Edu- FEBRUARY 28 cator Award and Johnny Day received the Speaker: John Knapp, welding inspector Section Meritorious Award. Affiliation: International Inspection, Inc. Topic: Nondestructive examination methods and certification District 18 Activity: Rosy Jensen presented a Section John Bray, director scholarship to Jason Williams. (281) 997-7273 sales@afﬁliatedmachinery.com PORTLAND FEBRUARY 9 District 19 Activity: The Section members toured the Neil Shannon, director Gunderson Corp. facility in Portland, Ore. (503) 201-5142 Jeff Powell, welding training supervisor, [email protected] led the tour of the manufacturing areas Speaker John Knapp (left) is shown with where the rail cars and marine barges are Sjon Delmore, Olympic Section chair. built. Fifty members and guests attended. ALASKA FEBRUARY 22 Speaker: James St. George, president PUGET SOUND Affiliation: STG, Inc., Anchorage MARCH 1 Topic: Erecting wind farms in rural Alaska Speaker: Phillip Formento, CWI, CWS Activity: The event was held in Anchor- Affiliation: ESAB age, Alaska, for 43 attendees. Topic: Filler metals Activity: Vice Chair Ken Johnson is organizing a one-day seminar on D1.1, Structural BRITISH COLUMBIA Welding Code — Steel, and ASME Boiler FEBRUARY 22 and Pressure Vessel Code, Section IX, Weld- Speaker: Scott Stanley, technical sales rep- ing and Brazing Qualifications. Welding resentative students from Everett Community College Affiliation: The Lincoln Electric Co. and Lake Washington Technical College Topic: Welding productivity improvements attended the program, held at Rock Salt Rosy Jensen presented an Olympic Section using hard automation Steak House in Seattle, Wash. scholarship to Jason Williams in February.

WELDING JOURNAL 85 Spokane Section members are shown during their tour of Ground Force Mfg. in Post Falls, Idaho, in March. held. The topic was pipelines, wellhead equipment, and oilfield maintenance services. Speakers included John Steele (CSM), Jesse Grantham (WJMG), Robert Sauders (Bohler Welding Group), Steve Weinhold (Anadarko Petroleum), Richard Campbell (Bechtel), Gean Burr (Eaton Metals), Steve Kalmbach (KASKO), Ted Vidimos (TEAM Industrial Services), and Steve Nelson (Colo. Pressure Vessel In- A scene at the Welding the Rockies Symposium cosponsored by the Colorado Section. spection Div.). AWS representatives Sam Gentry and Joe Krall discussed plans for the AWS-sponsored IIW Annual Assem- bly to be held July 8–13 in Denver. Gen- try is executive director, AWS Foundation, Inc.; Krall is managing director, global exposition sales. About 130 people participated in the program.

UTAH FEBRUARY 23 Speaker: Larry Zirker, senior engineer Utah Section members are shown at the February program. Affiliation: Battelle Energy Alliance Topic: Practical metallurgy SPOKANE Activity: This program was held at Weber MARCH 20 State University Training Center in Ogden, Activity: The Section visited Ground Force Utah, sponsored by the Miller Electric Mfg. in Post Falls, Idaho, to study the man- Mfg. Co. ufacture of equipment used in under- ground and open pit mines. The presenters included John Chambers, vice president; and Chad Wilson, plant manager. District 21 Highlights included the fabrication of Nanette Samanich, director large-scale fuel and lube trucks, rigid truck (702) 429-5017 frame chassis, and welding and hydraulics [email protected] operations. Attendees included 26 mem- AWCIWT Student Chapter bers, students, and guests. NOVEMBER 29 Paul Stone (left) and Phillip Formento are Activity: The Arizona Western College In- shown at the Puget Sound Section event. stitute of Welding Technology (AWCIWT) District 20 Student Chapter, headed by Advisor William A. Komlos, director Samuel Colton, traveled to the Lincoln (801) 560-2353 Electric Co. Center for Excellence in Cal- [email protected] ifornia to participate in a welding automation and simulation workshop. Alex Bautista, Lincoln district manager, con- COLORADO ducted the program. The event included MARCH 9 lectures and hands-on demonstrations Keynote speaker: Stephen Liu, professor using power sources, welding automation, Affiliation: Colo. School of Mines (CSM) fume-extraction technology, and welding Topic: Welding under oil simulation. Activity: The Section cohosted the third annual Welding the Rockies Symposium DECEMBER 2 Larry Zirker discussed metallurgy at the with CSM and Lincoln College of Tech- Activity: The AWCIWT Student Chapter Utah Section program in February. nology, Denver, Colo., where the event was members celebrated the end of semester

86 MAY 2012 AWCIWT Student Chapter members are shown at the Lincoln workshop. From left are Nestor Alaniz; instructors Nate Bailey, Kevin Knoll, Gonzalo Huerta Jr., and Chris Larson; Garrett Lakey; Manuel Robles; Omar Macias; Jesus Leyva; President Justin Skellett; John Stratz; George Padilla; Adrian Castillo; Trisha Haswood; and presenter Alex Bautista accompanied by Lincoln engineers wearing red shirts.

Shown at the December AWCIWT Student Chapter event are (from left) Manuel Robles, Adrian Castillo, President Justin Skellett, Omar Macias, John Stratz, Trisha Haswood, George Padilla, and Prof. Kevin Knoll. L.A./Inland Empire Section Chair George with a social at the Yuma Fun Factory in Rolla (left) is shown with Robert Armstrong. Yuma, Ariz. Justin Skellett, Chapter president, spoke on the achievements and ca- maraderie enjoyed by the students and the successes of the AWCIWT Chapter.

L.A./INLAND EMPIRE FEBRUARY 22 Speaker: Chris Koelliker Affiliation: Stud Welding Products Topic: History of stud welding Activity: The talk was followed by a hands- on demonstration of attaching anchors to a steel plate using stud welding. About 45 members attended the program, held at Sam Gentry (left) and Joe Krall discussed Shown at the Santa Clara Valley Section pro- Stud Welding Products in Downey, Calif. plans for the upcoming IIW Annual Assem- gram are (from left) Alex Gutierrez, Chair bly at the Colorado Section symposium. Tom Erichsen, and Daniel Sanchez. District 22 Dale Flood, director (916) 288-6100, ext. 172 International d.ﬂ[email protected] Section SANTA CLARA VALLEY MARCH 13 Speakers: Daniel Sanchez, welder; Alex ISRAEL Gutierrez, manager welding and NDE Activity: The Section recently held its an- services nual conference with 200 participants. The Affiliation: PG&E Applied Technology Section is hosting a CWI course for 15 stu- Service dents. So far, its courses have certified 75 Topic: Creating mapping and 3D images welding inspectors. Elections were held. using laser scanner for Pacific Gas and Jacky Ben-Dayan succeeds Shimon Ad- Adi Atsits (right), recently elected Israel Sec- Electric industry dess as chair of the Certifying Committee; tion chair, presents an appreciation award Activity: The program was held at Harry’s and Adi Atsits succeeds Eliezer Belinco as to Eliezer Belinco for his services as Section Hoffbrau in San Jose, Calif. Section chairman. chairman.

WELDING JOURNAL 87 Guide to AWS Services 550 NW LeJeune Rd., Miami, FL 33126; (800/305) 443-9353; FAX (305) 443-7559; www.aws.org Staff extensions are shown in parentheses.

AWS PRESIDENT INTERNATIONAL SALES TECHNICAL SERVICES William A. Rice Managing Director, Global Exposition Sales Department Information ...... (340) [email protected] Joe [email protected] ...... (297) Managing Director 1411 Connell Rd. Andrew R. Davis.. [email protected] ...... (466) Charleston, WV 25314 Corporate Director, International Sales International Standards Activities, American Coun- Jeff P. [email protected] ...... (233) cil of the International Institute of Welding (IIW) ADMINISTRATION Oversees international business activities involving cer- Executive Director tification, publication, and membership. Director, National Standards Activities Ray W. Shook.. [email protected] ...... (210) Annette Alonso.. [email protected] ...... (299) Sr. Associate Executive Director PUBLICATION SERVICES Manager, Safety and Health Cassie R. Burrell.. [email protected] ...... (253) Department Information ...... (275) Stephen P. Hedrick.. [email protected] ...... (305) Managing Director Metric Practice, Safety and Health, Joining of Plas- Sr. Associate Executive Director Andrew Cullison.. [email protected] ...... (249) tics and Composites, Welding Iron Castings, Welding Jeff Weber.. [email protected] ...... (246) in Sanitary Applications, Personnel and Facilities Welding Journal Qualification Chief Financial Officer Publisher Gesana Villegas.. [email protected] ...... (252) Andrew Cullison.. [email protected] ...... (249) Senior Manager, Technical Publications Rosalinda O’Neill.. [email protected] ...... (451) Executive Assistant for Board Services Editor AWS publishes about 200 documents widely used Gricelda Manalich.. [email protected] . . . . .(294) Mary Ruth Johnsen.. [email protected] . .(238) throughout the welding industry. Administrative Services National Sales Director Senior Staff Engineer Managing Director Rob Saltzstein.. [email protected] ...... (243) Rakesh Gupta.. [email protected] ...... (301) Jim Lankford.. [email protected] ...... (214) Filler Metals and Allied Materials, International Filler Society and Section News Editor Metals, UNS Numbers Assignment, Arc Welding and IT Network Director Howard [email protected] . .(244) Cutting Processes Armando [email protected] . .(296) Welding Handbook Staff Engineers/Standards Program Managers Director Editor Efram Abrams.. [email protected] ...... (307) Hidail Nuñ[email protected] ...... (287) Annette O’Brien.. [email protected] ...... (303) Thermal Spray, Automotive Resistance Welding, Oxy- fuel Gas Welding and Cutting Director of IT Operations Natalia [email protected] ...... (245) MARKETING COMMUNICATIONS Stephen Borrero... [email protected] . . . . .(334) Director Brazing and Soldering, Brazing Filler Metals and Human Resources Ross Hancock.. [email protected] ...... (226) Fluxes, Brazing Handbook, Soldering Handbook, Director, Compensation and Benefits Railroad Welding, Definitions and Symbols Luisa Hernandez.. [email protected] ...... (266) Public Relations Manager Cindy [email protected] ...... (416) Alex Diaz.... [email protected] ...... (304) Director, Human Resources Welding Qualification, Sheet Metal Welding, Aircraft Dora A. Shade.. [email protected] ...... (235) Webmaster and Aerospace, Joining of Metals and Alloys Jose [email protected] ...... (456) International Institute of Welding Brian McGrath .... [email protected] . . . . .(311) Senior Coordinator Section Web Editor Methods of Inspection, Mechanical Testing of Welds, Sissibeth Lopez . . [email protected] ...... (319) Henry [email protected] ...... (452) Welding in Marine Construction, Piping and Tubing, Liaison services with other national and international Friction Welding, Robotics Welding, High-Energy societies and standards organizations. Beam Welding MEMBER SERVICES GOVERNMENT LIAISON SERVICES Department Information ...... (480) Matthew [email protected] ...... (215) Hugh K. Webster ...... [email protected] Sr. Associate Executive Director Structural Welding, Machinery and Equipment Webster, Chamberlain & Bean, Washington, D.C., Cassie R. Burrell.. [email protected] ...... (253) (202) 785-9500; FAX (202) 835-0243. Monitors fed- Notes: Official interpretations of AWS standards may eral issues of importance to the industry. Director be obtained only by sending a request in writing to An- Rhenda A. Kenny... [email protected] ...... (260) drew R. Davis, managing director, Technical Services, CONVENTION and EXPOSITIONS Serves as a liaison between Section members and AWS [email protected]. Jeff Weber.. [email protected] ...... (246) headquarters. Oral opinions on AWS standards may be ren- dered, however, oral opinions do not constitute offi- Director, Convention and Meeting Services CERTIFICATION SERVICES cial or unofficial opinions or interpretations of AWS. Selvis [email protected] ...... (239) Department Information ...... (273) In addition, oral opinions are informal and should Managing Director not be used as a substitute for an official interpreta- ITSA — International Thermal John L. Gayler.. [email protected] ...... (472) tion. Spray Association Oversees all certification activities including all inter- Senior Manager and Editor national certification programs. Kathy [email protected] . . .(232) AWS FOUNDATION, INC. Director, Certification Operations www.aws.org/w/a/foundation Terry [email protected] ...... (470) General Information RWMA — Resistance Welding Oversees application processing, renewals, and exam (800/305) 443-9353, ext. 212, [email protected] Manufacturing Alliance scoring. Manager Chairman, Board of Trustees Selvis [email protected] ...... (239) Director, Certification Programs Gerald D. Uttrachi Linda [email protected] ...... (298) Oversees the development of new certification pro- Executive Director, Foundation WEMCO — Association of grams, as well as AWS-Accredited Test Facilities, and Sam Gentry.. [email protected]...... (331) Welding Manufacturers AWS Certified Welding Fabricators. Manager Corporate Director, Workforce Development Selvis [email protected] ...... (239) Monica Pfarr.. [email protected]...... (461) EDUCATION SERVICES Brazing and Soldering Director, Operations The AWS Foundation is a not-for-profit corporation es- Manufacturers’ Committee Martica Ventura.. [email protected] ...... (224) tablished to provide support for the educational and scien- Jeff Weber.. [email protected] ...... (246) tific endeavors of the American Welding Society. Director, Education Development Promote the Foundation’s work with your financial sup- GAWDA — Gases and Welding David Hernandez.. [email protected] . . .(219) port. Call (800) 443-9353 for information. Distributors Association Executive Director AWS AWARDS, FELLOWS, COUNSELORS John Ospina.. [email protected] ...... (462) Senior Manager Wendy S. Reeve.. [email protected] ...... (293) Operations Manager Coordinates AWS awards, Fellow and Counselor Natasha Alexis.. [email protected] ...... (401) nominees.

88 MAY 2012 Hosted by:

A distinguished panel of aluminum-industry experts will survey the state of the art in aluminum welding technology and practice during this two-day conference.

September 18th - 19th / Seattle, W

Early Bird Attendee Member Rate $575 / Non-member Rate $705

For the latest conference information and registration visit our web site at www.aws.org/conferencewwwww..aws.org/conference.aws.org/confeaws org/confe or call 800-443-9353, ext. 264.264.

Earn PDHs toward your AWSAWS recertification when you attend the conference. PERSONNEL

Airgas Names VP bama, Florida, Georgia, the Carolinas, for several key North American markets. and the southern half of Kentucky. Place brings 25 years of experience cor- Airgas, Radnor, Pa., a distributor of in- Ferrara has a wide range of experience in recting erosion and corrosion problems in dustrial gases and welding equipment and automotive component production, mission-critical equipment. Most recently, supplies, has named Doug Sherman vice light-metal processing, and project he served as director of sales for the president — communications. Previously, management. NanoSteel Co. where he led the power Sherman served since 2002 as director — plant material solutions sales efforts. marketing communications. CoroWare Adds Board Member Aluminum Association ArcOne Appoints Sales VP Appoints Vice Chair CoroWare, Kirkland, Wash., a devel- ArcOne, Taunton, oper and marketer of computer and ro- The Aluminum Association, Arling- Mass., a provider of botics software and hardware solutions, ton, Va., has appointed Layle K. (Kip) autodarkening weld- has named William Robert Norris to its Smith vice chairman. Smith has served as ing helmets, inverter board of advisors. Norris previously president and CEO of Noranda Alu- power sources, respi- served 15 years at Deere & Co., the Na- minum Holding Co. since 2008. Previ- ratory protection, tional Center for Supercomputer Applica- ously, he held various international and and head and face tions, and the U.S. Army Construction business leadership positions at The Dow protection products, Engineering Research Lab where he in- Chemical Co., most recently as COO of has promoted Fred troduced robotics products for military resolution performance products and Thomas to vice presi- and other market segments. CEO of covalence specialty materials. Fred Thomas dent sales. Previ- ously, Thomas was senior regional sales manager. His new CGW Fills Key Post Adept Technology Names position includes responsibility for Global VP Canada and the western region of the CGW-Camel Grinding Wheels, Niles, United States. Ill., has appointed Daniel Grantham west- Adept Technology, Pleasanton, Calif., ern sales manager and director of welding a supplier of vision-guided robots and au- Hainbuch Appoints distribution, responsible for western U.S. tonomous mobile solutions, has appointed states and western Canadian provinces. Robert J. Malley Jr. vice president of SE Sales Rep With more than 15 years of experience in global operations. Malley most recently the industry, Grantham was previously di- served as chief operating officer for MDC Hainbuch Amer- rector of U.S. sales at Walter Surface Vacuum Products and earlier was vice ica, Mequon, Wis., a Technologies. president of global materials and manu- supplier of precision facturing at Intervac. work-holding solutions for the automo- Integrated Global Services tive and other indus- Names Sales Manager Induction Heating Sales tries, has named Pete Force Expanded Ferrara to direct ap- Integrated Global Services, Rich- plication and sales mond,Va., a provider of metal surface pro- GH Induction Atmospheres, Rochester, support for cus- tection services for the power-generation, N.Y., has hired Lance Dumigan and Scott Pete Ferrara tomers in the south- paper, petrochemical, and other mission- Berry as regional sales managers. Dumigan, east region, including critical industries, has named Michael R. previously business development manager Virginia, Tennessee, Mississippi, Ala- Place regional sales manager responsible for Hover-Davis, will service the southeast region from Pennsylvania to Florida. Berry, with 30 years of experience in the heat- treating business, will service customers in DO YOUR OWN TESTING Michigan, Illinois, Indiana, and Ohio.

Bend Testers - Bend Specimen Cutting Obituary Fixtures - Coupons -Tensile Testers BT1B Kenneth E. Richter Sr. Visit our website TT1 for all sizes and Kenneth Edwin Richter Sr., 87, died models available Feb. 23 in Scottsdale, Ariz. He was an AWS Counselor and Life Member, and was a past chair of the AWS San Francisco Section and the AWS Educational Activi- ties Committee. Rotary International BSC-1PLT BT1C www.fischerengr.com ! (937)754-1750 — continued on page 92

For info go to www.aws.org/ad-index 90 MAY 2012

PERSONNEL Linde Div., as a and electron beam welding systems. In product and process 1980, Richter became president of the — continued from page 90 development engi- NuWeld and MCI divisions of Dimetrics neer where he where he made major contributions to the worked for 29 years. development of welding automation. In named him a Paul Harris Fellow. Richter There he made sig- 1985, he became president of the U.S. sub- joined the Army Airforce during World nificant contribu- sidiary of Kemppi, Inc., where he intro- War II where he served in the invasion at tions to the commer- duced inverter power supplies to the Omaha Beach and the Battle of the Bulge cial development of American marketplace. Richter enjoyed followed by two years in Europe with the the Heliarc (GTAW) flying, fishing, sailing, and football. 8th and 9th Air Force. Following dis- Kenneth Richter Sr. and Sigma (GMAW) He is survived by his wife Jane, a son, charge, he earned his master of science de- welding processes, two daughters, four grandchildren, and gree at Wayne State University. He began ST-1 curved-nozzle GMAW torch, Short two great-grandchildren. his career teaching at Hamtramck High Arc GMA welding process, argon-carbon School. In 1952, he joined Union Carbide, dioxide gas mixtures for GMA welding,

AWS Distinguished Welder Award

During the Board of Directors meetings held in conjunction with FABTECH 2011 in Chicago, Ill., the AWS Districts Council approved a new AWS award. This award will recognize an individual whose welding skills and experience would earn her or him the recognition of being an AWS Dis- tinguished Welder. A nomination packet should include information addressing the Definition and Candidate’s Application Criteria as outlined in the AWS Distinguished Welder Award Nomination Form (see pages 93 and 94). The focus of the nomination packet should include specifics of the individual’s skills. August 1 is the deadline for submitting the nomination to the address listed on the form. For details, contact Wendy Sue Reeve at [email protected].

92 MAY 2012 AWS Distinguished Welder Award Nomination Form

DATE______NAME OF CANDIDATE______

AWS MEMBER NUMBER______YEARS OF AWS MEMBERSHIP______PHONE______

HOME ADDRESS______CITY______STATE______ZIP CODE______

PRESENT COMPANY/INSTITUTION AFFILIATION______

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CITY______STATE______ZIP CODE______BUSINESS PHONE NO______

NUMBER OF YEARS EXPERIENCE AS A WELDER AND/OR SUPERVISOR______

Through supporting records, testimonies, and documentation a nomination packet for a nominee must be submitted by August 1 of the selection year for consideration. The amount of information submitted is not as significant as the specifics provided for the individual being nominated. Information submitted should address all the Definition and Selection criteria listed below:

Definition:

A Distinguished Welder consistently makes welds free of rejectable discontinuities and exhibiting uniformity, smooth bead appearance, and other visual attributes that identify excellent workmanship and welding aesthetics that come with practice and developed over many years of quality welding Must be able to pass multiple tests in multiple or single processes through mechanical and non-destructive testing Must be able to mentor other welders under him or her and promote their efforts to produce acceptable welds that exhibit superior workmanship Must be able to produce welds in a timely manner while safely following the company procedures Must be able to read blue prints and welding procedures with no supervision The Distinguished Welder is an all-around hand with skills in material preparation, lay-out and fit-up, and visual quality assessment

Candidate Application Criteria:

• Shall have a minimum of 15 years’ experience as a welder and/or supervisor • Shown to have passed multiple tests in multiple or single processes free of rejectable discontinuities and exhibit uniformity, smooth bead appearance, and other visual attributes that identify excellent workmanship and welding aesthetics learned over many years of quality welding • Must have good teamwork skills • Must be able to interpret and utilize various welding codes and standards, including but not limited to AWS, ASME, and API • Must be able to interpret welding and nondestructive examination symbols on drawings • Must be able to repair base materials and welding metal discontinuities • Maintains a safe work environment and is proficient in recognizing safety hazards • Must be able to perform proper use of Hazardous Materials and understand the use of Material Safety Data Sheets (MSDS) • Must be able to explain safety for specific welding processes • Must be familiar with AWS Standards and Safety Fact Sheets and OSHA 1910 Subpart Q or other applicable regulations • Troubleshoot and maintain equipment • Weld components in flat, vertical, horizontal, or overhead as appropriate for the given welding process • Recognize, set up, operate and maintain hand and power tools common to welding • Perform joint preparation and assure cleanliness, perform weld fit-up, maintain fabrication tolerance • Perform and maintain preheat and interpass temperatures • Recognize procedures to incorporate Post Weld Heat Treatment • Employ fabrication techniques to reduce welding stress and distortion • Understands basic welding metallurgy • Understand and follow Welding Procedure Specifications • Demonstrate experience in examination or measurements to verify that an item or activity conforms to specified requirements • Understand material inspection • Understand QA/QC • Perform visual inspection and understand various criteria.

A maximum of 10 individuals may be selected as a Distinguished Welder per year as determined by the selection Committee. Nominations shall remain valid for three years.

If the maximum number of Distinguished Welders allowed under the rules is reached, the additional candidates are deferred until the next year, consistent with their time eligibility. If less than the maximum number is identified, the remaining candidates are deferred until the next year, consistent with their time eligibility.

Supporting Letters:

Letters of support from those knowledgeable of the candidate’s skills and contributions are encouraged. These letters should address the metrics listed above and provide personal insight into the stature and contributions of the candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.

Return the completed Distinguished Welder Award nomination package to:

Wendy Sue Reeve Senior Manager, Award Programs and Administrative Support 550 N.W. LeJeune Road Miami, FL 33126

Email: [email protected] Telephone: 305-443-9353 Ext. 293 800-443-9353 Ext. 293 Fax: 305-443-7559 Final - wsr-3.22.12

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100 MAY 2012 SUPPLEMENT TO THE WELDING JOURNAL, MAY 2012 Sponsored by the American Welding Society and the Welding Research Council Reagent Selection in Austenitic Stainless Steel Solidification Modes Characterization

Out of eight different reagents tested to etch austenitic stainless steel weld metal, two showed the best results for microstructural characterization of solidification modes

BY M. ASUNCIÓN VALIENTE BERMEJO

ABSTRACT ditionally, the transition between solidification modes was related to a critical Cr /Ni ratio. However, the new results Although a wide range of reagents is recommended for the microstructural char- eq eq obtained by the author demonstrated that acterization of stainless steels in the literature, the current research compares eight the total alloying level was a key factor in different reagents according to the following criteria: clear contrast between austen- the transition between AF and FA solidi- ite and ferrite phases and morphologies, etching temperature, ease and simplicity of fication modes. In order to work on the reagents preparation and application, and absence or presence of artifacts. Experi- microstructural characterization of the mental results obtained when using Fry, oxalic acid, Lichtenegger-Blöch, Murakami, austenitic steel samples effectively, and modified Beraha, Kalling’s Nº2, Ferrofluid 230300-135-3, and Ferrofluid EMG 911 considering the wide composition range reagents are presented in this paper. The advantages and drawbacks of these reagents and number of reagents proposed in the in the study of the solidification modes in austenitic stainless steels under arc welding literature (Refs. 6–9), it was necessary to conditions are compared. As the conclusion of the current work, only Ferrofluid EMG select a reagent that was capable to pro- 911 and Kalling’s Nº2 reagents were found suitable based on the outlined criteria. vide the best etching results with the samples involved in the study. Consequently, the reagents selection was carried out ance of δ/γ interfaces than δ/δ or γ/γ in- Introduction prior to the main microstructural assess- terfaces where the eutectic liquid enriched ment. This paper presents the results ob- with impurities has better grain boundary In studying austenitic stainless steels, tained from the reagent selection process. wettability. Therefore, the microstructural the microstructural characterization of the The advantages and drawbacks of eight characterization of the transition between solidification modes (austenitic [A], different reagents were illustrated when AF and FA solidification modes in austenitic-ferritic [AF], ferritic-austenitic they were employed to etch austenitic austenitic stainless steels is essential in [FA], and ferritic [F]) (Refs. 1–3) is of ut- stainless steel weld metal in order to es- order to establish the material susceptibil- most importance. It is well known that the tablish the microstructural characteriza- ity to hot cracking. Microscopy is also use- hot cracking phenomenon can be experi- tion of their solidification modes. ful to detect brittle phases in those enced by austenitic stainless steels while A common feature of suitable metallo- austenitic stainless steels subject to high they are subject to certain heating/cooling graphic reagents is the formation of a se- processes and the temperature is around temperature cycles and containing high lective film on the surface according to the WELDING RESEARCH levels of δ-ferrite, due to possible spinodal their melting point. This could happen phases that are found in the sample. In decomposition (δ→ α+α′) or σ-phase for- during welding, casting, or hot forming. this research, the reagent was requested to mation. During the primary austenitic solidifica- be selective in front of δ-ferrite and γ- Recently, the author (Refs. 4, 5) es- tion modes (A, AF), the presence of im- austenite phases so that these two differ- tablished the influence of the alloying purities such as sulfur, phosphorus, and ent phases could be identified by level, in terms of total value of chromium boron tend to segregate to the liquid phase microscopy. The necessity to evaluate equivalent plus nickel equivalent and form low-melting point eutectics, eight different reagents to find the most (C +Nieq), on the transition between which are distributed along the boundaries req suitable ones comes from the well-known AF and FA solidification modes in of dendrite grains at the last stages of so- resistance that stainless steels show to austenitic stainless steel weld metals. Tra- lidification, causing cracking under the acids. The selectivity of the reagent could force of cooling contraction. However, if δ be achieved by different mechanisms, such the material solidifies primarily as -fer- as chemical or electrolytic etching, as well rite (FA, F), the solid-state transformation KEYWORDS δ→γ as magnetic fundamentals. Therefore, experienced ( ) will make the material from the eight reagents considered here, less susceptible to hot cracking due to the Metallographic Reagents δ five are based on chemical etching: Fry’s higher solubility of the impurities in the Ferrofluid reagent, Kalling’s Nº2 reagent, Lichteneg- phase as well as the better cracking resist- Austenitic Stainless Steels ger-Blöch’s reagent, Beraha’s reagent, and Arc Welding Murakami’s reagent. The last three are M. ASUNCIÓN VALIENTE BERMEJO (va- considered color etchants (Ref. 9). The [email protected]) is an independent researcher and consultant, Barcelona, Spain. colors observed by optical microscopy de-

WELDING JOURNAL 133-s Fig. 1 — Transversal cross section.

pend on the thickness of the nonmetallic dissimilar weld joints film formed as a result of the chemical re- (Ref. 16). action between the steel specimen and the reagent. These also depend on the etching Experimental conditions and crystallographic orienta- Procedure tion of the particular phase. Other 40 μm reagents used in this research are the ox- Two series of Fig. 2 — Faint contrast between austenite and ferrite. Fry’s reagent. alic acid, which acts through the elec- austenitic steel speci- trolytic mechanism, and the ferrofluids, mens were designed which achieve etching results based on the and prepared; the first magnetic nature of the ferritic phase. one consisted of 45 samples with a con- cooled and lubricated alumina sawblade δ The magnetic response of -ferrite and stant alloying level of Creq+Nieq = 40 wt- (Abrasive Cutter Buehler Metaserv). The WELDING RESEARCH the paramagnetism of γ-austenite is the % and the second one consisted of 42 transversal cross section of the cut surface basis for the magnetic etching technique. samples with a constant alloying level of (Fig. 1) was ground and polished according Initially, the technique was developed by Creq+Nieq = 30 wt-%. While the alloying to standard metallographic preparation pro- Bitter in 1931 and consisted of sprinkling level was kept constant, the Creq/Nieq ratio cedures. These included silicon carbide magnetic powder on the surface of a mate- was gradually increased from 1.22 up to grinding papers P400, P600, and P1200 rial under the effect of a magnetic field. 2.00. Chromium and nickel equivalents (Buehler-Met®) being sequentially used on Since then, the technique has advanced in (Creq, Nieq) were calculated using the ex- a sloped wet manual device, and polishing order to improve the practical application pressions established by Hammar and was carried out on semiautomatic turntables (Ref. 10). Nowadays, the ferrofluids are col- Svensson (Ref. 17). The base materials (500 rev/min fixed rotational speed) using loids of iron (II, III) oxide nanoparticles (10 used for sample preparation were three polishing cloths and diamond suspensions nm approximately) in a liquid solvent cov- grades of solid wires for gas tungsten arc (Buehler MetaDi®) of 6 and 1 μm sizes. ered by a surfactant, which avoids particle welding (GTAW), including one mild steel Polishing up to 0.25 μm diamond size was agglomeration and stabilizes the suspen- grade (AWS A5.18 ER70S-6) and two initially considered, and some samples were sion. The size and concentration of parti- austenitic grades (AWS A5.9 ER310 and prepared. But it was dismissed as soon as it cles, type of surfactant, and solvent or liquid ER312). The intended different alloying was proved that a too long polishing process carrier are variables that promote a wide compositions were prepared using differ- was not further improving the surface, in- range of commercial ferrofluids of which ent weight combinations of these wires. stead it introduced new undesired thinner the main industrial applications are related The precleaned wires were cut into seg- scratches. It is well known how sensitive to audio speakers manufacturing and bio- ments between 10–18 mm in length and stainless steels are to surface deformation medical (Refs. 11, 12). Practically, ferroflu- mixed in required proportions so that the in metallographic preparation; therefore, it ids are currently not commercially used as designed different levels of Creq+Nieq and was necessary to find a compromised bal- magnetic reagents, although some re- Creq/Nieq ratios were achieved. The total ance between doing the best possible final searchers (Refs. 10, 13, 14) have successfully weight of each batch of the samples was 50 polish with the lowest diamond size and get- used them to identify γ-austenite and δ-fer- g, which were melted in a pure argon at- ting a totally deformation-free surface for rite phases in duplex stainless steels since mosphere using the electric arc remelt fur- microstructural characterization. It was also 1985. Ferrofluids have also been used as nace based on GTAW process recognized that surface deformation could reagents in different applications such as re- recommended by the ASTM E1306-07 have been avoided in some events if the vealing the magnetic domain structures of (Ref. 18). available semiautomatic turntables had Fe78B13Si9 metallic glass ribbons (Ref. 15), The solid and homogeneous sample ob- worked at lower and variable rotating or contrasting austenite from martensite in tained was then cut into two halves by a speeds, and also if the grinding process

Table 1 — Reagents and Their Chemical Compositions

Reagent Chemical composition Ref.

Fry’s Reagent 5g CuCl2 + 40 mL HCl (37%)+ 30 mL distilled H2O + 25 mL absolute ethanol 6 Oxalic acid 10% 10 g oxalic acid + 90 mL distilled H2O6 Lichtenegger-Blöch 20 g NH4HF2 + 0.5 g K2S2O5 +100 mL distilled H2O 7, 20 Murakami’s Reagent 10 g K3Fe(CN)6 + 10 g NaOH + 100 mL distilled H2O 6, 8 Modified Beraha 2 g NH4HF2 + 1 g K2S2O5 + 20 mL HCl (37%) + 80 mL distilled H2O 9, 20 ° Kalling’s N 2 5 g CuCl2 + 100 mL HCl (37%) + 100 mL absolute ethanol 6, 8 Ferrofluid 230300-135-3 CoFe2O4 colloid in water solvent Ferrofluid EMG 911 Fe3O4 colloid in organic solvent

134-s MAY 2012, VOL. 91 A B

10 μm Fig. 3 — Oxalic acid etching on sample A31. A — SEM equipment; B — FEG-SEM equipment.

A B

Fig. 4 — Lichtenegger-Blöch etching on sample A31. A — 30 s, hot (500x) ; B — 45 s at boiling (200x). could have been done semiautomatically. Delta Pix Viewer LE Software) and scan- reagent are presented here. Based on the The maximum time between the final polish ning electron microscopy (SEM) equipped test results, those reagents considered as WELDING RESEARCH and the etching was three days; meanwhile, with energy dispersive X-ray spectroscopy the optimum ones are introduced, and samples were stored in a desiccator under (EDS) (Leica-Stereoscan 360) were used- some micrographs of austenitic stainless vacuum condition. for microstructural characterization. Oc- steel solidification modes are also de- The application of reagents was also casionally, for higher resolution, a field picted together with the different δ-ferrite conventional — applying the reagent on emission (FEG-SEM) equipment (Hitachi morphologies observed. the surface of the specimen, leaving the S-4100) was also used. reagent to etch for an established time, Fry’s Reagent rinsing with distilled water, and drying the Results and Discussion surface using ethanol and air. When using The immersion time recommended by ferrofluids, there was a variation on the The transversal cross section of the de- the bibliography (Ref. 6) ranged from a cleaning step, as it needed to be done with signed stainless steel samples was etched few seconds up to one minute. Initially the petroleum ether. using the eight proposed reagents listed in immersion time established was 10’s, but The chemical compositions of the eight Table 1. In order to evaluate the suitability an immediate pitting corrosion effect was reagents evaluated in this research are of each reagent, the following criteria were observed. Therefore, in order to slow shown in Table 1. The reason for selecting adopted: 1) absence of corrosion on the down the etching speed, some trials were these and not others was the availability in sample due to the reagent; 2) possibility of carried out decreasing the immersion time the laboratory of the primary components, using conventional analysis equipment; 3) and adding some extra ethanol from the together with the author’s interest in ex- etching at room temperature; 4) good con- initial quantity established in the literature ploring the effect of ferrofluids. Except for trast between austenite and ferrite phases; (Table 1). Finally, the optimum etching the ferrofluids, all reagents were prepared 5) absence of artifacts or false visual ef- condition was determined as 2 s with 20 in situ by dissolving the primary compo- fects; and 6) ease and simplicity to prepare mL of extra ethanol added, which made nents and were used immediately after and apply. the final reagent composition to be 5 g preparation. Details of the test conditions, advan- CuCl2, 40 mL HCl (37%), 30 mL distilled Optical microscopy (Axiovert 100A + tages, and drawbacks found for each H2O, and 45 mL absolute ethanol.

WELDING JOURNAL 135-s A B

20 μm

C modes but with a simi- tion mode). The impossibility to accurately lar Creq/Nieq ratio, control the voltage in the electrolytic cell samples A49 and A31. was also taken into consideration. In the case of sample A49, Cr +Ni was 30 Lichtenegger-Blöch Reagent WELDING RESEARCH eq eq wt-%, Creq/Nieq ratio was 1.45 with a ferrite For some authors (Refs. 7, 19), the most content of 0.89 FN, interesting feature of this reagent was the and its solidification fact that it could reveal the primary solidifi- mode was AF/FA. For cation microstructure experienced by the sample A31, the solidi- samples. The ferrite phase is usually dis- fication mode was FA, solved by chemical etchants, and that is the Creq+Nieq was 40 wt- reason why primary microstructure is not %, Creq/Nieq ratio was commonly revealed. However, despite hav- 1.44 and ferrite content ing experienced the solid-state transforma- δ→γ Fig. 5 — Beraha’s etching on sample A31. A — Micrograph; B — spot mi- 7.18 FN. tion , if the sample is etched using croanalysis inside the δ-ferrite dendrite; C — linear microanalysis. Results showed that Lichtenegger-Blöch’s reagent at room tem- 30 s of etching were perature (Ref. 20), samples with FA solidi- sufficient for samples fication mode should show the primary with FA solidification ferrite dendrite core in white, the primary Using the optimized etching condition, 6 mode (Sample A31). However, neither solidification microstructure in blue samples with different solidification modes optical microscopy nor the Leica SEM mi- (austenite in case of AF or ferrite in case of were prepared for SEM microscopy assess- croscopy were able to provide acceptable FA), and the former interdendritic liquid in ment. However, observation showed that images (Fig. 3A), and it was necessary to brown yellow. this reagent did not reveal the different mi- employ the Hitachi SEM equipment fitted After several trials using Beraha crostructures properly, as it was not possi- with field emission — Fig. 3B. The advan- reagents, which are known by etching the ble to distinguish austenite from ferrite tage of this equipment was that the elec- ferrite phase based on the breakdown of clearly — Fig. 2. All attempts in varying the tron beam was thinner and this the K2S2O5 in a HCl medium, the re- immersion time to increase the contrast be- guaranteed a resolution up to 1.5 nm. But searchers P. Lichtenegger and R. Blöch tween the phases resulted in the occurrence the downsides were that the equipment (Ref. 7) concluded that the replacement of of pitting corrosion. did not provide EDS microanalysis, and it the HCl used by Beraha for NH4HF2 used Based on the above results, Fry’s reagent also had limitations in accommodating the in the Lichtenegger-Blöch’s reagent had was rejected. dimensions of the samples used in the cur- the advantage to prevent the chromium- rent work. enriched ferrite (primary dendrite core) Electrolytic Etching Using Oxalic On the other hand, the sample with from being etched. Acid (10%) mainly AF solidification mode (sample In the current work, sample A31 A49) remained unaffected after 60 s of (Creq+Nieq = 40 wt-%, Creq/Nieq = 1.44, For electrolytic etching using oxalic acid etching, and it was not possible to observe FA, 7.18 FN) was subject to the reagent for (10%), the parameters recommended by any signs of etching on the ferrite phase by 30 s both at room temperature and in hot the bibliography (Ref. 6) were 6 V from a SEM microscopy. conditions. Results showed that the sam- few seconds up to one minute. In the cur- Therefore, electrolytic etching using ple was not etched at either conditions and rent study, the equipment available only oxalic acid (10%) was rejected due to the the effect was faint — Fig. 4A. Etching worked at a preset value of around 5 V, and low sensitivity shown for the samples with time and temperature were then increased it was not possible to determine the accu- low ferrite contents (AF solidification up to 45 s in boiling condition. Under this rate value of the voltage or to change it. In mode), and the necessity of using a field extreme condition, the reagent revealed order to find the optimal etching time, some emission equipment in order to have an the primary solidification mode (Fig. 4B), trials were carried out at 15, 30, 40, and 60 s acceptable image resolution for samples giving primary ferrite dendrite core in with two samples of different solidification with higher ferrite contents (FA solidifica- white, ferrite dendrite in blue, and inter-

136-s MAY 2012, VOL. 91 A B

dendritic austenite in brown. metabisulfite (K2S2O5) C Although according to the literature in a hydrochloric acid (Ref. 20), the primary solidification mode (HCl) medium. should have been revealed at room tem- Initially, 90 s of im- perature, but in the current work, it was mersion at room temper- necessary to bring the reagent up to its ature were applied. SEM boiling point in order to etch the sample. microscopy clearly Considering that temperature was a key showed darkened ferrite etching parameter, it was necessary to use dendrites on a bright the reagent at boiling temperature, and austenite background, phases presented variability in colors de- but a granular-like tex- pending on the solidification mode, this ture image appeared in- reagent was also ruled out. side of the dendrites, as shown in Fig. 5A. To Murakami’s Reagent check if the visual effect was due to an excess of This reagent can be used under differ- etching time, the immer- ent etching conditions (Refs. 6, 8) accord- sion time was reduced up ing to the type of stainless steel to be to 10 s. However, SEM analyzed. In the current study, it was used microscopy continued Fig. 6 — Kalling’s No. 2 reagent. A — Eutectic ferrite in AF solidifica- at room temperature for 5 and 10 s of im- showing the granular-like tion mode; B — skeletal ferrite morphology in FA solidification mode; C — lathy ferrite morphology in FA solidification mode. mersion, although the literature suggested texture inside the ferrite an interval of between 5 and 60 s. dendrites. Therefore, the According to Refs. 6 and 8, colors to be possibility of an excessive observed should be dark yellow for ferrite etching was ruled out. Kalling’s No. 2 Reagent WELDING RESEARCH and white for unaffected austenite, or An EDS spot microanalysis inside the brown in case the etching time was too long. dendrite (Fig. 5B) and a linear microanaly- References 6 and 8 recommend immer- However, keeping the sample im- sis (Fig. 5C) were carried out. Both results sion time of samples in Kalling’s Nº2 mersed for the minimum etching time, a showed the presence of sulfur inside the fer- reagent from a few seconds up a few min- wide range of color shades was observed ritic dendrite, which was completely unusual utes at room temperature. Different trials from the yellow, cinnamon, and brown according to the results obtained when the were conducted, and it was found that for under optical microscope. It was, there- same sample was etched with other samples with primary austenitic solidifica- fore, not possible to clearly distinguish the reagents. On the other hand, as it was al- tion mode, 2 s were suitable, but for primary phases due to the similarity in colors. ready expected and explained by microseg- ferritic samples between 8 to 10 s were nec- Possibly the main utility of this reagent regations during the solidification, the linear essary. Once the sample was etched, the fer- would be with those samples of which the microanalysis confirmed the enrichment in rite phase was shown brighter and austenite detection of sigma phase is crucial, as sigma chromium and depletion in nickel of the fer- matrix darker. It was proved that this phase in front of Murakami’s reagent would ritic dendrite and the opposite trend in the reagent was able to resolve the inside of the show a bright blue color in contrast with the austenitic matrix. ferritic dendrite and gave a good contrast rest of yellow-brown phases. The origin and source of sulfur inside between both phases without giving false ar- the ferritic dendrites could only be ex- tifacts. Therefore, it was considered as the Modified Beraha’s Reagent plained by the metabisulfite of the main reagent for the microscopical study of reagent. Therefore, considering that the the samples. Beraha’s reagents include a large granular morphology showed inside the Good contrast between ferrite and number of different types (Refs. 7, 9, 20). dendrites was not observed with any of the austenite matrix is illustrated in Fig. 6A–C In the case of the specific reagent for other reagents, it was concluded that the where the three main ferrite morphologies stainless steels, the etching mechanism is modified Beraha’s reagent very likely pro- for austenitic stainless steels are depicted: based on the production of sulfides from voked a false visual effect or artefact. Con- eutectic (A), skeletal (B), and lathy (C). the aqueous solution of potassium sequently it was rejected. This reagent was successfully used (Refs.

WELDING JOURNAL 137-s Fig. 7 — Ferrofluid 230300-135-3 on A, Sample A36. (500×). Fig. 8 — Ferrofluid 230300-135-3 on F, Sample A02. (500×).

A B WELDING RESEARCH

Fig. 9 — Ferrofluid EMG 911 on FA. A — Sample A32, skeletal ferrite morphology; B — Sample Fig. 10 — Ferrofluid EMG 911 on F, Sample A02. A57R, lathy ferrite morphology.

4, 5) in order to establish the influence of tion, and its subsequent processing with = 1.59) for FA mode, and A02 the alloy level on the transition between AF water caused the final ferrofluid to contain (Creq/Nieq>3) and A731 (Creq/Nieq = and FA solidification modes in weld metals protonated sulfites, which were responsi- 2.00) for F mode. of austenitic stainless steels. Within a range ble for the chemical etching on the sam- Very satisfactory results were obtained, of samples, it was possible to confirm the co- ples, independently from the level of as none of the samples was chemically existence of eutectic ferrite at the interden- magnetism. Therefore, despite it could etched, and the austenite and ferrite dritic boundary of primary austenite seem from the pictures that the reagent is phases were extremely contrasted color- dendrites with skeletal ferrite confirming able to contrast austenite phase from fer- fully using optical microscopy. primary ferritic solidification. rite phase, the fact is that this ferrofluid is Once the ferrofluid is applied and the not able to contrast both phases by the ex- sample is then rinsed with petroleum Ferrofluid 230300-135-3 pected residual magnetism mechanism. ether, the austenite phase is free from the nanoparticles of iron oxide, and the Ferrofluid 230300-135-3 is a CoFe2O4 Ferrofluid EMG 911 strength of the residual magnetism be- colloid in water solvent. In order to evalu- tween the nanoparticles and the ferritic ate this reagent’s behavior, it was applied Ferrofluid reference EMG 911 is a col- phase makes the nanoparticles be de- to the transversal cross section of a com- loidal suspension which contains 2 vol-% posited on the ferrite phase with different pletely austenitic sample, A36 of Fe3O4 particles of 10 nm nominal size thickness layers. The higher chromium en- (Creq/Nieq= 1.22, [Creq+Nieq] = 30 wt- in a light hydrocarbon medium. riched ferrite provokes higher residual %), and to a completely ferritic sample, Walker and Ginn (Ref. 14) obtained magnetism and, consequently, the higher A02 (Creq/Nieq> 3). good results in 1987 using a commercial fer- thickness of Fe3O4 nanoparticles layers, According to the fundamentals of the rofluid, which is not currently in the market, and a darker color is observed using opti- technique, it would have been expected with a 3.3 vol-% concentration that they di- cal microscopy. that the residual magnetism of the luted up to 1 vol-% using petroleum ether. Figures 9 and 10 illustrate the colorful CoFe2O4 acted on the ferritic phase and For the present research, ferrofluid EMG contrast between austenite phase in white would have not affected the austenite. 911 was diluted up to 1 vol-% Fe3O4 solu- and ferrite phase in blue or dark brown. Fig- However, as it is shown in Figs. 7 and 8, tion using the solvent EMG 900, which is an ure 9 depicts FA solidification mode with both phases, ferrite and austenite, experi- isoparaffinic hydrocarbon. Fig. 9A showing the skeletal ferrite mor- enced a chemical etch. It was thought that Samples with different solidification phology, while Fig. 9B presents the lathy the chemical etch was due to the fact that modes were selected: A01 ferrite morphology. Figure 10 shows F 2– a cation exchange resin with SO3 groups (Creq/Nieq<1.22) for A mode, A32 solidification mode with characteristic Wid- was used during the ferrofluid’s produc- (Creq/Nieq = 1.46) and A57R (Creq/Nieq manstätten austenite plates.

138-s MAY 2012, VOL. 91 Conclusions Acknowledgments 11. Raj, K., and Moskowitz, R. 1990. Com- mercial applications of ferrofluids. Journal of Although the literature has intro- The author gratefully acknowledges Magnetism and Magnetic Materials 85: 233–245. the support of Metrode Products Ltd., and 12. Raj, K., Moskowitz, B., and Tsuda, S. duced many reagents for metallographic 2004. New commercial trends of nanostruc- etching of stainless steel welds, it has is specially indebted to Zhuyao Zhang and tured ferrofluids. Indian Journal of Engineering been found that a previous selection Adam W. Marshall for providing the weld- & Materials Sciences 11: 241–252. among reagents is necessary in order to ing consumables and facilities to carry out 13. Ginn, B. J. 1985. A technique for deter- ensure first, a good contrast between this research. The author also acknowl- mining austenite to ferrite ratios in welded du- austenite and ferrite phases, and second, edges Anna Julià from the University of plex stainless steels. The Welding Institute to confirm the absence of artifacts or cor- Barcelona and Vanessa Rene from Fer- Research Bulletin. November, pp. 365–367. rosion due to the undesirable effect of rotec for the supply of ferrofluid reagents. 14. Walker, R. A., and Ginn, B. J. 1987. A magnetic “etching” technique for phase identi- reagent. It is also important that reagent The current research is part of the doc- fication in duplex ferritic-austenitic and other preparation and application are simple toral degree thesis entitled “Modelització stainless steels. ASM Int. 19th Annual Technical and easy (better if etching can take place del nivell de ferrita δ als acers inoxidables Meeting. Field Metallography, Failure Analysis at room temperature), and that conven- austenítics sotmesos a fusió per arc elec- and Metallography. Ohio: M. E. Blume, ed., vol. tional microscopy equipment is able to tric,” which was submitted for the degree 15, pp. 519–528. provide good results. of doctor in chemistry by the author at the 15. Birol, Y. 1998. Magnetic domain struc- University of Barcelona the 29th of June, tures in as-quenched and annealed Fe78B13Si9 Fry’s reagent has not been selected be- metallic glass ribbons. Turkish Journal of Physics cause of the difficulties in setting a proper 2010. It is also gratefully acknowledged 22: 481–488. immersion time in order to get an accept- the supervision of Pere Molera and Núria 16. Rowe, M. D., Nelson, T. W., and Lippold, able contrast between the phases but with- Llorca from the Department of Materials J. C. 1999. Hydrogen-induced cracking along out provoking pitting corrosion in the Science and Metallurgical Engineering at the fusion boundary of dissimilar metal welds. the University of Barcelona. Welding Journal 78(2): 31-s to 37-s. samples. 17. Hammar, Ö., and Svensson, U. 1979. In- Oxalic acid was rejected due to the low References fluence of steel composition on segregation and sensitivity shown for ferrite phase, and the microstructure during solidification of requirement for a field emission equip- austenitic stainless steels. The Metals Society. In- ment in order to have an acceptable image 1. Kujanpää, V. P., Suutala, N., Takalo, T., ternational Conference on Solidification and and Moisio, T. 1979. Correlation between solid- resolution. Casting of Metals. Sheffield (UK), pp. 401–410. ification cracking and microstructure in 18. ASTM E1306-07. 2007. Standard Prac- In the case of Lichtenegger-Blöch’s austenitic and austenitic-ferritic stainless steel tice for Preparation of Metal and Alloy Samples reagent, in order to have the samples welds. Welding Research International 9(2): by Electric Arc Remelting for the Determination etched adequately, it was necessary to use 55–75. of Chemical Composition. Philadelphia: ASTM it at boiling temperature. This fact, to- 2. Kujanpää, V. P., Suutala, N., Takalo, T., International. gether with the variability in colors of the and Moisio, T. 1980. Solidification cracking — 19. Folkhard, E. 1988. Welding Metallurgy of phases depending on the solidification estimation of the susceptibility of austenitic and Stainless Steels. Vienna: Springer-Verlag. ISBN austenitic-ferritic stainless steel welds. Metal 3-211-82043-4. mode, made the reagent to be ruled out. Construction 12(6): 282–285. Murakami’s reagent presented a wide 20. Weck, E., and Leistner, E. 1983. Metal- 3. Suutala, N. 1983. Effect of solidification lographic Instructions for Colour Etching by Im- range of color shades from yellow, cinna- conditions on the solidification mode in mersion. Part II: Beraha Colour Echants and mon, and brown under optical micro- austenitic stainless steels. Metallurgical Transac- their Different Variants. Vol. 77/II. Düsseldorf: scope. Therefore, it was not possible to tions A. 14A(2): 191–197. D.V.S. Verlag GmbH. clearly distinguish the phases due to the 4. Valiente Bermejo, M. A. 2010. Mod- δ similarity in colors. elització del nivell de ferrita (FN) als acers in- Modified Beraha’s reagent showed a oxidables austenítics sotmesos a fusió per arc electric. PhD dissertation. University of granular-like morphology coupled with Barcelona. ISBN 978-84-693-5713-2. traces of sulfur inside the ferritic den- 5. Valiente Bermejo, M. A. 2011. IIW Docu- WELDING RESEARCH drites, which can be explained by the ment IX-2359-11 Influence of the alloy level Do You Have an metabisulfite of the reagent. Conse- [Creq+Nieq] on the transition between AF and Aluminum Question? quently, it was rejected. FA solidification modes in austenitic stainless From the eight reagents evaluated, steel weld metals. 64th Annual Assembly of the In- only Kalling’s Nº2 and ferrofluid EMG ternational Institute of Welding. July, Chennai, India. E-mail your submission to the 911 accomplished the established crite- 6. ASM Metals Handbook. 1973. Metallog- ria. For microanalysis and SEM mi- raphy, structures and phase diagrams. Vol. 8. Welding Journal’s Aluminum Q&A croscopy, Kalling’s Nº2 would be the 8th edition, pp. 97–99. ASM International. author, Tony Anderson, at tony.an- most suitable reagent, while for optical Ohio. ISBN 27-12046. microscopy, Ferrofluid EMG 911 would 7. Lichtenegger, P., and Blöch, R. 1975. [email protected] or send it to be the most convenient one due to the Colour Etching of High Alloy Steels. Praktische his attention at Welding Journal, 550 excellent contrast between phases and Metallographie 12: 567–573. 8. Lippold, J. C., and Kotecki, D. J. 2005. NW LeJeune Rd., Miami, FL 33126. the ease of application. Welding Metallurgy and Weldability of Stainless Your aluminum question may be It is necessary to emphasise that al- Steels. New Jersey: Wiley-Interscience. ISBN 0- chosen for this bimonthly column though the physical background of ferroflu- 471-47379-0. ids is the same, not all the ferrofluids are 9. Vander Voort, G. F. 2005. Color metal- and help other individuals better un- able to contrast austenite from ferrite lography. Microscopy Today 13(6): 22–27. The derstand how to solve a particular Microscopy Society of America. ISSN 1551- phases. It is necessary to check that the sur- problem. factant and solvents used during the manu- 9295. 10. Gray, R. J. 1986. Magnetic Etching. In facture of the ferrofluid are not provoking a Vander Voort, G. F. Applied Metallography. New chemical etch on the sample, as Ferrofluid York: Van Nostrand Reinhold Co., Chapter 4, 230300-135-3 does. pp. 53–61.

WELDING JOURNAL 139-s Nonlinear Modeling of Dynamic Metal Transfer in Laser-Enhanced GMAW

By estimating an improved laser recoil pressure force, along with other factors, a modified nonlinear model was developed for this welding process

BY Y. HUANG, Y. SHAO, AND Y. M. ZHANG

ing the desired heat and mass by regulat- ABSTRACT ing the current (Ref. 6). A steady-state model for heat and mass transferred from In laser-enhanced gas metal arc welding (GMAW), which projects a lower-power the electrode to the workpiece was estab- laser onto the droplet, free flight metal transfer was obtained. Laser recoil pressure lished (Ref. 7). In the later research, ro- force is identified as the main reason to change the metal transfer process. For fur- bustness is also taken into account (Ref. ther control of laser-enhanced GMAW, this additional detaching force is estimated 8). An adaptive multi-input, multi-output WELDING RESEARCH at a reasonable level. A nonlinear model of dynamic metal transfer is established (MIMO) scheme was developed to con- based on the physics fundamental of this process. Laser recoil pressure force is com- trol both geometrical and thermal charac- bined into dynamic force balance theory to be as the reset criterion to detect the teristics of a weld based on lumped pa- droplet detachment. It is found that the simulation results agree with the experi- rameter and distributed parameter ment results, which indicate that the model could be used for the further closed- modeling and identification (Refs. 8–10). loop control. However, GMAW is a complex process, and it has many parameters to be moni- tored and controlled. The relationship be- where A is a numerical coefficient, B0 is a tween them cannot be considered linearly. Introduction vaporization constant, Ts is the surface The nonlinearities of GMAW should be temperature, and U = MaLv/(Nakb). Here, considered when establishing a model for Laser-enhanced gas metal arc welding Ma is the atomic mass, Ly is the latent heat this process. (GMAW) is an innovative process re- of evaporation, Na is Avogadro’s number, The laser recoil pressure force was esti- cently proposed and developed at the Uni- and kb is the Boltzmann’s constant. This versity of Kentucky (Refs. 1–3), shown in equation is relatively complicated, and mated in Ref. 1. However, it was estimated Fig. 1. It adds a relatively low-power laser Ref. 5 gave a simpler expression as fol- approximately, and it could only be used to to conventional GMAW, and the objective lows: illustrate the droplet detaching phenome- is to provide an auxiliary force to help de- non in laser-enhanced GMAW. To further 2 ρ control laser-enhanced GMAW, an estima- tach the droplet at a desired diameter with Pr = (P/A) / E (2) a desired welding current. In laser- tion of laser recoil pressure force with rela- enhanced GMAW, the droplet size is a where P/A is the power density of the tively less error is proposed and developed critical parameter that determines the laser, ρ is density of the vapor, and E is the in this paper. Considering the nonlineari- process stability and produces a desired energy needed to evaporate 1 kg metal. ties of laser-enhanced GMAW, a nonlinear appearance and quality of welds. Rela- However, all these equations give approx- model should be established for future con- tively large droplet sizes will lead to rip- imate estimation, and the estimating result trol. Based on the nonlinear model devel- ples in the welds and decrease the direc- may not be accurate enough. In some oped by Refs. 10 and 11, a modified non- tionality of the welds. In laser-enhanced cases, they may not be suitable to be used, linear model for laser-enhanced GMAW is GMAW, laser recoil pressure force is the such as molten metal in the arc zone. developed in this paper. The simulating re- additional detaching force compared to To fully control the GMAW process, sults are compared to the experimental one conventional GMAW. However, it is hard many models were proposed and devel- to test the model validation. to directly calculating this force value pre- oped for the GMAW process. PI control cisely as many physical coefficients are un- strategy could be developed for maintain- Experimental System and known. Conditions For the recoil pressure acting on a sub- Experimental System Setup strate during intense laser evaporation, KEYWORDS Ref. 4 gave the following:1/2 The principle of the laser-enhanced Gas Metal Arc Welding -1 GMAW proposed is shown in Fig. 1. A Pr = AB0Ts exp ⁄2 (–U/Ts)(1) (GMAW) laser beam aims to the droplet. The inten- Laser Recoil Pressure Force tion is to detach the droplet using the laser Nonlinear Model Y. HUANG, Y. SHAO, and Y. M. ZHANG recoil pressure as an auxiliary detaching ([email protected]) are with the Depart- Metal Transfer force to compensate for the lack of the ment of Electrical and Computer Engineering, electromagnetic or gravitational force as- University of Kentucky, Lexington, Ky. sociated with a relatively small amperage

140-s MAY 2012, VOL. 91 A

B Fig. 1 — Principle of laser-enhanced GMAW (Ref. 1). that is needed for a particular application, duct experiments. Pure rather than to provide an additional heat argon was used as the to speed the melting of the wire. The as- shielding gas, and the flow sociated additional heat from the laser rate was 12 L/min (25.4 should be negligible in comparison with ft3/h). The workpiece was that of the arc used. mild steel, and experiments Figure 2 shows important parameters were done as bead on plate that specify a realization of the laser- at a travel speed of 6.6 mm/s enhanced GMAW system used in this (15.6 in./min). The wire paper. In this research, the GMAW gun used was ER70S-6 of 0.8 and the laser head did not move. The mm (0.03 in.) diameter. The workpiece moved at a constant speed. The distance from the contact Fig. 2 — System parameters. A — Installation parameters; B — cam- direction of this movement was perpendi- tube to the workpiece was era installation. cular to the plane as shown in Fig. 2. A 20 mm as aforementioned. high-speed camera was placed in this di- The welding voltage was set rection with a distance about 1.2 m from 30 V, and the laser power intensity was 62 Figure 4 shows the mean current meas- the gun to record the metal transfer W/mm2. Four different wire feed speeds — ured in all experiments. It can be seen that process for later analysis. To conduct the 250, 300, 350, and 400 in./min — were used all the currents were lower than the tran- laser-enhanced GMAW process in an ex- to produce different welding current levels. sition current that is approximately 150 A pected way, parameters need to be set ap- For convenience, the parameters are pre- (Ref. 12) for the wire material and diame- propriately. As shown in Fig. 2, the three sented as a set (wire feed speed, voltage, ter. The effect of the laser on the current parameters used should be determined, laser intensity). is insignificant, no more than 5 A. and they are the contact tube to workpiece WELDING RESEARCH distance d1, angle between laser beam to θ GMAW gun , and the distance from the Table 1 — Constants Used for Laser Recoil Pressure Estimation and Nonlinear Model point where the laser interests the wire axis (d2). In Ref. 1, standards have been Symbol Value Unit Description found to set these parameters. Experi- mental results suggest that d1 be set θ U0 15 V Arc voltage constant around 20 mm, be selected to be around L 2.5e–5 H Source inductance 60 deg for easy installation at the expense s Bd 0.0008 kg/s Drop damping coefficient of reducing system compactness, and d2 be 3 C1 2.885e–10 m /(A s) Melting rate constant set at the range from 3 to 7 mm. C 5.22e–10 m3/(A Ω s) Melting rate constant Figure 3 shows the arrangement of the 2 Ea 636 V/m Arc length coefficient laser in relation to the gun. In this experi- K 3.5 N/m Drop spring constant mental setup, the laser beam is aligned d rw 0.0004 m Wire radius with the wire. In order to protect the end Ω Ra 0.022 Arc resistance of the laser from contamination from pos- Ω Rs 0.004 Source resistance sible fumes, a shielding board (not shown v 10 m/s Relative fluid to drop velocity in Fig. 3) is added between the laser and p Cd 0.44 Drag coefficient gun, and the laser is projected through a ρ 3 p 1.6 kg/m Plasma density hole on the shielding board to the wire. ρ Ω r 0.7836 /m Resistivity of the electrode ρ 3 Experimental Conditions w 7860 kg/m Electrode density μ 2 2 0 1.25664e–6 (kg m)/(A s ) Permeability of free space σ 2 A constant voltage (CV) continuous 1N/mSurface tension coefficient waveform power supply was used to con-

WELDING JOURNAL 141-s Fig. 3 — Installation of GMAW and laser (the shield board is not shown in Fig. 4 — Welding current under different wire feed speeds and different laser the picture). powers with welding voltage at 30 V.

be seen, the large additional detach force caused by the droplet did not touch laser. All these experimental results and the base metal be- related physical fundamentals are detailed

WELDING RESEARCH fore it detached, and in Refs. 2 and 3. there were no spat- As was observed previously, the appli- ters produced. The cation of the laser changed the metal reason to cause the transfer. In all cases, the diameter of the difference is that detached droplets was decreased as fur- laser recoil pressure ther shown in Fig. 8. The laser recoil pres- force is added into sure was identified as the major cause of laser-enhanced these observed changes. The detailed dis- GMAW to be an ad- cussion is shown in Refs. 2 and 3. The di- ditional detaching ameter change of droplet will be utilized force. In this case, to analyze the laser recoil pressure force in the lack of electro- the later section. magnetic force to detach the droplet is Pulsed Laser-Enhanced GMAW compensated by the Adding a lower-power laser could Fig. 5 — Illustration of metal transfer image. laser. For these two com- change the metal transfer mode in laser- parative experi- enhanced GMAW. In this case, spatters ments, the laser did could be reduced or eliminated, and it will Metal Transfer in Laser- not change the mean reduce the clean-up cost after welding and Enhanced GMAW welding current significantly as can be save much metal. In the aforementioned seen from Fig. 4. However, as the droplet experimental results, a continuous laser The diameter of the detached droplet did not touch the weld pool, the fluctua- was used to prove this proposal. A contin- was obtained from a series of high-speed tion of the welding current was reduced as uous power laser was not necessary for images in this study. All images presented can be seen in Fig. 7. The laser reduced the laser-enhanced GMAW. From the former as a series have the same dimension scale needed diameter (weight) of the droplet analysis, the laser was only used to gener- except for those presented individually. for detachment and changed the metal ate the recoil pressure as an additional de- The time interval of consecutive images in transfer type. taching force, which was actually not the same series is constant. Figure 5 illus- When the wire feed speed is 250, 350, needed before the detaching instant. To trates the scene in a typical metal transfer and 400 in./min, similar experiment results this end, the laser radiation could be acti- image. will be achieved. The metal transfer type vated onto the droplet only at the moment will be changed due to adding the laser. If when the droplet grew to the desired size. Metal Transfer it is short-circuiting transfer in conven- The continuous laser will be replaced with tional GMAW, laser-enhanced GMAW a pulsed laser. Further smaller laser power A typical metal transfer cycle is shown may change it to drop globular transfer. If energy will be adopted in laser-enhanced in Fig. 6A with wire feed speed at 300 conventional and laser-enhanced GMAW GMAW. in./min and welding voltage at 30 V in con- both produce drop globular, the latter re- Figure 9 shows the experimental re- ventional GMAW. From the images, it is duces the diameter of the droplet. If it is sults with the welding voltage at 30 V and found that this is a short-circuiting metal short-circuit or drop globular transfer in wire feed speed at 350 in./min. Different transfer process. Figure 6B is a typical conventional GMAW, laser-enhanced from the results shown in Ref. 2, the laser metal transfer cycle from the comparative GMAW may become the drop spray. The power was not continuous but pulsed in- experiment with an application of the established physics of metal transfer can stead. The frequency was 16 Hz with a laser at an intensity of 62 W/mm2. As can explain all these changes by counting the duty cycle of 30%, and the peak laser power intensity was set as 62 W/mm2 with

142-s MAY 2012, VOL. 91 a base intensity of 0. In this case, when the droplet did not grow to the desired size, no A laser was projected onto the droplet. The wire melts mainly due to resistance and arc heat. Because the detaching forces, mainly electromagnetic and gravitational, could not balance the retaining force, surface tension, the droplet would not detach. When it grew to a desired size, the laser pulse was introduced to generate an additional detaching force exerting onto B the droplet to compensate the lack of detaching force. The droplet would be detached to realize a free flight transfer instead of short-circuiting transfer. No spatters were generated in this process. Less electric energy was used, and it also reduced the clean-up cost after welding. All these properties of laser-enhanced GMAW made it a sustainable future industrial process. Fig. 6 — Typical metal transfer in comparative experiments with and without laser under 300 in./min, 30 V, 0 and 300 in./min, 30 V, 62 W/mm2. A — Without laser; B — laser intensity of 62 W/mm2. Laser Recoil Pressure Force Estimation fluid velocity of the plasma. face tension coefficient are constant, the In laser-enhanced GMAW, estimating The momentum force can be expressed surface tension is fixed, and it indicates the laser recoil pressure is a key issue for as that the retaining force keeps constant. To the further feedback control of this calculate aerodynamic drag force, the area process. To better understand the physics Fvm=  of the drop seen from above Ad should be fundamentals of the method, the forces af- med (6) calculated first. Ad can be given by fecting metal transfer are analyzed first. It . is well known that in conventional where v is the wire feed speed, and m is Arr=−π()2 2 (10) e d ddw GMAW, the major forces acting on the the change of the droplet mass. droplet include the gravitational, electro- The electromagnetic force, Fem, is Take the case of wire feed speed at 300 magnetic (Lorentz), aerodynamic drag, given by in./min, laser power intensity at 62 and momentum forces, plus surface ten- ⎛ ⎞ W/mm2, and welding voltage at 30 V as an r sion (Refs. 13–15). In laser-enhanced ⎜ d θ −−1 1 ⎟ example to analyze this force. The experi- 2 ⎜ln sin ⎟ GMAW, a laser is applied and an addi- μ I r 4 1cos− θ ment results (shown in Fig. 8) show that tional force is introduced as shown in Fig. F = 0 ⎜ w ⎟ (7) em ⎜ ⎟ the largest radius of droplet with these 10. To be simple, the dynamic-force bal- 4π 2 2 ⎜+ lnn ⎟ welding parameters is about 0.95 mm. In ance theory (DFBM) (Ref. 16) is used in ⎜ ⎟ ⎝ (1–cosθ )2 1+cosθ ⎠ this case, the largest aerodynamic drag this paper to conduct preliminary analysis force is about 8 × 10–5 N. It could be neg- of the forces for the laser-enhanced lected when estimating the laser recoil GMAW. μ where 0 is the magnetic permittivity, I is pressure. The calculating constants used WELDING RESEARCH the welding current, and θ is the half-angle are shown in Table 1 (Refs. 11, 17, 18). The force due to gravity can be ex- subtended by the arc root at the center of To estimate the momentum force, as pressed as the droplet. In the conventional GMAW the wire feed speed is a constant,. the process, the droplet is not detached when change of the droplet mass m should be 4 3 d F = m g = ⁄3 π r ρg (3) . g d d the retaining force Fσ is still sufficient to estimated first. md can be expressed by balance the detaching force Ft where md is the mass of the droplet, rd is ρ mCIClI =+πρ( ρ 2 ) (11) the droplet radius, is the droplet density, F = F + F + F + F (8) dw12 rs and g is the acceleration of the gravity. t g d m em The surface tension is given as In laser-enhanced GMAW, the total de- By calculating, it is found that the max- taching force F will be expressed by imum momentum force is around 5 × 10–5 π σ T Fσ = 2 rw (4) N. It could also be neglected when esti- F = F + F + F + F mating the laser recoil pressure force. σ t g d m em where rw is the electrode radius, while is To estimate the electromagnetic force, the surface tension coefficient. + Flaser recoil force (9) similar to the definition in Ref. 14, f2 is de- The aerodynamic drag force can be ex- fined as pressed as When the total detaching force FT could balance the surface tension, the 1 1 f =−−ln sin θ droplet will be detached. However, the 2 θ 1 4 1–cos FCAv=(ρ 2 5)laser recoil pressure force F is dddpp laser recoil force 2 22 2 unknown because there is less accurate + ln (12) − θ 2 1+cosθ where C is the aerodynamic drag coeffi- calculating theory to achieve this value. In (1 c o s ) d this case, the author proposes a calculat- cient, Ad is the area of the drop seen from above, and ρ and v are the density and ing method to estimate this force. p p As the radius of welding wire and sur- In this case, the electromagnetic force

WELDING JOURNAL 143-s A B

Fig. 7 — Current waveforms for 300 in./min, 30 V, 0 W/mm2 and 300 in./min, 30 V, 62 W/mm2. A — No laser; B — laser intensity of 62 W/mm2.

should be mainly physical fundamental analysis of the due to the exis- GMAW process, a nonlinear model has tence of the laser been set up (Refs. 10, 11, 17) for tradi-

WELDING RESEARCH pulse. In this case, tional GMAW. In laser-enhanced GMAW, the gravitational all the properties are the same as the ones force value differ- in conventional GMAW except laser ence could be con- pulse, which will be taken into account for sidered as the esti- the referred modified nonlinear model for mating laser recoil the laser-enhanced GMAW. pressure force. The First, a numbers of inputs, outputs, and gravitational forces states for the model should be defined. in conventional These are given as below. and laser-enhanced GMAW States: are shown in Fig. 12. When the wire x1 = I, welding current feed speed is at 300 x2 = ls, wire extension in./min, laser x3 = xd, droplet displacement power intensity is x4 = vd, droplet velocity 2 at 62 W/mm , and x5 = md, droplet mass Fig. 8 — Droplet sizes with welding voltage at 30 V under different wire feed welding voltage is speeds. at 30 V, the value Outputs: difference in the gravitational force y1 = I, welding current is about 1.75 × 10–4 y = r , droplet radius could be expressed as 2 d N. Considering the estimating errors and 2 ⎛ ⎞ μ Ir⎜ ⎟ other force value changes, the maximum Inputs: F =+0 ln d f (13) em ⎜ 2 ⎟ laser recoil pressure force could be about 4π r × –4 ⎝ w ⎠ 2.5 10 N. u1 = Uc, welding voltage For further control consideration, the u = WFS, wire feed speed In laser-enhanced GMAW, the half- 2 laser recoil pressure force estimating u = r , desired droplet radius angle subtended by the arc root at the cen- 3 d desired equation could be expressed as ter of the droplet θ is in the range from 90 Now, laser-enhanced GMAW can be to 150 deg (Refs. 2, 3, 14). As shown in Fig. F = η×r (14) described by the following nonlinear sys- 11, the value of f does not change signifi- laser recoil force d 2 tem. cantly when the half-angle varies from 90 to where η is the laser recoil pressure force 150 deg. The selection of the half-angle will coefficient, and it is about 0.15 to 0.30 not influence the estimating results. Let’s xfxgxu =+() () (15) N/m. recall the example case to analyze. As the mean welding current is a constant, the elec- y = h(x) (16) tromagnetic force will not change signifi- Nonlinear Model of Laser- cantly in a certain time interval between the Enhanced GMAW x = t(x), if L(x, u) ≥ 0 (17) moments with and without a laser. As Fig. 8 shows, the radius of the droplet Nonlinear Model Setup Now, let’s examine the electric circuit reduces when the laser is adopted in of the GMAW, as shown in Fig. 13. The GMAW. As the other main detaching Modeling of the GMAW process is im- electric relationship of the welding cur- force almost keeps the same, the change portant for process control. Based on the rent with other parameters could be ex-

144-s MAY 2012, VOL. 91 pressed by

 URIU−− − RI I = cL arcs (18) Ls

Where Uarc = U0 + RaI + Ea (L – ls) ρ 1 and RL = r (ls + ⁄2 (rd + x)). L is the distance from the contact tube to workpiece. As discussed in the former section, it is selected as 20 mm in this paper. Fig. 9 —Typical metal transfer in pulsed laser-enhanced GMAW. In this nonlinear system, the nonlinear state equations are listed below. 1 x =−+−−−[(uRRxUELx ) ( ) 1 11as0 a 2 Ls 1 −+ρ (x (rr+ x)) x ] (19) r 2 2 d 31 xuMRr =− /(π 2 ) (20) 2 2 w

i xx= (21) 34

i 1 x =−( Kx − Bx + F) (22) Fig. 10 — Major forces acting on the droplet in Fig. 11 — Variation of f as the function of half- 4 ddt3 2 x 4 laser-enhanced GMAW. angle θ. 5

i pressure force plays a significant role in xCxCxx=+( ρρ2 ) (23) 5 11 2rw 21 determining the detachment of the Simulation Results droplet. In this case, modified dynamic Based on the physics fundamentals of force balance theory was used to decide A simulation program for laser- laser-enhanced GMAW, a few equations whether the droplet is detached. The reset enhanced GMAW was developed in used are stated below. condition can be expressed by Simulink. It was based on the model described in the former section. To validate ⎛ ⎞1/3 the proposed model, the simulating re- ⎜ 3x ⎟ Ft = Fg + Fd + Fm + Fem = 5 sults should be compared to the experi- r ⎜ ⎟ (24) + Flaser recoil force > Fσ (31) d 4πρ mental results. ⎝ w ⎠ Let’s recall the example case again. If the detachment criterion is fulfilled, WELDING RESEARCH Wire feed speed u will be set at 300 MR=+ C x Cρ x x 2 (25) 2 11 2r 21 Then in./min (0.127 m/s), laser power intensity 2 at 62 W/mm , and welding voltage u1 at 30 x = x (32) V. To simulate the practical experiment η 1 1 Flaser recoil force = rd (26) environment, a Gaussian noise will be added to the welding voltage. The noise is FMRWFSu==**ρρ x2 = x2 (33) mw w2 with noise power at 0.00001, and the sam- 2 + πρ 1 pling time was selected at 0.0001. Other ()Cx C pxx ((27) x3 = (3x5/4 w) ⁄3 (34) 11 2r 21 constants used in this model were listed in Table 1. x4 = 0 (35) Fg = gx5 (28) Choose 1 s as the time interval to analyze. Continuous laser power was adopted. x5 = x5/2 (1/(1 + exp (–100x4))+ 1) (36) 1 The welding current and wire extension FCrrv=−πρ()22 2 (29) ddd2 wpp Otherwise, were shown in Figs. 14 and 15. From Fig. 14, it was found that the mean welding current was about 110 A. This result agreed 2 ⎛ ⎞ x1 = x1 (37) μ xr⎜ ⎟ with the results shown in Figs. 4 and 7. The F =+01 ln d f (30) em ⎜ 2 ⎟ wire extension was about 8 mm. The arc 4π r x2 = x2 (38) ⎝ w ⎠ length will be about 8 mm. By carefully an- x = x (39) alyzing the images shown in Fig. 6B, it was Combined with Equations 4 and 9, 3 3 found that the arc length was about 6 mm, these equations could be used to calculate and the wire extension was about 10 mm x = x (40) the states equations. 4 4 in the experiments. There are several rea- In laser-enhanced GMAW, laser recoil sons that could cause this simulation x5 = x5 (41)

WELDING JOURNAL 145-s WELDING RESEARCH

Fig. 12 — Gravitational forces in conventional GMAW and laser-en- Fig. 13 — Schematic image of the GMAW process. hanced GMAW.

Fig. 14 — Welding current waveform simulation result. Fig. 15 — Wire extension simulation result.

Fig. 16 — Droplet radius simulation result. Fig. 17 — Droplet mass simulation result.

Fig. 18 — Aerodynamic drag force simulation result. Fig. 19 — Momentum force simulation result.

error. In this nonlinear model, some con- than the transition current, the droplet it is slightly larger than the radius of the ditions that restricted the laser-enhanced needs to grow to a relatively large size to welding wire, free flight transfer was ob- GMAW were neglected. The weld pool achieve enough gravitational force to tained. From Fig. 8, it was found that the height above the workpiece was also not compensate for the lack of detaching radius of the droplet in the experiment considered. force. Short-circuiting metal transfer al- was about 0.97 mm. The simulation result The most important simulation result ways occurs. agrees well with the experimental results. is the droplet mass and size. Figures 16 When the laser was adopted, the To better understand the metal trans- and 17 show the simulating droplet radius droplet does not need to grow to such a fer process, the forces acting on the and droplet mass. In conventional large size. As shown in Fig. 16, the radius droplet will be analyzed. Figures 18–22 GMAW, as the welding current is lower of the droplet is about 0.95 mm. Although show the simulation results of detaching

146-s MAY 2012, VOL. 91 Fig. 20 — Electromagnetic force simulation result. Fig. 21 — Gravitational force simulation result.

Fig. 22 — Laser recoil pressure force simulation result. Fig. 23 — The total detaching force simulation result.

Fig. 24 — Droplet radius simulation result with a pulsed laser. Fig. 25 — Wire extension simulation result with a pulsed laser. WELDING RESEARCH

Fig. 26 — Laser recoil pressure force simulation result with a pulsed laser. Fig. 27 — The total detaching force simulation result. forces. As shown in Figs. 18 and 19, the closed to the gravitational force. It indi- with a constant laser shown in Fig. 16. Ex- aerodynamic drag and momentum forces cates that the laser recoil pressure force amining the wire extension (seen in Figs. acting on the droplet were small. For the was another main detaching force to de- 25 and 15), the same result was obtained. momentum force, it was almost a constant termine the droplet detaching process. It indicated that the laser did not influence during the welding process. The electro- Figure 23 shows the total detaching force. the wire melting, but only exerted an aux- magnetic force was still the main detach- As discussed in the former section, to iliary detaching force onto the droplet. ing force in the laser-enhanced GMAW, better utilize the laser power, a pulsed As the welding current and droplet ra- and it will compensate for most of the sur- laser will be used. In this nonlinear model, dius were not changed, and all the other face tension. The gravitational force in- the pulsed laser recoil pressure force was welding parameters were also not altered, creases with the increase of droplet mass, controlled by the droplet radius. When the the aerodynamic drag, momentum, elec- and the simulating result shows that it is an desired droplet radius was fulfilled, the tromagnetic, and gravitational forces were important detaching force. laser will exert an additional detaching not changed. Before the droplet grew to Laser recoil pressure force was an ad- force on the droplet. The laser recoil pres- the desired size, there was not a laser re- ditional detaching force in laser-enhanced sure force did not affect the welding cur- coil pressure force on the droplet. When GMAW compared to conventional rent (Refs. 1–3), so the welding current the criterion was fulfilled, the laser pulse GMAW. Compared to the results shown in will be kept the same with and without would be exerted on the droplet. Figure 26 Figs. 21 and 22, it was found that the mag- laser pulse. As shown in Fig. 24, the shows the laser recoil pressure force when nitude of laser recoil pressure force is droplet radius was also the same as the one a pulsed laser was adopted in the laser-

WELDING JOURNAL 147-s enhanced GMAW. sure force was combined into the detach- trol of an arc welding process. IEEE Control As shown in Fig. 27, the sudden in- ment criterion to determine the droplet Systems Magazine: 49–53. 8. Walcott, B. L., Zhang, Y. M., and Liguo, crease in the total detaching force Ft was detaching. caused by adding the laser recoil pressure • The simulation results have enough E. 2002. Robust control of pulsed gas metal arc Journal of Dynamic Systems, Measure- detaching force. accuracy, and they agree with the experi- welding. ment and Control 124(2): 281–289. From the analysis above, it is found ment results. It indicates that this nonlinear 9. Ebrahimirad, H., Ashari, A. E., Jalili- that this nonlinear model is suitable for model could be used for process control. Kharaajoo, H., and Gholampour, V. 2003. Ro- forecasting the droplet growing process, bust nonlinear control of current and arc length and for further process control. For the fu- Acknowledgment in GMAW systems. Proc. Conference on Control ture closed-loop control, the input weld- Applications 2: 1313–1316. ing voltage will be replaced by the real This work is funded by the National 10. Naidu, D. S., Moore, K. L., and Abdel- welding voltage, which will be obtained Science Foundation under grant CMMI- rahman, M. A. 1999. Gas metal arc welding control: Part 2 — Control strategy. Nonlinear from the voltage sensor. In this case, all 0825956 titled “Control of Metal Transfer the states calculating will be based on the Analysis 35: 85–93. at Given Arc Variables.” 11. Naidu, D. S., Moore, K. L., Yender, R., practical values. The results will be much and Tyler, J. 1997. Gas metal arc welding control: more accurate. If this model can be com- References Part 1 — Modeling and analysis. Nonlinear Analy- bined with sensing technology, such as sis, Methods and Applications 30(5): 3101–3111. image processing or spectrum sensing, the 1. Huang, Y., and Zhang, Y. M. 2010. Laser- 12. O’Brien, R. L., ed. 1991. Welding droplet in laser-enhanced GMAW will be enhanced GMAW. Welding Journal 89(9): 181-s processes. Welding Handbook, Vol. 2, 8th edi- controlled at any desired size under any to 188-s. tion. Miami, Fla.: American Welding Society. 2. Huang, Y., and Zhang, Y. M. 2011. Laser desired welding current. 13. Watkins, A. D., Smartt, H. B., and John- enhanced metal transfer — Part 1: System and son, J. A. 1992. A dynamic model of droplet observations. Welding Journal 90(10): 183-s to growth and detachment in GMAW. Interna- Conclusions 190-s. tional Trends in Welding Science and Technology. 3. Huang, Y., and Zhang, Y. M. 2011. Laser- Gatlinburg, Tenn. pp. 993–997. • The experimental system was set up, enhanced metal transfer — Part II: Analysis 14. Kim, Y-S., and Eagar, T. W. 1993. Analy- WELDING RESEARCH and a series of experiments was con- and influence factors. Welding Journal 90(11): sis of metal transfer in gas metal arc welding. 205-s to 210-s. ducted. Free flight metal transfer was ob- Welding Journal 72(6): 269-s to 278-s. 4. Semak, V., and Matsunawa, A. 1997. The 15. Lancaster, J. F. 1984. The Physics of tained with a welding current under a tran- role of recoil pressure in energy balance during sition current. Welding. Oxford, England: Pergamon Press. laser materials processing. Journal of Physics D: 16. Choi, J. H., Lee, J., and Yoo, C. D. 2001. • The dynamic balance force theory Applied Physics 30(18): 2541–2552. Dynamic force balance model for metal trans- could be used to explain the detaching 5. Liu, J. H., and Hu, W. Q. 1999. Analysis fer analysis in arc welding. Journal of Physics D: phenomenon in laser-enhanced GMAW. of forces on the weld pool and weld appearance Applied Physics 34: 2658–2664. The gravitational force difference due to during CO2 laser welding of A3 steels. Progress 17. Thomsen, J. S. 2005. Advanced control the mass change when the laser was in Lasers and Optoelectronics 9: 141–144. methods for optimization of arc welding. PhD adopted could be used to estimate the 6. Smartt, H. B., and Einerson, C. J. 1993. A dissertation, Aalborg University. laser recoil pressure force, and the result model for heat and mass input control in gas 18. Thomsen, J. S. 2006. Control of pulsed metal arc welding. Welding Journal 72(5): gas metal arc welding. International Journal of had a reasonable accuracy. 217–229. • A nonlinear model was set up for Modelling, Identification, and Control 1(2): 7. Henderson, D. E., Kokotovic, P. V., Schi- 115–125. laser-enhanced GMAW. Laser recoil pres- ano, J. L., and Rhode, D. S. 1993. Adaptive con-

Call for Papers

You are invited to submit papers for the 17th JOM International Conference on the Joining of Ma- terials to be held May 5–8, 2013, at Konventum Lo Skolen, Helsing∅r, Denmark.

The conference program will cover all aspects of developments in joining and material technology but papers are especially invited on the following topics: • Recent developments in joining technology: welding, soldering, brazing, • Advances in materials, metallurgy, and weldability • Mathematical modeling and simulation • Process monitoring, sensors, control. • Structural integrity and inspection • Applications with relevance to industry needs, automotive, oil & gas, power generation, • New developments in conservation, energy efficiency, and alternative energy resources • Weld quality, structural properties, and environmental considerations • Education, training, Qualification and Certification of welding personnel

Submit your name, address, and title of your presentation, along with a short abstract by Novem- ber 2, 2012, to Osama Al-Erhayem, JOM, Gilleleje Strandvej 28, DK-3250 Gilleleje, Denmark, or e-mail to [email protected].

148-s MAY 2012, VOL. 91 Analysis of Thermal Cycle during Multipass Arc Welding

A new method is proposed to account for convection and radiation heat losses from the surface during simulation of multipass welding thermal cycle

BY C. S. PATHAK, L. G. NAVALE, A. D. SAHASRABUDHE, AND M. J. RATHOD

t’ for volume heat source in a finite body is ABSTRACT given by t Convection and radiation heat loss from the plate surface during multipass gas tung- −= ∫ Qxyzt()', ', ', ' sten arc welding (GTAW) plays a very important role in deciding peak temperature. Txyzt(),,, T ∫∫∫ 0 ρc The heat losses from the surface can be efficiently incorporated in finite element for- v t ' mulation, but it is very difficult to derive an analytical expression for the same. A new G x,,,;, y z t x′′′′ y , z , t dx′′′′ dy dz dt (1) finn () method is proposed to account for convection and radiation heat losses from the surface during simulation of a multipass welding thermal cycle. The proposed method finds the temperature correction term for temperature distribution estimated using conduc- Gfin in Equation 1 is Green’s function for tion solution. Simulation results of an approximate analytical solution are compared a point heat source in the finite body that with experimental and finite element simulation results. Heat loss at thermocouple- satisfies the Neumann boundary condition plate junction due to contact conductance resistance induces error in temperature meas- of zero heat density (∂T/∂n = 0, where n is urement. The temperature drop due to this effect at the thermocouple junction is the normal direction) across its boundary compensated by considering this loss. surfaces (Ref. 7). Finding an analytical solution for Gfin would be almost an impos- sible task. An alternate approximate Introduction peak temperature values. approach to compensate for the Neumann Numerical techniques such as the finite boundary condition when dealing with a fi- A durability assessment of a weld joint element method are used increasingly by nite body has been proposed by re- needs the knowledge of residual stresses researchers particularly for complex weld searchers (Ref. 2). In this approach, the and distortion (Ref. 1). Thermal cycle his- geometries but this requires “tuning” or same Green’s function for the point tory during welding is a necessary input for calibration of the heat source to get a so- source in an infinite body is used, but the simulation of residual stresses. Many in- lution with acceptable accuracy. In the heat source in an infinite body is replaced vestigators have studied heat flow during present research work, a method to extend by the effective heat source Qeff(x', y', x', t') arc welding analytically, numerically, and an approximate analytical solution for in the finite body. The effective heat experimentally (Refs. 2–6). Analytical multipass welding is proposed and a tem- source produces the same amount of heat methods developed are capable of com- perature correction term is derived to ac- input into the finite body as the original WELDING RESEARCH puting temperature distribution with rea- count for convection and radiation heat heat source would in an infinite body. sonable accuracy. An approximate loss from the weld. The authors have ver- Using this approach, an approximate tem- analytical solution for plate with finite ified the proposed analytical solution ex- perature field in a finite body subjected to thickness using Green’s function and ef- perimentally and also with finite element volume heat is estimated by Equation 2. fective heat source to compensate for simulation results obtained from Neumann boundary condition (Ref. 2) has ABAQUS to an acceptable accuracy of t Qxyzt()', ', ', ' provided a very efficient tool to quickly 90% for the problem being investigated. Txyzt(),,,−= T ∫∫ ∫ ∫ 0 ρc simulate the transient thermal cycle dur- V t ' ing welding. This closed form solution has Temperature Rise for Volume Heat Source G ()xxy,,,;, zt x′′′′ y , z , t dxdydzdt′′′′ (2) a distinct advantage over a finite element in Finite Body inf procedure and doesn’t need a tedious procedure of modeling and discretization to The temperature rise during period t- The effective heat source Qeff(x', y', x', be followed. This solution can be extended t') in the finite body approximately com- to multipass welding using the principle of pensates for the Neumann boundary con- superposition; however, a closed form so- KEYWORDS dition when dealing with a finite body, lution considering convection and radia- which enables the use of the same Green’s tion heat losses is very difficult to achieve. Gas Tungsten Arc Welding function for the point source in an infinite Neglecting convection and radiation heat Weld Process Simulation body. loss for the weld pool gives relatively high Approximate Analytical Solution Modeling Multipass Welding C. S. PATHAK, ([email protected]) is Finite Element Method with Sinhgad College of Engineering, Pune, India. L. G. NAVALE is associated with MES COE, The modeling of multipass welding is Pune, India. A. D. SHASRABUDHE and M. J. more complex and difficult than single- RATHOD are associated with CoE, Pune, India. pass welding due to repeated phase

WELDING JOURNAL 149-s Fig. 1 — Variation of combined heat loss coefficient with surface tempera- Fig. 2 — Weldment specimen drawing. ture. WELDING RESEARCH

Fig. 3 — Simulated transient temperature time plot from code SANARC. Fig. 4 — Finite element model of plate for thermal analysis.

changes and annealing. Approximate an- and radiation. It is proposed to find a com- cient. Convective heat transfer coefficient alytical solution for multipass welding is bined heat transfer coefficient to take into is estimated using Equation 3 (Ref. 11). not yet reported. It is proposed in the pres- account the convection and radiation heat Nu k ent research work to use a method of su- loss. The surface heat flux due to this is h = air perposition in time domain and changing then found using the combined heat trans- L absolute time with differential time in fer coefficient. As an inverse problem, it is c (3) Equation 2. Thus, the time corresponds to assumed that an instantaneous plane heat Where, Nu is Nusselt number, kair is ther- the sum of welding and waiting time prior source equal to heat loss is acting, and mal conductivity of air, and Lc is charac- to beginning of the succeeding pass. Vari- temperature distribution due to this is cal- teristic length. Heat loss due to radiation is ation in the amount of heat input in each culated and then subtracted from the ear- accounted for by calculating the equiva- pass is taken into account. Dwell time is lier calculated temperature field. lent heat transfer coefficient hrad using accounted by converting real heat source Temperature correction done using this Equation 4. at the end of the weld run, to fictitious approach effectively compensates for con- ⎛ ⎞ zero value heat source traveling beyond vection and radiation heat loss from the hTTTT=+εσ 22()+ rad⎝ s a⎠ s a the plate length. boundary. An empirical relationship pro- (4) × –4 ε ε σ To include the effect of variable ther- posed by Vinokurov, heff = 24.1 10 Where is emissivity of body surface, is 1.61 mal properties in an analytical expression T , is used quite frequently by many re- Stefan Boltzmann constant, Ts is plate sur- is a very complex and difficult task. There- searchers (Refs. 6, 8, 9) to account for the face temperature, and Ta is atmospheric fore for better accuracy, temperature- combined effects of radiation and convec- temperature. This definition of the radia- dependent thermal properties of the work- tion. Researchers (Ref. 10) have used sim- tion heat transfer coefficient is analogous piece were updated while solving the inte- plified equations and terms for convection to convection in terms of a temperature gral part of Equation 2 using the and radiation loss for infinitely thin plate. difference (Ref. 11). Effective heat trans- numerical method. However, estimation of quantum of heat fer coefficient considering combined con- loss due to convection and radiation from vection and radiation is calculated using Engineering Approach to Account for Heat the weld plate surface has not been re- Equation 5. Loss to Surrounding Surface ported. In the present research work, the following procedure is adopted to find a hhh=+ Heat loss occurs from the material sur- combined temperature-dependent con- eff rad (5) face during welding by both convection vective and radiation heat transfer coeffi- Figure 1 shows the comparison be-

150-s MAY 2012, VOL. 91 Fig. 5 — Simulated transient temperature-time plot from FE code ABAQUS. tween Vinokurov’s solution and the pro- using an engineering ap- posed approach. The proposed method proach was later compared gives higher values of heff than calculated with finite element simulation from Vinokurov’s solution, the difference results obtained from the pro- being 10–20 up to 400°C. gram ABAQUS and with an For heat liberated to the surrounding experimentally measured Fig. 6 — Foam block support to thermocouple. area from the surface, Qa is calculated thermal cycle. using Equation 6. Case Study — Welding of Du- plex Stainless Steel Plates QhATsTa=−() Modeling Considerations a eff . (6) where A = area from which heat is being Duplex stainless steel has good weld- 1) A combined convection and radia- liberated to the surrounding area (as- ability, and it can be easily welded by both tion boundary condition as calculated sumed to be 5% of the total area). The re- manual and automatic gas tunsten arc weld- from Equation 5 is used on the top surface ing (GTAW), gas metal arc welding quired temperature correction, Tc, to and ε = 0.9 was assumed. compensate for convection and radiation (GMAW), plasma arc welding (PAW), 2) No forced convection was assumed, heat losses is calculated using Equation 7 shielded metal arc welding (SMAW) with and the effect of gas diffusion in the weld (Ref. 7). covered electrodes, flux cored arc welding pool was not considered. (FCAW), and submerged arc welding ⎛ 2 ⎞ 3) Neumann boundary condition was as- ⎜ ()xx− ′ ⎟ (SAW). Although weldability of duplex sumed during calculation of initial (uncor- ⎜ − ⎟ stainless steel is good, an important precau- ⎜ 4αt ⎟ rected) temperature field. Q ⎝⎜ ⎠⎟ tion is to limit as much as possible the hold- T = a e 4)Welding speed was assumed con- c ing time at an intermediate temperature πα stant. WELDING RESEARCH 2 t (7) between 300° and 980°C. Low thermal ex- Where α is thermal diffusivity, x' = x – vt is pansion in duplex grades reduces distortion Welding Parameters dimension in moving coordinate system, and residual stresses after welding. The so- and t is time. It should be noted that one- lidification of the duplex alloy is not prone The geometric parameters for a double dimensional heat flow is assumed in the to hot cracking due to low impurity levels; ellipsoidal heat source used in simulation above expression, which is quite realistic however, it may occur under high-restraint are listed in Table 1. The parameters men- for instantaneous plane heat source. Fi- conditions (Ref. 12). The weldment speci- tioned in Table 1 are in meters and based nally, the corrected temperature field is men was prepared as per the drawing shown on the specimen geometry and a weaving calculated as in Fig. 2.

T(x,y,z,t) = T(x,y,z,t) – Tc (z,t) (8) Table 1 — Double Ellipsoidal Geometry Table 2 — Welding Parameters The computer program SANARC was Parameters developed to calculate the integral expres- Pass Interpass Heat Input per Dwell Unit Length sion in Equation 2 using Gauss quadrature Pass a b c c numerical technique for the double semi- h h hf hb s (HI)(a) kJ/mm ellipsoidal distributed heat source during 1 0.001 0.002 0.012 0.02 1 6.322 multipass welding. For the same discretized 2 0.002 0.002 0.012 0.02 2 13 6.438 time interval, temperature correction term 3 0.003 0.002 0.01 0.02 3 646 7.835 for convective and radiation heat losses was 4 0.0045 0.003 0.01 0.02 4 97 8.932 calculated using Equation 7, and the tem- 5 0.006 0.003 0.01 0.02 5 72 7.145 perature field was accordingly updated. The Total 36.672 result of program SANARC developed to Avg. 7.335 account for convection and radiation losses (a) efficiency is not considered.

WELDING JOURNAL 151-s Fig. 7 — Temperature drop due to thermal contact resistance. Fig. 8 — Measured thermal cycle.

one of the major fac- timated from temperature data for various tors for inaccuracies in combinations of net heat input and weld simulation (Ref. 14). torch travel speed, which will be useful in Researchers (Refs. deciding these parameters.

WELDING RESEARCH 15–17) have studied the 3) The temperature distribution ob- effect of variable mate- tained will be useful to estimate the resid- rial properties on weld- ual stresses and any consequent ing simulation. The degradation in the mechanical properties temperature-depen- of the welded joint. dent physical properties of duplex stainless Simulation of Welding Thermal steel, as stated in Table Cycle Using Finite Element 3, were used for the Method simulation. The finite element method is the most Sensor Location widely used simulation technique due to its flexibility to adopt complex geometry and Fig. 9 — Comparison of simulated and measured thermal cycles. The thermal cycle boundary conditions. Finite element code was simulated for the ABAQUS is used to simulate transient ther- thermocouple loca- mal cycle during multipass welding. tions mentioned in ABAQUS has the capability to model solid pattern adopted while welding. Table 4. In this table, x is the distance from body heat conduction with general, temper- Interpass dwell time and heat input the weld start position, and y is the dis- ature-dependent conductivity; internal en- used during experimental investigations tance from the weld center. These results ergy (including latent heat effects); and (Table 2) were used as an input for simu- are from the simulation program SAN- quite general convection and radiation lation. Higher interpass dwell time after ARC as shown in Fig. 3. boundary conditions. Energy is related to the second pass was used to minimize the The use and application of the pro- temperature in terms of a specific heat, ne- effect of repeated heat exposures during posed analytical solution SANARC are glecting coupling between mechanical and multipass welding. mentioned below. thermal behavior. Latent heat effects at 1) Using simulated transient tempera- phase changes are given separately in terms Material Properties ture data and cooling rates, the austenite- of solidus and liquidus temperatures. When ferrite phase balance can be estimated, latent heat is given, it is assumed to be in ad- Material data, which change during a weld which is very useful information for the dition to the specific heat effect, and heat thermal cycle and during phase transforma- dual-phase alloy. conduction is assumed to be governed by tions, are usually missing (Ref. 13) and are 2) Heat-affected zone width can be es- the Fourier law.

Table 4 — Thermocouple Location Table 3 — Physical Properties of Duplex Stainless Steel Thermocouple x, mm y, mm (channel) Temperature °C 20 50 100 200 300 Density (kg/m3) 7805 1359 Thermal conductivity 17 17 18 19 20 27013 (W/m.K) 38530 Specific heat J/kg °C 450 450 500 530 42025 55023 63020

152-s MAY 2012, VOL. 91 The data acquisition system was started to an insufficient contact between the ther- 5. Lindgren, L. E. 2006. Numerical model- before welding and a small time lag was mocouple and the plate, which resulted in ing of welding. Computer Methods in Applied observed while recording temperature some loss of heat due to contact resistance. Mechanics and Engineering 195: 6710–6736. data as a result of inherent limitations of • Preflow and postflow of argon gas be- 6. Bonifaz, E. A. 2000. Finite element analysis of heat flow in single-pass arc welds. Welding hardware, hence for comparing the re- fore start of the weld pass and after com- Journal 78(8): 121-s to 125-s. sults, simulated profiles were shifted ac- pletion of the weld pass significantly 7. Carslaw, H. S., and Jaeger, J. C. 1959. cordingly to accommodate these effects. A reduced the interpass temperature and in- Conduction of Heat in Solids, Oxford University close match between simulated and exper- terpass dwell time in the first two passes; Press, Cambridge, UK, pp. 374. imental transient welding thermal cycle however, both dwell time and interpass 8. Frewin, M. R., and Scott, D. A. 1999. Fi- profile can be observed in Fig. 9 with a temperature increased marginally in the nite element model of pulsed laser welding. peak temperature accuracy of over 90%. last two or three passes. Welding Journal 78: 15–22. 9. Fan, H. G., Tsai, H. L., and Na, S. J. 2001. The accuracy achieved can be considered • The proposed solution SANARC is Heat transfer and fluid flow in a partially or satisfactory given the complexity of the computationally more efficient than the fi- fully penetrated weld pool in gas tungsten arc problem and range of temperature. nite element method and does not require welding. International Journal of Heat and Mass the time-consuming process of discretiza- Transfer 44: pp. 417– 428. Conclusions tion of domain. It is also useful in more ac- 10. Wang, S., Goldak, J., Zhou, J., Tcher- curate simulation of residual stresses and nov, S., and Downey, D. 2009. Simulation on microstructure at less computational cost. the thermal cycle of a welding process by • An approximate analytical solution space–time convection–diffusion finite ele- as proposed by Nguyen et al. was extended ment analysis. International Journal of Thermal to simulate multipass welding using prin- Acknowledgments Sciences 48: 936–947. ciples of superposition and fictitious 11. Cengel, Y. A. 2002. Heat Transfer: A source method. A procedure based on an The authors express their sincere Practical Approach. McGraw-Hill Companies. engineering approach was developed to thanks to authorities of University of Pune pp. 149. 12. Lippold, J. C., and Kotecki, D. J. 2005. find temperature correction terms to ac- for research grant BCUD/578. The authors are indebted to Mr. C. S. Kale of M/s Welding Metallurgy and Weldability of Stainless count for convective and radiation heat Steels. Wiley-Interscience. WELDING RESEARCH losses. The heat losses were accounted for SHOEI Finishing Pvt. Ltd. for providing 13. Onsoien, M. I., M’hamdi, M., and Ak- while solving the integral expression in facility and instrumentation to carry out selsen, O. M. 2010. Residual stresses in weld time domain. The proposed solution was experimental work. thermal cycle simulated specimens of X70 implemented by developing the computer pipeline steel. Welding Journal 89: 127-s to 132-s. program SANARC, and marginal reduc- References 14. Masubuchi, K. 1996. Prediction and control of residual stresses and distortion on tion in peak temperature was achieved. welded structures. Trans. JWRI 25(2): 53–67. •The finite element code ABAQUS 1. Dong, P., and Hong, J. K. 2001. Residual 15. Satonaka, S., Hari, K., and Matsumoto, was used to simulate a transient thermal stresses, notch stresses, and stress intensities at Y. 1993. Effects of material properties on tran- cycle with complex boundary conditions of welds: A unified assessment procedure with sient response in GTA welding. Transactions of moving heat source and temperature-de- self-consistency. Transactions SMiRT 16: 1773. Japan Welding Society 24(2): 63–69. pendent combined convective and radia- 2. Nguyen, N. T., Ohta, A., Matsuoka, K., 16. Zhu, X. K., and Chao, Y. J. 2002. Effects Suzuki, N., and Maeda, Y. 1999. Analytical so- tive heat transfer. Addition of filler metal of temperature-dependent material properties lution for transient temperature in semi-infinite on welding simulation. Computers and Struc- and latent heat effects were also consid- body subjected to 3D moving heat sources. tures 80: 967–976. ered in the program. Results obtained Welding Journal 78(8): 265-s to 274-s. 17. Little, G. H., and Kamtekar, A. G. from the finite element solution show 3. Murakawa, H., Minami, H., and Kato, T. 1998. The effect of thermal properties and higher peak temperature than the approx- 2001. Finite element simulation of seam weld- weld efficiency on transient temperatures dur- imate analytical solution. ing process. Trans. JWRI 30 (1): 111–117. ing welding. Computers and Structures 68: • Transient temperatures were recorded 4. Murthy, Y. V. L. N., Venkata Rao, G., and 157–165. Krishna Iyer, P. 1996. Numerical simulation of at the locations mentioned in Table 4 dur- 18. Moran, M. J., Shapiro, H. N., Munson, welding and quenching processes using tran- B. R., and DeWitt, D. P. 2003. Introduction to ing welding using modern and rugged in- sient thermal and thermo-elasto-plastic formu- Thermal Systems Engineering. John Wiley and strumentation. The lower peak temperature lations. Computers and Structures 60(1): Sons, Inc., pp. 366. for the spring-loaded thermocouple was due 131–154.

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154-s MAY 2012, VOL. 91 Weldability of Aluminum Alloys with High-Power Diode Laser

Higher penetration than previously reported under the conduction regime were obtained in welds of six aluminum alloys

BY J. M. SÁNCHEZ-AMAYA, Z. BOUKHA, M. R. AMAYA-VÁZQUEZ, AND F. J. BOTANA.

voking a fast heat transfer in the welding and CO2 (10640 nm) lasers. ABSTRACT piece that limits the concentration of energy In the literature, rather low values of in the weld pool), and low viscosity (re- weld penetration have been obtained in In the present work, a high- stricting the growth of the weld pool before aluminum alloys under the conduction power diode laser has been em- solidification). regime. Thus, complete penetration (1 ployed to weld six aluminum alloys Two laser welding regimes are reported mm) bead-on-plate and butt-joint welds of (1050, 2017, 2024, 5083, 6082, and in the literature (Refs. 2, 9, 10), so-called 5XXX and 6XXX aluminum alloys are 7075) under conduction regime. keyhole (or deep penetration) and conduc- obtained with a HPDL (Ref. 19). Bead- Controlling the experimental vari- tion (limited to conduction). The former on-plate conduction welds of 5182 alu- ables, butt joints with higher pene- mode requires the application of higher minum alloy of 1 mm thickness were also 6 2 tration than those previously re- power densities (typically above 10 W/cm ) obtained in Ref. 11 using a Nd:YAG laser. 6 2 ported in the literature for this than the latter (below 10 W/cm ). Under More recently, higher penetration con- regime could be obtained, demon- the keyhole regime, the high input energy duction butt joints have been reported by strating the weldability of all these allows the obtaining of deep-penetration the authors (Ref. 1), reaching penetration alloys with the employed methodol- joints, although it provokes high metal values up to 3.0 mm in Alloy 5083 and 2.3 ogy. Afterward, the depths and evaporation. In contrast, the conduction mm in Alloy 6082. widths of the beads were fitted to a regime is a more stable process, as metal va- The great majority of the studies deal- simple mathematical equation pro- porization is diminished due to the lower ing with laser welding of aluminum alloys posed by the authors. Taking into ac- input laser energy (Refs. 2, 10). Although under the conduction regime are devoted count the weld penetration values the conduction regime usually generates to investigating the influence of laser and the susceptibility to solidifica- limited penetration welds, its stability im- process conditions on the weld properties. tion cracking, the weldability order proves the weld quality, offering an alterna- However, much less numerous are papers was seen to be: 5083 > 7075 > 2017 tive joining mode for difficult-to-weld ma- focused on the study of the weld geometry = 2024 = 6082 > 1050. The magne- terials such as aluminum alloys. (Refs. 1, 8, 11). Thus, a model has been de- sium content and, to a lower extent, Numerous studies dealing with laser veloped to study the evaporation rate, fu- the zinc and silicon amount were ob- welding of aluminum alloys are presently sion zone geometry, and the composi- served to improve the weldability of available (Refs. 4, 11–18), though few of tional changes in 5182 aluminum alloy, the aluminum alloys. them were performed under the conduction showing a reasonable agreement with the

regime (Refs. 1, 2, 8, 11, 19). High-power experimental results (Ref. 11). Addition- WELDING RESEARCH CO2 (Refs. 13–16) and Nd:YAG (Refs. 4, ally, a three-dimensional numerical model Introduction 11, 12, 18) lasers were the most used equip- has been developed in Ref. 8 to analyze ment for these applications. High-power laser welding of 5083 aluminum alloy, al- Laser beam welding (LBW) is becoming laser diode (HPDL) was employed in rela- lowing the authors to obtain the morphol- an important industrial technology, being tively few works (Refs. 1, 2, 19), although it ogy, velocity field, and temperature field used in a great variety of processes due to its offers a clear advantage: The absorption of of the melted zone in steady state. The low heat input, high welding speed, high the HPDL wavelength by aluminum alloys predicted dimensions of the weld pool flexibility, high weld quality, and high pro- is higher than the CO2 and Nd:YAG wave- agreed well with experimental results duction rate (Refs. 1–5). LBW is also re- lengths (Ref. 20). Thus, the emission wave- (Ref. 8). A morphological study of 5083 ported elsewhere (Refs. 1, 5–8) to be diffi- length of the HPDL (808 nm) provokes a and 6082 butt joints was performed in Ref. cult to implement to aluminum alloys higher absorptivity in aluminum than the 1. The obtained depth values were fitted to because of their high reflectivity (leading to longer wavelengths of Nd:YAG (1064 nm) an equation that allows the estimation of absorption of a small fraction of the incident weld penetration from the input values of radiation), high thermal conductivity (pro- laser power and welding speed. KEYWORDS The first objective of the present work J. M. SÁNCHEZ-AMAYA (josemaria.sanchez has been to study the possibility of obtain- @titania.aero) is with Titania, Tests and Indus- Laser Beam Welding ing high-penetration welds of six alu- trial Projects, S.L. (Titania, Ensayos y Proyectos Conduction Regime minum alloys (1050, 2017, 2024, 5083, Industriales S.L.), Cádiz, Spain. Z. BOUKHA, Aluminum Alloys 1050, 2017, 6082, and 7075) with a HPDL under the M. R. AMAYA-VÁZQUEZ, and F. J. BOTANA 2024, 5083, 6082, 7075 conduction regime. Although high weld- are with LABCYP, Department of Materials Sci- ing depths have been previously reported ence, Metallurgy, and Inorganic Chemistry (De- Experimental Fitting partamento de Ciencia de los Materiales e Inge- High-Power Diode Laser in 5083 and 6082 samples (Ref. 1), the ap- niería Metalúrgica y Química Inorgánica), plicability of HPDL to obtain high-pene- University of Cádiz, Cádiz, Spain. tration welds in other aluminum alloys has

WELDING JOURNAL 155-s Fig. 1 — Laser equipment and mobile X-Y table.

not yet been studied. The second objective

WELDING RESEARCH has been to analyze the fitting degree of a simple mathematical expression proposed by the authors to the experimental weld depths obtained for the six aluminum alloys. The last aim has been to compare the weldability of the six aluminum alloys, taking into account the alloying elements. Fig. 2 — Examples of metallographic images (30×) of butt-joint weld beads in aluminum alloys, obtained with the indicated laser power and welding rate conditions.

Table 1 — Chemical Compositions of Aluminum Alloys (wt-%)

Element

Si Fe Cu Mn Mg Zn Cr Ti Ga V Al

1050-T0 0.13 0.32 <0.01 <0.01 <0.01 0.02 <0.01 <0.01 <0.01 <0.01 99.50 2017-T3 0.62 0.51 3.83 0.59 0.53 0.10 0.01 0.03 <0.01 <0.01 93.70 2024-T3 0.10 0.22 4.11 0.56 1.34 0.13 0.01 0.01 0.01 <0.01 93.49 5083-T0 0.10 0.30 0.02 0.50 4.22 <0.01 0.08 0.02 0.01 0.01 94.73 6082-T6 1.03 0.34 0.06 0.57 0.87 0.01 0.01 0.03 0.01 <0.01 97.04 7075-T6 0.06 0.16 1.25 0.08 2.32 5.47 0.20 0.01 0.01 0.01 90.41

Material and Methods Table 2 — Laser Power (P) and Welding Speed (v) Conditions to Obtain Butt Joints on Aluminum Alloy Samples Six aluminum alloys (1050, 2017, 2024, -1 5083, 6082, and 7075) were welded under Aluminum Alloys P/kW v/mm·s the conduction regime by means of a high- 1050 1.5, 2, 2.5, and 2.75 (5), 8.3, 13.3, 16.6, 25 power diode laser. The size of the 2017 1.5, 2, 2.5, and 2.75 5, 8.3, 16.6, 25 processed samples was 70 mm long and 14 2024 1.5, 2, 2.5, and 2.75 (5), (8.3), 13.3, 16.6, 25 mm wide. In a first part of the study in 5083 1.5, 2, 2.5, and 2.75 5, 8.3, 16.6, 25, 50, 75, 100 which the influence of the experimental 6082 2, 2.5, and 2.75 3.3, 5, 8.3, 16.6, (50), (83) variables were analyzed, butt joints were 7075 1.5, 2, 2.5, and 2.75 (8.3), 16.6, 25, 33.3 generated on samples with the thickness in which the sheet alloys were provided: 2 included in Table 1. All samples were perficial treatments leads to low magne- mm (1050, 2024, and 7075), 3 mm (5083), sandblasted with corindon particles to sium evaporation in the welds obtained and 4 mm (2017 and 6082). In a second promote laser absorption (Refs. 1, 2). Ac- under the conduction regime (Ref. 2). analysis in which the weldability of the dif- cording to recent measurements per- Thus, while other superficial treatments, ferent alloys was compared, bead-on-plate formed in our laboratory, this superficial such as the application of dark coatings, welds were generated on samples of 70 × treatment lead to absorptivity values generate weld beads with magnesium lost 14 × 2 mm3, the thickness of 5083, 2017, around 50% in 5083 samples. In addition up to 4%, sandblasting limits this evapo- and 6082 plates having been reduced to 2 to improving the laser absorption, the ap- ration up to 1%, leading consequently to mm. The compositions of these alloys are plication of sandblasting as previous su- improvements on the corrosion behavior

156-s MAY 2012, VOL. 91 of the melted zone (Ref. 2). A high-power diode laser, Rofin Model Table 3 — Width (w) and Depth (d) Values of Butt Joints of the Six Aluminum Alloys, in Function DL028S, with a maximum power of 2.8 kW, of the Laser Power (P) and the Welding Speed (v) was employed to weld the aluminum alloy AA5083 samples. Figure 1 includes an image of the AA1050 P (kW) v (mm/s) d/w laser equipment and the mobile X-Y table, P (kW) v (mm/s) d/w whose movement was controlled by Visual 1.5 5.00 1.93/4.09 1.5 5.00 2.00/4.98 1.5 8.33 1.36/3.66 Setup software. The laser beam conditions 1.5 8.33 1.36/3.19 1.5 16.67 1.10/2.94 were the same as reported in Ref. 1. Thus, 1.5 13.33 0.99/2.83 1.5 25.00 0.91/2.65 the surface samples were kept at the focal 1.5 16.67 0.73/2.52 1.5 50.00 0.71/2.31 position (spot size on surface is 2.2 × 1.7 2 8.33 1.71/3.65 2 5.00 2.38/4.67 mm), working the laser source in continu- 2 13.33 1.02/2.84 2 8.33 1.62/3.92 ous mode. The laser treatment always con- 2 16.67 0.99/2.90 2 16.67 1.16/3.18 sisted of one single linear scan of 60 mm, 2 25.00 0.99/2.86 2 25.00 1.00/2.88 performed at the interface between the pair 2.5 8.33 2.00/3.69 2 50 0.73/2.52 of samples to be welded (in butt joining) or 2.5 13.33 1.30/3.26 2 75 0.72/2.34 at the center of a single sample (in bead-on- 2.5 16.67 1.20/3.12 2 100 0.80/2.34 plate welding). In order to concentrate the 2.5 25.00 1.05/2.86 2.5 5 2.72/5.34 laser energy, the welding direction was the 2.75 13.33 1.31/3.52 2.5 8.33 1.85/4.41 X axis, the configuration providing a lower 2.75 16.67 1.23/3.21 2.5 16.67 1.20/3.42 width (1.7 mm) of the linear laser source. 2.75 25.00 1.12/2.90 2.5 25 1.09/3.11 Nitrogen was always employed as the 2.5 50 0.79/2.67 AA2017 2.5 75 0.70/2.49 shielding gas, at a flow rate of 15 NL/min, P (kW) v (mm/s) d/w 2.5 100 0.84/2.48 avoiding the oxide formation in aluminum 2.75 5 3.00/5.90 alloy welds (Refs. 5, 7). Although argon is 1.5 5.00 1.33/3.69 2.75 8.33 2.08/4.70 more commonly used as the shielding gas 1.5 8.33 1.13/3.14 2.75 16.67 1.29/3.60 for LBW of aluminum alloys (because it 1.5 16.67 0.82/2.66 2.75 25 1.13/3.25 minimizes the formation of gas porosity), 2 5.00 1.49/4.18 2.75 50 0.84/2.76 nitrogen has been employed in this research 2 8.33 1.22/3.47 2.75 75 0.87/2.60 because it was considered interesting to test 2 16.67 0.95/2.97 2.75 100 0.94/2.58 a cheaper shielding gas, taking into account 2.5 5.00 1.70/4.50 that LBW was performed under conduction 2.5 8.33 1.32/3.84 AA6082 P (kW) v (mm/s) d/w mode. This regime leads to highly stable 2.5 16.67 1.05/3.07 weld pools, and therefore produces welds 2.5 25.00 0.87/2.98 with lower porosity than those generated 2.75 5.00 1.72/4.70 2 3.33 1.85/4.09 under keyhole regime (Ref. 1). 2.75 8.33 1.30/3.85 2 5 1.20/3.21 (P) 2.75 16.67 1.11/3.33 2 8.33 1.11/2.99 The laser power and welding speed 2.75 25.00 0.97/3.11 2 16.67 0.83/2.52 (v) employed to obtain the butt joints of 2 50 0.70/2.26 each alloy are detailed in Table 2. As can be AA2024 2 83.35 0.54/1.94 seen, P ranged between 1.5 and 2.75 kW and P (kW) v (mm/s) d/w 2.5 3.33 2.11/4.67 v between 0.2 and 6 m/min (3.3 and 100 2.5 5 1.45/3.82 mm/s), the low and upper limits of both vari- 1.5 5.00 2.00/4.76 2.5 8.33 1.20/3.31 ables having been determined experimen- 1.5 8.33 1.99/3.62 2.5 16.67 0.91/2.88 tally. Thus, the fluences of these laser treat- 2.5 50 0.72/2.39 WELDING RESEARCH 1.5 13.33 1.31/3.01 ments ranged between 0.9 kJ·cm–2 (for P = 2.5 83.35 0.56/2.11 1.5 16.67 1.25/2.93 2 kW and v = 100 mm/s) and 37.5 kJ·cm–2 2.0 5.00 2.00/5.70 2.75 3.33 2.29/5.07 2.75 5 1.54/3.89 (for P = 2.75 kW and v = 3.3 mm/s). The in- 2.0 8.33 2.00/4.11 ferior limits (the less energetic condition, 2.0 13.33 1.68/3.46 2.75 8.33 1.20/3.39 2.75 16.67 0.96/2.92 with low P and high v) of each alloy were 2.0 16.67 1.40/3.23 those leading to weak welds. Lower aggres- 2.0 25.00 1.32/2.89 2.75 50 0.83/2.56 sive conditions than this lower limit were 2.5 5.00 2.00/6.46 2.75 83.35 0.70/2.12 2.5 8.33 2.00/4.42 discarded, as the input energy was not high AA7075 enough to generate and stabilize a weld 2.5 13.33 2.00/3.75 P (kW) v (mm/s) d/w 2.5 16.67 1.53/3.50 pool leading to the joint. On the other hand, 2.5 25.00 1.46/3.11 the upper limits (high P and low v) were 1.5 8.33 2/4.41 those provoking complete-joint-penetra- 2.75 5.00 2.00/6.52 1.5 16.67 1.45/3.32 2.75 8.33 2.00/4.63 1.5 25 1.15/2.90 tion welds. The welding speed values lead- 2.75 13.33 2.00/3.95 2 8.33 2.00/5.00 ing to both lowest and highest energetic 2.75 16.67 1.59/3.58 2 16.67 1.66/3.65 conditions have been marked between 2.75 25.00 1.34/3.13 2 25 1.21/3.13 brackets in Table 2. 2 33.33 1.09/2.94 The bead-on-plate laser treatments 2.5 8.33 2.00/5.35 were performed at two rates: 16.6 and 33.3 2.5 16.67 2.00/4.18 mm/s, keeping invariable the rest of the ex- 2.5 25 1.43/3.38 perimental conditions (sandblasted sam- 2.5 33.33 1.21/3.1 ples, P = 2 kW, 15 L/min N2, etc.). These 2.75 8.33 2.00/5.40 treatments correspond to laser fluences of 2.75 16.67 2.00/4.27 5.5 and 2.7 kJ·cm–2, respectively. 2.75 25 1.46/3.52 The depth and width of butt-joint and 2.75 33.33 1.18/3.19

WELDING JOURNAL 157-s bead-on-plate welds were measured from metallographic images of the bead cross- sections, after cutting, mounting, polishing, and etching (with Keller) the welds. Each weld condition (alloy-P-v) was performed at least in triplicate to ensure accuracy of the results. Thus, the depth-width pairs of data reported here are the mean of at least three values.

Results and Discussion

Influence of Laser Power and Processing Rate on Weld Morphology

Metallographic images at 30× of cross sections of some butt joints in aluminum alloys have been included in Fig. 2. As can be easily observed, the morphology of the welds follows a semicircle shape, with a depth/width ratio of up to 0.5, confirming that the laser welding was performed under a conduction regime. The so-called “welding percentage” parameter was measured macroscopically in

WELDING RESEARCH each weld. This parameter depicts the ratio between the length of the welded interface and the length of the interface exposed to the laser beam (Ref. 1). Thus, the welding percentage can range between 0%, when no joint is achieved, and 100%, when the specimens are totally welded. The welding percentage measurements are shown in Fig. 3. Generally, in the six studied alloys, the welding percentage decreases as the Fig. 3 — Welding percentage of aluminum alloys as function of the welding speed (v) and the laser power (P). input energy diminishes (lower P and higher v). However, very high energies can also lead to a decrease of this parameter, as next section. dependency of the d/w ratio on the weld- can be observed in the AA2024 welds ob- Subsequently, the measured w and d ing speed (v) being modulated by b’. Thus, –1 tained at 5 mm·s . These results show that values were fitted to Equation 1, allowing the higher are a’ and b’ for an alloy, the P and v conditions should be carefully opti- the estimation of a and b, constants for narrower will be the welds generated. mized for each alloy to obtain appropriate each alloy. The results are shown in Table welds. Note that the 5083 alloy could be 4. The experimental conditions leading to P =+b welded at higher welding speeds than the a (1) complete penetration (high energy) were vd⋅ w others, although with low welding percent- not taken into account to the data fitting age values — Fig. 3. According to the ob- of Equation 1, as in these cases, the d/w retained results, it can be stated that the six b′ lationship deviates from its normal ten- dw/ = a′+ (2) aluminum alloys can be generally welded dency. Neither the low energetic condi- v with values of P between 1.5 and 2.75 kV tions giving to welding percentage values –1 and v between 5 and 25 mm·s . Under lower than 60% were considered to the fit- these conditions, the welding percentages −⋅′ ⋅ ′ ting. Our studies have shown that d/w val- = Pbb− ba are usually higher than 50%. ues are practically independent of P, being d (3) av⋅ a The width (w) and depth (d) values of mostly modulated by v. Thus, taking into all welds obtained under the conditions in- account the experimental relationship be- The obtained penetration values of dicated in Table 2 have been included in tween the d/w values and v (Equation 2), welds obtained for the six aluminum alloys Table 3. From the overall data obtained, it a’ and b’ constants were estimated. The under different P and v have been com- can be emphasised that high penetration obtained a’ and b’ values are included in pared with those values estimated from welds could be achieved under the con- Table 5. Finally, d values (in mm) were es- Equation 3. These data have been jointly duction regime for the six aluminum al- timated taking into account the experi- plotted in Figs. 4–9. It can be confirmed loys. Complete penetration was reached in mental variables (P and v) and the calcu- that, keeping invariable the experimental four alloys, 1050 (2 mm), 2024 (2 mm), lated fitting constants (a, b, a’, and b’), as conditions, the estimated values are very 5083 (3 mm) and 7075 (2 mm). The higher indicated in Equation 3. Taking into ac- similar to the experimental ones, proving thickness of the other two alloys, 2017 and count that the fittings provide positive a the validity of the proposed analytical 6082 (4 mm), makes complete-joint-pene- values and negative b values in all cases, it expression. tration welding more difficult to achieve can be deducted that the lower are the ab- under the conduction regime. A compari- solute values of both coefficients, the Weldability Order of Aluminum Alloys son of welds generated on samples with deeper are the welds obtained. Similarly, the same thickness is carried out in the a’ and b’ are related to the weld shape, the From the obtained results in the previ-

158-s MAY 2012, VOL. 91 Fig. 4 — Measured and estimated penetration values (d) of 1050 butt joints, Fig. 5 — Measured and estimated penetration values (d) of 2017 butt joints, in function of the processing rate (v) and the laser power (P). in function of the processing rate (v) and the laser power (P).

Fig. 6 — Measured and estimated penetration values (d) of 2024 butt joints, Fig. 7 — Measured and estimated penetration values (d) of 5083 butt joints, in function of the processing rate (v) and the laser power (P). in function of the processing rate (v) and the laser power (P). ous section, it can be easily appreciated that of the six alloys, different bead-on-plate sidered that the higher the values of d and under the same experimental conditions (P welds were generated on samples with the VF for a certain alloy, the higher its (laser) and v), the weld depth values are different same thickness (2 mm). The penetration weldability. Table 6 summarizes the ob- for each alloy studied. As the thickness of (d), d/w ratio, and the volume of fused ma- tained results. It is clear that 5083 is the alloy the samples is important in the conduction terial (VF) were the parameters measured with the highest weldability (highest d and regime, in order to compare the weldability to characterize the welds. It has been con- VF values), followed by 7075. Thirdly, 2017, 2024, and 6083 show a lower weldability than 5083 and 7075; these three alloys pre- Table 4 — a’ and b’ Values Estimated from Equation 1 senting comparable values of the analyzed Alloy a (kJ·mm-2) b (kJ·mm-1) R2 parameters. Lastly, 1050 is the alloy presenting the lowest weldability, showing the 1050 0.2535 -0.391 0.3767 welds with lowest values of d and V . This 2017 0.6106 -1.4377 0.9312 F weldability order of aluminum alloys is in 2024 0.238 -0.4944 0.7641 5083 0.3043 -0.647 0.9694 good agreement with earlier results ob- 6082 0.4900 -0.716 0.9002 tained by Martukanitz et al. (Refs. 21–23), 7075 0.1547 -0.2889 0.7792 in which CO2 and Nd:YAG lasers were employed to weld different aluminum alloys under the keyhole regime. Table 5 — a’ and b’ Values Estimated from Equation 2 Weld cracking of aluminum alloys has to be taken into account in LBW because of -1 Alloy a’ b’ (mm-sec ) R2 their relatively high thermal expansion, 1050 0.3133 0.8910 0.5464 large change in volume upon solidification, 2017 0.3010 0.3398 0.7578 and wide solidification temperature range 2024 0.4413 0.0947 0.0044 (Ref. 22). The susceptibility to cracking so-

5083 0.3030 0.9636 0.8910 lidification was seen to be different for the WELDING RESEARCH 6082 0.2934 0.5123 0.9218 studied aluminum alloys: 5083 is the alloy 7075 0.3131 2.2323 0.7986 presenting the lowest cracking susceptibility, followed by 7075. Aluminum Alloys

WELDING JOURNAL 159-s Fig. 8 — Measured and estimated penetration values (d) of 6082 butt joints, Fig. 9 — Measured and estimated penetration values (d) of 7075 butt joints, in function of the processing rate (v) and the laser power (P). in function of the processing rate (v) and the laser power (P).

2017, 2024, 6082, and 1050 presented higher Thus, the alloy with highest content of this the literature to increase the bead pene- cracking susceptibility, their weld beads element (5083) is the one with highest weld- tration in laser welding (Ref. 29). Thus, showing similar levels of solidification ability. The following alloy in weldability is this alloying element is indicated to im- cracks. This different susceptibility to solid- the 7075, the one presenting the second- prove the weldability of aluminum alloys

WELDING RESEARCH ification cracking can also be quantified tak- highest magnesium content. These argu- under keyhole regime (Ref. 25). Zinc con- ing into account the lower limit of the laser ments agree with those reported in the re- tent generally decreases both the thermal fluence above which welds free of cracks are cent literature, in which the magnesium conductivity and the melting temperature generated for each alloy. It has been exper- content is also indicated to improve the of aluminum. The results obtained in the imentally observed that under low fluence laser weldability, as it stabilizes the weld present work (Tables 1 and 6) indicate that LBW treatments, the low-penetration pool and improves the absorption of laser the weldability of aluminum alloys is less welds generated suffered from cracking, the energy (Refs. 1, 5). This element is also influenced by this alloying element than by low energy applied not being able to stabi- claimed to decrease the thermal diffusivity magnesium. Thus, although Alloy 7075 lize the weld pool and generate the joint. In- and conductivity of the aluminum alloys has higher volatile compounds (7.79% of terestingly, the lower limit of the laser flu- limiting the heat conduction, and conse- Mg + Zn content) than Alloy 5083 (4.22% ence above which the welds (without quently, allowing the concentration of en- of Mg + Zn content), it is Alloy 5083 that cracks) become stable was different for ergy in the weld pool (Refs. 5, 24, 25). In this has better weldability. This fact suggests each alloy, basically depending on the dif- context, the thermal conductivity has been that the relatively high weldability of 7075 ferent susceptibility to the solidification previously reported (Refs. 2, 26–28) to be a may be mainly attributed to the 2.32% Mg, cracking of the alloys. According to Table 3, key physical property affecting the weld- although the 5.47% of Zn can also con- the minimum laser fluence to obtain welds ability of aluminum alloys under the contribute at a lower extent. with welding percentages higher than 80% duction regime, providing their relatively The addition of silicon to aluminum is is 5.5 kJ·cm–2 for AA1050 (2 kW and 16 high values in comparison with other alloys. also known to improve its weldability (Ref. mm/s), 5.5 kJ·cm–2 for AA2017 (2 kW and It is also indicated in Ref. 5 that Mg in 25), as it decreases the thermal conductiv- 16 mm/s), 5.5 kJ·cm–2 for AA2024 (2 kW 5XXX series alloys increases the bead pen- ity, decreases the melting temperature, and and 16 mm/s), 1.1 kJ·cm–2 for AA5083 (2.5 etration under keyhole welding, as a conse- improves the fluidity (Ref. 30). The Si con- kW and 100 mm/s), 5.5 kJ·cm–2 for AA6082 quence of the keyhole stabilization and the tent is also claimed to decrease the thermal (2 kW and 16 mm/s), and 2.7 kJ·cm–2 for decrease of the threshold power density, as conductivity of Al-Si diamond composites AA7075 (2 kW and 33 mm/s). These mini- a consequence of their high vapor pres- and Al-Si matrix (Ref. 31). From the results mum laser fluence values are observed to sures. It is, therefore, clear that magnesium obtained in the present work, it is difficult reveal the relative susceptibility to solidifi- is a very active element, decreasing the sur- to state clear conclusions regarding the ef- cation cracking of the different alloys (from face tension of the molten metal and en- fect of silicon on the weldability of alu- lowest to highest susceptibility: 5083 > 7075 hancing the melting efficiency (Ref. 5). minum alloys. Even though taking into ac- > 2017 = 2024 = 6082 = 1050). These re- Other volatile elements, such as zinc in count the composition of the alloys with sults are in good agreement with the ob- 7XXX series alloys, have been claimed in similar weldability (2017, 2024, and 6082) in tained data regarding the weld penetration ability, allowing the authors to establish the following weldability order: 5083 > 7075 > Table 6 — Depth/Width (d/w) and Fused Volume (VF) of Bead-on-Plate Welds Performed at Two 2017 = 2024 = 6082 > 1050. Processing Rates on the Six Aluminum Alloys The data included in Tables 1 and 6 allow v (mm/s) v (mm/s) the authors to analyze the relative influence 16.6 33.3 3 3 of alloying elements on the weldability of Alloy d/w (mm/mm) VF (mm ) d/w (mm/mm) VF (mm ) aluminum alloys under the conduction regime. Thus, according to these results, the 1050 1.10/2.61 135 0.52/2.00 49 magnesium content is seen to be the most 2017 1.48/3.32 231 0.82/2.42 93 2024 1.45/3.07 210 0.96/2.62 118 influencing element, being the main com- 5083 > 2/4.01 379 1.16/2.87 157 positional factor controlling the different 6082 1.48/3.14 219 0.79/2.42 90 bead weld penetration of aluminum alloys. 7075 > 2/3.84 340 0.96/2.70 122

160-s MAY 2012, VOL. 91 Table 1, it is possible to establish that silicon Acknowledgments 15. Ancona, A., Sibillano, T., Tricarico, L., content moderately contributes to enhanc- Spina, R., Lugara, P. M., Basile, G., and Schi- ing the weld penetration. Thus, 6082 and The present work has been financially sup- avone, S. 2005. Comparison of two different noz- 2017 alloys have lower magnesium content ported by the Ministerio de Educación y Ciencia zles for laser beam welding of AA5083 aluminum alloy. J. Mater. Process. Tech. 164–165: 971–977. and higher silicon content than 2024. Pro- (project DELATIAL, Reference MAT2008- 06882-C04-02 and project LENTEC, Ref. PTQ- 16. Sibillano, T., Ancona, A., Berardia, V., viding that Alloys 6082, 2017, and 2024 pres- 09-01-00629) and by the Junta de Andalucía (pro- Schingaro, E., Basilea, G., and Lugara, P. M. ent similar weldability, it is deducted that ject SOLDATIA, Ref. TEP-6180). The authors 2006. A study of the shielding gas influence on the the lower magnesium content is compen- would like to thank students Xavier Bouchon and laser beam welding of AA5083 aluminum alloys sated with the higher silicon content. How- Maëlys Le Coz, from “École polytechnique de by in-process spectroscopic investigation. Opt. ever, similar to the influence of the Zn con- l'université de Nantes” for their active collabora- Lasers Eng. 44: 1039–1051. tent, Si seems to have a much lower effect tion on these projects. 17. Tricarico, L., Spina, R., Sorgente, D., An- cona, A., Sibillano, T., and Basile, G. 2007. Ex- than magnesium on the weldability of alu- perimental analysis of AA5083 butt joints welded minum alloys. References by CO2 laser. Key Eng. Mat. 344: 745–750. To sum up, the weldability order ob- 18. Haboudou, A., Peyre, P., Vannes, A. B., served in the six aluminum alloys has been 1. Sánchez-Amaya, J. M., Delgado, T., and Peix, G. 2003. Reduction of porosity content as follows: 5083 > 7075 > 2017 = 2024 = González-Rovira, L., and Botana, F. J. 2009. generated during Nd:YAG laser welding of A356 6082 > 1050. The magnesium has been Laser welding of aluminum alloys 5083 and 6082 and AA5083 aluminum alloys. Mat. Sci. Eng. A– seen to be the most influencing alloying el- under conduction regime. Appl. Surf. Sci. Struct. 363: 40–52. 255(23): 9512–9521. 19. Abe, N., Tsukamoto, M., Maeda, K., ement on improving the weldability of alu- 2. Sánchez-Amaya, J. M., Delgado, T., De Namba, K., and Morimoto, J. 2006. Aluminum minum alloys. Zinc and silicon are also Damborenea, J. J., López, V., and Botana, F. J. alloy welding by using a high power direct diode seen to improve the weldability, although 2009. Laser welding of AA 5083 samples by high laser. J. Laser Appl. 18(4): 289–293. the influence of these latter alloying ele- power diode laser. Sci. Technol. Weld. Join. 14 (1): 20. 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In fact, welds of the six and mechanical properties of 2A12 aluminum erties and characteristics of laser beam welds of alloys with higher penetration than those alloy in CO2 laser-MIG hybrid welding. Appl. automotive alloys. Proceedings of the Society of previously reported under the conduction Surf. Sci. 255 (16): 7307–7313. Automotive Engineers International Congress regime have been obtained. 7. Campana, G., Ascari, A., Fortunato, A., and Exposition, Society of Automotive Engi- The depths and widths of the obtained and Tani, G. 2009. Hybrid laser-MIG welding of neers, SAE Technical Document 960168. welds were fitted to a simple mathemati- aluminum alloys: The influence of shielding 24. Van Horn, K. R. 1978. Aluminum. Met- gases. Appl. Surf. Sci. 255(10): 5588–5590. als Park, N.Y.: ASM, pp. 167–177. cal equation proposed by the authors. The 8. Tobar, M. J., Lamas, I. M., Yáñez, A., 25. Sakamoto, H., Shibata, K., and expression allowed the estimation of the Sánchez-Amaya, J. M., Boukha, Z., and Botana, Dausinger, F. 2003. Effect of alloying elements WELDING RESEARCH weld depth for each alloy under different F. J. 2010. Experimental and simulation studies on weld properties in CO2 laser welding of alu- laser welding conditions, taking into ac- on laser conduction welding of AA5083 aluminum alloys. Welding Journal 82(7): 509–513. count only the input values of laser power minum alloys. Physics procedia 5: 299–308. 26. Luijendijk, T. 2000. Welding of dissimi- and welding speed, providing a reasonable 9. Duley, W. W. 1998. Laser Welding, Chapter lar aluminum alloys. J. Mater. Process. Tech. 103: fitting to the measured experimental pen- 3 and 4. New York, N.Y.: John Wiley & Sons. 29–35. 10. Okon, P., Dearden, G., Watkins, K., Sharp, 27. Chen, B. K., Thomson, P. F., and Choi, S. etration values. M., and French, P. 2002. Proc. 21st Int. Cong. on K. 1992. 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WELDING JOURNAL 161-s Friends and Colleagues:

I want to encourage you to submit nomination packages for those individuals whom you feel have a history of accomplishments and contributions to our profession consistent with the standards set by the existing Fellows. In particular, I would make a special request that you look to the most senior members of your Section or District in considering members for nomination. In many cases, the colleagues and peers of these individuals who are the most familiar with their contributions, and who would normally nominate the candidate, are no longer with us. I want to be sure that we take the extra effort required to make sure that those truly worthy are not overlooked because no obvious individual was available to start the nomination process.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue of the Welding Journal. Please remember, we all benefit in the honoring of those who have made major contributions to our chosen profession and livelihood. The deadline for submission is July 1, 2012. The Committee looks forward to receiving numerous Fellow nominations for 2013 consideration.

Sincerely,

Thomas M. Mustaleski Chair, AWS Fellows Selection Committee Fellow Description

DEFINITION AND HISTORY The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by: ∗ Sustained service and performance in the advancement of welding science and technology ∗ Publication of papers, articles and books which enhance knowledge of welding ∗ Innovative development of welding technology ∗ Society and chapter contributions ∗ Professional recognition

RULES 1. Candidates shall have 10 years of membership in AWS 2. Candidates shall be nominated by any five members of the Society 3. Nominations shall be submitted on the official form available from AWS Headquarters 4. Nominations must be submitted to AWS Headquarters no later than July 1 of the year prior to that in which the award is to be presented 5. Nominations will remain valid for three years 6. All information on nominees will be held in strict confidence 7. No more than two posthumous Fellows may be elected each year

NUMBER OF FELLOWS Maximum of 10 Fellows selected each year. AWS Fellow Application Guidelines

Nomination packages for AWS Fellow should clearly demonstrate the candidates outstanding contributions to the advancement of welding science and technology. In order for the Fellows Selection Committee to fairly assess the candidates qualifications, the nomination package must list and clearly describe the candidates specific technical accomplishments, how they contributed to the advancement of welding technology, and that these contributions were sustained. Essential in demonstrating the candidates impact are the following (in approximate order of importance).

1. Description of significant technical advancements. This should be a brief summary of the candidates most significant contributions to the advancement of welding science and technology. 2. Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited in (1). Where possible, papers and articles should be designated as to whether they were published in peer-reviewed journals. 3. Inventions and patents. 4. Professional recognition including awards and honors from AWS and other professional societies. 5. Meaningful participation in technical committees. Indicate the number of years served on these committees and any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.). 6. Contributions to handbooks and standards. 7. Presentations made at technical conferences and section meetings. 8. Consultancy — particularly as it impacts technology advancement. 9. Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology. 10. Participation on organizing committees for technical programming. 11. Advocacy — support of the society and its technical advancement through institutional, political or other means.

Note: Application packages that do not support the candidate using the metrics listed above will have a very low probability of success.

Supporting Letters Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These letters should address the metrics listed above and provide personal insight into the contributions and stature of the candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.

Return completed Fellow nomination package to:

Wendy S. Reeve American Welding Society Senior Manager Award Programs and Administrative Support 550 N.W. LeJeune Road Miami, FL 33126

Telephone: 800-443-9353, extension 293

SUBMISSION DEADLINE: July 1, 2012 (please type or print in black ink) CLASS OF 2013 FELLOW NOMINATION FORM

DATE______NAME OF CANDIDATE______

AWS MEMBER NO.______YEARS OF AWS MEMBERSHIP______

HOME ADDRESS______

CITY______STATE______ZIP CODE______PHONE______

PRESENT COMPANY/INSTITUTION AFFILIATION______

TITLE/POSITION______

BUSINESS ADDRESS______

CITY______STATE______ZIP CODE______PHONE______

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION______

MAJOR & MINOR______

DEGREES OR CERTIFICATES/YEAR______

LICENSED PROFESSIONAL ENGINEER: YES______NO______STATE______

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE______

POSITION______YEARS______

COMPANY/CITY/STATE______

POSITION______YEARS______

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

______

______IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS FELLOW ACCOMPANY NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE IN- CORPORATED WITHIN THE CITATION CERTIFICATE.

SEE GUIDELINES ON REVERSE SIDE SUBMITTED BY: PROPOSER______AWS Member No.______Print Name______The Proposer will serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.

NOMINATING MEMBER:______NOMINATING MEMBER:______Print Name______Print Name______AWS Member No.______AWS Member No.______

SUBMISSION DEADLINE July 1, 2012 The Electrode That Takes the Stress Out of Stress-Corrosion Resistant Welding…

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