wmukj

February 2009

ding Aerospace Industry •Guns and Torches Updat Accurate Fill d Mea Crash Resistance of Aluminum

PUBLISHED BY THE AMERICAN SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING One Word Defines y^ Select-Arc's New El^ctrodeune and ReputatidAtkfpr Quality—.

r.

\ m

rf

Select-Arc, Inc. has earned teristics, consistent deposit ' higher deposi- Discover for yourself the an outstanding reputation chemistry and excellent tion rates improve produc- many benefits of specifying in the industry as a manu- overall performance you tivity and reduce welding Select-Arc's new premium facturer of premium quality have come to expect from costs. stainless steel electrodes. Call tubular welding electrodes Select-Arc. us today at 1-800-341-5215 for carbon and low alloy SelectAUoy's smooth bead or you can visit our website steel welding. The chart below shows contour, easy peeling slag, at www.select-arc.com for that SelectAlloy flux cored minimal spatter, closely more information. Now Select-Arc has controlled weld deposit expanded its range of Typical Deposition Rates for compositions and metal exceptional products Various Stainiess Steel Consumables soundness deliver addi- with the introduction tional savings. SELECT of a complete line of .0 45' Fli xCor .045" vletaK :ored Elect rode El ectrod The Select 400-Series austenitic, martensitic // metal cored electrodes and ferritic stainless 7 s A ^ offer the same advan- steel electrodes. Both ft y\ 600 Enterprise Drive the new SelectAlloy 45" So idWir e tages as SelectAlloy and 4 Xo /' Elect ode EO. Box 259 and Select stainless are ideally suited for Fort Loramie,OH 43845-0239 steel wires deliver the difficult-to-weld appli- . 5/32" Covered Phone: (937) 295-5215 superior feedability su- ^, cations, such as auto Fax: (888) 511-5217 perb welding charac- (amps) exhaust systems. www. select-arc. com

For Info go to www.aws.org/ad-index Weld greener.

Weld smarter.

Get the clean, green, smart weld wire you need. National Standard wire produces less smoke and fumes for a cleaner, safer workplace and less spatter for less rework and cleanup. Recyclable packaging and CopperFree® weld wire help you create a greener environment. Proprietary engineered matte, textured finish holds the right amount of lubricant for smoother feeds and higher productivity. It produces cleaner welds and more arc stability. And it reduces wear and tear to your welding equipment for a smarter operation. National Standard weld wire exceeds AWS specifications. Manufactured in the USA with precise alloy chemistries, it's drawn to exact diameter for maximum consistency and strength. Use the cleanest, greenest, smartest weld wire and make things better for the environment... and for your business. Contact your National Standard distributor or visit www.nationalstandard.com.

o NATIONAL STANDARD A HEICO WIRE GROUP COMPANY

Customer Service: 800-777-1618 www.nationalstandard.com A cleaner weld. A greener weld.

For Info go to www.aws.org/ad-index AA

f

Cold Metal Transfer - CMT "The cool new way to weld"

CMT incorporates wire motions into the digital process. Virtually spatter free MIG welding This makes it possible to weld with lower thermal input and high possible with 100 % C02 process stability. Welcome to the Fronius "Cold Revolution"! Perfect characteristics for cladding FRONIUS USA, LLC equals low dilution 10421 Citation Drive, Suite 1100, Brighton Michigan 48116, USA Tel: 1-810-220-4414, Fax: 1-810-220-4424 Thin sheet, low heat input, low distortion email: [email protected] www.fronius-usa.com

PERFECT WELDING For Info go to www.aws.org/ad-index CONTENTS February 2009 • Volume 88 • Number 2 AWS Web site www.aws.org Features Departments 28 In-Process Quality Assurance for Aerospace Welding Washington Watchword 4 In-process quality assurance can be used to preclude the Press Time News 6 occurrence of defects in aircraft and aerospace structures V. R. Dave et al. Editorial 8 News of the Industry 12 34 Current Technology in Welding Guns and Torches Highlights are presented of the latest guns and torches Aluminum Q&A 20 technology for gas metal arc, flux cored arc, and gas New Products 24 tungsten A. Cullison, K. Campbell, and M. R. Johnsen Welding Workbook 54

Coming Events 56 38 How to Accurately Measure Fillet Welds A manufacturer of tubular assemblies for the aerospace and Society News 61 other industries developed a novel method for taking fillet weld readings Tech Topics 73 J. Pavilanis Guide to A WS Services 87

42 Optimizing Crash Resistance of Welded Aluminum Structures New Literature 92 Numerical design tools were developed to aid in the Personnel 94 selection and optimization of alloy composition, temper, and process conditions for age-hardening aluminum alloys Classifieds 99 O. R. Myhr et al. Advertiser Index 102 46 Real-Time Crack Detection in Aerospace Structures A system has been developed for detecting the initiation of cracks during low-cycle fatigue tests in real time and prior to damage occurring to components and tooling

Welding Research Supplement

21 -s Hyperbaric GMA Welding of Duplex Stainless Steel at 12 and 35 Bar Tests showed excellent mechanical properties were achieved in underwater duplex stainless steel welds made under dry hyperbaric conditions O. M. Akselsen et al. Welding Journal {\SSfi 0043-2296) is published 29-s Control of Longitudinal Bending Distortion of Built-Up monthly by the American Welding Society for $120.00 per year in the United States and posses- Beams by High-Frequency Induction Heating sions, $160 per year in foreign countries: $7.50 The location and intensity of induction heat input were per single issue for domestic AWS members and determined in order to mitigate longitudinal bending distortion $10.00 per single issue for nonmembers and of built-up beams during fabrication $14.00 single issue for international. American Welding Society is located at 550 NW LeJeune Rd., J. U. Park et al. Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and addi- 35-s Three-Dimensional Analysis of Molten Pool in GMA-Laser tional mailing offices. POSTMASTER: Send address Hybrid Welding changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671. Canada Post: Publications Analytical models of GMA and laser keyhole welding were Mail Agreement #40612608 Canada Returns to be merged to simulate hybrid welding and show the flow patterns of sent to Bleuchip International, P.O. Box 25542, the molten pool London, ON N6C 6B2

J.-H. Cho and S.-J. Na Readers of Welding Journal my make copies of articles for personal, archival, educational or re- search purposes, and which are not for sale or re- sale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

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

Small Business Administration Cabinet charging pollutants into the air and water, laundering money, and Status May Be Restored making criminally false statements.

Support is growing in Washington to once again make the ad- Most OSHA Whlstleblower Complaints Lack ministrator of the U.S. Small Business Administration (SBA) a Merit Cabinet-level position. The SBA briefly held Cabinet status under the Clinton administration. The rationale is that the SBA adminis- It is a violation of federal law for an employer to retaliate in any trator will have greater stature as a Cabinet member and therefore manner against an employee who reports a workplace safety or can promote the mission of the SBA more effectively. This move health violation or otherwise exercises his or her rights under fed- would also emphasize the importance of small business to the U.S. eral occupational safety and health laws. In 2008, of the 1259 retal- economy. Key members of Congress and President-Elect Barack iation charges investigated by the Occupational Safety and Health Obama's transition team have endorsed this action. Administration (OSHA), 80% were either dismissed or ultimately withdrawn. Only 20% were found have to merit. Definition of 'Independent Contractor' May Economic Stimulus to Go beyond Public Be Narrowed Works A common method of attempting to predict what legislation may be favored by the new administration is by examining bills that Most of the attention given to the planned economic stimulus President-Elect Barack Obama introduced while serving as a U.S. legislation that is expected to be enacted in early 2009 has been on Senator. One such bill would have made it more difficult for em- public works infrastructure projects, but there are several other as- ployers to classify workers as independent contractors as opposed pects that are relevant to industry. Those identified include the to employees. Employers do not have to provide benefits to inde- following: pendent contractors, and therefore many employers prefer that • Provision of a $3000 refundable tax credit for each additional classification. full-time employee hired by companies in 2009 and 2010; The legislation advocated by then-Senator Obama would have • Extension of the small business investment expensing limit to voided a provision in the law that currently allows employers to $250,000 through the end of 2009; designate workers as independent contractors based on long-stand- • Elimination of all capital gains taxes on investments made in ing practice in that particular industry. The bill also would have small and startup businesses; greatly expanded the authority of the Internal Revenue Service in • Making the Research and Development tax credit this area, including with respect to issuing regulations on how work- permanent; ers should be classified. • Creation of a nationwide emergency lending facility for small businesses to be run through the Small Business Administration's Disaster Loan Program; OSHA Issues Final Personal Protective • Temporary elimination of the fees on the SBAs 7(a) and 504 Equipment Rule Correction loan guarantee programs for small businesses; • Creation of an Advanced Manufacturing Fund to identify and The final Occupational Safety and Health Administration invest in the most compelling advanced manufacturing strategies; (OSHA) rule on Clarification of Employers' Duty to Provide Per- • Doubling of federal funding for the manufacturing extension sonal Protective Equipment and Train Each Employee became ef- partnership program that works with manufacturers across the fective December 12. The rule revises OSHA standards to clarify country to improve efficiency, implement new technology, and that, for employers to be in compliance, they must provide personal strengthen company growth; protective equipment (PPE) and training for each em- • Doubling of federal funding for basic research; and ployee covered by the standards. • Creation of a national network of public-private business The final rule does not impose any new substantive require- incubators. ments. The duty to provide PPE of all types, including respira- tors, and training to employees already exists in the law, and this Federal Web Site Managers Urge President- new final rule adds no new compliance burden. Rather, the final rule achieves greater consistency in the applicable OSHA regu- Elect to Increase Transparency lations, provides clearer notice of the nature of the employer's Government officials in charge of managing federal Web sites duty under existing PPE and training provisions, and clarifies are urging the incoming administration to establish Web commu- that separate per-employee citations and penalties may be im- nications as a core government business function and transform posed by OSHA. these Web sites into truly helpful sources of information for the U.S. public. There are approximately 24,000 U.S. government Web Environmental Protection Agency Creates sites currently in operation, but most tout organizational achieve- 'Most Wanted' Web Site ments instead of effectively delivering basic information and serv- ices. Legal, security, privacy, and internal policy concerns are partly The U.S. Environmental Protection Agency has established the responsible, according to the Federal Web Managers Council, but first-ever federal database of fugitives accused of violating environ- in addition many federal agencies tend to focus more on technol- mental laws and evading arrest. The Web site, www.epa.gov/fugitives, ogy and Web site infrastructure than improving content and includes photos of the accused, summaries of their alleged envi- service delivery. • ronmental violations, and information on each fugitive's last known whereabouts. The alleged violations include smuggling of - Contact the AWS Washington Government Affairs Office at depleting substances, illegally disposing of hazardous waste, dis- 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected],- FAX (202) 835-0243.

FEBRUARY 2009 ISO 9001:2000 Certified

WELD MOLD COMPANY YOUR ONE-STOP SHOP FOR WELDING ALLOYS SINCE 1945

We offer:

• Stock tool steel alloys from .035" to 156" in spool and cut lengths. Electrodes from 1/16" to 3/4" diameter. www.weldmold.com

• Stock maintenance and repair alloys .035-.156 solid, metal cored, flux cored in spool and cut length. phone 800.521.9755 • All grades of hard facing products, electrodes, flux cored and open arc wires. fax 810.229.9580 • 100 lb minimums for custom electrode manufacturing. Brighton, Mi 48116 • 250 lb minimums for custom metal cored, flux cored

or open arc wire. For Info go to www.aws.org/ad-index PI7E55 TIME NEWS WELflM?

Publisher Andrew Cullison American Welding Society Adds $1.1 Miiiion to Schoiarship Endowments Editorial Editorial Director Andrew Cullison The American Welding Society (AWS), Miami, Fla., has recently added $1.1 million Editor Mary Ruth Johnsen to the multimillion-dollar portfolio of scholarship endowments of the AWS Foundation. Associate Editor Howard M. Woodward Funding from the American Welding Society's cash reserves will enable the AWS Foun- Associate Editor Kristin Campbell dation to increase its scholarship awards to future welding professionals. Peer Review Coordinator Erin Adams "This major new endowment is specifically targeted to those individuals who are seeking a career in welding," said Sam Gentry, executive director, AWS Foundation. Publisher Emeritus Jeff Weber "This will help meet the urgent need for welding personnel in the American workplace." Graphics and Production There is a projected shortage of 200,000 in the United States by 2010, and Production Manager Zaida Chavez retiring welders are exceeding new welders coming into the field. Also, according to Senior Production Coordinator Brenda Flores Gentry, the average age of a is currently about 54. Welders are now needed in manufacturing and construction, particularly in major Advertising energy and infrastructure projects across the country. Local AWS District volunteers National Sales Director Rob Saltzstein are going to be the primary means of distributing the new scholarship money in accor- Advertising Sales Representative Lea Garrigan Badwy dance with local industry needs. Senior Advertising Production Manager Frank Wilson "Volunteer leaders in AWS Districts know the needs and trends of local industry," said Gentry, "so they can efficiently distribute scholarships to the best candidates, whether Subscriptions they are entering a technical school program or a college." Subscriptions Representative Edalia Suarez [email protected]

Aerospace Weiding Minneapolis Achieves EASA Approval American Welding Society 550 NW LeJeune Rd., Miami, PL 33126 Aerospace Welding Minneapolis, Inc., Eagan, Minn., has gained Part 145 EASA ap- (305) 443-9353 or (800) 443-9353 proval from the European Aviation Safety Agency. This certificate has been issued under the terms of the current Bilateral Aviation Safety Agreement and the associated Main- Pubiications, Expositions, Marketing Committee tenance Implementation Procedures. It allows the company to export all overhauled D. L. Doench, Chair and repaired parts to customers in any EASA member country. Hobart Brothers Co. Furthermore, AWI's staff includes a FAA designee with Designated Manufacturing T A. Barry, Vice Chair Inspection Representative status, allowing for the issuance of Export Certificates of Air- Miller Electric Mfg. Co. worthiness on all of the Aero-Power® brand parts. J. D. Weber, Secretary American Welding Society P. Baka, The Lincoln Electric Co. Employers Cautioned against Cutting Back on Workplace S. Bartholomew, ESAB Welding & Cutting Prod. Safety in Times of Economic Difficulty D. Brown, Weiler Brush J. Deckrow, Hypertherm American Society of Safety Engineers' (ASSE) President Warren K. Brown of Fair- D.DeCorte, RoManMfg. born, Ohio, recently referred to reports of some companies cutting safety processes hop- J. Dillhoff, OKI Bering ing to reduce costs. "Workplace safety processes must be in place at all times," Brown J. R. Franklin, Sellstrom Mfg. Co. D. Levin, Airgas said. "They are even more critical during business downturns." J. Mueller, Thermadyne Industries Laura Comstock, president-elect of the ASSE South Carolina Chapter, also offered R.G.Pali,/.PMraen Co. input. "Some safety-related purchases and testing can be deferred, but other purchases, J. F. Saenger Jr., Consultant such as those for employee personal protective equipment like hardhats, safety glasses, S. Smith, Weld-Aid Products and respirators, are critical to operations," Comstock said. D. Wilson, Wilson Industries Plus, the South Carolina ASSE chapter suggests employees can take measures to J. C. Bruskotter, Ex Off., Bruskotter Consulting Services help companies save money. This can be done by following safe working procedures and H. Castner, Ex Off., Edison Welding Institute practices to prevent injuries, related downtime, and expenses; properly using, cleaning, L. G. Kvidahl, Ex Off, Northrup Grumman Systems and caring for protective equipment; reusing gloves whenever possible for as long as G. E. Lawson, Ex Off, ESAB Welding & Cutting Prod. possible; and keeping track of safety glasses and reusable hearing protection. E. C. Lipphardt, Ex Off., Consultant "Money cut from safety processes now could have an enormous cost later; this can S. Liu, Ex Off, Colorado School of Mines be from injury and health care costs, fines, lost production time, employee morale, or E. Norman, Ex Off., Southwest Area Career Center R. W. Shook, Ex Off, American Welding Society worst of all, employee injury or even death. There are better and smarter ways to pro- tect the bottom line," Brown added.

KUKA Lands Key Aircraft Order Copyright © 2009 by American Welding Society in both printed and eiec- tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information deveioped by the authors KUKA Robotics, Clinton Township, Mich., has received a blanket order from the of specific articles are for informational purposes only and are not in- tended for use without independent, substantiating investigation on the European aircraft manufacturer Airbus S.A.S. This is for the delivery of 41 omniMove part of potential users. mobile platforms, which feature a flexible horizontal range of motion in all directions and can rotate on the spot, for assembly of the Airbus A350 XWB. The assembly plat- forms will be used in the French, British, German, and Spanish Airbus factories to sub- BPA assemble the plane's wings and fuselage sections. The term of the blanket order is five years.

FEBRUARY 2009 We Back Them Better Because We Build Them Better. " New 2-YEAR WARRANTY on all oike Aronson/Ransome positioning eqoipment.

fhen y . 7^ positioning equipment that's this reliable, you can back it with a standard i/arranty that no one else en tries to offer: a full 2 years n materials and workmanship. And should your Koike positioner ever need service-under warranty or after-we'll send out from our U.S. factory one of the same master technicians who build our positioners. We're the only company in the industry who does that, too. Koike offers positioners that can handle standard parts or awkward objects in any shape and at any angle from 100 lbs. to 4 million lbs. So we probably have the positioning equipment that can make your welding more profitable. We definitely have the warranty that will keep you up and running. B

Koike Aronson, Inc./Ransome Arcade, NY USA 800-252-5232 Houston, TX 800-868-0640 www.koike.com For Info go to www.aws.org/ad-index EDITORIAL American Welding Society Founded in 1919 to Advance the Science, Technology and Application of Welding

Officers AWS Gears New Membership President Victor Y. Matthews The Lincoln Electric Co.

Package to Welders Vice President John C. Bruskotter Bruskotter Consulting Services, LLC The Membership Committee and the staff of the AWS Membership Department are Vice President John L. Mendoza always looking for enhancements to our membership benefits. Following two years of CPS Energy concentrated effort to better service the needs of our members who identify themselves as welders, AWS is now ready to introduce the most significant additions to our benefits in many years. Vice President William A. Rice Jr. While the overall number of AWS members continues to grow, the number of mem- OKI Bering bers identifying themselves as welders remains steady — about 8% of the total. Through Treasurer Earl C. Lipphardt a national firm that specializes in large surveys, AWS contacted a large number of Consultant welders asking them directly about the present membership package and soliciting their ideas on enhancements that may make a Society membership more attractive to a Executive Director Ray W. Shook greater number of welders. American Welding Society In direct response to their suggestions, the Membership Committee has developed several new member benefits, which include the following: 1. Discounts on tools/equipment of the trade. The welders contacted during the sur- Directors vey emphasized that a valuable benefit would be discounts on their needed tools. AWS B. P. Albrecht (At Large), Miller Electric Mfg. Co. has worked with GAWDA (Gases and Welding Distributors Association) to provide this J. R. Bray (Dist. IS), Affiliated Machinery, Inc. benefit. Participating welding distributors will now offer a discount on materials for AWS H. R. Castner (At Large), Edison Welding Institute members. The names and locations on these distributors will be maintained on the AWS Web site (www.aws.org). The magnitude of the discount and the materials included as a D. B. DeCorte (At Large), RoMan Mfg. Inc. member benefit will be determined by each individual distributor. G. Fairbanks (Dist. 9), Fairbanb Inspection & Testing Services 2. Access to AWS health insurance program. Many welders identified the need for D. A. Flood (Dist. 22), Tri Tool, Inc. affordable health insurance as a valuable benefit. AWS has finalized an agreement with M. V. Harris (Dist. 15), Vallej' National Gases a major insurance underwriter to offer not only health insurance but also many other types of insurance coverage for AWS members. R. A. Harris (Dist. 10), Consultant 3. Publications exclusively for welders. The survey revealed that welders would like D. C. Howard (Dist. 7), Concurrent Technologies Corp. information that was specifically directed toward their interests. One item that was iden- J. Jones (Dist. 17), Thermadyne tified by a high percentage of the respondents was a package of welding projects that can be used to construct a variety of items. To address this request, AWS and the Lincoln W. A. Komlos (Dist. 20),ArcTech LLC Electric Foundation will make the well-known and respected Arc Welding Projects, D. Landon (Dist. 16), VermeerMfg. Co. Volume IV, available as a new publication selection for welders who have just become R.C.Lanier(Dist.4),HttC.C. members of the Society. G. E. Lawson (Past President), ESAB Welding & Cutting Prod. 4. Welders Exchange Bulletin Board on the AWS Web site. A method for the "welder" members to better communicate with other welders was also requested. Through the J. Livesay (Dist. 8), Tennessee Technology Center addition of a new bulletin board feature on the AWS Web site, a welder will be able to D. L McQuaid (At Large), DL McQuaid & Associates ask a question, share a successful project, or seek a to a problem. Other welders, S. Mattson (Dist. 5), Mattson Repair Service then, will be able to easily respond and share their experiences. This bulletin board will S. P. Moran (Dist. 12), Miller Electric Mfg. Co be dedicated to allowing welders to communicate with their peers. 5. Discounts on dental plans, prescriptions, and more. AWS is providing a compre- R. L. Norris (Dist. 1), Consultant hensive package of discounts on many things that should add value to a membership. It T. C. Parker (Dist. U), Miller Electric Mfg. Co. is anticipated that many of these programs will become a welcome incentive to welders K. A. Phy (Dist. 6), Entergy Nuclear Operations, Inc. wanting to join AWS. W. R. Polanin (Dist. 13), Illinob Central College As you can see, AWS went directly to welders, asked what they would like to have as a member benefit, and as a result, has developed a new plan in response to the interests N. Saminich (Dist. 21), Ninyo & Moore defined by this vital segment of our industry. The N. S. Shannon (Dist. 19), Carbon Testing of Portland Membership Committee is pleased to offer this new T.A.Siewert(AtLarge),iV/5r program and anticipates these benefits will be attrac- tive to welders. E. Siradakis (Dist. \\),Airgas Great Lakes On a closing note, I am asking for your help in K. R. Stockton (Dist. 2), PSE&G Maplewood Testing Serv. spreading the news. Share this information with the G. D. Uttrachi (Past President), WA Technology, LLC welders you know and encourage them to take advan- D. R. Wilson (At Large), Wilson Industries tage of the opportunity to not only join the premier welding society in the world, but to reap the values M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute provided by these newly added benefits.

Lee G. Kvidahl Chair, AWS Membership Committee

FEBRUARY 2009 U P C 0 M 1 N G WORK SHOPS March 3,2009 March 5,2009 March 11,2009 New Brunswick Le Centre deformation Heli-One Community College en metallurgie de Laval 4300-80th Street TITANIUM 950GrandviewAve. 155, boulevard Sainte-RoseEst Delta, BCV4K3N3 ^^^^ ^^^^ Room B-2007 Porte 22 ^^^B ^^^^ Saint John, NBE2L3V1 Laval, QCH7H1P2

Registration available at www.titanium.org Or contact ITA at 303-404-2221

For Info go to www.aws.org/ad-index THE 12thALUMINUM WELDING CONFERENCE & EXHIBITION

' / Earn PDH's toward your AWS recertification •j^ or renewal — when you attend —— the conference!

The premier event dedicoted to oluminum welding technology! Because of atfeixrtes such at kflhl h»gfi strengthk) woigM rato. and corroaion resistance ak/rnrxm lends itself to a wds vanety of ndustnal applications However, because its chemcal and physical properties are drtfereni from those of steel, waking of ati/mum raqufrM special procetaea, techrxues. and expertise At IM confererM. a dtttrgitshed panel of alinvitfn njutry experts ^^ The 12th Aluminum Welding Conference & Exhibition will also provide several cpportunMs lor you to netwodt informaty wifi speakers and other pa-.r td-.s d-i *«l as lu M 3" yxhtd].-- iMBHk| pndM Md MMces available to Ihe aunrum IMM^ RdMl| For fhe latesf conference and exMwlDr tnformation or to register for the conference wsif our wetisife af ivww aws.org conferences or crfl 800-44J-9353. ert 455.

To main Ublttop txMM space or for questions about extaMng af the oonforenoe. pfease caiV 800-44J-9353, ert. 229 American Welding Society

The Aluminum Association May 5-6,2009

Conference Program *

Overview of Aluminum Welding Design and Performance of Aluminum Welds Tony Anderson Tony Anderson ESAB Welding & Cutting Products ESAB Welding & Cutting Products Florence. SC Florence. SC

The Aluminum Designation System & Application of the AWS D1.2 Characteristics of Aluminum Alloys Structural Welding Code—Aluminum PetePoHak KyleWitttams The Aluminum Association. Inc Alcoa Technical Center Arlington VA Alcoa Center. PA

Aluminum Welding Metallurgy Robotic Applications Tony Anderson Jay Cinder ESAB Welding S Cutting Products ESAB Welding i Cutting Products Ftorence. SC Florence. SC

Metal Preparation for Aluminum Welding High Energy Density Beam Welding of Witttam Christy Aluminum Novebs Inc WHSam Christy Kingston. Ontario. Canada NoveHslnc. Kingston, Ontario. Canada Filler Alloy Selection Primary Characteristics Tony Anderson Cutting Methods for Aluminum Alloys ESAB Welding & Cutting Products Jay Cinder Ftorence. SC ESAB Welding 4 Cutting Products Florence. SC of Aluminum Alloys Mark Burke Overview of Solid State Joining MMoo Processes for Aluminum Mississauga Ontario. Canada Donald J SpineHa Alcoa Technical Center and Variable Alcoa Center. PA Polarity of Aluminum Willtam Chnsty Friction Stir Welding Aluminum Novebs Inc Jay Grrxter Kingston, Ontario. Canada ESAB Welding & Cutting Products Florence. SC Aluminum Weld Discontinuities: Causes and Cures Resistance Spot Welding of Aluminum Kyle WfHiams Donald J Spinetla Alcoa Technical Center Alcoa Technical Center Alcoa Center. PA Alcoa Center. PA

Question and Answer Sessions Bemie AlfshuUer. Moderator Rio Tmto Alcan Kingston. Ontario Canada NEWS OF THE INDUSTRY

Empire Connector Pipeline Project Gets Finished

National Fuel Gas Co.'s wholly owned subsidiary, Empire This project expanded the 157-mile-long Empire State Pipeline Pipeline, Inc., Williamsville, N.Y., has placed its Empire Con- by about 77 miles. The Empire Connector, extending from Victor, nector Pipeline in service. Construction is now complete, but N.Y., to Corning, N.Y., links the existing Empire State Pipeline property restoration will continue into the spring and summer. that runs from an interconnection with TransCanada Pipeline near Buffalo, N.Y., to Syracuse, NY., to the Millennium Pipeline project. Costs are estimated to be approximately $187 million. Also, a 20,000-hp compressor station was built as part of the project. Located in Oakfield, NY., it increases the pipeline's ability to deliver gas along the expanded pipeline system. The Empire Connector and Millennium Pipelines are part of an expansion project designed to bring energy supplies to the Northeast. These projects, along with the Algonquin Gas Trans- mission, LLC, and Iroquois Gas Transmission System, L.P., ex- pansion projects, will provide 525,400 dekatherms per day of new natural gas supply to growing markets. A positive economic imprint has been left by this project on the communities along the route. More than 800 jobs were cre- ated with approximately 420 full-time construction jobs, 70% of which were filled with workers from the region.

National Fuel Gas Co. recently announced the Empire Connec- An Empire Connector crew member works on welding together tor Pipeline has been completed and is in service. It runs from 40- and 80-ft sections of coated pipeline. As many as five weld- Victor, N. Y, to near Coming, N. Y, linking the existing Buffalo- ing passes may be necessary to properly join sections of pipe. to-Syracuse Empire State Pipeline to the Millennium Pipeline They must meet high inspection standards required by the con- project. The pipeline is shown being placed in the trench with tractor, pipeline company, and federal regulators. The welds are care. Expert crews using sidebooms coordinate its installation. 100% visually inspected and X-rayed.

Plans Underway for the International at least 12 countries will present new achievements in more than 80 papers during the eight concurrent sessions. These encom- Brazing & Soldering Conference pass practically all fields of joining technology including solders and soldering technology; ceramics, composite, and glass join- The American Welding Society (AWS) and ASM Interna- ing; filler metals; design, testing, and reliability of joints; brazing tional have once again joined to bring the 4th Interna- fundamentals; brazing processing; light metals joining; and new tional Brazing & Soldering Conference (IBSC) to Orlando, Fla., brazing applications. Also to be presented are plenary sessions April 26-29. This conference, held every three years, offers pre- titled Development of New Brazing Filler Metals and The Impact conference education sessions as well as three days of technical of "Green" Legislation Requirements on Soldering Technology sessions on the latest developments in the brazing and soldering Advancement. industries. In addition, top companies in the industry will exhibit The AWS C3 Brazing Committee members have volunteered their latest brazing and soldering products, giving participants their time to participate in organizing the event together with the opportunity to evaluate new products, problem-solve, and AWS and ASM International staff. network with their peers. Information regarding the conference can be found at Major players of the world brazing community have commit- www.aws.org/education/ibsc or by calling (800) 443-9353 (305- ted to participate in the IBSC 2009. Scientists and engineers from 443-9353 outside North America), ext. 455.

FEBRUARY 2009 Industry Leaders Cosponsor Symposium to Raise Weiding Awareness

Miller Electric Mfg. Co. President Mike Weller (center) was im- pressed by the welding and technical skills of Oshkosh North High School seniors Lucas Dowd (left) and Casey LaMarche for their junior year project — a custom chopper built from the ground up.

At the recent Career Horizons: Welding symposium, more than 100 Wisconsin high school counselors, educators, and adminis- trators discovered the bright future welding offers. Miller Electric Mfg. Co., Airgas, Miron Construction, and • XXL TOUCH SCREEN for intuitive AZCO Inc. sponsored the event, which is an initiative of the New graphically assisted programming. North Manufacturing Alliance. •Automatic Procedure Generation Attendees were informed about the salary potential and wide (APG). variety of careers that can originate with an education in weld- • Load/store and transmit all data ing. Presentations by current welding students, graduates of weld- via USB or Ethernet connection. ing programs, industry experts, and high school administrators were featured. There are 2900 unfilled welding jobs in Wiscon- • Complete and comprehensive traceability. sin alone and 360 new openings are created each year. A goal was to encourage high school personnel to reach out to the industries and businesses in their communities to form P4, the intelligent and communicating partnerships improving the quality of the schools' technical edu- cation programs. Another focus was to dispel the myths welding orbital welding power source. is a low-paying occupation with little potential for advancement. ASTRO ARC P0LYS0UDE INC EADS Sets up Office at National Research 24856 Avenue Rockefeller Council Canada's Location VALENCIA, CA 91355 [email protected] T. 661-702-0141 - F. 661-702-0632 EADS, a provider of aerospace, defense, and related services, has opened an office at the National Research Council Canada's www.astroarc.com (NRC) site. This will enhance its commitment to aerospace re- For info go to www.aws.org/ad-index

WELDING JOURNAL search and technology development in Canada. Also, opening ESCO Tool Moves to New Building an office within the NRC's Institute for Aerospace Research (NRC-IAR) facility in Montreal is a step in establishing a long- term closer working relationship between the two organizations. Currently, they have two joint projects underway, and one is between NRC-IAR Aerospace Manufacturing Technology Cen- tre and EADS Innovation Works that involves friction stir weld- ing. NRC and EADS are considering joint projects that could in- clude the NRC-IAR Structures and Materials Performance Lab- oratory, and other NRC institutes. Southeast Supply Header to Award $60,000 in Scholarships for Technical Career Fields

Pearl River Community College in Mississippi is one of six community colleges to receive a one-time $10,000 contribution in scholarship monies from Southeast Supply Header, LLC ESCO Tool recently acquired and refurbished a 60,000-sq-ft build- (SESH), a 50/50 joint venture between Spectra Energy Corp. and ing in Holliston, Mass. Founded as the Evans Supply Co., Win- CenterPoint Energy, Inc. Additional recipients include Louisiana chester, Mass., and purchased by the Brennan family in 1975, this Technical College - Tallulah Campus, Mississippi Gulf Coast firm has been located in Medfield, Mass., since 1980. It manufac- Community College, Jones County Junior College, Copiah- tures a range of portable end prep tools and saws for cutting and Lincoln Community College, and Bishop State Community Col- machining tube and pipe in preparation for welding. "We have been lege, Mobile, Ala. Scholarships will be awarded to students en- the beneficiary of a growing power industry and are moving into a rolled in these colleges' technical-vocational programs beginning larger building in response to worldwide demand for our tools, which in summer or fall semesters of 2009. are used for maintaining and upgrading existing power facilities as "Our industry is in real need of workers skilled in industrial well as for new construction," said Matthew Brennan, president. and technical trades such as civil engineering technology, survey- ing, construction management, drafting/design, and welding," said Andrea D. Grover, director, stakeholder outreach. Spectra Autumn Career Fair Held at Hobart Institute Energy. This became emphasized as construction was recently completed on the SESH pipeline system, a 274-mile interstate The Hobart Institute of Welding Technology, Troy, Ohio, re- pipeline running from Delhi, La., to Coden, Ala., including 211 cently hosted a career fair for upcoming and recent graduates. miles through Mississippi. The event allowed students to talk with representatives from

Stand Out.

Tl># Amcric wt WfoMing Society (AW8). uobvfitarKJs that 006 size dOM no( 11 all For that reason, weVe created FOUR dMtrant lavto of oorporla mambaohip. starting for as IMa as S150 par year. •lowing you to select a program that beat fits with the way your company oparatat. WMh an M ym history in the welding industry, d 50,000* members worldwide, AWS Corporate Membership offers

CALL US FOR MORE INFORMATION, OR TO JOIN AT: (800) 443-9353. EXT. 480. OR (305) 443-9353. EXT. 480. Coniacllb: OR VISIT US ON-LINE AT WWW.AWS.ORG MEMBERSHIP.

FEBRUARY 2009 more than a dozen different companies across the country. VITRONIC Presents the VINTEC Award 2008 Linda Akers, a recruiter for Westech (also known as WOTCO), to Daimier AG Casper, Wyo., arrived a day before the fair to make presentations to students. This company produces custom-designed metal fabri- cations and wear materials for the construction and mining indus- tries. All its welders are qualified to the requirements of AWS Dl.l, Structural Welding Code — Steel. "Welders must be able to weld with %2 in. and Yu, in. gas shielded flux cored welding wire," said Akers. "They must pass a welding test on plate and a written test covering symbols and blueprints...The work is all indoors, and there are no travel requirements for our welders. We currently have both first and second shift openings." Janet Piechocki, admissions representative with Hobart Insti- tute, organized the event and explained each company gave the time, effort, and expense to participate and talk with students who had their own individual needs and enticements.

Macsteel Service Centers USA Increases with New Facility

Macsteel Service Centers USA recently expanded business operations with opening a new 100,000-sq-ft service center in Portland, Ore. A formal plant opening and ribbon-cutting event is planned for this spring. The Pacific Northwest region including Oregon, Washington, Dr. -Ing. Norbert Stein (right), president and sole shareholder of and Idaho will be serviced. Plus, the center will process and stock VITRONIC GmbH, recently presented the VINTEC Award 2008 carbon, stainless, and aluminum flat rolled and wide flange beams. to Giinter Kasper (left), head of axle production, Daimler AG, at Future plans call for the product line to include channels, angles, the EuroBLECH trade fair in Hannover, Germany. The award was tubes, and plates. presented after the joint development and installation of a welding James L. Rapae has been named manager of plant operations. concept at the Daimler plant in Mettingen. Welded joints are auto- The company has also hired six additional employees to fill out matically inspected and optimized using F/i?Owsl, a weld joint in- the Portland staff. spection system from VITRONIC.

BUY AMERICAN Joe Fuller, LLC

COMUK nKC! OMI/TY! DCIMRT? Mi H

vm.joeMler.com

,r»: ir» ,T

ECONOMICMLY PEICED TIJMGSTEi GM1DEE SAFETl Enclosed diamond wheel grinding area ^ WELD QMLITl 20 Ra finish improves tungsten life, starting & arc stability • lakalnai** PRODOCTfflTY: Longitudinal diamond grind your tungsten under 30 seconds VALUE: Diamond flat, grind & cut your tungsten economically

DIAMOND GROUND PRODUCTS, INC. 2550 Azurite Circle Newbury Park CA 91320 Phone (805) 498-3837 • FAX (805) 498-9347 Email: sales@diaiiiondg):oimcLcom *!; •ktaK^t* Ulk«i%M|Hk Visit our website: www.diamondground.com

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index WELDING JOURNAL American Welding Society

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, 2009. The Committee looks forward to receiving numerous Fellow nominations for 2010 consideration.

Sincerely,

Nancy C. Cole Chair, AWS Fellows Selection Committee A JOB DONE RIGHT.

This is the promise Titan Contracting has given its customers for more than 30 years. With a superior tank and vessel operation, as well as highly reputable mechanical and power divisions, Titan credits its continued success to providing its skilled craftsmen with only the best tools and products available. That's why Titan uses Stoody Nickel Flux Cored Wires.

"Since we've replaced solid MIG wires such as Alloys 625 and C276 with Stoody's Nickel Flux Cored Wires, productiv- • ity and quality improvements have been significant. They «« advance our ability to automate, eliminating the chance of human error," says Tank Division Manager, Darrell Jones. "It replaces any conventional welding wire because of its 1 'all position'capabilities."

As one of the leading fabricators and erectors of FGD Scrubber Systems in the nation. Titan has used Stoody Nickel Flux Cored Wires to tackle tough welds on absorbers and wet electrostatic precipitators (WESPs). "We rely on Stoody for speed, productivity and quality," says Jones, "and Stoody's customer support is far superior to any of the other specialty /^ & alloy wire companies we have tried in the past." DARRELL JONES Tank Division Manager Titan Contracting & Leasing, Inc. ^i# Owensboro, KY titancontracting.com A THEMAADYNC Corwty Wan Contracting carries the torch - will you? THERMADYNE, A GLOBAL CUTTING AND WELDING LEADER, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, and fabrication. Victor, Thermal Dynamics, Thermal Arc, Arcair, Tweco, Stoody, Cigweld and TurboTorch are among the Thermadyne family of brands that you can count on for safety, reliability and quality. ~ **\ STOODY

www.thermadyne.com THERMADYNE.

American Welding Society Sustaining Company Member ALUMINUM Q&A BY TONY ANDERSON

Q11 have worked with aluminum and alu- minum welding for many years and have often heard many different metallurgical terms — solid-solution hardening, solu- tion heat treatment, precipitation hard- ening, age hardening, natural aging, ar- tificial aging, annealing, stabilizing, and stress relieving — used for describing the various heat-treating techniques and con- ditions used for aluminum alloys. Can you explain the different heat treatments and how they can influence manufacturing procedures used for welding, forming, and machining?

Al In order to appreciate the effect of thermal treatment on aluminum alloys, we should first understand the principal effects of alloying elements and solid- solution hardening. Pure aluminum is not heat treatable but it "work hardens" or gains strength when mechanically worked such as bend- ing or stretching. The addition of alloying elements to aluminum does not remove Fig. 1 — These 600-lb spools of aluminum welding wire are about to undergo an anneal- this characteristic; all aluminum alloys ing operation to remove the work hardening effect produced by previous wire drawing gain strength when cold worked. Adding operations. elements to aluminum affect the metal in many respects. One of the most signifi- precipitation heat treatment at higher metalworking procedures or end use re- cant effects is that some aluminum alloys ) usually is employed to de- quirements call for maximum ductility. In can now be made stronger through the use velop maximum strengths as quickly as Fig. 1, we see spools of aluminum weld- of thermal treatments. possible. Close control is essential to en- ing wire positioned in a furnace. These Solid-Solution Hardening. Aluminum sure the correct metallurgical structure spools are about to undergo an annealing alloys are made by dissolving other met- that will produce the desired properties. operation to remove the work hardening als in aluminum to form solid . Solid-solution hardening followed by effect of the previous wire drawing oper- Some atoms of the alloying metals replace precipitation hardening is the principal ation before subsequent manufacturing certain aluminum atoms in the metallur- heat-treatment method used for strength- operations are carried out. The annealed gical structure; this is called substitutional ening the heat-treatable aluminum alloys. condition is the material's lowest strength. solid solution. Other thermal treatments used to pre- Stabilizing. Certain nonheat-treat- Other atoms of alloying elements oc- pare various aluminum alloys for opti- able, work-hardening alloys containing cupy spaces between the base metal atoms mum workability and application require- magnesium, such as 5052, gain ductility in its metallurgical structure (lattice); this ments include annealing, stabilizing, stress but lose strength upon room is termed interstitial solid solution. In both relieving, and refrigeration. aging. Such age-softening alloys often are cases, the metallurgical structure is usu- Annealing. Aluminum and all of its al- stabilized by heating to 225° to 350oF (110° ally distorted by the new atoms in the loys may be annealed to remove the hard- to 180oC) to accelerate the softening to structure, thus increasing strength. These ening or strengthening effects of cold its ultimate limit. alloys may then be further strengthened working or heat treatment described pre- Stress Relieving. Internal stresses built by heat treating and/or work hardening. viously. Annealing is accomplished by up by temperature gradients in aluminum Precipitation Hardening. Heat-treat- heating the metal above its recrystalliza- may be caused by many factors: during able aluminum alloys contain alloying el- tion temperature 650-800oF (345-4250C), quenching (rapid cooling), after heat ements that are more soluble at elevated depending upon the alloy, and maintain- treatment, cooling after welding or cast- temperatures than at room temperatures. ing the required level until recrystalliza- ing, from distortion of rolling, forging, ex- When these alloys are solution heat tion is complete in work-hardened alloys. truding, bending, or drawing operations. treated to put these elements back into For heat-treatable alloys, either a con- These internal stresses can be reduced by solid solution and then rapidly quenched, trolled cooling rate or low-temperature either thermal or mechanical treatments. a supersaturated condition is produced. soaking treatment is necessary in order to Thermal treatments employing tem- The strength of the alloy is developed precipitate particles of the alloying peratures below those required for an- as the alloying elements precipitate out elements. nealing often are used for nonheat-treat- of the solution during the passage of time. Annealing is used to restore ductility able wrought alloys with some loss of This effect is referred to as precipitation to make the alloy easier to work, both at strength and an increase in ductility. or age hardening. Varying degrees of age intermediate stages of fabrication, in Where applicable, the metallurgically hardening occur at room temperature which extensive metal deformation (work superior procedure of stressing the metal (natural aging), but artificial aging (or hardening) has taken place, or whenever mechanically is used. This produces a

!• FEBRUARY 2009 small, controlled amount of plastic defor- machinability rating, designated as A mation (1-3%) to effect employed stress through E. Tables are available that pro- TONY ANDERSON is corporate technical train- relief with no resultant loss of strength. vide this information as well, based on alu- ing manager for ESAB North America and coor- This treatment aligns the residual minum alloy type and designated heat- dinates specialized training in aluminum welding stress in the direction of working and also treated temper.^ technology for AlcoTec Wire Corporation. He is a reduces the differences between compres- Registered Chartered Engineer and holds numer- sive stresses in the outer layer of the metal Acknowledgment ous positions onAWS technical committees. He and the interior tensile stresses within. is chairman of the Aluminum Association Tech- nical Advisory Committee for Welding and author Mechanical stress relieving is accom- I would like to thank the Aluminum of the book Welding Aluminum Questions and plished by stretching or compressing the Association for allowing me to use infor- Answers currently available from theAWS. Ques- metal in hydraulic machines. mation from its publication. Forming and tions may be sent to Tony Anderson do Welding Refrigeration. Hardening of naturally Machining Aluminum. This popular re- Journal, 550 NWLeJeune Rd, Miami, EL 33126, aging heat-treatable alloys can be retarded source for persons interested in forming or via e-mail at [email protected]. significantly by refrigeration immediately and machining aluminum is available at after solution heat treatment; the lower www.aluminum.org in its bookstore. the temperature the longer the "workable life," within limits. Some applications of this practice are quite sophisticated, par- ticularly where aerospace components are being fabricated. However, a typical sim- rxn IRUKER ple use of refrigeration is for storage of Alloy 2024 wire or rod to gain maximum Bruker AXS Handheld workability when cold-heading rivets are produced from this alloy.

The Influence of Heat Treatment on Manufacturing Procedures

Welding. Typically, the same welding procedures can be used for heat-treatable alloys in various tempers. While the orig- inal temper of a base material can have some direct effect on the strength of the completed weld, the predominant effect on the weld strength is from the heat in- troduced into the base material during welding. Regardless of the heat-treated condition, the heat-affected zone (HAZ) of the base material will determine the welded transverse tensile strength of a groove weld. The design engineer will usu- ally select a specific heat-treated temper based on its physical properties and suit- ability for the specific application. The welding engineer will then design a weld- ing procedure to best achieve the required mechanical results after welding. Regard- less of the heat-treated condition of the base material used, welding procedures should be qualified to establish the suit- ability of the completed weld for its in- Fast alloy ID and chemistry tended service. Forming and Machining. The heat- Completely non-destructive treated condition of aluminum alloys can Prevents material mix-up certainly influence the procedures used for forming and machining of these ma- terials. In forming operations, such as SD bending, using the correct bend radii is es- The Bruker SI TURB0 XRF analyzer uses innovative SDD technology sential to prevent fracturing during this to provide complete identification and analysis of alloys in any application. manufacturing process. Tables are avail- The result is the fastest, most accurate analysis of alloys in the industry. able that provide the approximate bend radii for various aluminum alloys of dif- wvvw.handheldxrf.com ferent thicknesses and tempers for plate [email protected] and tubes. These requirements differ de- pending on the heat-treated condition of HANDHELD XRF the alloy. think forward The correct tooling for machining of aluminum alloys is dependent on its For info go to www.aws.org/ad-index

WELDING JOURNAL ' _

SSI if^r

Conference sessions will cover topics such as:

• Failures at high temperature • New consumable bit technology for spot joining • Joining high temperature materials • Explosion welding • Laser welding and brazing • Resistance projection welding applications • GMAW and GTAW processes • Magnetic pulse welding • Challenges of joining CSEF steels • Ultrasonic soldering and brazing • Friction stir spot welding • Bonded transition joints • Inertia • Brazing applications

Joining Dissimilar Metals Conference II Orlando, Florida • March 3^1, 2009

Earn PDH's toward your AWS recertification or renewal when you attend the conference!

American Welding Society Founded in 1919 to advance the science, technoiogy and appiication of weiding and aiiied joining and cutting processes, inciuding brazing, soidering and thermai spraying. One of the most discussed topics and sources of misunderstanding involves joining dissimilar materials by welding. Vendors probably receive more phone calls with questions on this subject than any other. The traditional welding codes are nearly silent on the issue. Many companies do not have—or have lost—expertise in this area. The most difficult-to-weld challenges—including various material combinations involving aluminum, creep-enhanced ferritic steels, nickel alloys, titanium, copper, ceramics, and more—will be covered. New chemistries are coming to the aid of existing filler metals, making them more amenable to dissimilar metals welding. Advances in ultrasonic and laser brazing, projection and consumable bit resistance welding, friction stir welding, hot-wire GTAW, controlled short-circuit transfer GMAW, explosion welding, and magnetic pulse welding will also be discussed in terms of their successful application to the joining of dissimilar materials.

Joining Dissimilar Metals Conference II Brazing of Dissimilar Metals - Challenges Hilton in the Walt Disney World Resort and Opportunities Amit Jain, Senior Brazing Applications Engineer, Lucas- Orlando, Florida • March 3-4,2009 Milhaupt, Inc. - A Handy & Harman Company.

Understanding and Avoiding Dissimilar A GMA and GTA Process for the Welding of Weld Failures at High Temperature Dissimilar Metals John N. DuPont, R.D. Stout Distinguished Professor of Materials Tom Rankin, Vice President and GM, ITW Jetline Engineering Science and Engineering and Associate Director of the Energy Research Center, Lehigh University The Role of Ferrite in Dissimilar Metal Dissimilar Joining of High Temperature Welding Donald J. Tillack, Consultant to the Nickel Institute Materials Using a New Nickel-Base Filler Metal Dissimilar Joining Challenges with Creep Greg Chirieleison, Technical Services Manager, Haynes Wire Co. Strength-Enhanced Ferritic Steels William F. Newell, Vice President, Euroweld Ltd. Explosion Welding - A Highly Versatile Welding Technology Ultrasonic Soldering and Brazing of Jeffrey A. Nicol, Vice President, Sales and Marketing, DMC Clad Dissimilar Materials Metal Shankar P. Srinivasan, Tim Freeh, Dan Hauser, and Karl Graff, Edison Welding Institute Laser Welding and Laser Brazing Applications Friction Stir Spot Welding of Dissimilar Craig Bratt, Fraunhofer Center for Coatings and Laser Alloys Applications Tom North, Department of Materials Science and Engineering, University of Toronto Dissimilar Materials Projection Welding- Bonding Mechanisms and Process Metallurgically Bonded Transition Joints Brett H. Keener, General Manager, Sypris Technologies, Tube Characteristics Turns Division Jerry E. Gould, Technology Leader, Resistance Welding and Solid State Welding Processes, Edison Welding Institute Bimetal Welds: Is a High Level of Integrity Possible in Tubulars? Spot Joining of Dissimilar Combinations of Al Wadleigh, President, Interface Welding Steel and Light Metals Using a New Consumable Bit Technology Michael Miles, Associate Professor, Manufacturing Engineering Magnetic Pulse Welding Joins Dissimilar Technology, Brigham Young University; and Zhili Feng, Group Metals Leader, Materials Joining and NDE Group, Materials Science and Jeff Compton, Advanced Computational & Engineering Technology Division, Oak Ridge National Laboratory Services

To register or to receive a descriptive brochure, call (800) 443-9353 ext. 455, (outside North America, call 305-443-9353), or visit www.aws.org/conferences NEW PRODUCTS

Video Microscope Works on Aerospace Parts, Makes Repetitive Inspections Faster

The Luxxor video microscope allows users to quickly and easily attach either a micro- scope lens or a borescope to its mount. Key applications include those found in manu- facturing aerospace and automotive parts. The microscope attachment features a f/4.5 zoom lens delivering sharp close-up views of the exterior of any metal machined part, cast- ing, or welded part with magnification ranges from 15 to 83 x. A quick change to the borescope attachment (not included) allows for high-quality internal inspection. In addi- tion, users can switch from external to inter- nal inspection mode by replacing the stan- dard lens with a Hawkeye Precision borescope or a borescope from most other Mffu manufacturers; capture video or still images with included computer software; document inspection images; store and e-mail docu- mented images; measure defects or features accurately with a metrology capability; and adjust exposure and contrast levels to obtain the sharpest image quality.

Gradient Lens Corp. www.gradientlens.com (800) 536-0790

System Saves Gas and shielding stream causing weld quality problems. The simple-to-use device Improves Weld Quality mounts without any alterations to the flowmeter. First, set the desired maximum flow rate. The Flow Rate Limiter then clamps over the flow control knob by tight- ening a set screw preventing increases from the set level. If the application dic- tates, welders can still reduce flow. A key locking system ensures maximum settings are maintained. The device is also usable on regulator/flowmeters or pipeline supply flowmeters. sten size, from 0.020 to 0.125 in., and Blue Lightning sets the optimal starting param- WA Technology eters. Additionally, the Dynasty 200 pro- www.NetWelding.com vides advanced AC waveforms to optimize (843) 667-1334 arc characteristics; it gives extended AC balance from 30 to 99% to control the amount of oxide cleaning and AC fre- Recently, U.S. patent 7,462,799 was GTA Power Sources Offer quency control of 20-250 Hz to control granted for a device that allows a maxi- Improved Arc Starts the width of the arc cone and arc . mum shielding gas flow rate to be locked Both models offer DC GTA, pulsed DC on most popular welding flowmeters. This The Dynasty® 200 AC/DC GTA/SMA GTA, SMA, and air carbon arc gouging. prevents excess gas flow settings that are and Maxstar® 200 DC GTA/SMA power They also have the company's Auto- wasteful and create a turbulent shield sources now feature Blue Lightning• Line• power management technology. causing air to be pulled into the gas technology. This enables consistent, reli- The Dynasty 200 is 45 lb, and the stream. The company indicates its able high-frequency arc starting from 200- Maxstar 200 is 37 lb. flowmeter tests show most flowmeter A to micro-thin, 1-A applications. The brands are capable of flowing over 125 products' versatility makes them good for Miller Electric Mfg. Co. 3 ft /h. Any GMA shielding gas flow setting aerospace and precision fabrication ap- www.MillerWelds.com over about 50 to 55 ft3/h pulls air into the plications. Users enter the chosen tung- (800) 426-4553

FEBRUARY 2009 Machining Center Yieids v.4 control technology to allow for high- and longevity. It works well with all power Aircraft Structurai Parts feed machining without losing accuracy and sources and all metals from mild steel to monitoring software for users to watch titanium. All tungsten electrodes sold by bearing temperature and vibration during the company are manufactured with cutting. The standard coolant system in- adherence to AWS and ISO standards. cludes spindle head and terrace washing, ceiling showers, and table washing. A cen- Arc-Zone.com ter trough chip removal system assists high www.arc-zone.com metal removal operation. (800) 944-2243 Makino Fiaw Detectors Provide www.makino.com (800) 552-3288 Fiexibie Soiution Piatform

Tungsten Eiectrode Suitabie for Aii Metais MAGI is an offering in the MAG series suited to meet the manufacturing needs of the aerospace industry. This 5-axis machin- ing center is designed to handle quick, high- precision aluminum production of parts up to 1500 mm. Plus, it is positioned to pro- duce structural parts such as ribs, leading edges, and trailing edges of aircraft wing The improved ArcTime• hybrid per- The Phasor family of flaw detectors in- structures. The x-, y-, and z-axis travels of formance tungsten electrode presents op- corporates conventional and phased array 1520 x 1100 x 1350 mm allow for part sizes timal performance for all GTA and plasma ultrasound technology in three upgrade- up to 1500 x 1500 mm and 1300 kg. The arc welding applications. The new elec- able models. This platform lets inspectors product's construction features a three- trodes are packaged in Arc-Zone's clear select the model suiting their application point support system and a 60-position au- tubes, and the tungsten is color coded light in aerospace, oil and gas, power genera- tomatic tool changer. It is equipped with a blue. According to Jim Watson, company tion, or transportation. The first product, 33,000-rev/min, 107-hp HSK80 spindle de- president, manufacturers of aerospace Phasor XS, provides high resolution and signed to easily access deep pockets. Also, parts have selected the product due to probability of inspection. It further offers it contains Super Geometric Intelligence good ignition properties, low burn-off rate. timed or encoded TOPView software for

Pulse Arc Welding Equipment The Laser Alternatives at a Fraction a* of the Cost Weld Where Soldering Is Not Possible £?

Precision Welding

-.DIVERS Aelectronic Bonding, Inc ^ACADEMY 800 Waterman Avenue East Providence, Rl 02914 401-284-4501 • 888-494-2663 Fax 401-284-4504 Diu^Acalemy Iniernaiional abiusa.net • [email protected] 800-238-DIVE wwwdiversacademycom

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

WELDING JOURNAL corrosion mapping. The Phasor 16/16 Weld is the mid-level solution producing full-color image scans that can be stored as a jpg for remote analysis and archiving. This is supplied with a weld probe and package making it good for detecting cracking, incomplete fusion, inclusions, or porosity in welds during fabrication and in service. Last, the Phasor CV is a con- ventional single-channel ultrasonic flaw detector. Each solution is compliant with all major inspection codes and suitable for a range of tasks.

GE Sensing & Inspection Technologies www.gesensmg.com (800) 833-9438 the coating without any special prepara- tion or apparatus. Welding spat- CO2 Laser Nozzles Operate other CO2 lasers. Brass nozzle lock rings ter does not stick to it either. What's more, are optional. with Sensor Heads the tubing can be bent 90 deg without Laser Research Optics cracking or flaking and is iron phosphated, LRO CO2 laser nozzles are available fully primed, rust resistant, oil free, and with 1.2-, 1.5-, 2.0-, and 3.0-mm orifices. www.Iaserresearch.net (888) 239-5545 clean. Users can go directly to cutting, They also feature ± 10 |jm orifice size ac- welding, and painting operations quicker. curacy to optimize cutting performance. Powder Primed Tubing The product is manufactured in accor- These nozzles, compatible with mechani- dance with ASTM A500 and ASTM A513 cal or sensor heads, are offered with Comes Ready to Use standards. It is available in a broad range straight and tapered tips from 0.375 to of square sizes up to 7 x 7 in., rectangles 0.96 in. L and thread sizes from % to % in. The EPOX Z KOTE process accom- up to 10 x 4 in., and rounds to 8.625 OD. They are machined from brass, copper, plishes high-speed application, thin film aluminum, and ceramic. In addition, they deposition in a high-performance epoxy Atlas Tube, Inc. make suitable replacements for Mit- powder coat primer. A benefit of this tub- www.atlastube.com subishi®, Prima®, Laserdyne®, and ing is the ability to weld directly through (800) 733-5683 9 e JMti**/

of MANUFACTURING

WESTEC brings you exciting ideas, know-how and business connections you won't find at other events. Find out what more than 1.3 million WESTEC manufacturers know: that WESTEC has its finger on the pulse of West ADVANCED PRODUCTIVITY EXPOSITION Coast Manufacturing. Get to WESTEC 2009 and bring your team! March 30 - April 2, 2009 For information visit www.westeconline.com Los Angeles Convention Center Los Angeles, CA ^4BP^ ^A? •C^T'^E Manufacturing ^^m IAMT ^••^ Engineers m*Mfi Get Inspired. The APEX Series of Events is produced by SME

For info go to www.aws.org/ad-index FEBRUARY 2009 Heavy-Duty Welding Table Horizontal Sander, Polisher Designed to Be Modular Features Powerful Motor WefoTsc PREMIUM TIE PRODUCTS J i \

The BuildPro• series of welding ta- bles are constructed of precision, hard- HAND TORCHES ened steel plates with X-in. holes in a 2- The 400 GHXM series tools offer five in. grid pattern. Each plate can be re- gear train options for a wide range of fin- moved and reconfigured to extend the ishing speeds (525 to 5500 rev/min). The width of the tabletop to better accommo- 1.2-hp motor handles flap, inflatable, and date large as well as small projects. A va- surface finishing wheels, and mandrel riety of tools such as sliding arm clamps, mounted abrasives. The lightweight tool pliers, magnet squares, or vises can be is available with threaded outlet, collet, used with it. The TX-in.-wide spaces be- or combination arbor. Also, extended tool tween the plates makes it easy to place length allows two-handed control for clamps at any point on the tabletop. The greater precision during finishing. table's heavy-duty, 4-beam support base provides a 2-ton load capacity. T.C. Service Co. www.tcservice.com Strong Hand Tools• (800) 321-6876 www.stronghandtools.com (800) 989-5244 — continued on page 95

Grind, Polish and Deburr Stainiess Steei and Other Metais Slip-on Abrasives Save Time & Money Shadow-free satin finish - up to a mirror polish

Double-sided Boa Pipe Sander is the A Deburring of Sheet Handrail Polishing Solution Metal up to .2" Thick • Sand & poiish steei, stainiess steei WATER COOLERS and aiuminum • Grind down weid seams • Sanding arm snakes up to 270° TIE SPOT around the radius EUNS Simple, one-step of the pipe - operation rotate siightiy for 40, 60, SOandlOO fuii 360° coverage grit fiap wheeis • Easy repiacement MADE IN USA 220 V or 440 V, 3-phase of abrasive beits TEC Torch Company, Inc. www.tectorch.com UNITEC Surface Finishing Solutions Since 1955 1-800-700-5919 • www.csunitec.com For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

WELDING JOURNAL In-Process Quality Assurance for Aerospace Welding

This system is emerging as a new technique for quaiity assurance for a wide range of processes that wiii be critical for welding aircraft and aero-structures

BY VIVEK R. DAVE, DANIEL A. HARTMAN, AND MARK J. COLA

In-process quality assurance (IPQA) Fig. 1 shows a rocket motor case from a Such aircraft can have millions of individ- is an emerging field of enquiry in manu- captured V-2 in New Mexico. Even after ual parts (many of which are rivets) and facturing technology originating in the 64 years, the welds in the rocket motor hundreds of thousands of discrete part 1980s and recently expanding in several case and the fuel tubing lines are clearly numbers. areas of welding for aerospace applica- visible. tions. In this article, we will review the un- In terms of airframe construction, riv- derlying technology for in-process quality eting has been widely practiced since the New Challenges to the Old assurance as well as recent applications in 1930s. Early aluminum alloys such as 2017- Aerospace Manufacturing aerospace and other critical parts manu- T4 were weldable, but it was not until the Paradigm facturing. The historical context of the 1940s and later that alloys such as 3003 and concept is traced as applied in particular 6061 became widely commercially avail- If we fast-forward to the late 20th and to the aerospace industry. able. Aircraft such as the Martin B-10 early 21st centuries, we see several influ- In-process quality assurance is the di- shown in Fig. 2, the first all-aluminum encing factors or trends that will funda- rect interrogation of process physics and monoplane bomber, were riveted. Riveting mentally change aircraft and aerospace dynamics as opposed to exclusive reliance took hold as the airframe assembly tech- construction irreversibly. on machine tool monitoring or postprocess nique of choice, and it has not fundamen- • Escalating costs of commodity metals. inspection. It complements these other tally changed conceptually during the The cost of raw materials is escalating technologies and provides valuable nearly 75 years it has been practiced, al- as global demand outpaces supply, and process information not available through though significant improvements in alloys there does not seem to be a near-term other means. Applications to real-time and techniques have been made over the reversal of this trend. With spot com- closed-loop control are also possible. In- decades. By 1950 and onward, a basic pat- modity prices so high, long-term pur- process quality assurance is used to pre- tern for welding in aerospace manufactur- chasing agreements will be fundamen- clude the occurrence of defects altogether. ing was established, namely that aero- tally altered in the future. engines contain welded parts, whereas air- • Demise of the primary metalworking frames are almost exclusively riveted. industry. To get large forgings is not a Historical Background In terms of the larger airframe pieces trivial feat, and many of the suppliers such as beams, spars, stringers, longerons, that met demand in the past are either Evolution of the Aerospace frames, formers, etc., these have typically out of business or critical skills and Manufacturing Paradigm been machined out of monolithic pieces know-how have been lost. of forged, rolled, or extruded aluminum • Escalating cost of energy. Energy costs In the earliest days of aerospace man- or titanium. Such construction practices are no longer a negligible part of the ufacturing, welding on engine and rocket have culminated in modern airliners such overall raw material and manufactur- parts was not uncommon. For example. as the Boeing 777 and the Airbus A350. ing costs.

VIVEK R. DA VE ([email protected]), DANIEL A. HARTMAN, and MARK I. COLA are with BeyondS-Sigma Div., Technology Management Co., Inc., Santa Fe, NMex.

FEBRUARY 2009 Fig. 1 — Welds in a 1945 V-2 rocket motor case (original photo Fig. 2 — Martin B-10 Bomber, the first all-aluminum riveted by authors). monoplane bomber. (Maxwell Air Force Base public domain images.)

• Escalating cost of labor. Labor costs at ditive techniques based on laser or elec- additive manufacturing processes, there least in North America and Europe re- tron beams. is the danger of burying a defect in lower main comparatively high. In still devel- • More efficient assembly techniques. layers and not being able to detect it later. oping economies like India and China, There is a movement away from rivet- Lastly, for welded fabrications that elimi- labor rate differentials will shrink over ing to consider welded fabrication for nate forgings by welding nearer-net shape time. metal fuselage parts on the one hand, piece parts, there is the danger that post- • Availability of skilled labor. The histor- as well as much more extensive use of process inspection will be time-consum- ical manufacturing practices that have composite fuselage parts on the other. ing, expensive, and in some cases incon- been prevalent in aerospace manufac- Laser beam welding, for example, can clusive. This will obviate the gains made turing since WWII have relied on a be up to an order of magnitude faster by going to all-welded construction in the steady pool of trained technicians and than riveting as a final assembly tech- first place. craftsmen, but this supply is in jeopardy nique for aero-structures. Therefore, it is seen that quality assur- in many countries. The motivating factors for these tech- ance and quality control must also evolve • Drive toward reduced aircraft weight and nological developments are as follows: to meet the new challenges posed by these "greener" aircraft. Weight savings of just • The need to use less raw material historic shifts in aerospace manufactur- a few hundred pounds in a modern air- • The need to reduce energy use in man- ing practices. IPQA, or in-process quality liner can result in life cycle fuel savings ufacturing assurance, represents just such an advance of millions of dollars. Additionally, there • The need to reduce lead time of criti- and is a critical enabling technology in the will be increasingly stringent regulations cal assemblies, thus ensuring on-time new aircraft and aerospace manufactur- worldwide to limit carbon emissions and delivery ing paradigm. to make "greener" aircraft. • The need to reduce part count by elim- IPQA is not a new idea per se, but only inating riveting and moving toward within the last seven years has it become Emergence of a New unitized fabrications a practical reality. This is due to the con- Manufacturing Paradigm • The need to reduce labor costs through fluence of various events: greater automation and even au- • Inexpensive computing power of PCs These trends are having and will con- tonomous machine tool operation following "Moore's Law" now into the tinue to have a profound influence on air- • The need to create lighter, more fuel- gigahertz clock speeds for a computer craft and aerospace design and manufac- efficient aircraft with a lower carbon costing $1400 or less. ture. Starting in the 1990s and continuing footprint, again enabled by welded • Availability of data storage well into the to this day, there have been various initia- fabrication. hundreds of gigabytes tives both in North America and Europe • Commercial availability of a wide array to deal with the consequences of the Obstacles to Achieving the of sensors above-mentioned influencing factors. New Paradigm • Ready availability of a large data band- There seem to be at least two major focus width areas of interest and concern right now: There are significant challenges on this • Significant evolution of the algorithms • More efflcient material utilization. New new path of welded aircraft and airframe capable of dealing with large, ill- discrete parts manufacturing tech- fabrication. One of the main challenges is defined, multidimensional data sets. niques are being introduced that greatly quality. The traditional paradigm of using When all these elements are put to- reduce the "buy-to-fly" ratio, i.e., the sheet metal skins riveted to structural gether, it is possible to achieve IPQA, which metal that must be bought to make an members that are machined from large is simply the on-machine, real-time assess- aircraft. These new technologies focus starting stock is difficult to overcome and ment of part and process quality based on on welding or additive manufacturing has a 50-plus-year history of successful direct observation of process physics, not to create parts from raw material feed- flight operations. To quote the famous inspection of physical part attributes. stock directly or from simpler, less ex- economist John Maynard Keynes, "The pensive piece parts. The various join- difficulty lies not in the new ideas, but in Elements of IPQA ing techniques being used include fric- escaping the old ones..." tion welding, arc welding, high-energy- Additionally, for processes that build The best way to understand IPQA vis- density-beam welding, and material ad- up parts layer by layer using a variety of a-vis conventional postprocess inspection

WELDING JOURNAL START; conditioning ld«nHflca»ion Piece being /nocmalizatlon of -tfomalnt of welded on to of raw ttrvtor int«r««t baseplate dM«

CI«««lfic«Nonr I of nominal •• F«Mur« offoomlntl •xtrtction condition* and mov«on

Fig. 4 — Schematic of linear friction weld (LFW) with no under- cut. "Setting of •*»• ^^ coo«l*t«ntcoo*lft«nt 'V pf oc««» limit* Fig. 3 — Steps in the IPQA process.

ill-defined, large volume, and nearly im- Table 1 — IPQA as Compared to Conventional Postprocess Inspection possible to interpret. As a result, the IPQA Postprocess Inspection feature extraction step of IPQA is per- haps the most important in that it Prevent Errors - detect and prevent Find Defects - looking for defects, not achieves a million-fold reduction in errors, not looking for defects preventing errors data density while preserving key process physics that allow discrimina- Process Dynamics - measure and control Product Attributes - inspect physical tion between nominal, off-nominal, and process dynamics, not inspecting parts attributes, not measurement and control anomalous events. of process dynamics • Process limits. Once features have been established, it is now necessary to de- Forward-Looking - find and correct errors Backward-looking - finding defects when lineate which features are within ex- before defects happen it is too late to correct underlying errors pected values for a nominal process, and which are not. This is based on a Constant and Pervasive - looking at the process Discontinuous and Sporadic - inspecting clear understanding of baseline process dynamics for each and every part in sub- only certain features of certain parts and performance, i.e., what the end user millisecond time increments achieving constant intermittently at best vigilance considers nominal. • Classification and notification. Based Same Timescale as Manufacturing - time scales Slower Timescale than Manufacturing - on the analysis of limits, it is possible to commensurate with the manufacturing process inspection times up to ten times longer condense many features into just a sin- time than the manufacturing process itself gle actionable end result. Either the process is behaving in a nominal man- ner, or it is not. This classification of is through the comparisons shown in Table ity, it is necessary to go through several process behavior can then be used to 1. IPQA is not simply machine monitor- steps. These steps allow the journey from notify the operator to intervene, or ing. The correct functionality of the ma- raw, ill-defined data to concise, actionable could form the basis for a closed loop chine tool is a necessary, but not sufficient, quality inference. Figure 3 shows the cycle adaptive control system to eliminate the condition for getting an acceptable part. of events that must take place to success- underlying cause of error in real time. IPQA goes beyond machine monitoring fully execute IPQA. to look for process conditions that pro- • Data collection, filtering, and condi- duce low probability of occurrence anom- tioning. First, the ill-defined raw data Case Study: IPQA as Applied to alies. An anomaly is a metallurgical or are conditioned, normalized, and Linear Friction Welding geometric defect that occurs in a weld de- aligned spatially with respect to spite the fact that all machine monitoring "process start" and "process stop." Linear friction welding (LFW) is one parameters are perfectly normal and the • Identification of domains of Interest. of the newer discrete part manufacturing machine tool is putting out the expected Then, domains of interest are found technologies that has been used for com- process response. within this data set. For example, such pressor parts in aero-engines and is being domains of interest could be process envisioned for use in aerospace structural IPQA in Practice events such as changes in slope of key component manufacture as well. In LFW, control variables such as force or dis- one side of the joint is oscillated, and the In order to realize on-machine, real- placement. two pieces are brought together under a time assessment of part and process qual- • Feature extraction. Raw data alone are forging . Material then heats up

!• FEBRUARY 2009 Undercut Flash

Base piate

Fig. 5 — Schematic of linear friction weld (LFW) with undercut. Fig. 6 — Quality metric matrix corresponding to a nominal LFW condition.

Fig. 8 — Example of typical GMA weld bead in Ti-6Al-4V with- out IPQA.

Fig. 7— Quality metric matrix corresponding to a LFW undercut Fig.9- • Example of typical GMA weld bead in Ti-6Al-4V with condition. IPQA.

and flows out of the joint region so that ill-defined, but through the feature ex- of GMAW for titanium aerospace appli- unaffected base metal comes into contact traction approach, setting of process lim- cations: thus forming a true metallurgical bond. its, and classification scheme, we were • Sensitivity to contamination Although the process is intrinsically re- able to reduce this large data set to a ma- liable, there are possible defect conditions trix of numbers known as a Quality Met- • Spatter occurring especially at the outer edges of ric Matrix that shows which features are parts that could result in defects being re- within expected nominal values, and • Instability of arc due to excessive mo- tained in the final part if these conditions which are not. The result is that a green tion of cathode spot are not removed by postweld machining square in this matrix indicates a feature operations. Figures 4 and 5 schematically within expected ranges, and a red square • Shape of weld bead show one such condition, namely under- represents an anomalous feature. Figures cut. This is the case where the edge of the 6 and 7 show that we can clearly see the • Control of heat input, especially on weld remains unwelded and there is a difference between welds with undercut these sections. notch, or undercut, extending from the and those without undercut based on edge into the weld region. If this region is these multisensor data. The key to overcoming the challenges too deep, it may not clean up during post- listed above and achieving process con- weld final machining. Case Study: IPQA as Applied to trol is to simultaneously track and control In this study, we collected multiple GMAW of Titanium for Repair of three sets of dynamical behaviors — the channels of data including machine tool Aerospace Parts power supply dynamics, the weld pool dy- data and other auxiliary data. The chan- namics, and the dynamics of droplets nels collected included oscillation ampli- Gas metal arc welding (GMAW) is not melting off of the consumable electrode. tude, forge pressure, joint temperature, normally considered for welding of aero- Figures 8 and 9 show the typical weld acceleration in the moving and stationary space parts, but it does have significant beads made without IPQA and then with jaws, acoustic emission in the moving and cost and productivity advantages if the re- IPQA, where all three of these process dy- stationary jaws, and sound. The resultant quired weld quality can be obtained. namics were simultaneously monitored raw data files are extremely complex and There are significant challenges in the use and controlled.

WELDING JOURNAL Other Applications

IPQA is currently being applied to the NUdaltoy following proprietary applications: • Linear friction welding of aero-engine parts Stainless, Nickel, • Linear friction welding of airframe parts • Rotary friction welding of airframe and Low Alloy parts welding • Rotary friction welding of automotive Consumables parts • GMAW of titanium aero-engine parts

• Consistent High • Orbital arc welding of tubing for food Quality Products and drug processing plants • Hot wire gas tungsten arc welding of • Technical Support power generation components. Conclusions In stock: St. Louis and Houston In-process quality assurance is rapidly emerging as a new technique for quality 1.800.776.3300 inference and quality assurance for a wide range of manufacturing processes that will www.miclalloy.com be critical for welding aircraft and aero- structures. Many companies are investi- gating and adopting IPQA since it has the For info go to www.aws.org/ad-index potential to eliminate the bottlenecks at inspection and to automatically flag very subtle process variations before they lead Less handling, easier positioning, to defects. In terms of integration into the over- faster and cleaner welds. all quality system, the best time to incor- porate IPQA for any given process is dur- ing process development. At this time, the characteristic signatures of normal and abnormal process behavior can be deter- mined, which then in turn determine the ability of the process to make acceptable parts. It has been our experience that even with as few as 12 instances of a baseline configuration (normal process behavior), the IPQA system can "lock onto" the sig- Atlts Pipemate and Idler Rolls Atlas Rotary Table Positioners nature of normal, and conversely can start to identify abnormal process behaviors. • Unfl Mlh der rots supports MHMd • ThrMtnodcfc 9*UMe, 100fc cjp»ly toads up to 1000 lb lO^ttiabit.ZOOKi capacty This is a significantly smaller set of in- stances or parts than what is required by • ROMM PV* and to up to i r oa 14-tatte. 500 b capacty even so-called small lot SPC techniques. • PorttM. low preMe tor sftop or Md • Hawy dury groundNig ocua tor akk IPQA does have some imitations how- gMlinrtt MCorTIC •aMno • Dual ^aad 0 to 30 Irvtnn or 0 to 60 ever, and the main limitation is that it can- * Low proMt tor bench tnounkng not define quality a priori. IPQA requires mgn ntqutney IBW piavwai * Foot swicti tor toaliannQ spsod and expert input from the manufacturing en- «i6U gineer or the quality engineer to ensure • Front panel spotd jnd mtaOon controts that the normal baseline signature estab- Other handling and welding aids.Atlas Pipe Supports. lished does indeed correspond to process conditions that are capable of making a Atlas Roller Stands. Atlat Pipe Dollies good part, as independently verified by ATLAS WELXMNO ACCESS off-line, postprocess inspection. Thus Troy. Ml 48089 IPQA once properly calibrated can detect 800-962-9353 anomalous behavior, but the calibration E-mflft cu8ltfTi6r9ervc0OBlaMMtdrQ com is critical and requires manufacturing and W8lm 8f WWdbig A S«My Products — Sine* 1*M process expertise.^ Sotd TIMW

Perform Precision Weld Preps On: • Oil Lines • Fuel Lines • Breather Lines • Pneumatic Lines

On The Following Materials: • Stainless Steel Are you a technician fabricating or repairing tubing in the • Titanium aerospace industry? Wachs machine tools deliver the precision • Inconel® preps required to achieve repeatability with today's high tech • Hastelloy® orbital welders. • Exotic Alloys Wachs precision clamps and collets are unmatched for producing perfectly square and flat ends for high integrity, defect free welds. Three Wachs machines cover most facing and squaring needs:

Model TS (Tube Squaring) machine ranges from .25" (6.35mm) up to 1" (25.4mm)

Model FS (Microfittlng Facing) machine handles micro-fittings and tubing ranging from .125" (3.2mm) up to 1" (25.4mm)

Model TF (Tube and Fitting Facing) — machine handles larger sizes ranging from .5" (12.7mm) up to 4.5" (114.5mm)

E.H. WACHS COMPANY For additional details Superior Equipment. Complete Support. on our full line of 600 Knightsbridge Parkway • Lincolnshire, Illinois 60069 Superior Equipment, visit 1.800.323.8185 • +1.847.537.8800 • FAX+1.847.520.1147 www.wachsco.comWV For Info go to www.aws.org/ad-index Current Technology in Welding Guns and Torches

Here's a look at some of the most up-to-date guns and torches for gas metal arc, flux cored arc, and gas tungsten arc welding

BY ANDREW CULLISON, KRISTIN CAMPBELL, AND MARY RUTH JOHNSEN

The gas metal arc welding gun and gas Time-Tested in Tough Applications. welding wires ranging from 0.035 to 0.062 tungsten arc welding torch are two of the The interchangeable drive rolls and pull in. (0.9 to 1.6 mm) in diameter. The swan most intimate pieces of equipment motor in the handle of PPA26 and neck can be positioned a full 360 deg, and welders come into contact with while per- PPW401 push-pull gas metal arc welding it is covered with a heat-resistant rubber forming their jobs. During the course of guns accommodate soft aluminum, as well to extend service life. The gun can handle a day they will be holding that gun or torch as hard steel welding wire. The air-cooled applications from light to heavy duty. The for hours, so it better perform well and be PPA26 has a 60% duty cycle rating at 260 complete series includes Omega 2 rated comfortable to handle. Manufacturers A with CO2 and 220 A with a mixed gas. at 60% duty cycle, 250 A with COj and are well aware of this and have been de- Model PPW401 (Fig. 2) is water-cooled, 200 A with mixed gas; and the Omega 4 signing to those needs. Below are some of and it has a 100% duty cycle with CO2 at 450 A with CO2 and 400 A with mixed the guns and torches equipment suppli- rated at 360 A and 320 A with a mixed gas. gas. AlexanderBinzel Corp., Frederick, Md., ers feel you should be familiar with to help They both can be used with welding wires (800) 542-4867, www.abicorusa.com. you in your job. ranging in diameter from 0.023 to 0.062 Welding Guns Handle Heavy Plate. in. (0.6 to 1.6 mm), and both mount on The new line of Magnum® PRO semiau- any standard wire feeder. The guns come tomatic welding guns are designed for with standard 15-, 25-, and 36-ft cable heavy-duty applications, but they are con- lengths and are available with 180-, 30-, structed with simplicity in mind. The gun and 45-deg goosenecks. CM Industries, has few parts, and it is easy to disassem- Inc., Lake Zurich, III, (847) 550-0033, ble for maintenance and then reassemble. www.cmindustries. com. Four models — 250 A, 350 A, 450 A, and 550 A — accommodate welding wires in diameters ranging from 0.035 to Vu in. — Fig. 1. All the guns are rated at 100% duty cycle, and the capacity goes up to 500 A. Intended for heavy plate applications, an optional locking trigger allows welders to move their hand away from the arc for Fig. 3 — The Omega • 3 is rated at 350 A more comfort. In addition to a heavy-duty and can be used for light- to heavy-duty nozzle, a compact nozzle is available for applications. maneuvering in tight corners. Lincoln Electric Co., Cleveland, Ohio, (216) 383- 2162, www.lincolnelectric.com. Fig. 2 — The PPW401 push-pull welding GTA Torch Features Soft-Grip Han- gun has proven itself in tough applications. dle. The LS17 air-cooled torch is a new addition to Weldcraft's Legacy• Series of GTA torches — Fig. 4. It is rated at 150 Made for Efficient Current Transfer. A/DC and 125 A/AC, both at 60% duty The Omega• 3 semiautomatic welding cycle. Extra highlights are as follows: an gun is designed with a direct crimped gun interchangeable fingertip switch that pro- body, a tight interface tolerance, and a vides remote amperage control and can neck locking screw to improve current be replaced without any tools; a knuckle Fig. 1 — The Magnum® PRO welding guns transfer — Fig. 3. The Omega 3 is rated joint at the base of the torch handle per- for gas metal arc and flux cored arc welding at 350 A, 60% duty cycle with C02 gas and mitting greater control and easier move- are brand new to the market. 300 A with mixed gas. It accommodates ment while minimizing stress on the power

ANDREW CULLISON is publisher, KRISTIN CAMPBELL is associate editor, and MARY RUTH IOHNSEN ([email protected]) is editor of the Welding Journal.

FEBRUARY 2009 cables and back end of the torch body; an and wires of 0.030-0.045 in. ESAB Weld- lengths; rear plug connections for Tweco, air-cooled design that prevents overheat- ing & Cutting Equipment, Florence, S. C, Miller, Lincoln, and Euro-Kwik; and ing and allows for long-term, welding per- (800) 372-2123, www.esab.com. options/features include metal jacketed formance and greater user comfort; and and swivel conductor tube, dual schedule, a styled soft-grip handle that prevents slip- locking trigger, and long tubes. ping to improve overall torch control. The Tweco, Denton, Tex., (800) 426-1888, product is available with a HVi- or 25-ft www.tweco.com. single-piece rubber cable assembly, each Small GTAW Torches Get to Those of which comes standard with a protective Hard-to-Reach Places. TEC Torch has sheath to prolong cable life. Each pack- added a 125-A water-cooled and a 60-A age comes with a 14-pin connector and air-cooled model to its line of WeldTec® control wire for connection to a Miller® Micro TIG welding torches — Fig. 7. The power source. Many models are offered torches are designed to perform small, in- with a manual gas control valve allowing Fig. 5 — Making up the family of conven- tricate work and to reach into less-acces- the user to adjust shielding gas flow. Weld- ient and versatile MXL • GMA guns are sible areas. Both models share chucks and craft, Appleton, Wis., (800) 752-7620, (from top) MXL" 340, MXLT" 270, and clear glass nozzles. They come with a www.weldcraft.com. MXL• 200. straight, pencil-style nozzle, but can be fit- ted with 45-, 90-, and 180-deg chucks. The standard torch neck length is 3!4 in., but Ergonomically Designed Platform special order models are available from 2 Given by GMA Gun. The Spray Master• to 12 in. They feature a low-maintenance, GMA gun, developed by Tweco, is built dual O-ring head design; flexible, soft rub- on the success of the company's Number ber hose and power cable options; and DX 4 GMA gun — Fig. 6. David Wilton, vice models offer a glove-soft leather protec- president, Tweco Global Welding Prod- tive cable cover. TEC Torch Co., Inc., ucts, said, "We felt that welders would be San Marcos, Calif, (760) 747-3700, receptive to a more comfortable feel and www.tectorch.com. a higher duty cycle rating from their guns." Smaller and lighter, it features an er- gonomically designed platform that is more comfortable to hold. This gun was also designed to improve user comfort by providing a rotatable conductor tube with an articulating head that helps lock the gun angle for certain positions. This makes it easier to reach different joint configurations and tight joints. The series has a high-duty cycle rating of 80% with argon mixed gases, offering good per- Fig. 4 — This LSI 7 air-cooled torch is de- formance in extreme welding applications. signed to improve comfort, control, and Its longer trigger life with its blade-style Fig. 7 — Standard neck length for the welding productivity. design creates electrical contact by slid- WeldTec® Micro TIG torches is 3'A in., but ing over each other in a sort of self-clean- models with necks from 2 to 12 in. long can ing action. Plus, the company's Knuckle- be special ordered. GMA Guns Connect Easily. ESAB's head• flexible conductor tube — en- MXL• GMA guns offer ergonomic han- abling users multiple adjustments and dles that not only reduce fatigue but also containing a patent-pending mechanical System Allows Custom Neck Combi- promote comfort and easier use — Fig. 5. ball and socket design — can be used on nations for Most GMAW Applications. Optimum cooling is permitted by the a Spray Master• to increase its range of Tregaskiss now offers the QUICK swan-neck design for extended life of the welding capabilities. Qualities of the 450 LOAD• gooseneck system for its curved- neck and wear parts. The guns have a model are as follows: 450-A air cooled; handle TOUGH GUN• hand-held, semi- Euro-style central connection. Spring- comes in 10-, 12-, 15-, 20-, and 25-ft automatic GMAW guns — Fig. 8. The sys- loaded contact pins in the central connec- tem allows gooseneck combinations to be tor ensure positive trigger connection. In changed quickly and easily, minimizing addition, cable life is improved by molded downtime and providing the exact angle cable strain reliefs. These guns come in for specific welding applications. The sys- 10- and 13-ft lengths with a choice of stan- tem accommodates a variety of gooseneck dard, straight, or conical gas nozzle styles. lengths and styles. A toolless quick-release In particular, the MXL• 200 has gun am- feature requires the opening and closing perage ratings at 35% duty cycle of 200 A of one latch to switch out different goose- for C02 and 170 A with Ar/C02; it ac- neck styles. It also allows the gooseneck commodates wires from 0.023 to 0.040 in. to be rotated 360 deg, making it easier to The MXL• 270 provides gun amperage reach awkward joints or to weld in con- ratings at 35% duty cycle of 270 A for CO2 fined areas. In addition, the gooseneck and 260 A with Ar/C02, plus wires Fig. 6 — Shown are two GMA guns (from system is combined with the company's 0.030-0.045 in. The MXL•340 has gun left) Number 4 along with the Spray Mas- QUICK LOAD liner system, which allows amperage ratings at 35% duty cycle with ter• 450 model that handles heavy-duty, a new liner to be installed from the front pulse, and spray applications. C02 of 340 A and with Ar/C02 of 320 A, end of the gun, further minimizing down-

WELDING JOURNAL time. Tregaskiss, Windsor, Ont., Canada, (877) 737-3111, www.tregaskiss.com.

Fig. 8 — Various gooseneck styles can be switched out without tools with the QUICK LOAD• gooseneck system on Tregaskiss's curved-handle TOUGH GUN• GMAW guns.

Rubber Grip Handle Makes Guns More Comfortable. Designed for high- deposition welding that features high cur- rent loads over long, continuous joints, THE LEADING MANUFACTURER AND MASTER DISTRIBUTOR OF Bernard's new HD Q• and S• series BRASS, BRONZE, AND COPPER ALLOYS IN THE USA GMAW guns are available in 300- to 600- A models — Fig. 9. They feature a one- For info go to www.aws.org/ad-index piece straight handle for maneuverabil- ity; a rubber overmold provides a better grip for increased operator comfort. It also features an -protected locking trigger with an optional dual-schedule WELDHUGGER switch. Both guns feature the company's COVER GAS DISTRIBUTION SYSTEMS Stay-Tite• technology, which incorpo- • Flows gas evenly rates long-lasting compression fittings and Snake Kit over and behind the large, tapered neck-to-handle connec- weld pool. liable/ 1 • Reduces oxidation tions to ensure that the gun runs cool and and discoiorization delivers a consistent electrical current to • Designed for trailing shield and a variety the weld pool. The HD gun is also inte- of other applications. grated with Bernard's GMAW gun con- $349? • 316L Stainless steel figurator, which allows users to customize nozzles and manifolds. the gun with a variety of cable, neck, con- sumable, and direct plug options. Bernard Trailing Welding Equipment, Beecher, III., (800) % Shield Kit 946-2281, www.bernardwelds.com.^

MS"'-""-'-" M SSSPsS K Basic Kit '"''

$249? $249:*

USEtB HUGGER. Fig. 9 — The HD Q• and S• series guns Toll Free: (877) WELDHGR (877) 935-3447 Fax: (480) 940-9366 come in 300- to 600-A models designed for Visit our website at: www.weldhugger.com high-deposition GMAW applications.

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

FEBRUARY 2009 Aviation Maintenance X Gets a BIG LIFT! •tt* PFERD Abrasives, Brushes, Power Tools and Long Experience Bring Better MRO Solutions

PRECISION BEFORE PLANES REFERENCES & RELIABILITY

PFERD was solving metalworking problems Our list of references reads like the "WHO'S long before planes were invented; over 100 WHO IN THE AIRCRAFT INDUSTRY". years to be precise. And precise is the perfect Check them out. Then check our reliability. word for PFERD performance; precise prod- Call Now for a ftee catalog and brochure ucts for metal finishing and cutting and precise and the name of the nearest PFERD distribu- tor who can deliver these solutions right on application support to meet your critical MRO time. 1-800-342-9015. Email at solutions® requirements. pferdusa.com. Or call our Aviation Markets Manager, Lou Padmos, at 336-213-0158. He 11 show you how PFERD can give your GOT YOU COVERED aviation maintenance a big lift.

There's a PFERD tool to handle every maintenance task on every part of an aircraft; exterior skin, engines, landing gear, wings, tail section and even inside the cabin. For instance, wherever crack filling is called for, PFERD tools do a better job with weld preparation and dressing. Where fan blades need attention, Lou Padmos Aviation Markets Manager PFERD COMBIDISC®s are fast becoming the first choice for contouring correction work because they're faster and cooler. New TC bur designs with special cut patterns have just been added to PFERD's extensive line to handle the heaviest of heavy duty jobs with precision. PFERD has a wide range of wheels, discs, files and brushes to finish any part like new. Whether it's an exotic alloy, composite material, stainless, titanium or a non ferrous metal, you're covered. PFERD 30 Jytek Drive, Leominster, MA 01453 (800)342-9015 fax (978) 840-6421 www.pferdusa.com PFERD makes the difference email: [email protected] For Info go to www.aws.org/ad-index How to Accurately Measure Fillet Welds A tubular assemblies manufacturer devised a unique method for taking fillet weld readings

BY JOE PAVILANIS

Woolf Aircraft Products, Inc., got its Woolf Aircraft has the capability of recent achievements was to become reg- start in Wayne, Mich., in 1942 fabricating bending tubing from 0.125 through 7 in. istered to SAE AS9100B, Quality Man- tubular assemblies for B-24 bombers. in diameter and has a selection of more agement Systems —Aerospace — Require- Today, the company operates out of a than 450 radius dies, which gives its cus- ments, in 2008. It has 13 welders qualified 100,000-sq-ft facility in Romulus, Mich., tomers many options. It also has an ex- to the requirements of AWS D17.1, Speci- and supplies tubular assemblies for a wide tensive material inventory, stocking more ficiation for Fusion Welding for Aerospace variety of industries, including defense, than 1400 different sizes and types of ma- Applications, in all metals that are fabri- transportation, power generation, and terial. The company commonly fabricates cated in thickness ranges from 0.020 to agriculture. Aircraft and aerospace re- stainless steel, Inconel•, carbon steel, 0.250 in. thick, as well as various project- main prime segments of the company's chrome-moly steel, aluminum, and tita- specific certifications to the ASME Boiler business, however. Its 125 employees can nium, and also has experience with mag- & Pressure Vessel Code, Section IX, and fabricate just about any type of tubular nesium, Hastelloy® X, AL6XN, and an array of customer-specific welding assembly. other exotic alloys. One of the company's specifications.

JOE PAVILANIS ([email protected]) is process I quality engineer, Woolf Aircraft Products, Inc., Romulus, Mich.

FEBRUARY 2009 Fig. 1 — The adapter mounts to a digital caliper designed to seat Fig. 2 — The reading gives the distance from the weld root to the directly onto the corner of a 90-deg angle. weld face, which is the weld throat.

Fig. 3 —A — When touching the weld face, the digital scale shows the actual distance from the root to the face, providing a measurement of the actual weld throat; B — a close-up of the throat measurement.

Problem/Issue pany that is registered to the quality man- digital scale is then set to "zero" and then agement systems of ISO9001:2000 and used in the same manner against the fil- AS9100B, Woolf must meet the require- let weld. The reading on the caliper gives Many of the weld sizes that Woolf is ment that all measurement systems used the distance from the "root" (corner) of required to produce are often less than to accept product be traceable to NIST. the weld to the face of the weld, which is 0.125 in. and as small as 0.040 in. The com- Woolf Aircraft needed a tool that the weld throat — Fig. 2. pany has found that traditional fillet weld could provide an actual "variable" read- When touching the face of the weld, gauges do not work that well for inspect- ing over a range of fillet weld sizes and the digital scale will reveal the actual dis- ing and verifying the sizes of welds. Even be traceable to NIST. Officials there be- tance from the root of the weld to the face, if you have a custom gauge made as Woolf lieved that most industries have that same which is the actual weld throat — Fig. 3. has done, it is often so small it is difficult need; therefore, the company developed Using a similar technique to measure to make any sort of determination. This an inspection tool/system that it can use the length of a leg, as shown in Fig. 4, the makes the inspection of these welds very to measure a leg length, as well as the ac- individual leg lengths will be determined. slow and difficult. In addition, it is diffi- tual weld throat. With these two known A traditional caliper is used in this cult to obtain actual readings when doing measurements, this information can then measurement. dimensional inspection reports. be used to determine the actual size as Now that the two variables are known Currently, most gauges that are used well as the convexity/concavity of a spe- — leg length and actual throat length — to measure welds are attribute by nature, cific fillet weld. many determinations can be made regard- which means that they only make a com- ing the weld size. Since the example shown parison to a template rather than an ac- Caliper Weld Inspection in Fig. 4 is a 45-deg right triangle, then tual reading. There are some gauges that both legs should be equal length — Fig. 5. will provide a measurement against an im- Method printed scale to allow an estimation of the size, but these gauges are not calibrated Workers at Woolf Aircraft made an Applicable Industries and do not offer a variable reading that is adapter that mounts to a digital caliper traceable to the National Institute of Stan- that has been designed to seat directly into Officials at Woolf Aircraft believe this dards and Technology (NIST). As a com- the corner of a 90-deg angle — Fig. 1. The measurement system can be useful to a

WELDING JOURNAL Fig. 4 —A —A similar technique, using a traditional caliper, is used to measure the leg length; B — a close-up of the leg measurement.

wide variety of industries besides aero- space, such as military, automotive, com- mercial, power generation, etc., and that the entire welding community and every •• ako know tw acM kg IMB* of industry it serves is in need of the ability to make variable measurements. This article provides a basic overview of how the system works. You may have questions as to how useful it is if your fil- let weld is not a 90-deg angle, or if it can be used to check for misalignment or to measure weld reenforcement on tube and pipe groove joints. Options are available f Bj niMMnng f« tog fengti l« T* to handle those situations that are not cov- toto*VnIningttstaowi NowVw I temttttcwbtdtltnnwrtttwtl ered in this discussion. Contact the author jS v oonwcty vd concwty Mutt bt for additional information. Conclusions

This system allows for variable meas- urement of the weld legs, actual throat length, calculation of the theoretical throat length, convexity, and concavity. Fig. 5 — Once the two variables are known, other factors are known about the weld size. Also, by using calibrated digital instru- ments during the inspection, the inspec- tion system is then traceable to the Na- tional Institute of Standards and Technol- quality management systems such as ISO dards require that anything used to accept ogy, which satisfies the expectations of 9001:2000 and SAE AS9100B. These stan- product dimensions must be calibrated. Using this system helps Woolf Aircraft meet the measurement expectations of the various quality system requirements and provide variable measurements with- DO YOUR OWN TESTING out the need for cutting and etching in order to obtain these measurements.^

Bend Testers - Bend Specimen Cutting Fixtures - Coupons -Tensile Testers Acknowledgments

BT1B H The author would like to thank the fol- Visit our website lowing individuals at Woolf Aircraft for for all sizes and their support in this project and with the models available preparation of this article: Adam Woolf; Al Swistara, vice president. Engineering; Doug Kochan, toolmaker; Dane Borowski, tube fabricator; and Adam FisdiER ENqiNEEniNq COMPANY 3 Pavilanis, weld engineer intern. www.flscherengr.com* (937)754-1750

For info go to www.aws.org/ad-index FEBRUARY 2009 We Can Meet Yours, Too! When critical welding conditions necessitate To learn more about the many reasons you should performance without compromise, you can depend insist on Arcos high alloy, stainless and nickel on Arcos to provide you with a comprehensive line electrodes for your essential welding applications, of premium quality high alloy, stainless and call us today at 800-233-8460 or visit our website nickel electrodes to conform to your stringent at www.arcos.us. requirements. Arcos Industries, LLC You can be assured of our commitment to superior One Arcos Drive • Mt. Carmel, PA 17851 welding products because Arcos quality meets or Phone: (570) 339-5200 • Fax: (570) 339-5206 exceeds demanding military and nuclear application specifications. Arcos' dedication to excellence has earned these prestigious certifications: • ASME Nuclear Certificate # QSC448 • ISO 9001:2000 Certificate # GQC230 • Mil-143208A Inspection • Navy QPL sArcos

For Info go to www.aws.org/ad-index Optimizing Crash Resistance of Welded Aluminum Structures

Combining precipitation, yield strength, work-hardening, and mechanical models has proved useful to optimize the load-bearing capacity of welded automotive components made of age-hardening Al-Mg-Si alloys

BY O. R. MYHR, 0. GRONG, O. G. LADEMO, AND T. TRYLAND

Welded components made of age- hardening aluminum alloys are to an increasing extent used within the transport and automotive in- dustries because of their high strength, good formability, low density, and good resistance to general corrosion. However, in certain cases, the application of such al- loys is restricted by a low heat-affected zone (HAZ) strength level due to soften- ing reactions occurring during welding, which tend to reduce the overall load- bearing capacity of the component. This represents a major challenge in engineer- ing design. Fig. 1 — Drawings illustrating the different heat treatment and welding operations used in The manufacturing of welded automo- manufacturing crash components made of age-hardening aluminum alloys. tive components from age-hardening alu- minum alloys involves a series of thermal and mechanical operations. These alloys have a strong memory of the past process steps due to interactions between different types of particles that form at various tem- peratures (Refs. 1-3). In particular, the dif- ferent heat treatment and welding opera- tions that are used toward the end of the process chain (Fig. 1) have a large influence on the resulting structural performance. However, as illustrated in Fig. 2, the selec- tion and optimization of alloy composition, temper, and process conditions cannot readily be based on experimental testing, Fig. 2 — Diagram illustrating the number of variables involved in the fabrication of welded since the number of possible combinations crash components made of age-hardening aluminum alloys. The designations T1-T7, is too large. Consequently, numerical de- WP1-WP4, and PWHT1-PWHT3, refer to different temper, welding, and heat-treatment sign tools are desired. conditions, respectively.

OLE RUNAR MYHR ([email protected]) and TORE TRYLAND are with Hydro Aluminium Structures, NO-2831 Raufoss, Norway. 0YSTEIN GRONG is with Norwegian University of Science and Technology, Dept. of Materials Science and Engineering, NO-7491Trondheim, Norway. ODD-GEIR LADEMO is with SINTEF, Materials and Chemistry, NO-7465 Trondheim, Norway. All authors are also associated with the Structural Impact Laboratory (SIMLAB), Center for Research Based Innovation, Dept. of Structural Engineering, Norwegian University of Science and Technology, Trondheim, Norway.

FEBRUARY 2009 Realistic prediction of the mechanical performance of welded components and Table 1 - - Chemical Composition of Aluminum Alloys Referred to in Text (in wt -%) structures calls for the use of a rather so- Alloy Si Mg Fe Mn Cu phisticated numerical simulation tech- AA6060 0.45 0.44 0.21 0.04 0.02 nique. In this article a new multiscale AA6082 1.04 0.67 0.20 0.54 0.03 modeling approach is presented, where advanced physical-based models for the microstructure and strength evolution during heat treatment and welding of Al- Mg-Si alloys are combined with nonlinear finite element modeling. This multipur- pose simulation tool is versatile and applicable for a range of different prob- lems, including the optimization of the crash performance of welded automotive components.

Case Studies

Experimental Program

The component consists of a two- chamber extruded profile with 2.2-mm- Fig. 3 — Details of the component design and testing conditions. A — Geometry and di- thick walls and an 8-mm-thick flat extru- mensions of a crash-box; B — experimental setup used for measuring the resulting load- sion as shown in Fig. 3A. The chemical displacement response. composition of the AA6060 base metal is given in Table 1. The parts were age-hard- 0 ened at 185 C before welding and subse- WELDSmt quently stored at room temperature for about four weeks before the final struc- tural testing. The tube was welded against the flat extrusion using fully automatic gas rjLMVWV metal arc welding (GMAW), four straight weld segments, a welding speed of 14.3 mm/s, and a net arc power of 3.6 kW (as- suming an arc efficiency of 0.8). A series of hardness measurements was carried out Fig. 4 — Diagram illustrating the coupling between the different models used in the numer- across the HAZ after about four weeks of ical simulations. full room-temperature aging to check the accuracy of the yield strength model. Fi- nally, the component was subjected to cantilever loading using the setup shown in Fig. 3B, while recording the applied force and the corresponding crosshead displacement.

Coupiing of Microstructure and Mechanicai Modeis

Figure 4 shows the coupling between the different models that are in play, i.e., the weld simulation code WELD SIM•, the microstructure-based NaMo model, and the mechanical LS-DYNA model. Be- cause their theoretical basis has been doc- umented elsewhere, just a brief descrip- tion of each submodel is given here. The thermal module of WELDSIM• (Refs. 5-8) was used to predict the tem- perature field resulting from the welding as illustrated by the peak temperature dis- tribution in Fig. 5 A. As shown in Fig. 4, the calculated thermal history is input to the microstructure model named NaMo Fig. 5 — Typical outputs from the numerical simulations. A — Predicted peak temperature (Nano Structure Module) (Refs. 1-4). distribution during welding; B — transmission electron microscope image of the precipitate This contains a precipitation model that structure within a specific region of the FIAZ; C —predicted variation in particle number calculates the evolution of the particle size density and mean particle radius across the FIAZ; D — comparison between predicted and distribution with time, and can be used to measured hardness profiles across the HAZ.

WELDING JOURNAL B !

Fig. 6— Calculated stress-strain curves for D the three HAZ positions, A, B, and C, defined in Fig. 5A.

quantify the characteristics of the precipi- 40 tate structure shown in Fig. 5B. Following complete aging and welding, the precipi- tate structure varies significantly across I* the HAZ, as shown in Fig. 5C, which pres- ents plots of the predicted particle number density n and the mean particle radius Fas a function of the distance from the weld interface. Rather complex dislocation- based models are then employed to con- vert the computed precipitate parameters c 1 4 • 1> 1 « into an equivalent room-temperature yield strength (or hardness) (Refs. 2-4). Figure 5D shows a comparison between predicted and measured HAZ hardness Fig. 7 — Summary of results from the experimental and numerical case study. A — profiles after complete natural aging, Photograph of the welded component after testing; B — shell model of the component using the yield strength model in NaMo. demonstrating the spatial variation of the initial yield stress; C — comparison of predicted The work-hardening behavior of the and measured load-displacement curves for AA6060; D — summary of predicted load- different peak-temperature regions of the displacement curves for AA6060 and AA6082. HAZ is then calculated by employing the work-hardening model in NaMo de- scribed in Ref. 4, based on inputs from the Simulation of the the AA6060 alloy are encouraging and precipitation model. By combining the re- Structural Performance provide a motivation for extending this sults from the yield strength and the work- modeling concept to other alloy combina- hardening models, the complete stress- Figure 7A is a photograph of the tions and process routes as well. This is strain curves in any position of the HAZ welded crash component following test- done in Fig. 7D. In the figure, simulation can be estimated. Examples of calculated ing, revealing that failure occurred in the results for a medium-strength AA6082 stress-strain curves are given in Fig. 6 for HAZ close to the weld interface. The FE composition, as shown in Table 1, are com- the three specific HAZ positions defined model shown in Fig. 7B consists of shell el- pared to corresponding results for in Fig. 5A. ements having a characteristic element AA6060 from Fig. 7C. It follows that a Finally, the commercial FE-code LS- size of 0.7 mm. Such small elements are re- change in the alloy composition from a DYNA (Ref. 10) was used to simulate the quired to capture the strong spatial varia- soft AA6060 to a medium-strength load-bearing capacity of the welded com- tion in material properties and the corre- AA6082 alloy results in a significant in- ponents using a shell-based modeling ap- sponding severe strain localization in the crease in the predicted ultimate load. proach. This was done by transferring the HAZ. In addition to simulations of the ac- These simulation results are interesting, predicted stress-strain curves for each po- tual case, i.e., welding of the AA6060 in both from an academic and practical point sition of the solution domain to the me- the initially peak aged (T6) condition fol- of view, because they illustrate in a quan- chanical model. LS-DYNA is a general- lowed by complete room-temperature titative manner how the present modeling purpose nonlinear finite element code for aging, another simulation was performed approach can be used to optimize the analyzing large deformation responses of where testing was assumed to take place load-bearing capacity and crash perform- inelastic solids and structures with both immediately after welding. ance of welded aluminum structural com- implicit and explicit solution capabilities. Figure 7C shows a comparison of pre- ponents simply by manipulating the alloy The full constitutive model includes dicted and measured load-displacement composition and the applied heat-treat- isotropic linear elasticity, nonlinear curves. The simulation of the actual case ment schedules. isotropic strain hardening, a state-of-the- (i.e., complete room-temperature aging art anisotropic yield criterion, and the as- following welding) tend to overestimate Concluding Remarks sociated flow rule. Further details of the the ultimate strength of the component, constitutive model, its numerical imple- while the overall agreement is better if the A new multiscale modeling approach, mentation in LS-DYNA, and previous ex- comparison is done on the basis of the sim- involving the use of combined precipita- perience on the use of shell element analy- ulated load-displacement curves repre- tion, yield strength, work-hardening, and ses for the problem at hand are given in senting the as-welded condition. mechanical models, has been devised that Refs. 11-14. The preliminary results obtained for proved useful to optimize the load-bear-

FEBRUARY 2009 ing capacity of welded crash components and work hardening models for Al-Mg-Si 2D/3D and STM-2D). SINTEF report made of age-hardening AI-Mg-Si alloys. alloys, 9th Intl. Summer School on Alu- STF80MKF05180. The main parameters that influence the minum Alloy Technology, Thermome- 10. Livermore Software Technology structural performance are, in addition to chanical Processing and Forming, Trond- Corp., LS-DYNA Keyword User's Manual, geometry and boundary conditions, the heim, Norway, Aug. 20-24. Vols. I and II, Version 960, 2001. following: 1) alloy composition; 2) initial 5. Myhr, O. R., Klokkehaug, S., Fjasr, 11. Lademo, O.-G, Berstad, T, Eriks- base plate temper condition; 3) applied H. G., Grong, 0., and Kluken, A. 0.1998. son, M., Tryland, T, Furu, T, Hopperstad, heat input during welding; and 4) subse- Modeling of microstructure evolution, O. S., and Langseth, M. 2008. A model for quent postweld heat-treatment schedule residual stresses and deformations in process-based crash simulation. Intl. Jour- — all being fully accounted for in the nu- 6082-T6 aluminum weldments. Welding nal of Impact Engineering 35(5): 376. merical simulations.^ Journal 77(7): 286. 12. Lademo, O.-G, Hopperstad, O S., 6. Fjasr, H. G., Myhr, O. R., Klokke- Berstad, T, and Langseth, M. Prediction References haug, S., and Holm, E. J. 2001. Advances of plastic instability in extruded aluminum in aluminum weld simulations applying alloys using shell analysis and a coupled 1. Myhr, O. R., and Grong, 0. 2000. WELDSIM•. 11th Intl. Conf. on Computer model of elasto-plasticity and damage. Modeling of non-isothermal transforma- Technology in Welding. Columbus, Ohio. Journal of Materials Processing Technology tions in alloys containing a particle distri- 7. Myhr, O. R., and Grong, 0. 2008. 166,247. bution. .4rtflAto«: 48,1605. Utilizing a predictive tool for designing 13. Reyes, A., Hopperstad, O. S., 2. Myhr, O. R., Grong, 0., and Ander- welded aluminum components. Welding Lademo, O.-G, and Langseth, M. 2006. sen, S. J. 2001. Modeling of the age hard- Journal 87(5): 36. Modeling of textured aluminum alloys ening behaviour of Al-Mg-Si alloys. Acta 8. Myhr, O. R., and Grong, 0. 2009. used in a bumper system: Material tests Mater. 49, 65. Novel modeling approach to optimisation and characterization. Computational Ma- 3. Myhr, O. R., Grong, 0., Fjasr, H. G., of welding conditions and heat treatment terials Science 37(3): 246. and Mariorara, C. D. 2004. Modeling of schedules for age hardening Al alloys. Sci- 14. Wang, T, Hopperstad, O. S., the microstructure and strength evolution ence and Technology of Welding and Join- Lademo, O.-G, and Larsen, P. K. 2007. Fi- in Al-Mg-Si alloys during multistage ther- ing. In press. nite element analysis of welded beam-to- mal processing. ^4rtfl Mater. 52, 4997. 9. Berstad, T, Lademo, O.-G, and column joints in aluminum Alloy EN AW 4. Grong, 0., and Myhr, O. R. 2007. Hopperstad, O. S. 2005. Weak and strong 6082 T6. Finite Elements in Analysis and Combined precipitation, yield strength texture models in LS-DYNA (WTM- Design 44,1.

Real Time Digital X-Ray Systems for Weld Quality Inspection

Dcfcct/Kesolution < .001"

High Spetrd Imjgtr Acquisition

Aulomated Peteclor Qualification Software

User Iriendly

Upgradeable to CT

vmrn-.tuiMiMv. w MADF. NOKIH SIAK IMA(,I\(,, INC IN VVVVVV.4NSI.COM l.HOn.f>"lS.H"W2

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

WELDING JOURNAL Real-Time Crack Detection in Aerospace Structures Component and tooling damage is detected before faiiure during low-cycie fatigue testing

— Fig. 1. When the beginning of a crack is detected, the system automatically stops the LCF test before component failure. This exclusive crack detection interlock capability allows an attended or unat- tended LCF test to be halted when com- ponents or tooling develop cracks — be- fore a damaging rotor burst event. Conventional LCF procedures require that the testing is stopped periodically in order to inspect for cracks in the compo- nent and tooling. This involves removing the test article from the spin rig fre- quently, thereby greatly extending the cost and schedule of the testing program. The real-time crack detection system can re- duce the number of required inspections, thereby enabling more cycles between inspections.

Reai-Time Crack Detection Fig. 1 — Example of a fatigue crack detected before the component failed. The test in a Criticai Jet Engine automatically stopped once the crack was detected. Appiication

The development of jet engines and results in loss of the component and can A major aerospace jet engine original other high-speed machinery re- also cause damage to tooling and other equipment manufacturer (OEM) recently quires extensive testing to establish test facility equipment. ran a series of low-cycle fatigue tests on a the integrity and useful life of high-speed critical component, which involved the rotating components. A fundamental testing of multiple sets of rotors. The com- evaluation technique for turbine engine Preventing Component pany contracted Test Devices, Inc., and rotors is to empirically test and validate Destruction another vendor to perform testing on two the number of cycles the rotors can with- rotor sets each. The RT-CDS was used for stand, either to a predetermined number In order to avoid premature compo- testing and monitoring by TDI, while the or all the way to failure. This type of test nent burst, either from crack formation in other vendor used a conventional LCF is typically referred to as a low-cycle fa- the component itself or the tooling (the testing procedure. tigue (LCF) test. arbor, or spindle, that holds the compo- The two companies began their testing During a standard LCF test, an engine nent in place). Test Devices, Inc. (TDI) at the same time. Early in the testing pro- rotor component is cycled up and down developed a patented application known cedure, one of the rotors at the alternate in speed in a spin rig in order to validate as the real-time crack detection system vendor was destroyed at approximately a prescribed number of cycles. Tradition- (RT-CDS), for detecting the initiation of 80% of its expected life because of a crack ally, these LCF tests end in either success- cracks during LCF tests. rupture in the spin tooling hardware. The ful completion of the full cycle count, or The crack detection system automati- spin test equipment incurred substantial in a complete rotor burst caused by a fa- cally detects fatigue-induced cracks dur- damage. tigue-induced crack in the part. This often ing an LCF test with 80 to 90% accuracy During TDI's testing, a signature in-

Information supplied by Test Devices, Inc., Hudson, Mass., www.testdevices.com; contact: David Woodford, (978) 562-4923.

FEBRUARY 2009 dicative of a crack was detected, and the Specifically, the test program was de- COR-MET crack detection system automatically signed to evaluate the fatigue behavior of SPECIAtTY COW1D WlWt stopped the test. The customer then per- a blade replacement weld process. Crack AMD COATtD ELECTWODES formed a component ultrasonic inspec- growth and propagation of flaws in the tion and found two cracks. Early detec- weld plane were monitored. tion by the RT-CDS prevented the de- struction of the part, tooling, and equip- Benefits of the New System COR•NICKEL ment. If the cracks had not been discov- ered, the test article would have been lost By detecting cracks in the rotors be- without preserving the initiation site and fore they failed, cost savings were sub- Flux Cored crack face (which are critical for follow- stantial and damage to the rotors under up metallurgical analysis). test, as well as the test equipment, were Welding Wire A second rotor failed at the alternate prevented. Time can be saved by reduc- vendor after approximately 70% of its ex- ing the number of periodic inspections, pected life as a result of an undetected the number of interruptions, and avoid- AWS A5.34 crack in the OEM tooling. The RT-CDS ing time lost in replacing damaged com- detected and automatically stopped LCF ponents and equipment. testing of a second rotor when a crack oc- The system can also provide initiation curred in the tooling. and crack growth analysis data that give N82 FC-G The two rotors that were tested using customers the ability to determine the lo- conventional methods were destroyed as cation, mode, and cause of a crack. The ENiCr3T0-1/4 a result of fatigue-induced cracks in the knowledge base of the fatigue life of spin- tooling. As a result, the engine manufac- ning rotors and other application-critical turer lost two valuable components that components can be increased. N100A FC-G could have been saved. The system can be used on a variety of The RT-CDS has also been used dur- equipment including jet engine rotors, ENiCrFe2T0-1/4 ing a low-cycle fatigue testing program for turbochargers, rocket pumps, electric mo- evaluating flaw tolerances in the weld tors, gas turbine rotors, and compressor plane between air foils and the rotors. rotors.^ N182 FC-G ENiCrFe3T0-1/4 N625L FC-G Fora ENiCrMo3T0-1/4 W^ rid of Difference... N276 FC-G .Modular Fixturing for Welding ENiCrMo4T0-1/4

Whether your world of short run N22 FC-G welding jobs Is flat, round, square, rectangular or any . N117FC-G you manage short runs and design changes easily. You'll ENiCrCoMo1T0-1/4 see a world of difference.

Call Today! (866) DR BLUCO (372-5826) COR-MET, INC. or visit our web site: www.BLUCO.com 12500 Grand River Rd. Brighton, Ml 48116

PH: 810-227-3251

Bluco Corporation FAX: 810-227-9266 3500 Thayer Ct, Aurora, IL 60504 (866) DR BLUCO (372-5826) www.cor-met.com www.BLUCO.com [email protected] For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

WELDING JOURNAL 4th International ^^^^^^^^^^^^ Brazing & Soldering dSNk j^AmericanWeidingSociety Conference (IBSC) April 26-29, 2009 -ilSton in the Wait Disney WorSd Resort, CrSando, Florida Recognized by industry professionals as the world's premier event for the brazing and soldering community. •Interaction with hundreds of professionals, scientists and engineers from around the globe •Exchange and discussion of research, development and application of brazing and soldering •Comprehensive technical programs for brazing and soldering •Valuable networking opportunities •Pre-conference educational programs •OverdO exhibitors •Key information on trends, products, processes and techniques Areas covered at IBSC The following is a listing of some of fhe topical areas that have been covered at the IBSC. Stay tuned for full program information to be provided in the future. This premier event is truly one that anyone involved in the brazing and soldering community should plan to attend. • Aircraft and Aerospace • Furnace/Vacuum Brazing • Automotive and Transportation • Joint Design and Reliability • Brazing and Soldering Standards • Lead-free Solders • Ceramic/Glass to Metal Joining • Light Metals • Chemical and Petroleum Production • Materials and Process Design/Control • Composite Materials • Medical/Dental • Electronic Packaging/Sensors • Mining & Heavy Equipment • Filler Metal Properties • Modeling and Process Control • Fluxes and Atmospheres • Consumer Products • Fixture Design and Use • Factory Automation • Musical Instruments • Job-Shop & Process Customization • Power and Electrical Equipment • Thermal Management • Sensors/Microelectronics • Vacuum Brazing • Solder Joining Methods • Gases and Plumbing • Special/Advanced Brazing Processes • LEAN Brazing Processes • Structural Solder Applications • Low-volume Critical Components • Test Methods and Evaluation Register Today At: www.aws.org/education/ibsc or call 800-443-9353, ext. 213 (outside North America 305-443-9353) or for more information, call (800)443-9353, ext. 455, email: [email protected] [email protected] Registration includes: Evening Reception on Monday, April 27, 2009 & Networking Dinner on Tuesday, April 28, 2009

www.aws.org/educafion/ibsc Earn PDH's toward your AWS recertification or renewal when you attend the conference!

Reach the innovators, influencers and decision-makers in the brazing and soldering industry from around the world. Exhibit and Sponsorship Opportunities IBSC provides a forum to showcase the latest trends, products, processes and techniques in the industry. The exposition features exhibitors tram all sectors of the brazing and soldering community and draws decision-makers with purchasing power from around the world. There is no better opportunity to conduct business with the brazing and soldering community than to have a presence at this conference. ASM International and AWS are dedicated to delivering the audience you want and the value you need. Your exhibitor tee includes one technical session pass tor you or someone in your organization to attend the full conference. Plan now and reserve your space and/or sponsorship for 2009!

Exhibit Dates and Times Monday, April 27 Noon - 6:00 PM Lunch: Noon - 1:00 PM Networking Reception: 6:00 PM - 7:00 PM Tuesday, April 28 9:30 AM - 3:00 PM Lunch; Noon- /:00 PM Wednesday, April 29 9:30 AM - 3:00 PM Lunch: Noon - 1:00 p.m. Pricing; Tabletop Exhibit* .$1200 Tabletop Exhibit* and Reception Sponsorship .$1800 Reception Sponsorship Only ...$750

^Complimentary full conference registration included with your tabletop! Customized packages that best meet your needs also available! To download a complete Exhibit/Sponsor Information Packet, visit the web at www.aws.org/education/ibsc/tabletop.html Reserve Your Exhibit Space — and Sponsorship Today For more information or to reserve exhibit space and sponsorship at the IBSC call (440) 338-1733, or (440) 338-5422, email: [email protected] or [email protected]

Co-sponsored by; American Welding Society JSNV American Welding Society ^

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, 2009. The committee looks forward to receiving these nominations for 2010 consideration.

Sincerely,

Alfred F Fleury Chair, Counselor Selection Committee World Class Benefits

For The World Class Members of AWS There is a crisis in health care and AWS has dane

something about it. We are praud to introduce an

outstanding package of benefits for our members, a

single source with more than fifty insurance companies,

offering value-priced health, dental, vision, disability,

accident, cancer and life insurance.

Simply visit www.worldclassbcnefifs.com/aws

or call 800-955-041 8 to learn more.

Managed By:

Worn DNVIIU ISM K\M t Sm\n » s. IM . www.worldclassbenefits.com/aws WELDING WORKBOOK Datasheet 303 Fusion Welding for Aerospace Applications

Due to the criticality of many aerospace weldments, the iden- selection of fill material, it is only to be used as a guide by the tification, storage, and use of all welding consumables (including fabricator. The fabricator is responsible for verifying the correct wires, rods, inserts, fluxes, gases, etc.) require proper controls. It application of any filler material through the Welding Procedure is important to store fluxes and covered electrodes in a clean, dry Specification/Procedure Qualification Record cycle. environment or in sealed containers. To prevent moisture accu- Welding fluxes are to be labeled and segregated by type and/or mulation, employ heating as necessary. Low-hydrogen shielded by their particular application. To prevent moisture pickup, store metal arc welding (SMAW) and flux cored arc welding (FCAW) fluxes in sealed containers or keep them in a suitably clean and electrodes should be handled and stored according to the manu- dry environment. Clean, unfused flux may be reused after recon- facturer's recommendations or according to AWS A5.1, A5.5, ditioning according to the manufacturer's recommendations. A5.20, or A5.29, as appropriate. Proper identification and stor- Consumables used in welding are to be identified using an es- age of consumables will have a positive contribution to the qual- tablished standard or specification or by a standard specified in ity of the product. the procurement specification. If the identification marking is Filler materials, when used in the welding process, must be destroyed or missing, don't use the consumable. When specified specified by the Engineering Authority. Tables 1-3 list the filler on the engineering drawing or a contract document, traceability materials normally used in welding aerospace base metals. Un- of the consumables must be maintained throughout the welding less the Engineering Authority allows the use of the table in the process.

Table 1 — Filler Metal for Welding Aluminum Alloys Using GMAW, GTAW, and PAW Processes (a)

Base Metal Filler Material Filler Material Specification

1100 ER1100 or ER4043 AWS A5.10 Table 3 — Filler Metal for Welding Corrosion-Resistant Steels and 3003 ER1100 or ER4043 AWS A5.10 Heat-Resistant Alloys Using GMAW, GTAW, and PAW Processes (a) 2219 ER2319 AMS 4191 or AWS A5.10 Base Metal Filler Material Filler Material 5052 ER5356 or ER4043 AWS A5.10 Specification 6013 ER4043 AWS A5.10 6061 ER4043 or ER5356 AWS A5.10 304L and 316L ER308L AWS A5.9 (a) Refer to C5.12 i n the Commentary and 5.12 in the main body of the AWS D 17.1 321 and 347 ER321 or ER347 AWS A5.9 specification. A286 A286 AMS 5804 or AMS 5805 21-6-9 ER219 AWS A5.9 PH 13-8Mo WPH 13-8Mo ELC AMS 5840 PH 15-7Mo WPH 15-7MO-VM AMS 5812 PH 15-5 15-5PH or ER630 AMS 5826 or Table 2 — Filler Metal for Welding Titanium Alloys Using GMAW, AWS A5.9 GTAW, and PAW Processes W PH 17-4 WPH 17-4 or AMS 5825 or ER630 AWS A5.9 Base Metal Filler Material Filler Material Specification PH 17-7 PH17-7 AMS 5824 WPH 15-7MO-VM AMS 5812 Commercially CF AMS 4951 Pure Titanium ERTi-4 AWS A5.16 Inconel® 600 ERNiCrFe-5 AWS 5.14

3A1-2.5V Ti ERTi-3Al-2.5V AWS A5.16 Inconel® 625 Inconel® 625 AMS 5837 Hastelloy® W or AMS 5786 or 5Al-2.5Sn-Ti 5Al-2.5Sn AMS 4953 ERNiMo-3 AWS A5.14 ERTi-5Al-2.5Sn AWS A5.16 Inconel® 718 Inconel® 718 AMS 5832 6A1-4V or 6-4 AMS 4956 Inconel® X750 ERNiCrFe-7 AWS A5.14 6A1-4VELI ERTi-6Al-4V AWS A5.16 //7 1 Rpfrr tn rS 17 in the i ^ommentnn? nrtd 5 T? in the m/7/ n hodvofthe 4WS ml 1 (a) Refer to C5.12 in the Commentary and 5.12 in the main body of the A WS Dl 7.1 specification. specification.

Excerpted from AWS D17.1: 2001, Specification for Fusion Welding for Aerospace Applications.

FEBRUARY 2009 CH

j-u KI^IL'JKI um ^JU &

North America's Largest Forming, Fabricating & Welding Event November 15-18,2009 Chicago McCormick Place • North & South Halls Chicago, Illinois USA

in 11 m i

- -. . . J^: LlLJ-l. \mm .-.- ••

:i:;:i!i:;:i::: fi ' --S^i

North America's largest metal forming, fabricating & welding trade show heads to Chicago for 2009. Reach new markets and buyers located in one of the strongest manufacturing regions of the country. Reserve your booth now! Space is limited. Call today for exhibiting information.

cosponsored by (gJSI) industry partner American Welding Fabricators & Manufacturers Society of Manufacturing Precision Metalforming Society Association, Intl Engineers Association NAM (800)443-9353 (800)432-2832 (800)733-3976 (800)541-5336 www.aws.org/show www.fmafabtech.com www.sme.org/fabtech www.metalform.com COMING EVENTS NOTE: A DIAMOND (*) DENOTES AN AWS-SPONSORED EVENT.

Indian Institute of Welding Nat'l Welding Seminar and Weld India ILSC® Int'l Laser Safety Conf. March 23-26, John Ascuaga's Expo 2009. Feb. 5-7, Bombay Exhibition Center, Mumbai, India. Visit Nugget Hotel, Reno, Nev. Sponsored by Laser Institute of Amer- www. iiwindia. com/events/current_events/weld_india_expo_2009. htm. ica, www.laserinstitute.org/conferences/ilsc; or call (407) 380-1553.

PACE 2009, The Power of Paint and Coatings. Feb. 15-18, New Spring Robot Safety Conf. March 23-25, Knoxville Marriott, Orleans Convention Center, New Orleans, La. Visit Knoxville, Tenn. Contact Robotic Industries Assn. at www.pace2009. com. [email protected] or [email protected].

HOUSTEX. Feb. 24-26, George R. Brown Convention Center, ABB Automation & Power World 2009. March 24-26, Orlando Houston, Tex. Contact Society of Mfg. Engineers, (800) 733-4763, World Center Marriott, Orlando, Fla. Visitwww.abb.com/a&pworld. www. sme. orglhoustex. Heat Treating of Light Alloys. March 25, 26, Doubletree Hotel, • Joining Dissimilar Metals Conf. March 3,4, Orlando, Fla. Con- Anaheim, Calif. Visit www.asmintemational.org. tact American Welding Society, (800/305) 443-9353, ext. 455; visit www.aws.org. WESTEC. March 30-April 2, Los Angeles Convention Center, Los Angeles, Calif. Contact Society of Mfg. Engineers, (800) 733- • Laser Additive Manufacturing Workshop. March 3, 4, Holiday 4763; or visit www.sme.org/westec. Inn, Riverwalk, San Antonio, Tex. As a cooperating society, AWS MicroMfg. and NanoMfg. Conf. & Exhibits. March 31-April 1, members will receive discounted registration fees. Contact Laser Sheraton Bloomington Hotel, Minneapolis, Minn. Contact Soci- Institute of America, www.laserinstitute.org. ety of Mfg. Engineers, (800) 733-4763, www.sme.org/micro, www. sme. org/nano. Lean for the Supply Chain. March 3-5, Crown Plaza Hotel, San Jose, Calif. Contact Society of Mfg. Engineers, (800) 733-4763, North American Steel Construction Conf. and AISC Steel Con- www.sme.org. struction Expo. April 1-4, Phoenix, Ariz. Visit www.aisc.org. • GAWDA, Gases and Welding Distributors Assn., Spring Man- 2nd Annual Global Marine Renewable Energy Conf. April 15,16, agement Conf. March 22-24, Sheraton Chicago Hotel & Towers, The Carnegie Institution for Science, Washington, D.C Contacts Chicago, 111. Visit www.gawda.org. (877) 463-3846; [email protected]. rC370SA Cold Saw TECHNICAL TRAINING The Hobart Institute of Welding Technology has infinitely^ offers our comprehensive Technical Training variable courses throughout the year! Upcoming dates: Prep for AWS Certified Welding Supervisor Exam blade speed Feb 16-20' Jun 22-26- Aug 10-14' Nov 30-Dec 4 Prep for AWS Welding Inspector/Educator Exam for precise Feb23-Mar6- May 11-22- Jun8-19- Jul 13-24 cutting Visual Inspection Feb 17-18- Apr 7-8- Jun30-Jul 1- Nov 23-24 • Infinitely variable blade speed control to match Welding for the Non Welder the job requirement Apr 27-30- Jun 22-25- Aug 17-20- Oct 12-15 • Semi-Automatic push button solenoid operation Arc Welding Inspection & Quality Control • Air-over-hydraulic system for optimum sawing rates Mar 16-20- May 4-8- Jul 27-31- Oct 19-23 • Vertical column construction for vibration-free sawing Weldability of Metals, Ferrous & Nonferrous • Air vise with infinitely variable clamping pressure Feb 23-27- Mar 23-27- Apr 20-24- May 18-22 to prevent distortion Liquid Penetrant & Magnetic Particle Inspection • Full electronic control/information system Apr 13-17- Aug 3-7- Oct 26-30 6700 Quality way Portage. Ml 49002 1-800-332-9448 RMTSna 269-321-0060 or visit us at www.welding.org Fax: 209-321-0000 for more information. © 2009 Hobart Institute of Welding KALAMAZOO www.kmtsaw.com UOBART INSTITUTC Technology, Troy, OH I lOFWELDINWELDING TECHNOLOGY J_l St. of Ohio Reg. No. 70-12-0064HT For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index FEBRUARY 2009 The Aluminum Assn. Spring Meeting. April 20-22, Omni La neerlng Show. May 19-21, Place Bonaventure, Montreal, Que., Mansion del Rio, San Antonio, Tex. Visit www.aluminum.org. Canada. Contact Society of Mfg. Engineers, (800) 733-4763, www.sme.org. • GAWDA Spring Management Conf. 2. April 21-24, Asheville, N.C. Sponsored by Gases and Welding Distributors Assn. Visit EASTEC. May 19-21, Eastern States Exposition Grounds, W www.gawda.org. Springfield, Mass. Contact Society of Mfg. Engineers, (800) 733- 4763; or visit www.sme.org/eastec. • IBSC, 4th Int'l Brazing and Soldering Conf. April 26-29, Hilton Hotel in the Walt Disney World Resort, Orlando, Fla. Cospon- • AWS/Weldmex. June 2-4, Monterrey, Mexico. Contact Ameri- sored by AWS and ASM International. Contact American Weld- can Welding Society, (800/305) 443-9353, ext. 229; or visit ing Society, (800/305) 443-9353, ext. 229; visit www.aws.org. www.aws.org.

JOM-15,15th Int'l Conf. on the Joining of Materials, and 6th Int'l Beljlng-Essen Welding & Cutting Fair. June 2-5, Shanghai, China. Conf. on Education In Welding. May 3-6, Helsin0r, Denmark. Visit www. beijing-essen-welding. de. Contact JOM Institute, [email protected]. AeroMat® 2009 Conf. and Expo. June 7-11, Dayton Convention AISTech 2009, The Iron & Steel Technology Conf. and Expo and Center, Dayton, Ohio. Call ASM customer service (800) 336- Asla-Paclflc Partnership Technology Showcase 2009. May 4-7, St. 5152, ext. 0; e-mail [email protected]; or visit Louis, Mo. Contact Association for Iron & Steel Technology http://asmcommunity.asmintemational.org/content/Events/aeromat www.iss.org. 09/.

Offshore Technology Conf. May 4-7, Reliant Center, Houston, • Weld Cracking VII 'The Heat-Affected Zone' Conf. June 9, 10, Tex. yis,\twww.otcnet.orgl2009. Columbus, Ohio. Contact American Welding Society, (800/305) 443-9353, ext. 229; or visit www.aws.org. • 12th Aluminum Welding Conf. May 5,6, Toronto, Ont., Canada. Contact American Welding Society, (800/305) 443-9353, ext. 229; First Int'l Conf. on Welding Technologies. June 11-13, Gazi Uni- visit www.aws.org. versity, Ankara, Turkey. Visit www.icwet09.org.

RAPID 2009. May 12-14, Renaissance Schaumburg Convention • Shipbuilding Conf. June 16, 17, New Orleans, La. Contact Center, Schaumburg, 111. Contact Society of Mfg. Engineers, (800) American Welding Society, (800/305) 443-9353, ext. 229; or visit 733-4763, www.sme.org/rapid. www.aws.org.

Advanced Manuf. Expo, and Plant Maintenance & Design Engl- Western Manufacturing Technology Show. June 16-18. North-

BEVEL-MILL® We've Got You Productive! PLATE BEVELERS Get Your Welding *Super capacity Wire to the Feeder *Fast-clean bevels up to 1 3/16" *Variable angle Fast'N *Made inJP| U.S.A. quality Easy®

DuraDome® Payout Systems Electrode Factory Conduits Reps Connectors Wanted! For All Feeders Our bulk welding Several models available electrode accessories FREE CATALOG make conversion or Call 1-800-886-5418 retrofit/AST" W£/1SK® Fax 1-810-632-6640 with ff/VC/HVCK in mind! www.heckind.net 1275 Harvard Drive ELECTRON BEAM Kankakee, IL 60901 USA P.O. Box 425 TECHNOLOGIES. INC Ph: 815-935-2211 Hartland, Michigan 48353 FAX: 815-935-8605 teckINDUSTRIES iNC, www.electronbeam.com

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index WELDING JOURNAL lands Park-AgriCom, Edmonton, Alb., Canada. Contact Society round in Allentown, Pa., and at customers' facilities. Contact: of Manufacturing Engineers, (800) 733-4763; or visit Welder Training & Testing Institute, (800) 223-9884, www.sme.org. [email protected]; visit www.wtti.edu.

• FABTECH International & AWS Welding Show now including CWI Preparatory and Visual Weld Inspection Courses. Classes METALFORM. Nov. 15-18, McCormick Place, Chicago, 111. This presented in Pascagoula, Miss., Houston, Tex., and Houma and show is the largest event in North America dedicated to showcas- Sulphur, La. Contact: Real Educational Services, Inc., (800) 489- ing the full spectrum of metal forming, fabricating, tube and pipe, 2890, [email protected]. welding equipment, and technology. Contact American Welding Society, (800/305) 443-9353, ext. 455; or visit mw.flvra.o^. Environmental Online Weblnars. Free, online, real-time semi- nars conducted by industry experts. For topics and schedule, visit Educational Opportunities www.augustmack.com/Web%20Seminars.htm. ASME Section IX Course. Feb. 10-12, New Orleans, La.; April EPRINDE Training Seminars. EPRI offers NDE technical skills 6-8, Las Vegas, Nev.; June 1-3, Houston, Tex. Contact Walter J. training in visual examination, ultrasonic examination, ASME Sperko, (336) 674-0600; www.sperkoengineering.com. Section XI, and UT operator training. Contact Sherryl Stogner, (704) 547-6174; [email protected]. Automotive Body In White Training for Skilled Trades and Engineers. Orion, Mich. A five-day course covers operations, Essentials of Safety Seminars. Two- and four-day courses are troubleshooting, error recovery programs, and safety procedures held at numerous locations nationwide to address federal and for automotive lines and integrated cells. Contact Applied Mfg. California OSHA safety regulations. Contact American Safety Technologies, (248) 409-2000, www.appliedmfg.com. Training, Inc., (800) 896-8867, www.trainosha.com.

Boiler and Pressure Vessel Inspectors Training Courses and Fabricators and Manufacturers Assn. and Tube and Pipe Assn. Seminars. Columbus, Ohio. Call (614) 888-8320; visit Courses. Call (815) 399-8775; visit www.fmametalfab.org. www.nationalboard.org. Firelighter Awareness Online Course. A self-paced, ten- CWI/CWE Course and Exam. Troy, Ohio. This is a ten-day pro- module certificate course taught online by fire service profes- gram. Contact Hobart Institute of Welding Technology, (800) sionals. Fee is $195. Contact Industrial Scientific Corp., (800) 332-9448, www. welding, orgltechnicallschedule2008.html. 338-3287; www. indsci. com/serv_trainJfha_online. asp.

CWI/CWE Prep Course and Exam and NDT Inspector Training. Gas Detection Made Easy Courses. Online and classroom cours- Courses. An AWS Accredited Testing Facility. Courses held year- es for managing a gas monitoring program from gas detection to confined-space safety. Contact Industrial Scientific Corp., (800) 338-3287; www. indsci. comlserv Jrain. asp.

Helller NDT Courses. Contact Hellier, 277 W Main St., Ste. 2, TRIANGLE Niantic, CT 06357; (860) 739-8950; FAX (860) 739-6732.

f^ ENGINEERING, INC. Inspection Courses on ultrasonic, eddy current, radiography, dye Services for the Welding Industry penetrant, magnetic particle, and visual at Levels 1-3. Meet SNT- TC-1A and NAS-410 requirements. Contact TEST NDT, Inc., (714) 255-1500, www.testndt.com. WTS-TB Weld Test Stand Model No.WTS-ASSY Laser Safety Online Courses. Courses include Medical Laser Safety Officer, Laser Safety Training for Physicians, Industrial The Weld Test Stand Laser Safety, and Laser Safety in Educational Institutions. allows for quick, Contact Laser Institute of America, (800) 345-3737, secure clamping and www. laserinstitu te.org. positioning of pipe or plate test Laser Safety Training Courses. Courses based on ANSI Z136.1, assemblies. Safe Use of Lasers, presented in Orlando, Fla., or at customer's site. Contact Laser Institute of America, (800) 345-3737, •All position plate fixtures will www. laserinstitu te.org. hold up to 1.5" thickness without backing, in any position Machine Safeguarding Seminars. Contact Rockford Systems, • Pipe and plate fixtures also Inc., (800) 922-7533, www.rockfordsystems.com. sold separately for use with bench vise or other stand • Pipe fixture wall thickness Machining and Grinding Courses. Contact TechSolve, up to 10" sch 160 www. TechSolve.org. • Shipped unassembled •Assembled weight 85 lbs. WTS-BASE NACE Int'l Training and Certification Courses. Contact 6 Industrial Way National Assoc. of Corrosion Engineers, (281) 228-6223, Hanover, MA 02339-2425 www.nace.org. (781)878-1500 • (781)878-1374 NDE and CWI/CWE Courses and Exams. Allentown, Pa., and at Sustaining Fax(781)878-2547 Member www.trieng.com customers' locations. Contact Welder Training and Testing Institute, (800) 223-9884, www.wtti.edu. For info go to www.aws.org/ad-index

FEBRUARY 2009 AWS Certification Schedule Certification Seminars, Code Ciinics and Examinations Application deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee. Certified Welding Inspector (CWI) 9-Year Recertification Seminar for CWI/SCWI LOCATION SEMINAR DATES EXAM DATE LOCATION SEMINAR DATES EXAM DATE Anchorage, AK Mar. 22-27 Mar. 28 Denver, CO Peb. 23-28 NO EXAM Portland, OR Mar. 22-27 Mar. 28 Dallas, TX Mar. 30-Apr. 4 NO EXAM Boston, MA Mar. 22-27 Mar. 28 Sacramento, CA May 4-9 NO EXAM Phoenix, AZ Mar. 22-27 Mar. 28 Pittsburgh, PA Jun. 1-6 NO EXAM York, PA EXAM ONLY Mar. 28 San Diego, CA Jul. 13-18 NO EXAM Miami, PL Mar. 29-Apr. 3 Apr. 4 Orlando, PL Aug. 24-29 NO EXAM Chicago, IL Mar. 29-Apr. 3 Apr. 4 Dallas, TX Oct. 5-10 NO EXAM Corpus Christi, TX EXAM ONLY Apr. 11 Miami, PL Nov. 30-Dec. 5 NO EXAM Dallas, TX Apr. 19-24 Apr. 25 For current CWIs and SCWIs needing to meet education requirements without taking the exam. If needed, recertification exam can be taken at any site listed Springfield, MO Apr. 19-24 Apr. 25 under Certified Welding Inspector. Baton Rouge, LA Apr. 19-24 Apr. 25 Long Beach, CA Apr. 19-24 Apr. 25 Certified Welding Supervisor (CWS) Mobile, AL EXAM ONLY Apr. 25 LOCATION SEMINAR DATES EXAM DATE Houston, TX. Mar. 2-6 Mar. 7 San Francisco, CA Apr. 26-May 1 May 2 Baton Rouge, LA Apr. 20-24 Apr. 25 Portland, ME Apr. 26-May 1 May 2 Las Vegas, NV Apr. 26-May 1 May 2 Columbus, OH Jun. 1-5 Jun. 6 Minneapolis, MN Jul. 20-24 Jul. 25 Waco, TX EXAM ONLY May 2 Philadelphia, PA Aug. 31- Sep. 4 Sep. 5 Miami, PL EXAM ONLY May 14 Tulsa, OK Oct. 5-9 Oct. 10 Nashville, TN May 10-15 May 16 Long Beach, CA Nov. 30-Dec. 4 Dec. 5 Jacksonville, PL May 10-15 May 16 CWS exams are also given at all CWI exam sites. Baltimore, MD May 10-15 May 16 Long Beach, CA EXAM ONLY May 30 Certified Radiographic Interpreter (CRI) Detroit, MI May 31-Jun. 5 Jun. 6 LOCATION SEMINAR DATES EXAM DATE Miami, PL May 31-Jun. 5 Jun. 6 Miami, PL Mar. 9-13 Mar. 14 Albuquerque, NM May 31-Jun. 5 Jun. 6 Indianapolis, IN Apr. 20-24 Apr. 25 Spokane, WA Jun. 7-12 Jun. 13 Miami, PL Jun. 22-26 Jun. 27 Oklahoma City, OK Jun. 7-12 Jun. 13 Houston, TX Jul. 27-31 Aug. 1 Birmingham, AL Jun. 7-12 Jun. 13 Miami, PL Oct. 19-23 Oct. 24 Hartford, CT Jun. 14-19 Jun. 20 Radiographic Interpreter certification can be a stand-alone credential or Pittsburgh, PA Jun. 14-19 Jun. 20 can exempt you from your next 9-Year Recertification. Beaumont, TX Jun. 14-19 Jun. 20 Corpus Christi, TX EXAM ONLY Jun. 20 Certified Welding Educator (CWE) Seminar and exam are given at all sites listed under Certified Miami, PL EXAM ONLY Jul. 16 Welding Inspector. Seminar attendees will not attend the Pargo, ND Jul. 12-17 Jul. 18 Code Clinic portion of the seminar (usually first two days). New Orleans,LA Jul. 12-17 Jul. 18 Sacramento,CA Jul. 12-17 Jul. 18 Senior Certified Welding Inspector (SCWI) Kansas City, MO Jul. 12-17 Jul. 18 Exam can be taken at any site listed under Certified Welding Inspector. No preparatory seminar is offered. Phoenix, AZ Jul. 19-24 Jul. 25 Orlando, PL Jul. 19-24 Jul. 25 Code Clinics & Individual Prep Courses Milwaukee, WI Jul. 19-24 Jul. 25 The following workshops are offered at all sites where the CWI Cleveland,OH Jul. 26-31 Aug. 1 seminar is offered (code books not included with individual prep Los Angeles, CA Jul. 26-31 Aug. 1 courses): Welding Inspection Technology (general knowledge and prep course for CWI Exam-Part A); Visual Inspection Workshop Louisville, KY Jul. 26-31 Aug. 1 (prep course for CWI Exam-Part B); and Dl.l and API-1104 Denver, CO Aug. 2-7 Aug. 8 Code Clinics (prep courses for CWI Exam-Part C). Philadelphia, PA Aug. 2-7 Aug. 8 San Diego, CA Aug. 9-14 Aug. 15 On-site Training and Examination Miami, PL Aug. 9-14 Aug. 15 On-site training is available for larger groups or for programs Charlotte, NC Aug. 16-21 Aug. 22 customized to meet specific needs of a company. Call ext. 455 for more information. San Antonio, TX Aug. 16-21 Aug. 22 Bakersfield,CA Aug. 16-21 Aug. 22 International CWI Courses and Exams Rochester, NY EXAM ONLY Aug. 22 AWS training and certification for CWI and other programs are Portland, ME Aug. 23-28 Aug. 29 offered in many countries. Por international certification Salt Lake City, UT Aug. 23-28 Aug. 29 program schedules and contact information, please visit Seattle, WA Aug. 23-28 Aug. 29 httpl/twww. aws. orglcertificationlinter_contact. html Corpus Christi, TX EXAM ONLY Aug. 29

For information on any of our seminars and certification programs, visit our website at www.aws.org/certification or contact AWS at (800/305) 443-9353, Ext. 273 for Certification and Ext. 455 for Seminars. Please American Welding Society' apply early to save Fast Track fees. This schedule is subject to change without notice. Please verify the dates with the Certification Dept. and confirm your course status before making final travel plans.

!> AWS 2009 CER1324-2 'elding is the most vital and fundamental manufacturing process in the construction of and metal hull boats. Keeping in tune with the progress of new innovative developments, as well as their potential value and impact to the industry, is essential for those in the shipbuilding community.

The 2009 Shipbuilding Conference will address the critical importance of welding in the shipbuilding industry by providing current information on new and emerging technologies being developed for shipbuilding applications. ^ In addition to the formal sessions being presented, the conference will J provide several opportunities for you to network informally with experts fr academia and industry, as well as with conference participants. An exhibition showcasing products and services available to the shipbuilding industry will ^ also be featured during this two-day conference.

For the latest conference and exhibitor information or to register 1 the conference visit our website at www.aws.org / conferences or call 800443-9353, ext. 455.

To secure tabletop exhibit space or for question about exhibiting at the conference, please ^ call 800-443-9353, ext. 223.

^- %

j* r^ 4

^ I ./

1 SOCIETYA/EI/re BY HOWARD M. WOODWARD Industry Leaders Recognized at the Show

The 2009 AWS board of directors are shown at the FABTECH International & AWS Welding Shon

The four members of the 2008 class of AWS Fellows are (from left) The AWS Counselors are (from left) David J. Nangle, Kenneth E. John N. DuPont, Jerry E. Gould, Gerald A. Knorovsky, and Harshad Richter, Richard A. Patterson, Jeffrey S. Noruk, Charles E. Daily, and K. D. H. Bhadeshia, pictured below. Matthew J. Lucas Jr. DonaldD. Ragerwas not present for the photo.

The 2008 classes 2008 Class of Fellows sity professor, he has been instrumental of AWS Fel- Harshad Kumar Dharamshi Hansraj in the education of future researchers and lows and Coun- Bhadeshia has been a pioneer in model- leaders in the field of metallurgy. Dr. selors were inducted ing microstructure and properties in steel Bhadeshia has received numerous presti- October 6 during the weldments. His main research focus has gious awards for his achievements. He is FABTECH Interna- been the theory of solid-state transforma- a Fellow of the Royal Society, a Fellow of tional & AWS Weld- tions with emphasis on the prediction of the Royal Academy of Engineering, and ing Show held in Las microstructure development in complex a Foreign Fellow of the Indian Academy Vegas, Nev. metallic alloys. In his capacity as a univer- of Engineering.

WELDING JOURNAL John N. DuPont has pioneered new military, he worked as a boilermaker Jeffrey Scott Noruk is a research techniques for modeling solidification mi- welding for Pac-Car, Todds, Lockheed, leader, welding engineer, and mentor. His crostructure under nonequilibrium solid- and J. A. Jones, in addition to working as areas of expertise include welding process ification using liquidus projections from an inspector and repair welder for other development, robotic automation, laser- ternary phase diagrams. His efforts firms. He worked for ten years with Bech- based vision for weld tracking, welding brought a better understanding of weld- tel Corp., and obtained his teaching cer- inspection, process monitoring, and con- ing to several commercially important tificate from Washington State Univer- trol. He worked on a project that stainless steel and nickel-based alloys. Dr. sity and taught welding inspection classes launched the first friction stir welded DuPont is currently a full professor at at Seattle Central College. Since 1980, component for the North American au- Lehigh University. He has published Daily has served as president and CEO tomotive market. The project helped to more than 150 papers and received nu- of Welding and Management Consult- introduce friction stir welding into a high- merous prestigious awards. He serves on ants, a business specializing in building volume production application. Noruk various AWS and ASM International management and inspection teams to has mentored graduate students at the technical committees, the editorial solve welding and construction problems. University of Wisconsin and The Ohio boards of three scientific journals, and the He serves on the welding advisory board State University, is a member of several IIW Committee IX on Welding of Stain- of Lake Washington Technical College advisory boards in the welding field, and less Steel and Nickel-Base Alloys. He is and has served the AWS Puget Sound Sec- has been involved with various AWS tech- a coorganizer of six international ASM tion in several leadership capacities. He nical committees on robotic and automo- conferences. has personally formed and financially tive welding for more than 20 years. supported many AWS Student Chapters, Jerry E. Gould has been a leader in encouraging young people to continue Richard Alan Patterson has been with defining mechanistic interpretations of their educations while promoting the the Los Alamos National Laboratory for resistance and solid-state processes. His welding industry. most of his career, working on the Polaris, research includes the first numerical sim- Trident, and cruise missile systems as well ulations for resistance spot welding to in- Matthew J. Lucas Jr. has specialized as the Strategic Defense Initiatives (Star clude the effect of contact resistances, and in brazing and welding, component de- Wars). He served on the DOE Blue Rib- analyses to interpret current ranges, den- sign, process development, personnel bon Panel on Accident Survivability and drite formation, and the mechanics of training, and management. He worked Security Control of Nuclear Weapons, electrode wear. Dr. Gould coauthored the for Union Carbide Corp., Babcock and held key roles with the Anti-Submarine first model for prediction of thermal dis- Wilcox, and General Electric Co. He re- Warfare Team, the Interagency Task tributions and profiles in friction stir tired from GE in 2004 after 31 years of Force on Uranium Melting and Casting, welding. His work has helped promote service. He worked in the fabrication and and the DOE Interlaboratory Strategic the understanding of advanced high- repair of aerospace components as a Plan for Materials. Patterson is a distin- strength steels for automotive spot weld- welding and brazing engineer and labo- guished welding researcher, program ing applications. He has taken active roles ratory manager. He joined the Belcan manager, mentor, conference organizer, in AWS and other professional organiza- Corp. in 2005 as senior engineer, provid- and developer of specialty welding equip- tions, editorial boards, and review panels ing on-site braze consultations. Lucas cur- ment for manufacturing weapons. of a number of welding-related publica- rently serves on about 20 AWS technical tions. He has been a mentor and educa- committees, chairs the Technical Activi- Donald D. Rager, an AWS Life Mem- tor through his association with The Ohio ties Committee, and was an organizer of ber, has served in the metals-fabrication State University, teaching advanced re- the AWS D17 Aerospace Welding Com- industry for more than 37 years. He is sistance welding theory and applications. mittee. He is a Peer Reviewer for Weld- president of Rager Consulting, Inc., Coles ing Journal, and is a reviewer for brazing Point, Va., a licensed professional engi- Gerald A. Knorovsky has worked on chapters for AWS Handbook and ASM neer in Virginia and Ohio, and a recog- the selection of materials and processes International publications. nized expert in the field of joining alu- that optimize joining technology using arc minum and structural steel. He has served and laser beam welding. Dr. Knorovsky David J. Nangle, with The Lincoln on the Aluminum Association Welding pioneered the use of unique characteri- Electric Co. since 1979, has served as a Committee, presented seminars, and pub- zation and diagnostic methods for small- technical sales representative, district lished papers in the Welding Journal, and scale joining processes to achieve a bet- manager, and as distributor sales man- holds a U.S. patent for Apparatus for and ter understanding of the process physics ager responsible for the company's chan- Method of Joining Stranded Cable. A weld- and of micro and nano joining processes. nels of distribution throughout North ing engineering graduate of The Ohio He is a recognized expert in the many America. In 1999, he was named presi- State University, Rager has contributed joining processes used by the DOE com- dent of Harris Calorific, and in 2005, he his skills to many AWS technical commit- plex for manufacturing weapons, includ- additionally became president of J. W tees, chairing the Dl.l Structural Weld- ing solid-state and fusion welding Harris Co. These two companies merged ing Committee, and serving on the Tech- processes as well as brazing and solder- into the Harris Products Group, a Lin- nical Activities Committee, D1C Sub- ing. He has published widely and received coln Electric subsidiary, where he serves committee 3 on Fabrication (22 years), numerous awards. He has served as a as president and CEO. He is vice presi- DIG Subcommittee 7 on Aluminum member of the AWS C6 Committee on dent and group president for The Lincoln Structures (28 years), DIB Subcommit- Friction Welding since the early 1990s, Electric Co. and president of Welding tee 2 on Qualification (25 years), ex-offi- and served many years as a principal re- Cutting Tools and Accessories, LLC, the cio member of the B2 Committee on Pro- viewer for the Welding Journal. Cleveland-based retail division of Lincoln cedure and Performance Qualification, Electric. Nangle served on the AWS and is a past member of the Welding 2008 Class of Counselors board of directors from 1992 to 1996, was Handbook Committee. Charles E. Daily has served the weld- a member of the Finance Committee ing industry for more than 65 years. He from 1996 to 2004, and served on several Kenneth E. Richter Sr., an AWS Life served in the military during World War committees for the Gases and Welding Member, is a past chairman of the AWS II and the Korean War. After leaving the Distribution Association. San Francisco Section, AWS Educational

FEBRUARY 2009 Stephen Liu Peng-Sheng Wei William L. Harris Dale H. Lange ToddA. Palmer

Activities Committee, and an ASM Inter- sity in Taiwan before taking his present building industries. He is an AWS Certi- national committee, and is a Paul Harris position. His graduate students special- fied Welding Inspector and an AWS Cer- Fellow of Rotary International. He began ize in the advancement of electron beam, tified Welding Educator. He is the owner his career as a high school welding in- laser beam, and resistance welding proj- of D. L. Welding Consultant Firm where structor, then worked 28 years as a prod- ects. He has published more than 50 pa- he works on welding procedures, produc- uct and process development engineer for pers on welding-related topics. tion process analysis, troubleshooting, the Linde division of Union Carbide and materials testing. His recognitions in- Corp. Later, at NuWeld and the MCI di- Howard E. Adkins Memorial clude the NWTC Outstanding Teacher vision of Diametrics, he made major in- Instructor Membership Award Award, NWTC Faculty Association novative contributions to the develop- William L. Harris, senior welding in- Teaching Award, the Marinette Area ment of welding automation. As presi- structor at Mississippi Gulf Coast Com- Chamber of Commerce Educator of the dent of Kemppi Inc., he introduced in- munity College, has taught welding for Year Award, and the Catholic Central verter power supplies for OTA and GMA more than 31 years. He established the High School Foundation Touchey Award. welding to the U.S. market, and at Aztec college's AWS Student Chapter where he International Engineering Technology he has served as faculty advisor for the past Robert J. Conkling was instrumental in the design and man- 28 years. An AWS member for 30 years, Memorial Award ufacture of an automatic GTA welding he currently serves as chair of the AWS 2008 SkillsUSA Championships Gold system. Currently, Richter is president of Pascagoula Section, is an AWS Certified Medalist Schools Richter Industries, Inc., in Scottsdale, Welding Inspector (CWI), and has been First Place — High School Ariz. a Certified Welding Educator. He re- Niagara Public Schools, Niagara, Wis. ceived his associate degree in welding First Place — Postsecondary Comfort A. Adams technology and master instructor certifi- College of Eastern Utah, Price, Utah Lecture Award cation at the college. Harris was part of Welding in the Deep Oceans: the Mississippi State Department of Ed- A. F. Davis Conquest of the Other Frontier! ucation welding team that developed the Silver Medal Award Stephen K. C. Liu, an AWS Fellow and first model curriculum for postsecondary Machine Design a Distinguished Member, is a professor welding in the state. He was a consultant Transferring Electron Beam Welding of metallurgical and materials engineer- for the Mississippi State Research and Parameters Using the Enhanced Modified ing at Colorado School of Mines where Curriculum Unit that produced a manual Faraday Cup he received his PhD in metallurgical en- used to train students in the gas tungsten Todd A. Palmer earned his PhD in ma- gineering. Before joining the faculty in arc welding process, and is involved with terials science and engineering (1999) 1987, Liu was a research metallurgist at Web-enhanced welding education utiliz- from Pennsylvania State University. Since ACESITA steel mill in Brazil and an as- ing Blackboard and D2L platforms for 2007, he has been at the Applied Re- sistant professor in industrial and manu- posting assignments, welding instruction, search Laboratory at Pennsylvania State facturing engineering at Pennsylvania and online exams. The students need only University where he is a research associ- State University. He has received AWS attend the lab for hands-on skills train- ate and an assistant professor in the De- citations including the Adams Memorial ing. He also developed a two-day Certi- partment of Materials Science and Engi- Membership Award, McKay-Helm fied Welding Inspector training seminar neering. For the previous seven years, he Award, Robert L. Peaslee Brazing and a CWI training manual with instruc- was at Lawrence Livermore National Award, Honorary Membership Award, tion provided in the CD format. Harris Laboratory, Livermore, Calif., where he and Plummer Education Lecture Award. has received several citations, including was a metallurgist with the Materials Sci- He is a Fellow of ASME and ASM Inter- Section Educator, Section Meritorious, ence and Technology division in the national and chosen for the SAE Teetor and CWI of the Year Awards. Chemistry, Materials, and Life Sciences Educational Award in 1986. Currently, Directorate. He is currently chair of the Liu chairs the AWS Technical Papers Dale H. Lange joined the Northeast C7B Subcommittee on Electron Beam Committee and is a member of the Chap- Wisconsin Technical College in Welding and Cutting, vice chair of the C7 ter Council of ASM International. Marinette, Wis., as a full-time welding in- Committee on High Energy Beam Weld- structor in 1980, and received his MS in ing and Cutting, and is a member of the Adams Memorial vocational education in 1984 from the Welding Research and Development Membership Award University of Wisconsin — Stout. He Committee. He is also a member of the Peng-Sheng Wei, an AWS Fellow and works with local industries setting up spe- peer review panel for the Welding Jour- a Fellow of ASME, is a full professor at cial courses and updating the college cur- nal, the editorial board for Science and the University of California at Davis riculum to meet their needs. Lange is a Technology of Welding and Joining, and a where he received his PhD in mechanical qualified structural and pipe welder who key reader for Metallurgical and Materi- engineering. He taught engineering has worked for a variety of industrial man- als Transactions. Palmer has received the courses at National Suyn Yat-Sen Univer- ufacturers in the pressure vessel and ship- A. F Davis Silver Medal Award, Koichi

WELDING JOURNAL Kenneth D. Nicklas T. M. Mustaleski Jr. Michael H. Tosten Scott L. West William R. Kanne Jr. Benjamin J. Cross

Masubuchi Award, and William Sprara- Technical Services, Y-12 LLC, where he tions, and solid-state and fusion welding gen Memorial Award from the American currently is a research staff member in the of tritium-containment materials. Welding Society, the Geoffrey Belton Applied Technologies Division. Nicklas Award of The Iron and Steel Society, and works in the areas of welding metallurgy Scott L. West is a senior fellow engi- the ASM International Graduate Student and process and procedure development. neer in the Defense Programs Technology Paper Competition. From June 1995 to He has received several DOE Awards of Section of the Savannah River National June 1998, he received an American Excellence for quality improvements and Laboratory, with responsibility for evalu- Welding Society Graduate Research Fel- technical achievements. He served two ating the service behavior of weldments lowship. He has authored more than 40 terms as chairman of the AWS Northeast used for storage and transport of nuclear articles and reports. His current research Tennessee Section, and has been the Sec- materials. For 21 years, he has worked on interests involve the characterization of tion's treasurer since 1994. welding process applications and equip- phase transformations in structural ma- ment development, welding metallurgy, terials using synchrotron-based in situ Thomas M. Mustaleski Jr., an AWS weld simulation, failure analysis of welded X-ray diffraction techniques, and high- Fellow and Life Member, received his components, residual stresses in weld- energy-density electron and laser beam metallurgical engineering degree from ments, with responsibility for developing welding and joining processes. Rensselaer Polytechnic Institute with procedures and specifications for control graduate work at the University of Wis- of welding. Earlier, he worked for West- John W. Elmer, an AWS Fellow, joined consin and the University of Tennessee. inghouse Electric Corp. involved in the Lawrence Livermore National Labora- Currently, he is chairman of the Ameri- development of tube-to-tubesheet welds tory (LLNL) in 1982 where he is currently can Council of the International Institute for breeder reactor steam generators, the group leader for materials and join- of Welding (IIW). He also chairs the IIW working mainly with chromium-molybde- ing. He received his ScD in metallurgy Select Committee on Welding for Aircraft num steels. He received his PhD from The from Massachusetts Institute of Technol- and Aerospace Applications. He has Ohio State University where his graduate ogy in 1989. Elmer is primarily concerned served as the U.S. delegate to IIW Com- work focused on monitoring and control with joining using electron and laser mission V, vice delegate to Commission of resistance spot welding and weldability beams, arc welding, vacuum brazing, sol- IV, and as lead U.S. representative to SC of cast nickel-based superalloys. He has dering, and bonding. He has au- AIR. He also serves as a representative to received the AWS Charles H. Jennings thored more than 120 technical papers on SC QUAL. Mustaleski served two terms Memorial Award. topics relating to in-situ observations of as an AWS director-at-large, three terms welds using synchrotron radiation, mate- as a vice president, AWS president (2003- William R. Kanne Jr., recently retired, rials joining, metallurgy, rapid solidifica- 2004), and various officer posts for the worked 36 years at the Savannah River tion, high-energy-density beam-material Milwaukee and Northeast Tennessee Sec- National Laboratory where he held lead- interactions, electron beam diagnostics, tions. He recently retired from BWSXT ership roles in the technology areas of explosive welding, and the kinetics of Y12, Oak Ridge, Tenn., where he worked solid-state resistance welding, and weld- phase transformations. He is a Fellow of since 1974. There, he was involved in weld- ing irradiated stainless steel and iridium ASM International, a registered Profes- ing metallurgy and process and procedure alloys. His earlier work concerned physi- sional Engineer, and holds ten U.S. development. cal metallurgy, compatibility of radioiso- patents. His awards include the Comfort topes with high-temperature alloys, liquid A. Adam's Lecture, William Spraragen Maintenance and Surfacing metal corrosion, and creep and disloca- Award, Prof. Masubuchi-Shinsho Corpo- Repair Techniques for tion structures in intermetallic com- ration Award, A. F Davis Silver Medal Fusion Reactor Applications pounds. Kanne received his PhD in met- Award, Warren F Savage Memorial Michael H. Tosten received his PhD in allurgy from the University of Wisconsin. Award, and Samuel Wylie Miller Memo- metals science and engineering from A Fellow of ASM International, he has rial Medal Award. He currently serves on Pennsylvania State University in 1988. He filled leadership roles locally and nation- many committees for AWS and ASM In- has been with the Savannah River Site for ally. He was a vice president and board ternational, and is an adjunct professor at more than 20 years where he is a princi- member of the International Metallo- the Pennsylvania State University. pal scientist in the Materials Science and graphic Society (IMS), and a member of Technology Directorate at the Savannah the American Welding Society for more Kenneth D. Nicklas received his BS de- River National Laboratory. Tosten has than 30 years where he served as a Prin- gree in metallurgical and materials engi- more than 27 years of experience with cipal Reviewer on the Technical Papers neering from the University of Pittsburgh, transmission electron microscopy. He has Committee. He has been awarded one followed by graduate studies at the Uni- published papers regarding phase trans- patent, published 30 papers, and received versity of Tennessee. Since 1980, he has formations, hydrogen and helium effects best paper awards from AWS and IMS. been employed at the Y-12 National Se- in stainless steels, phase separation and Twice he was cited to receive the Westing- curity Complex of Babcock and Wilcox radiolysis of nuclear waste glass formula- house Signature Award of Excellence.

FEBRUARY 2009 Stephen W. Banovic Thomas A. Siewert Dongcheol Kim TaeHyungKim Young Whan Park

Benjamin J. Cross holds a PhD in in- gation, Banovic was awarded the Depart- W. H. Hobart ternational business administration. He ment of Commerce Gold Medal for Sci- Memorial Award is a registered Professional Engineer in entific/Engineering Achievement in 2005. Estimation of Weld Quality in High- the state of Colorado, and he has 26 years Frequency Electric Resistance Welding of experience, including nuclear propul- Thomas A. Siewert, an AWS Distin- with Image Processing sion for the U.S. Navy, commercial nu- guished Member and a Life Member, Dongcheol Kim received his PhD de- clear power generation, nuclear weapons leads the Structural Materials Group of gree in welding engineering from the materials production, fission and fusion the Materials Reliability Div. at the Na- Hanyang University, Seoul, Korea, in research and development, and interna- tional Institute of Standards and Tech- 2000. From 2000 to 2002, he worked for tional nuclear nonproliferation. Cur- nology (NIST), Boulder, Colo. For 25 Research Institute of Industrial Science rently, Cross is the manager of the nu- years, his group has studied reliability is- & Technology, Pohang, Korea, as a weld- clear energy programs at Savannah River sues in the national infrastructure, ing researcher for weld quality monitor- National Laboratory, where he is con- pipelines, and buildings, including the ing and optimization of flash butt, high- cerned with fission and fusion research collapse of the World Trade Center tow- frequency resistance, and gas metal arc and development, and nuclear energy- ers. Currently, his group is studying safety welding processes. From 2002 to 2007, he related technical support activities. He issues affecting steel bridges and worked for Shipbuilding & Plant R&D has published several technical and man- pipelines carrying gas, oil, ethanol, and Institute, Samsung Heavy Industries agerial articles in peer-reviewed journals. hydrogen. After receiving his PhD from Company, Geoje, Korea. As a welding He is actively involved in the American the University of Wisconsin in 1976, he engineer he was involved in many weld- Nuclear Society, and is a member of the worked at Alloy Rods as a researcher ing projects including shipbuilding, con- American Society of Mechanical Engi- until joining NIST in 1984. He has chaired struction of bridges, and offshore struc- neers, Institute of Nuclear Materials the American Council of the IIW, is a Peer tures. His welding research includes the Management, Fusion Power Associates, Reviewer for Welding Journal, and con- development and application of tandem and Citizens for Nuclear Technology tributed to Welding Handbook. In the electrogas welding systems and the de- Awareness. early 1980s, he served as chairman of the velopment of automatic welding systems AWS York-Central Pennsylvania Section, for the New Tacoma Narrows Bridge proj- Structure Design and currently is an AWS director-at-large. ect. In 2007, Kim joined the Korean In- Failure of Welded Floor Truss stitute of Industrial Technology Connections from the Exterior Wall during Dalton E. Hamilton Memorial (KITECH) as a senior researcher. His Collapse of the World Trade Center Towers CW! of the Year Award work focuses on the monitoring and the Stephen W. Banovic received his PhD Joseph Kane, an AWS Distinguished control of resistance spot, resistance lap in materials science and engineering from Member active in the Long Island Sec- seam, high-frequency resistance, flash Lehigh University in 1999. His disserta- tion, has worked for more than 30 years butt, and arc welding processes. He has tion focused on the weldability and high- in the welding industry. As an AWS Sen- published numerous papers on welding temperature corrosion resistance of iron- ior CWI, Kane has worked as a QC and parameter optimization and weld quality aluminum weld overlay coatings. In 2000, QA inspector, and welding consultant. monitoring and control. Two papers have he was awarded a National Research He has inspected bridge fabrications, gas appeared in the Welding Journal. Council Postdoctoral Fellowship at Na- pipelines, structural steel projects, high- tional Institute of Standards and Tech- way and indoor signage, aircraft compo- Tae Hyung Kim received his PhD de- nology (NIST) to study the influence of nents, floating boom structures, and gree in mechanical engineering from microstructural variables on sheet metal boiler installations. Most recently, Kane Hanyang University, Seoul, Korea, in formability. In 2002, he became a full- served as a QA inspector for the Free- 2006. From 2006 to 2007, he conducted time materials research scientist in the dom Tower in the new World Trade Cen- his postdoctoral research at the univer- Metallurgy Division. His current research ter construction project in New York City. sity in spot welding, and machine and focuses on the fundamental linkages be- A member of the AWS Certification quality monitoring. Kim has published tween microstructure and the mechani- Committee since 1977, he is chairman of several papers on the subjects of spot cal response of advanced lightweight ma- the Structural Inspector Subcommittee, welding, quality monitoring, and control terials for automotive applications and and the Dalton E. Hamilton CWI of the using artificial intelligence. innovative ballistic materials. His other Year Selection Subcommittee. He also interests include microstructural charac- serves on the Ethics Subcommittee, CWI Young Whan Park received his PhD terization, measurement of crystallo- Plus Subcommittee, Welding Engineer degree in welding and artificial intelli- graphic texture of thin film and bulk ma- Subcommittee, QC-1 Subcommittee, and gence from Hanyang University, Seoul, terials, and failure analysis. He has pub- other certification task groups. He served Korea, in 2006. Currently, he is a re- lished more than 40 papers. For his role on the AWS board of directors as District searcher with the Pohang Iron & Steel in the NIST World Trade Center investi- 2 director from 1992 to 1998. Co., Pohang, South Korea. His research

WELDING JOURNAL e\

Munjin Kang Choong-Myeong Kim Chul-Ku Lee Sehun Rhee Cipriani Davis Chon-Liang Tsai

includes welding process simulation and ing engineering research for 23 years and site engineer. Since 1990, he has been with optimization for automotive steel appli- is currently taking doctorial studies at the Metal Industries Co. Ltd., Trinidad cations in resistance spot welding, and Hanyang University, Seoul, Korea. His ca- and Tabago, West Indies. In 2005, he be- laser welding using artificial intelligence reer has been devoted to the field of arc came CEO and continues to serve as an algorithms. He has published papers on welding and electric resistance welding of instructor, training coordinator, and gen- the subject in various scientific journals. carbon steels for shipbuilding, pipeline, eral manager of the Training Division. and steel structures. He also specializes Davis, a Certified Welding Inspector, is Kieun Sung received his PhD in me- in fracture analysis of welded joints. chairman of the AWS Trinidad and To- chanical engineering from Hanyang Uni- bago International Section. versity, Seoul, Korea, in 2008. Currently, Chul-Ku Lee received his PhD in me- he is with the university's Research Insti- chanical engineering from Hanyang Uni- John W. Elmer. See biography under tute of Industrial Science. His research in- versity, Seoul, Korea. For more than 30 A. F Davis Silver Medal Award. terests include microfabrication joining years, he has been in welding engineering applications and its processes. From 2002 research and education and is currently International Meritorious to 2005, he was a military researcher at teaching at Seoul National University of Certificate Award the university where he carried out many Technology. He is also a visiting profes- Cipriani Davis. His biography appears projects for the development of welding sor at the The Ohio State University and under Honorary Membership Award. automation systems using laser vision sen- the University of Central Florida. His re- sors. Sung has developed special laser vi- search areas include welding process de- Chon-Liang Tsai, an AWS Fellow, is a sion sensors for nuclear reactor repair sys- velopment, , solid- full professor in the welding engineering tems and published several papers in var- state welding, and laser beam welding. program at The Ohio State University. He ious research and scientific journals. Lee is an active member of the Korean holds a PhD from Massachusetts Institute Welding Society and has served on its of Technology. He has worked in welding Munjin Kang has more than 20 years board of directors. engineering research and education for of experience in welding engineering, about 30 years, and has published more welding system development, weld quality Sehun Rhee received his PhD in me- than 150 technical papers in various peer- monitoring, and automation practice and chanical engineering from the University reviewed journals and conference pro- research. He received his PhD in welding of Michigan in 1990. Since 1994, he has ceedings. He is best known for his accom- engineering from the Hanyang University, served as a professor at Hanyang Univer- plishments in applying advanced com- Seoul, Korea, in 2000. Currently, Kang is sity. His research focus has been on weld- puter technologies to develop solutions a director of the Industrial Technology ing monitoring systems using neural net- for structural applications, and his inno- Center at the Korean Institute of Indus- works, fuzzy logic, and spot and laser weld- vative modeling techniques for the analy- trial Technology (KITECH). His research ing for automotive applications. Rhee's sis of welding-induced residual stresses focuses on arc and resistance spot welding recent research projects have involved ad- and distortion. Tsai founded the Welding system developments, monitoring and hesive bonding, microjoining for MEMS, Society of the Republic of China (Taiwan) control of high-frequency resistance weld- and electronic and macroscale joining in 1987, the International Welding Tech- ing processes, and flash butt welding processes. His publications have appeared nology Research Laboratory in Taiwan in processes. Prior to joining KITECH in in a number of research journals. 1994, and the AWS Taiwan Section in 2003, he worked for the Research Institute 1995. Recently, he helped to establish the of Industrial Science & Technology (1986- Honorary Membership Award AWS Korean International Section. 2003), Pohang, Korea, as a welding re- Cipriani Davis received his MS in searcher for the development of mesh training and performance management William Irrgang Memorial Award seam welding systems, development of from Leicester University, UK, in 2008. John W. Elmer. See biography under flash butt welding systems, weld quality In 1973, he worked with the Caribbean In- A. F Davis Silver Medal Award. monitoring of high-frequency resistance dustrial Research Institute as a senior ma- welding, and the development of inverter chinist, and in 1978, served as a technical Charles H. Jennings arc welding systems. Many of his papers vocational teacher at John S. Donaldson Memorial Award have been published in various research Technical Institute in Port of Spain, The Discontinuous Weld Bead Defect in journals, including the Welding Journal Trinidad. In 1986, he taught at San Fer- High-Speed Gas Metal Arc Welds nando Technical Institute in California. Tam C. Nguyen is a member of the Choong-Myeong Kim is a principal re- Davis returned to Trinidad where, from welding, joining, and engineering faculty searcher with the Joining Research 1987 to 1989, he was with Damns Williams at Conestoga Polytechnic. He received his Group, Technical Research Laboratories Aimes, Ltd. At Caribbean Tyre Co. he PhD in mechanical engineering from the of the Pohang Iron and Steel Co., Pohang, served as senior extrusion technician, and University of Waterloo in 2005. Prior to South Korea. He has been active in weld- at Caribbean Research Institute he was his PhD work, he served as a product de-

FEBRUARY 2009 Tarn C. Nguyen David C. Weckman David A. Johnson Muralidhar Tumuluru Min Hyun Cho David F. Parson velopment and welding engineer at Cen- using experimental and numerical mod- using numerical simulation as a tool for terline (Windsor) Ltd. Nguyen's research eling approaches. welding process optimization. focuses on welding process optimization to provide higher welding speeds. Nguyen has James F. Lincoln David F. Farson has more than 30 been awarded one patent, coauthored five Gold Medal Award years of experience in the welding engi- peer-reviewed papers, and made several The Effect of Coatings on the neering and laser materials processing technical presentations. During his studies, Resistance Spot Welding Behavior field. He received his PhD in electrical he received numerous awards and scholar- of780MPa Dual-Phase Steel engineering from The Ohio State Uni- ships including Natural Science and Engi- Muralidhar Tumuluru received his versity where he currently is a faculty neering Research Council Postgraduate degrees in materials and welding engi- member in the Industrial and Systems En- Scholarships, Paul Niessen-Cominco neering from Rensselaer Polytechnic In- gineering Dept. teaching laser materials Medal for Excellence in Materials Experi- stitute and The Ohio State University. He processing and manufacturing process mentation, Alumni Outstanding Academic has 27 years of experience in welding, of automation and control. He worked at Achievement Award, and the Sandford which he has worked the last 11 years at Westinghouse Electric R&D Center and Fleming Foundation Silver Medal. the U.S. Steel Research and Technology Penn State University Applied Research Center. The main focus of his research Laboratory where he served as deputy David C. Weckman received his PhD has been to characterize the joining be- head of the Laser Processing Dept. and in mechanical engineering from the Uni- havior of advanced high-strength steels a graduate faculty member. He has au- versity of Waterloo, Canada. He joined developed for automotive applications. thored more than 115 papers, and is a rec- the university's Materials Engineering He has lectured widely and authored nu- ognized expert in his field. Farson has and Processing group faculty where he merous publications on the subject. He served as president of Laser Institute of teaches materials science and engineer- teaches welding technology for U.S. America where he was elected a Fellow ing, solid body mechanics, welding Steel's internal training program and has in 1997. He coedited the Handbook of processes, and welding design. He has conducted presentations for welding per- Laser Materials Processing reference conducted research on the joining of a sonnel at various automotive companies book, and serves as associate editor of the wide range of alloys using laser welding, on the joining aspects of advanced high- UA Journal of Laser Applications. Addi- friction welding, and various arc welding strength steels. Prior to joining U.S. Steel, tionally, he serves on the AWS Awards, processes employing thermomechanical he worked for Westinghouse Electric Technical Papers, Research, and Confer- and thermofluids numerical modeling Corp. and Spang & Co. Tumuluru has ence Committees. and experimental techniques. His current been an AWS member since 1980. He is research includes high-speed welding of a member of the AWS A5 Committee on Prof. Kolchl Masubuchl Award aluminum alloys using lasers and various Filler Metals and Allied Materials, AC02 Manabu Tanaka received his PhD de- arc welding processes, and gas metal arc Commission II on Arc Welding, and gree in welding engineering from Osaka welding of advanced high-strength steels. D14H Subcommittee on the Surfacing of University, Osaka, Japan, in 2000. Since He has received the Charles H. Jennings Industrial Rolls. He serves as vice chair 1992, he has been with the university as Memorial Award and the A. F Davis Sil- of the D8 Committee on Automotive a research associate in the Joining and ver Medal Award. He currently serves on Welding, and chairs the task group up- Welding Research Institute, and currently the editorial board of Science and Tech- dating D8.9, Recommended Practices for is teaching as a professor. His major fo- nology of Welding and Joining and is a Test Methods for Evaluating the Resistance cuses of study have been in the physics of member of the AWS Welding Research Spot Welding Behavior of Automotive Sheet welding, including plasma diagnostics, and Development Committee. Steel Materials. electrode phenomena, and numerical modeling. His current research concerns David A. Johnson received his PhD McKay-Helm Award the evolution of the unified numerical degree in mechanical engineering from Simulation Study of a Hybrid Process simulations from gas tungsten arc to gas McMaster University, Canada, in 1994. for the Prevention of metal arc in order to clearly understand In 1997, he joined the Fluid Mechanics Weld Bead Hump Formation the physical behavior of the gas metal arc group faculty within the Department of Min Hyun Cho received his PhD de- welding process. Tanaka has authored Mechanical Engineering at the Univer- gree in welding engineering from The more than 80 publications. He is the re- sity of Waterloo. Johnson teaches fluid Ohio State University in 2006. His post- cipient of many citations from the Japan mechanics, experimental design and doctoral research work focuses on laser Welding Society including the Best Paper measurements, and rotating machinery. conduction mode welding simulation Award for Encouragement, the Best Pres- He has conducted research on the fluid sponsored by Los Alamos National Lab- entation Award, Physics of Welding mechanic aspects of gas metal arc weld- oratory. He studies welding processes and Award, the Best Author Award, and the ing processes, turbulent jet studies, and the analysis of welding defects, such as Kihara Prize from the Association for numerous studies of turbomachinery hump formation, incomplete fusion, etc.. Weld Joining Technology Promotion.

WELDING JOURNAL Omer W. Blodgett Claudia B. Bottenfield Phillip D. Winslow David R. Sigler James G. Schroth

Samuel Wylie Miller two terms. Currently, she is an associate Memorial Medal Award trustee for the AWS Foundation, Inc., Omer W. Blodgett, an AWS Fellow, re- where she has cochaired the silent auc- ceived his ME degree from the University tions held during the FABTECH Interna- of Minnesota, and an honorary Doctor of tional & AWS Welding Shows. Bottenfield Science degree from LeTourneau Univer- is also involved in SkillsUSA, the Occu- sity where the Omer Blodgett Endowed pation Advisory Committee, York County Chair of Welding and Materials Joining School of Technology, the Weld Shop An- Engineering has been established in his nual Car Show Committee, Women in honor. He was welding superintendent Construction, and various educational ca- with the Globe Shipbuilding Co. in Supe- reer advisory boards. Yar-Ming Wang Dusanka Radovic rior, Wis., from 1941 to 1945. Since 1945, he has served as senior design consultant Phillip D. Winslow has worked for standing the fatigue behavior of high- at The Lincoln Electric Co. He has been more than 40 years in the sales and mar- strength aluminum alloys and nondestruc- a lecturer at Lincoln Electric's machine keting management areas of the welding tively evaluating fatigue damage using and structural design seminars and has industry. He received his degree in busi- laser interferometry. At GM, he has been frequently spoken on welded design at ness management from the University of a member of the R&D Center for 26 years. AWS Sections and national meetings. New Hampshire in 1964, and continued His major research activities have in- Blodgett has conducted his structural de- advanced studies in marketing at Dart- cluded the development of stainless steel sign seminars all over the world. He is an mouth College and the University of materials for catalytic converters, joining advisory member of the AWS Structural Southern New Hampshire. From 1964 to of advanced lightweight materials for body Welding Committee, and was active on 1968, he served as a captain in the United structures, and development of manufac- the AISC Committee on Specifications States Air Force. In 1968, he joined turing processes for fuel cells. He cur- and the Welding Research Council's Task Uniroyal, Inc., first as a sales representa- rently holds nine patents and has authored Group on Beam to Column Connections. tive then regional sales manager, and a 23 publications. Blodgett received the AWS A. E Davis product manager. In 1974, he joined the Silver Medal Award for his work in struc- Nashua Corp. in managerial positions. In James G. Schroth received his PhD in tural design. In 1968, he was the lecturer 1988, he joined Markem Corp. as a divi- metallurgical engineering from The Ohio for the Educational Lecture Series at the sion manager. In 1991, he left to work for State University. Joining General Motors AWS Annual Meeting. He received the Aavid Thermal Technology, a supplier of in 1985, he currently is a Technical Fellow AWS Honorary Membership Award, Sil- thermal management components, serv- and lab group manager in the Materials ver Quill Editorial Achievement Award, ing as vice president of worldwide sales and Processes Lab of General Motors R and the T R. Higgins Lectureship Award and marketing. He joined Hypertherm, & D Center, where he oversees technol- from AISC. Blodgett has authored nu- Inc., in 1992, where he worked until his ogy innovations in sheet metal forming merous articles and handbooks including retirement in 2007. During this time, he and interfacial phenomena. His research Design ofWeldments and Design of Welded served variously as vice president of its interests include physical and mechanical Structures. He is a licensed Professional North American, European, and Asian metallurgy of advanced high-strength Engineer in the state of Ohio and named marketing and sales divisions. Through- steels and frictional aspects of aluminum a Fellow of ASCE, and ASME. out his career, Winslow has served as chair sheet forming at elevated temperatures. of the Welding Equipment Manufactur- He has extensive experience with automo- National Meritorious Award ers Committee and a consultant to the tive applications of steels, stainless steels, Claudia B. Bottenfield is sales and U.S. Department of Commerce on ex- aluminum, and copper alloys in various marketing manager with Dressel Welding porting of capital goods. forms. Schroth, who holds 18 patents, is Supply, Inc. in Lancaster, Pa. Prior to join- an expert on sheet steels for both body ing the company, she was with Arc Welder Robert L. Peaslee and power-train applications, and for hot Group, Baltimore, Md., for 28 years. A Brazing Award aluminum-forming and brazing technol- graduate of the Business College of Mary- Sulfide-Induced Corrosion of Copper- ogy. He has developed a family of mi- land, she has taken many courses offered Silver-Phosphorus Brazed Joints in croalloyed steels specifically for copper- by United Abrasive, Lincoln Electric, Vic- Welding Transformers brazed power-train applications. tor, Harris Calorific, Arcair, and others. David R. Sigler joined General Motors Bottenfield has been an active member of Research Laboratory in 1982 after receiv- Yar-Ming Wang received his PhD in AWS since 1983. She has held various of- ing his PhD in metallurgical engineering metallurgical engineering from the Mis- ficer positions in the Maryland, Lancaster, from Wayne State University. As a Na- souri University of Science and Technol- and York-Central Pennsylvania Sections, tional Science Foundation Fellow at ogy. In 1977, he worked as a research as- and has served as District 3 director for WSU, his research focused on under- sistant professor at the university and as

FEBRUARY 2009 Thomas W. Eagar Susan R. Fiore

a research scientist at Sprague Electric and Technology of Welding andloining and the Korean government. In 2005, he re- Co. For more than 29 years he has been is a Principal Reviewer for the Welding turned to the university where he cur- with General Motors where he is cur- loumal. He has published more than 200 rently is completing work on his PhD. rently a staff researcher in the Materials papers and holds 13 patents. Yang's current research interests include and Processes Laboratory at the R&D macrosegregation during arc welding, Center. His areas of research include bat- Safety and Heaith Award friction stir welding of aluminum and tery development for electric and hybrid Susan R. Fiore received her M.S. de- magnesium alloys, and hot tearing of vehicles, coating technology (anodiza- gree in materials engineering from Rens- creep-resistant magnesium-alloy cast- tion, conversion coatings, plasma CVD, selaer Polytechnic Institute. She began ings. His thesis will focus on macrosegre- and plating), automotive corrosion pro- her career in welding consumable devel- gation in arc welding caused by dissimi- tection, and corrosion testing methods. opment at The Lincoln Electric Co. In lar filler metals. He has contributed to Wang, who holds ten U.S. patents, has au- 1988, she joined L-TEC Welding and Cut- numerous papers on topics relating to thored more than 30 technical papers. In ting Products, which later became part of macrosegregation in arc welding and fric- 2004, he received the Abner Brenner the ESAB Group. At ESAB, she was re- tion stir welding of magnesium and alu- Award from The American Electro- sponsible for consumable development, minum alloys. platers and Surface Finishers Society. hazard communication, and technical service. She specialized in developing Sindo Kou, an AWS Fellow, received Dusanka Radovic received her mas- high-strength steel alloys. In 2000, she his PhD in materials science and engi- ter's in chemical engineering from Wayne joined Edison Welding Institute. As a sen- neering from the Massachusetts Institute State University. Radovic has worked 30 ior engineer in the Engineering and Ma- of Technology. He worked at General years in the General Motors R&D De- terials Group, she worked on weldability Motors Research Laboratory in 1978, and partment. Her studies focus on electro- studies, failure analyses, and consum- as an associate professor at Carnegie- chemical research and corrosion. ables optimization programs. She re- Mellon University from 1979 tol983. In cently joined EWI's Program Manage- 1983, Kou joined the University of Wis- Plummer Memorial ment Office as a project manager. In her consin-Madison where he became a full Education Lecture Award current position, Fiore manages a wide professor in 1985. He is currently chair Why Is Welding Important? range of research and development proj- of the Department of Materials Science Thomas W. Eagar, an AWS Fellow, re- ects for both commercial and government and Engineering. He has authored two ceived his ScD from Massachusetts Insti- entities. Fiore has been an AWS member texts. Welding Metallurgy and Transport tute of Technology (MIT) in 1975. Fol- for more than 25 years. She is a member Phenomena and Materials Processing. Kou lowing graduation, he worked for Beth- of the AWS Safety and Health Commit- has received numerous honors including lehem Steel Corp. Homer Research Lab- tee, where she served as chair from 1999 the John Chipman Award from Iron and oratories briefly, then returned to MIT to 2005. She has also served on the SH-1 Steel Society of AIME, Adams Memorial as a faculty member where he currently and SH-4 subcommittees as well as the Membership Award, ASM International is professor of materials engineering and ANSI Z49 committee. She has presented Fellow status (1998), Chancellors' Award engineering systems. In 1995, he was ap- talks on the OSHA hexavalent chromium for Distinguished Teaching from the Uni- pointed and served for five years as head standard at numerous venues. Her arti- versity of Wisconsin, Benjamin Smith of the Department of Materials Science cles, "Reducing Exposure to Hexavalent Reynolds Award for Excellence in Teach- and Engineering. Among his numerous Chromium in Welding Fumes," and ing from the College of Engineering, Uni- citations, Eagar received the Adams Me- "Choosing the Proper Self-Shielded versity of Wisconsin, Charles H. Jennings morial Membership Award, Comfort A. FCAW Wire," were published in the Memorial Award, Warren F Savage Me- Adams Lecture Award, Charles H. Jen- Welding loumal. morial Award, and William Spraragen nings Memorial Medal Award, Cham- Memorial Award. pion H. Mathewson Gold Medal of Warren F. Savage AIME, Warren F Savage Award, William Memoriai Award Siiver Quiii Spraragen Memorial Award, William Ir- Weld-Bottom Macrosegregation Editorial Achievement Award rgang Award, Silver Quill Award, and the Caused by Dissimilar Filler Metals Welding — Binding Ancient Technology Henry Marion Howe Medal of ASM In- Youngki Yang received his MS degree to Modem Life on The History Channel ternational. Eagar was elected an ASM in metallurgical engineering from Seoul Gloria Morris and Philip Kruener Fellow and an AAAS Fellow. In 1997, he National University in 1997. In 1999, he have written and produced more than 80 was elected a member of the National entered the University of Wisconsin ma- hours of award-winning television, docu- Academy of Engineering. In June 2003, terials science and engineering PhD pro- mentary, and corporate programming. he testified before Congress on manufac- gram. From 2003 to 2004, he took part in Their documentary work can be seen reg- turing employment in the United States. an educational program on international ularly on The History Channel and the He is on the editorial board of Science businesses sponsored and organized by Discovery Channel.

WELDING JOURNAL ^ Matthew J. Perricone John N. DuPont Arnold R. Murder Ernest D. Levert Sr. Robert White Sr.

William Spraragen component alloys. He has authored a ported included the Atlas Space Vehicle, Memorial Award number of papers that have been pub- Tomahawk Cruise Missile, Ground The Influence of Molybdenum on lished in peer-reviewed journals. Launched Cruise Missile, and the Space Stainless Steel Weld Microstructures Shuttle. Levert is president of the Feder- Timothy Anderson received his PhD in John N. DuPont. See the biography ation of Materials Societies, chairman of materials science and engineering from under the incoming class of Fellows. the IIW Commission IV, Power Beam Lehigh University in 2008. His graduate Processes, and serves as the U.S. Delegate research, conducted under the guidance Arnold R. Marder received his PhD in at the IIW annual assemblies. He served of John DuPont, focused on the weld re- metallurgy and materials science from as president of the American Welding So- pair of single-crystal nickel-based super- Lehigh University. Marder worked for ciety (2002-2003). Levert's many awards alloys. His other research interests fo- Curtiss-Wright Corp. from 1962 to 1965, include the Lockheed Martin MFC Pro- cused on solidification processes, includ- then served more than 20 years at the duction Technical Excellence Staff: Weld- ing microstructural development of Mo- Homer Research Laboratories of Bethle- ing Engineering and Materials Joining, bearing filler metals, solidification crack- hem Steel Corp. In 1986, he joined the Lockheed Martin NOVA Award for Out- ing studies, and thermodynamic model- Lehigh University faculty. Retired in 2007, standing Leadership, The OSU College ing of complex alloy systems. He has made he is currently an emeritus professor in of Engineering Distinguished Alumnus numerous conference presentations and the Department of Materials Science and Award, The OSU Minority Engineering published a number of papers on his proj- Engineering. Marder's research interests Program Excellence Award, NTA Techni- ects. Anderson received graduate re- include processing-structure-property re- cal Achiever Award, and was nominated search fellowships from AWS and the lationships of materials. In particular, his for the National Black Engineer of the Navy Joining Center. In 2006, he was research involved coatings and alloys for Year for Professional Achievements in awarded the IIW Granjon Prize in the Ma- ambient and high-temperature environ- Industry. terials Behavior category. Anderson is ments, including erosion, oxidation, and currently employed as a research engineer sulfidation. He has an ongoing interest in Eilhu Thomson at ExxonMobil Upstream Research Co. the physical metallurgy of steel and is still Resistance Welding Award active in research on weld overlay coating Robert White Sr. (awarded posthu- Matthew J. Perricone is a senior scien- of superalloys and iron aluminide inter- mously) dedicated more than 50 years to tist and project manager in the Technical metallics, and weldability studies of Cr- developing and building custom-made re- Consulting Services division at RJ Lee Mo steels. sistance welding machines. In 1960, he es- Group (RJLG) in Monroeville, Pa. Prior tablished the Janda Company where he to joining RJLG, he worked as a senior R. D. Thomas designed and built more than 3000 ma- member of the technical staff in the Join- Memorial Award chines for the U.S. government and the ing and Coatings division of Sandia Na- Ernest D. Levert Sr., an AWS past pres- aerospace, building, wire products, and tional Laboratories, where he received a ident, is an AWS Counselor, a Life Mem- sheet metal industries. He also designed 2007 Employee Recognition Award as ber, and Distinguished Member of the So- an array of resistance welding machines team leader of a project focused on laser ciety. He received his welding engineer- for manufacturing products as diverse as welding. He has worked as a materials sci- ing degree from The Ohio State Univer- multihead missile fins, meshes, floor pan- entist in governmental, academic, and in- sity (OSU). He joined Lockheed Martin els, elevators, wire baskets, shelves, racks, dustrial sectors with much of his techni- Missiles and Fire Control in Dallas, Tex., shopping carts, cabinets, office furniture, cal focus on physical metallurgy and the in 1986, where he currently works in the televisions, dishwashers, oven chassis, slot joining processes of welding, brazing, and Production Engineering Department as machines, seat frames, brake shoes, truck soldering. Perricone received an AWS the senior staff manufacturing engineer. frames, concrete cages, and solar panels. graduate research fellowship. At Lehigh Some of his projects include the Interna- Some of his designs include fully auto- University, where he studied the physical tional Space Station Thermal Control mated welding, loading, unloading, and metallurgy of welding under the guidance Units Program, Patriot Advanced Capa- stacking stations. White was recognized of John N. DuPont, he earned his PhD in bility, Army Tactical Missile System, Line- as a leading authority in the field of resist- 2005. At ASM International, he served as of-Sight Missile Program, Joint Strike ance welding. Lockheed Martin acknowl- a member of the 2008 Nominating Com- Fighter Program, Advanced Missile Pro- edged his achievements with an award for mittee, is the immediate past chair of the grams, Terminal High-Altitude Area De- his "dedication and significant contri- Emerging Professionals Program, and fense Project, and the Multiple-Launch butions to a program of great national serves on Chapter Council as the Repre- Rocket System. He is a Registered Pro- importance." sentative for District X. His research in- fessional Engineer in the state of Texas. terests include the physical metallurgy of Previously, Levert worked for General George E. Willis Award welding and joining processes, as well as Dynamics, Convair Div., San Diego, as a Chon-Llang Tsal. See bio under Inter- microstructural development in multi- welding engineer. The programs he sup- national Meritorious Certificate Award. •

FEBRUARY 2009 Tech Topics

Standards for ANSI Public Review C7.1M/C7.1:200X, Recommended sions in metric SI Units and U.S. Custom- A3.0M/A3.0:200X, Standard Welding Practices for Electron Beam Welding (and ary Units. Clauses 1-7 constitute a body Terms and Definitions. Revised — $102. Allied/Related Processes). This document of rules for the regulation of welding in Review expires 2/2/09. presents recommended practices for elec- steel construction. The provisions for B5.14:200X, Specification for the Qual- tron beam welding. It is intended to cover Clause 9 have been distributed through- ification of Welding Sales Representatives. common applications of the process. out the D1.5 code. Clauses 8, 10, and 11 Revised — $102. Review expires 1/19/08. Processes definitions, safe practices, gen- do not contain provisions, as their ana- D1.8/D1.8M:200X, Structural Welding eral process requirements, and inspection logue Dl.l sections are not applicable to Code — Seismic Supplement. Revised — criteria are provided. Stakeholders: Laser the D1.5 code. Clause 12 contains the re- $57. Review expires 1/19/08. welders, welders, and anyone interested quirements for fabricating fracture criti- AWS was approved as an accredited in high-tech welding processes. Reino cal members. Stakeholders: Structural en- standards-preparing organization by the Starks, ext. 304. gineers, designers, manufacturers, American National Standards Institute D1.1/D1.1M:2010, Structural Welding welders, qualifiers, inspectors, and fabri- (ANSI) in 1979. AWS rules, as approved Code — Steel. This code covers the weld- cators involved in welding bridges. Selvis by ANSI, require that all standards be ing requirements for any type of welded Morales, ext. 313. open to public review for comment dur- structure made from the commonly used D1.6/D1.6M:2007-AMD 1, Structural ing the approval process. The above three carbon and low-alloy steels. Clauses 1-8 Welding Code — Stainless Steel. This code standards were open for public review constitute a body of rules for the regula- covers the requirements for welding stain- until the dates shown. Draft copies may tion of welding in steel construction. The less steel structural assemblies. Stake- be obtained from Rosalinda O'Neill, ext. code includes eight normative and 12 in- holders: Structural engineers working 451, [email protected]. formative annexes and a code commen- with stainless steel, manufacturers, tary. Stakeholders: Structural engineers welders, qualifiers, and inspectors. Selvis New Standards Projects working with steel, designers, manufac- Morales, ext. 313. Work has begun on revising the fol- turers, welders, qualifiers, inspectors, and lowing six standards. Directly and mate- fabricators. Selvis Morales, ext. 313 Standards Approved by ANSI rially affected individuals are invited to D1.2/D1.2M:200X, Structural Welding D14.8M:2009 (ISO/TR 17844:2004 contribute to their development. Contact Code —Aluminum. This code covers the YDT),StandardMethods for the Avoidance the staff engineer listed with the docu- welding requirements for any type struc- of Cold Cracks. New standard approved ment for more information. Participation ture made from aluminum structural al- 11/11/08. on AWS Technical Committees and Sub- loys, except for aluminum pressure ves- B163M/B16.3:2009, committees is open to all persons. sels and pressure piping. Clauses 1-7 con- Guide for Robotic Arc Welding. Revision C4.2/C4.2M:200X, Recommended stitute a body of rules for the regulation approved 11/13/08. Practices for Safe Oxyfuel Gas Cutting of welding in aluminum construction. A A5.26/A5.26M-97 (R2009), Specifica- Torch Operation. This document contains commentary on the code is included with tion for Carbon and Low-Alloy Steel Elec- the procedures to be used in conjunction the document. Stakeholders: Structural trodes for Electrogas Welding. Reaffirmed with oxyfuel gas cutting equipment and engineers working with aluminum, de- 11/20/08. the latest safety requirements. Complete signers, manufacturers, welders, quali- lists of equipment are available from in- fiers, inspectors, and fabricators. Selvis Technical Committee Meetings dividual manufacturers. Stakeholders: Morales, ext. 313. March 17-20, Dl Committee on Struc- This document will be used by oxyfuel gas D1.5M/D1.5:200X, Bridge Welding tural Welding. Tucson, Ariz. Call Selvis cutters (operators) involved with steel Code. This code covers the welding re- Morales, ext. 313. plate cutting, tooling fabrication, manu- quirements for AASHTO highway March 30, 31, A5 Committee on Filler facturers of equipment, and building con- bridges made from carbon and low-alloy Metals and Allied Materials. Orlando, struction. Annette Alonso, ext. 299. steels. The 2008 edition contains dimen- Fla. Call Rakesh Gupta, ext. 301.

Member-Get-A-Member Campaign

Listed are the Dec. 16 standings for the B. Mikeska, Houston1 L. Contreras, South Florida — 8 current campaign. See page 69 of this Weld- R. Peaslee, Detroit1 J. Compton, San Fernando Valley — 5 ing Journal or visit www.aws.org/mgm for W Shreve, Fox Valley1 C. Daon, Israel — 5 rules and prize list. Call the Membership M. Karagoulis, Detroit1 W Rice, Tri-State — 5 Dept., (800) 443-9353, ext. 480, regarding S. McGill, NE Tennessee1 E. Ezell, Mobile — 4 your member proposer point status. T Weaver, Johnstown/Altoona1 R. Newman, Maine — 4 Winner's Circle G Woomer, Johnstown/Altoona1 B. Vernyi, Cleveland — 4 Sponsored 20+ new members. R. Wray, Nebraska1 C. Becker, Northwest — 3 The superscript indicates the number of M. Haggard, Inland Empire1 R. Ellenbecker, Fox Valley — 3 times the member has achieved Winner's B. Franklin, Mobile — 3 Circle status since June 1, 1999. President's Roundtable L. Moss, Sangamon Valley — 3 J. Compton, San Fernando Valley7 Sponsored 9-19 new members. M. Rahn, Iowa — 3 E. Ezell, Mobile6 P. Betts, Mobile — 12 M. Wheat, Western Carolina — 3 J. Merzthal, Peru2 D. Wright, Kansas City — 3 G. Taylor, Pascagoula2 President's Club L. Taylor, Pascagoula2 Sponsored 3-8 new members. — MGM continued on next page

WELDING JOURNAL — MGM continued from previous page A. Baughman, Stark Central — 36 R. Evans, Siouxland — 11 A. Rowe, Philadelphia — 36 C. Kipp, Lehigh Valley — 10 President's Honor Roll A. Zinn, Eastern Iowa — 34 D. Vranich, North Florida — 10 C. Alfaro, San Diego — 2 T Moore, New Orleans — 32 C. Abram, Columbus — 9 M. Boggs, Stark Central — 2 J. Carney, Western Michigan — 26 A. Badeaux, Washington, D.C. — 9 M. Boyer, Detroit — 2 E. Norman, Ozark — 26 S. Colton, San Diego — 9 B. Donaldson, British Columbia — 2 S. Siviski, Maine — 26 R. Ledford Jr., Birmingham — 9 E. Dupree, Tidewater — 2 R. Newman, Maine — 24 R. Norris, Maine — 9 F. Hendrix, New Jersey — 2 R. Cook, Utah — 23 V. Facchiano, Lehigh Valley — 9 R. Johnson, Detroit — 2 D. Schnalzer, Lehigh Valley — 22 D. Kowalski, Pittsburgh — 8 J. Padilla, Cuautitlan Izcalli — 2 H. Hughes, Mahoning Valley — 20 M. Rabo, Sacramento — 8 J. Poison, L.A./Inland Empire — 2 R. Munns, Utah — 20 N. Carlson, Idaho/Montana — 7 J. Sisson, Niagara Frontier — 2 D. Pickering, Central Arkansas — 18 W Galvery Jr., Long Bch./Or. Cty. — 7 K. Smith, North Texas — 2 T Strickland, Arizona — 17 B. Hallila, New Orleans — 7 A. Stute, Madison-Beloit — 2 J. Boyer, Lancaster — 15 D. Howard, Johnstown/Altoona — 7 D. Thomason, Chicago — 2 C. Donnell, Northwest Ohio — 15 S. MacKenzie, Northern Michigan — 7 B. Whatley, Albuquerque — 2 W. Harris, Pascagoula — 14 D. Zabel, Southeast Nebraska — 7 M. Yung, Portland — 2 J. Roberts, Sacramento — 14 J. Geesey, Pittsburgh — 6 P. Zammit, Spokane — 2 R. Hutchinson, Long Bch./Or. Cty. — 13 C. Schiner, Wyoming — 6 A Mattox, Lexington — 13 D. Kearns, Northern Michigan — 5 Student Member Sponsors R. Rummel, Central Texas — 13 R. Olesky, Pittsburgh — 5 Sponsored 4 or more students. D. Saunders, Lakeshore — 13 J. Reed, Ozark — 5 D. Berger, New Orleans — 110 A Stute, Madison-Beloit — 13 C. Hobson, Olympic Section — 4 B. Benyon, Pittsburgh — 41 D. Taylor, Kern — 13 S. Robeson, Cumberland Valley — 4

New AWS Supporters

Sustaining Companies quality and quick turnarounds. Its lasers Elite Structures, Inc. Classic Protective Coatings, Inc. and micro gas tungsten arc welding 303 Old Quitman Rd., Box 207 N7670 State Hwy. 25 processes are housed in a clean room suit- Adel,GA 31639 Menomonie, WI 54751-5928 able for medical, aerospace, and mold re- (715) 233-6267; FAX (715) 233-6268 pair opeations. Other services include Engineered Building Products, Inc. www. classicprotectivecoatings. com fabrications up to five tons, CNC machin- 18 Southwood Dr. Representative: John Newklrk ing, and production sawing. Bloomfield, CT 06002 Classic Protective Coatings, Inc., is a nationwide industrial contractor special- ICM Georgia Inc. izing in tank rehabilitation. It provides Supporting Companies 6795 Oak Ridge Commerce Way SW the largest high-production welding, Econospan Structures Corp. Austelle, GA 30168 sandblasting, waterblasting, industrial R. R. 2 Site 26, Comp 24 coatings, and containment equipment at Chase, BC V0E 1M0, Canada TesTex Canada locations nationwide. Accomplishments 555 Edinburgh Dr., Ste. 9 include roof and rafter replacement, seis- Paldar Quality Structure Eng. Pr. Co. Moncton, NB E1E 4E3, Canada mic upgrades, safety and security up- PO Box 1431745657 grades, and elevation and location changes. Tehran 0098, Iran The Steel Construction Group Inc. 7035 Bee Caves Rd., Ste. 206 Ironwood Industries, Inc. Portagas, Inc. DBA Cyltex, LLC Austin, TX 78746 18249 U.S. Hwy. 41 S. 6717B Polk St. Spring Hill, FL 34610 Houston, TX 77011 Phones: (800) 647-6113; (352) 754-8512 Educational Institutions Representative: Brian J. Flegel Affiliate Companies Allegan County Area Ironwood Industries, Inc., is a diversi- BSM Consulting Engineers, Inc. Technical & Education Center fied steel services company. It specializes 801 Commercial St., PO Box 502 2891 116th Ave. in the fabrication and erection of struc- Astoria, OR 97103 Allegan, MI 49010 tural and miscellaneous steel products. Based in Florida, it serves the southeast. Cavlness Welding Inc. Ideh Azma Iranian 1004 River Ave. 14155-5634 Peclslon Certified Welding, Inc. Roanoake, VA 24013 Tehran 15949-45911, Iran 203 N. Jersey St. Dayton, OH 45403 Certified Inspection Services Ltd. Jefferson College (937) 781-9353; FAX (937) 781-9665 941 Thomas 1000 Viking Dr. www.precisioncertifiedwelding.com Winnepeg, MB R2L 2C6, Canada Hillsboro, MO 63050 Representative: Brad A. Verburg Precision Certified Welding, estab- Eco-Tec Inc. Jollet Junior College lished in 1989, is a full-service welding 1145 Squires Beach Rd. 1215 Houbolt Rd. and fabrication company committed to Pickering, ON L1W 3T9, Canada Joliet, IL 60431

FEBRUARY 2009 SECTIONA/EI/ra District 1 Russ Norris, director (207)283-1861 [email protected] CENTRAL MASS./ RHODE ISLAND NOVEMBER 20 Activity: The Section members partici- pated in a six-hour-long training program presented at Old Colony Regional Vo- Tech High School in Rochester, Mass. The event allowed one-on-one training for each of the school's junior class. The presenters were Al Caron and Jon Mar- land of Local 51 United Associations of Plumbers, Pipefitters, and Refrigeration, Student welders learned a lot during the training program hosted by the Central Massachu- based in East Providence, R.I. setts/Rhode Island Section.

District 2 Kenneth R. Stockton, director (908)412-7099 kenneth.stockton ©pseg.com NEW JERSEY MAY 20 Activity: The Section members partici- pated in a vendors' day event held at EAf- faire Restaurant in Mountainside, N.J.

SEPTEMBER 16 Speakers: Denis Hache, senior technical sales engineer; and Kristy Wlelkiewlcz, Shown at the Central Massachusetts/Rhode Island Section training program are (from left) innovator business unit manager Chairman Douglas Desrochers, presenters Al Caron and Ion Marland, and Michael Richard. Affiliation: Western Enterprises Topic: Gas manifold systems Activity: The program was held at Snuffy's Pantagis Renaissance in Scotch Plains, N.J.

NOVEMBER 18 Speakers: Richard Senna and Ronald Za- karzewski, welding instructors Affiliation: United Association of Jour- neymen and Apprentices of the Plumb- ing and Pipe Fitting Industry Topic: Accelerated welder training at UA Activity: The meeting was held at Snuffy's Clambar in Scotch Plains, N.J.

PHILADELPHIA NOVEMBER 12 Speaker: Frank Srogota, regional sales Shown at the September New lersey Section program are (from left) speakers Denis Hache manager and Kristy Wielkiewicz with Chairman Seann Bradley.

WELDING JOURNAL Speaker Frank Srogota (left) shares a New Jersey Section Chair Seann Bradley (far right) presents speaker gifts to welding instruc- hearty handshake with Gary Atherton, tors Ronald Zakarzewski (left) and Richard Senna. Philadelphia Section chair.

Affiliation: Kriebel Engineered Equip- ment Ltd. Topic: Fume collection Activity: This Philadelphia Section pro- gram was held in Essington, Pa. District 3 Michael Wiswesser, director (610)820-9551 mike @ welderinstitute. com

NOVEMBER 10-14 Activity: Claudia Bottenfield joined other District 3 members to facilitate a week-long training program for Certified Welding Inspectors in State College, Pa. John Bailey of General Electric pre- sented the course in ultrasonic testing Level 1. Attendees included Fran Lancaster Section board members manning theAWS information table in December in- Brieden, Mike Mehan, Kurt LaLonde, cluded (from left) Chairman Mike Sebergandio, Justin Heistand, Trina Siegrist, and Tim Troy Rider, Eric Roberts, Larry Dudek, Siegrist. Adam Morrison, David Puccio, Tom Hoskin, and Claude Stimpson.

LANCASTER DECEMBER 10 Activity: The Section hosted an AWS in- formation table and participated at the Lancaster County Career and Technol- ogy Center's open house in Mount Joy, Pa. Section board member John Boyer, a welding instructor at the center, pre- sented hands-on welding activities for the students. Working the AWS table were Chairman Mike Sebergandio, Technical Representative Justin Heistand, Secre- tary Trina Siegrist, and Tim Siegrist, communications chairman. District 4 Shown at the District 3 CWI training program are (from left) Fran Brieden, Mike Mehan, Roy C. Lanier, director Kurt LaLonde, instructor John Bailey, Troy Rider, Eric Roberts, Larry Dudek, Adam Morri- (252)321-4285 son, David Puccio, Tom Hoskin, and Claude Stimpson. [email protected]

FEBRUARY 2009 District 5 Steve Mattson, director (904) 260-6040 steve.mattson ©yahoo.com ATLANTA NOVEMBER 12 Speakers: Leroy Bundrage, Georgia Power Co.; and Cajun Seeger, Mechani- cal Trades Institute, Local 72 Topic: The shortage of qualified welders and the importance of technical colleges Activity: District 5 Director Steve Matt- son reviewed the Section's scholarship program. John Scott discussed how the SkillsUSA and VICA programs have helped to increase the number of stu- dents entering the workforce. Kevin Ward commented on how NCCER and the training program can help move Shown at the Atlanta Section program are (from left) District 5 Director Steve Mattson, trainees into the workforce faster. speakers Cajun Seeger and Leroy Bundrage, and Chair Robbie Zappa.

SOUTH CAROLINA NOVEMBER 20 Speaker: Bill Masten, quality assurance AMERICAN! Affiliation: Nucor Steel Co. Topic: Metallurgy and quality control SOCIETY ^^

District 6 ISOUTH ^ Kenneth Phy, director (315)218-5297 kphy ©gmail. com • District 7 • Don Howard, director (814)269-2895 [email protected] ^^^^ 1 Shown at the South Carolina Section program are (from left) Vice Chair Ben Magrone, CINCINNATI/DAYTON speaker Bill Masten, and Odell Haselden, treasurer. DECEMBER 9 Speaker: Candice Mehmetli, develop- ment manager for clean energy Weldlnq Societ Affiliation: Edison Welding Institute Topic: Opportunities in the wind power industry Activity: The Dayton Section announced its activities page is now available on the AWS Web site. This joint meeting of the Cincinnati and Dayton Sections was held at Bullwinkle's in Miamisburg, Ohio.

JOHNNY APPLESEED NOVEMBER 22 Activity: The Section hosted a welding competition at Ivy Tech Community Col- lege in Fort Wayne, Ind., for 29 contest- ants. William R. Richman, owner of Richman Welding Works, Defiance, Bill Richman (left) receives his AWS Life Ohio, received his AWS Life Member Membership Award from Eric Tart, secre- Candice Mehmetli accepts a speaker gift Award for 35 years of service to the So- tary, Johnny Appleseed Section. from Steve Whitney, Dayton Section chair.

WELDING JOURNAL ciety. The top welders in the Johnny Ap- pleseed Section contest were Gary Cearns, Joe Payne, and Zach Straw. The judges for the event, ail AWS CWIs, were Dan Nlchter, Kevin Langdon, and Wayne Porter.

District 8 Joe Livesay, director (931)484-7502, ext. 143 joe. livesay @ ttcc. edu

CHATTANOOGA OCTOBER 21 Speaker: Jim Hurley, southeast regional sales manager Affiliation: Trumph Inc. Topic: The current state of the art in laser material processing Activity: Bill Brooks received an appre- Shown judging at the Johnny Appleseed Section welding competition are (from left) CWIs ciation award for serving as Section chair. Dan Nichter, Kevin Langdon, and Wayne Porter. The meeting was held at Komatsu Restaurant in Chattanooga, Tenn.

HOLSTON VALLEY NOVEMBER 18 Activity: The Section members toured the Edwards & Associates — Custom Helicopters facility in Piney Flats, Tenn. Following the tour, the members had din- ner at Pardner's Barbecue Restaurant where Gary Killebrew of Airgas, Inc., spoke on gas metal arc welding machines.

District 9 George D. Fairbanks Jr., director (225) 473-6362 fits @ bellsouth.net Bill Brooks (left) receives his chairman's Jim Hurley (right) receives a speaker gift appreciation certificate from Don Russell, from Chattanooga Section Chair Bill MOBILE Chattanooga Section treasurer. Brooks. NOVEMBER 13 Speaker: Connie Bowling, director Affiliation: AWS Foundation, Solutions Opportunity Squad Topic: Workforce development Activity: The Section will present a Cer- tified Welding Supervisor preparatory course in March. For information, call Secretary Eleanor Ezell at (251) 457- 8681. The meeting was held at Saucy-Q Bar B Oue in Mobile Ala.

NEW ORLEANS NOVEMBER 15 Activity: The Section hosted its 2008 stu- dent welding competition at New Orleans Pipe Trades Local 60 in Metairie, La. The judges were CWIs Paul C. Hebert, Tony Demarco, John Pajak, Cris Gotangco, Speaker Connie Bowling is welcomed to Chris Fernandez (left) is shown with and Travis Moore. The students repre- the lectern by Josh Sanders, Mobile Section Matthew Howerton, New Orleans Section sented New Orleans Pipe Trades Local chair. chairman, at the Nov. 15 program.

FEBRUARY 2009 Shown at the New Orleans Section Nov. 18 program are (from left) speaker Gurdon Beginning welder winners in the New Orleans Section contest on Nov. 15 are (from left) Is- Camus, Aldo Duron, and Chair Matthew rael Velazquez, Jontell Jeffrey, Jodi Clelland, Aaron Lee Lukinvich, Titus Turner, with Chair Howerton. Matthew Howerton.

60, Ironworkers Local 58, and several Louisiana Technical College campuses. Chris Fernandez, New Orleans Pipe Trades Local 60, was named the 2008 in- structor winner.

NOVEMBER 18 Speaker: Gurdon Camus Affiliation: Capital Safety Group of Red Wing Topic: Fall protection techniques Activity: This New Orleans Section meet- ing was sponsored by Ironworkers Local 58. Aldo Duron, with Local 58, organ- ized the program.

PASCAGOULA NOVEMBER 18 Activity: The Section held it annual stu- dent night for 115 attendees. Speakers The advanced welder winners in the New Orleans Section contest on Nov. 15 are (from left) included Connie Bowling, AWS Founda- Troy West, Warren Andy, Gary Campbell Jr., Leroy Bell, and Brian Addison, shown with tion director Solutions Opportunity Chairman Matthew Howerton. Squad; and Charles Bennett, CEO of Ad- vance Technology, Inc. Bowling in- formed the students about the scholar- ship opportunities available through AWS and distributed literature to assist them in making career choices. Bennett discussed the local need for welders and the need for good welder training. Other speakers included AWS Vice President John Bruskotter and James McNulty, training manager at Signal International. District 9 Director George Fairbanks presented the AWS District and Section awards. The members of the Mississippi Gulf Coast C. C. Jackson County Student Chapter hosted the event. The meeting was held on the campus. District 10 Richard A. Harris, director Charles Bennett (left) receives a speaker (440) 338-5921 Speaker Connie Bowling is shown with gift from William Harris, Pascagoula Sec- richaharris ©alltel.net William Harris, Pascagoula Section chair. tion chairman. WELDING JOURNAL Student Chapter members learned about welding scholarships at the Pascagoula Section program held Nov. 18.

BemieDurkin shows Shane Steele, a prom- John Bohr, Detroit Section vice chair, chats ising young stud welder, the tricks of the Kia McDevitt presents Bernie Durkin a with Santa (a.k.a. Don Czemiewski), so- trade at the CCCTC Student Chapter event. speaker gift at the CCCTC program. cial chairman, at the recent holiday party. District 11 Eftihios Siradakis, director (989)894-4101 ft. siradakis ® air gas. com

DETROIT DECEMBER 11 Activity: The Section hosted its annual holiday party at Ukrainian Cultural Cen- ter in Warren, Mich. Don Czernlewskl, who donned a Santa Claus costume, was the MC. The event featured a silent auc- tion and other contests that raised more than $1000 for the Section's scholarship fund. District 12 Everyone tried their hand at stud welding at the CCCTC Student Chapter event. Sean P. Moran, director (920) 954-3828 CCCTC MAHONING VALLEY [email protected] Student Chapter OCTOBER 23 NOVEMBER 20 Activity: The Section members joined LAKESHORE Activity: The Coiumbiana County Career members of the Warren, Ohio, ASM In- DECEMBER 11 & Technical Center Student Chapter ternational Chapter to tour CMI-EFCO, Speaker: Thomas Proft, president studied stud welding at the school weld- formerly Electric Furnace Co., in Salem, Affiliation: T L. Proft and Associates ing lab. Bernie Durkin of Nelson Stud Ohio. They had the opportunity to study Topic: Designing to prevent fastener and Welding conducted the program with as- the manufacture of industrial heat treat- weld failures sisstance from Huck Hughes, Student ing furnaces for galvanizing, annealing, Activity: The meeting was held at Mack- Chapter advisor. and other applications. inaws Grill & Spirits in Green Bay, Wis.

FEBRUARY 2009 Shown at the Madison-Beloit Section program are (from left) Frank Juckem, Jim Smith, Gary Bergstrom, Jim Pfeil, Chair Ben Newcomb, Bill Dawson, speaker Scott Raether, Burt Wheeler, Terry Schindler, and Jim Harrison.

Speaker Thomas Proft (right), anAWSLife Member, is shown with Nick Freiberg, Lakeshore Section chair.

Shown at the Detroit Section's holiday party are long-time AWS members (from left) Chuck Padden, Bemie Bastion, Carl Hildebrand, and Amos Winsand.

The students had a great time working with the latest equipment at the Madison-Beloit Section students' night program.

MADISON-BELOIT OCTOBER 15 Activity: The Section members toured the Overture Center for the Arts guided by Scott Raether, director of operations at Novum Structures. The tour pointed out the use of architectural design and how welding is involved to facilitate the unique design of the building. The meet- ing continued at the Coliseum Bar and Shown at the November Chicago Section board meeting are (back, from left) Anghelina If- Grill in Madison, Wis., where Raether timie, Marty Vondra, Craig Tichelar, and Pete Host; seated are Chairman Hank Sima and presented a talk on the center. Vicky Landorf.

WELDING JOURNAL NOVEMBER 12 Activity: The Madison-Beloit Section hosted its annual students' night program at Madison Area Technical College in Madison, Wis. On hand were represen- tatives from Lincoln Electric, Miller Electric, ESAB, and 3M to demonstrate their wares and show the students how to operate the equipment. Fifty-two stu- dents participated in the event.

District 13 W. Richard Polanin, director (309) 694-5404 rpolanin @ icc.edu Shown at the December Chicago Section program are (from left) Eric Krauss, speakers Bill Miller and Steven Kocheny, and Chairman Hank Sima. CHICAGO NOVEMBER 12 Activity: The Section members toured LB Steel in Harvey, 111., to study operations in its heavy metal fabrication shop. About 50 attendees participated in the program.

NOVEMBER 19 Activity: The Section held its board meet- ing at Bohemian Crystal Restaurant in Chicago, 111.

DECEMBER 10 Speakers: Bill Miller, sales manager, and Steven A. Kocheny, applications engi- neer, laser technology Affiliation: Leister Technologies, LLC Topic: Laser welding of plastics Activity: The program was held at Bo- hemian Crystal Restaurant.

Steve Roth (left) and Gary Ward demonstrated forge welding techniques for members of the District 14 Indiana and Dayton Sections. Tuiiy C. Parker, director (618)667-7795 [email protected] INDIANA/DAYTON NOVEMBER 11 Activity: The Indiana Section members traveled to the Miami County Fair Grounds in Troy, Ohio, for a joint meet- ing with the Dayton Section. Steve Roth and Gary Ward of the Southern Ohio Forge and Anvil Association demon- strated forge welding. The featured proj- ect was making an ax head from a flat piece of steel then forge welding a high- carbon steel tip onto the part.

LEXINGTON NOVEMBER 20 Activity: Jeff Staton, a division manager for Hypertherm, presented a demonstra- Students participating in the Sangamon Valley welding contest are (from left) Cy Sills, Dal- tion of the latest plasma arc cutting ton Wagner, Cody Swisher, Michael Creek, Brett Ellis, Thomas Rigdon, Kevin Smith, Austin equipment for the Section members and Buhlig, and John Behner. local welding students.

FEBRUARY 2009 SANGAMON VALLEY NOVEMBER 20 AMERICAN Activity: The Section members held their WELDlNi students' night program during the De- catur Area Technical Academy's open SOCIETY house and parents' night program in De- catur, III. Nine students competed in the Section-sponsored welding demonstra- tion contest. Kevin Smith received the first place prize. The other welders in- cluded Cy Sills, Dalton Wagner, Cody Swisher, Michael Creek, Brett Ellis, Jeff Staton discussed plasma arc cutting Thomas Rigdon, Austin Buhlig, and techniques at the Lexington Section's pro- John Behner. The competition prizes gram in November. were donated by Ilmo Products and S. J. Smith Welding Supply.

Oren Reich (left) receives his silver mem- bership certificate from Ryan Rummel, District 15 Central Texas Section chairman. Mace V. Harris, director (612)861-3870 macevh ® aol.com stitute. Hot Springs, Ark. Topic: The image of welding District 15 Activity: The meeting was held at the NORTHWEST Arkansas Career Training Institute. DECEMBER 10 Activity: The Section hosted its annual certification open forum moderated by CENTRAL TEXAS Vice Chair Bob Sands, a welding engi- OCTOBER 28 Shown at the Northwest Section's open neer and supervisor at Production Engi- Speaker: Frank Wilkins, chairman forum are moderator Bob Sands (left) and neering Corp. The topic was "Why Do Affiliation: Texas State Technical College Chairman Todd Bridigum. We Need Welding Procedures?" The (TSTC) welding department event was held in Shoreview, Minn. Topic: The future of the welding indus- AMERICAN try and the growing need for welders WELDING Activity: The program was held at TSTC in Waco, Tex. SOCIETY Activity: Oren Reich received his silver District 16 membership certificate for 25 years of David Landon, director . (641)621-7476 service to the Society. [email protected] SIOUXLAND NORTH TEXAS DECEMBER 9 NOVEMBER 18 Activity: The Section members toured Speaker: Robert Steinbock AKG Midwest, Inc., in Mitchell, S.Dak., Affiliation: Superbolt Inc. _r. / to study the manufacture of coolers and Topic: Gaining the advantage with multi- Speaker Frank Wilkins (right) is shown heat exchangers for construction and jackbolt tensioners with Ryan Rummel, Central Texas Section agriculture equipment. Following the Activity: This was a joint meeting with chair. tour and a question and answer session, members of the local chapter of ASME. the members visited the Mitchell Tech- About 65 people attended the program, nical Institute Technology Center for a held at the University of Texas at Arling- tour of the facility. The presenter was ton, Tex. The Section is collecting canned Doug Greenway, director of business and foods in support of the North Texas Food industrial training. Bank.

DECEMBER 9 Activity: The North Texas Section hosted District 17 its annual silent auction at Humperdinks J. J. Jones, director Restaurant in Arlington, Tex. The event (940)368-3130 raised $1080 for the Section's scholarship jjones @ thermadyne. com program.

CENTRAL ARKANSAS SEPTEMBER 25 District 18 Bruce Weisman (left) receives the District Speaker: Dennis Pickering, Section John Bray, director Director Certificate Award from Neil Shan- chairman and welding instructor (281)997-7273 non, District 19 director, at the Alaska Sec- Affiliation: Arkansas Career Training In- sales @ affHiatedmachinery.com tion program in September.

WELDING JOURNAL m \

Peter Macksey (left) receives the District Director Certificate Award from Neil Shan- non, District 19 director, at the Alaska Sec- Albuquerque Section awardees include (from left) Pat Baumann, Wade Florence, Jim Kunz, tion program in September. Richard Moku, Charlie Robino, and Phil Fuerschbach.

ViitlmK , District 19 Neil Shannon, director (503)419-4546 neilshnn @msn. com

ALASKA SEPTEMBER 26 Speaker: Neil Shannon, District 19 direc- tor Affiliation: Carlson Testing, project man- ager Topic: Electroslag surfacing of naval propulsion shafting Activity: Bruce Weisman and Peter Macksey received District Director Cer- tificate Awards. The meeting was held at Peggy's Restaurant in Anchorage, Speaker Carl Heinrich (right) is shown with Alaska. John Little at the British Columbia Section Speaker Mike Hosking (left) is shown with program. Tom Lienert, Albuquerque Section chair. NOVEMBER 21 Speaker: Scott Sheafer, advanced tech- nical sales specialist Affiliation: Olympus NDT ^ [ f. Topic: Multitechnology flaw detectors ^h A f Activity: Bruce Weisman, certification ^u^pv^v chair, announced the 2009 CWI seminar mm and examinations schedule. The Alaska Section will host a CWI seminar followed ^^^J\ by the exam in late March, plus an exam- ^^T 4 ination (no seminar) in September. For more information on these events, con- H 1 tact Peter Macksey at (907) 264-2804; jj [email protected]. *\fM M1 m BRITISH COLUMBIA NOVEMBER 13 \^Mm Speaker: Carl Heinrich, CEO Affiliation: Roboweld Topic: Robotic welding of heavy-thick- wk ness mining truck wheels Don McLeod receives his Life Member- Activity: Don McLeod received his Life ship Certificate from Pat Newhouse, Colorado Section Chair James Corbin (left) Membership Award for 35 years of serv- British Columbia Section chair. is shown with speaker Dave Bennett. ice to the Society. The meeting was held

FEBRUARY 2009 Utah Section members celebrated their annual turkey shoot event at Impact Guns.

at Roboweld in Coquitlam, B.C., Canada. Following the talk, the members toured the facility. District 20 William A. Komlos, director (801)560-2353 bkoz@arctechllc. com ALBUQUERQUE NOVEMBER 20 Speaker: Mike Hosking, manager, join- ing and coating department Affiliation: Sandia National Laborato- ries Eighty-one Sacramento Valley section members attended the November program. Topic: Comparison of soldering, brazing, and welding technologies SOUTHERN COLORADO Activity: Phil Fuerschbach and Charlie NOVEMBER 17 Robino received their Silver Membership Activity: The Section members toured Certificates and pins for 25 years of serv- Springs Fabrication in Colorado Springs, ice to the Society. Awards were presented Colo., to study its new high bay tank fa- to Pat Baumann: District CWI of the cility. Participating in the tour were Tom Year; Mike Thomas: Section CWI of the Neppi, president, Steve Bixler, and Be- Year; Wade Florence and Richard Moku: linda Popovich. Section Meritorious; Jim Kunz: Section Appreciation; and Jameson Butler: Stu- dent Member Award. The program was UTAH held at Central New Mexico Community NOVEMBER 18 College in Albuquerque, N.Mex. Activity: The Section held its annual turkey shoot at Impact Guns in Roy, Utah. Wayne Western coordinated the COLORADO event. NOVEMBER 13 Speaker Regis Geisler (right) is shown with Speaker: Dave Bennett, VP of sales Don Robinson, Sacramento Valley Section Affiliation: Eaton Metal chair. Topic: Fabrication of large pressure ves- sels Activity: Awards were presented to Mar- District 21 District 22 jorie Oliver: Section CWI of the Year; Nanette Samanich, director Dale Flood, director Bob Teuscher: District Director; and Fred (702)429-5017 (916)288-6100, ext. 172 Schaefer: Section Meritorious. weldor07@aol. com [email protected]

WELDING JOURNAL SACRAMENTO VALLEY NOVEMBER 19 Speakers: Regis Geisler, welding sales en- gineer; and Mark Ehrllch Affiliation: The Lincoln Electric Co. Topic: Proper welding techniques using NR 232 flux core wire Activity: Following Geisler's talk, he and Ehrlich demonstrated the welding pro- cedures in the American River College welding lab, managed by instructors Mark Reese and Melvin Johnson.

SAN FRANCISCO DECEMBER 3 Activity: Sixty-five Section members and guests attended a special holiday presen- tation of the Flaming Lotus Girls and Colorado Section Chair James Corbin (left) is shown with award winners (from left) Mar- their pyrotechnic artworks. The program jorie Oliver, Bob Teuscher, and Fred Schaefer. was held at Spenger's Restaurant in Berkeley, Calif.

Director Awards Announced

District 9 Director George Fairbanks has nominated the fol- lowing members for this award: Charlie Lewis — Acadiana Section Marcie Jacquet — Acadiana Section Leslie Bertrand — Acadiana Shown during the Southern Colorado Section tour of Springs Fabrication are (from left) Section Belinda Popovich, Tom Neppi, and Steve Bixler. The District Director Award provides a means for District di- rectors to recognize individuals who have contributed their time and effort to the affairs of their local Section and/or District.

Membership Counts

Member As of Grades 1/01/09 Sustaining 516 Supporting 315 Educational 488 Affiliate 467 Welding distributor 49 Total corporate members...... 1,835 Individual members 49,666 Student + transitional members 5,406 Shown at the San Francisco holiday program are (from left) Caroline Miller, Section Chair Total members 55,072 Liisa Pine, Rebecca Anders, and Jessica Hobbs.

FEBRUARY 2009 Guide to AWS Services

American Welding Society 550 NW LeJeune Rd., Miami, FL 33126 www.aws.org; (800/305) 443-9353; FAX (305) 443-7559 (Staff telephone extensions are shown in parentheses.)

AWS PRESIDENT WEMCO — Welding Equipment EDUCATION SERVICES Victor Y. Matthews Manufacturers Committee Managing Director [email protected] Manager Dennis Marks., [email protected] (449) The Lincoln Electric Co. Natalie Tapley.. [email protected] (444) 7955 Dines Rd. Director, Education Services Administration Novelty, OH 44072 and Convention Operations John Ospina.. [email protected] (462) PUBLICATION SERVICES ADMINISTRATION Department Information (275) Executive Director Managing Director AWS AWARDS, FELLOWS, COUNSELORS Ray W. Shook., [email protected] (210) Andrew Cullison.. [email protected] (249) Senior Manager Wendy S. Reeve., [email protected] (293) CFO/Deputy Executive Director Welding Journal Coordinates AWS awards and AWS Fellow and Frank R. Tarafa.. [email protected] (252) Publisher Counselor nominees. Andrew Cullison.. [email protected] (249) Deputy Executive Director TECHNICAL SERVICES Cassle R. Burrell.. [email protected] (253) Editor Department Information (340) Mary Ruth Johnsen.. [email protected] (238) Managing Director Senior Associate Executive Director Andrew R. Davis., [email protected] (466) Jeff \Nebet.. [email protected] (246) National Sales Director Int'l Standards Activities, American Council of Rob Saltzstein.. [email protected] (243) the Int'l Institute of Welding (IIW) Executive Assistant for Board Services Gricelda lHanaWch.. [email protected] ... .(294) Society and Section News Editor Director, National Standards Activities Howard Vlooax\[email protected].. .(296) ing Journal, which provides information on the Metric Practice, Safety and Health, Joining of state of the welding industry, its technology, and Plastics and Composites, Welding Iron Castings Director Society activities. Publishes Inspection Trends, the Hidail [email protected] (287) Welding Handbook, and books on general welding Technical Publications subjects. AWS publishes about 200 documents widely used Database Administrator throughout the welding industry. Natalia Svia\[email protected] (245) Senior Manager Rosalinda O'Neill., [email protected] (451) Human Resources MARKETING COMMUNICATIONS Director, Compensation and Benefits Director Staff Engineers/Standards Program Managers Luisa Hernandez., [email protected] (266) Ross Hancock., [email protected] (226) Annette Alonso.. [email protected] (299) Automotive Welding, Resistance Welding, Oxy- Manager, Human Resources Webmaster fuel Gas Welding and Cutting, Definitions and Dora A. Shade., [email protected] (235) Angela [email protected] .(456) Symbols, Sheet Metal Welding Stephen Borrero.. [email protected] (334) INT'L INSTITUTE of WELDING Joining of Metals and Alloys, Brazing and Sol- Senior Coordinator dering, Brazing Filler Metals and Fluxes, Brazing Sissibeth Lopez .. [email protected] (319) MEMBER SERVICES Handbook, Soldering Handbook Provides liaison services with other national and Department Information (480) international professional societies and standards Rakesh [email protected] (301) organizations. Deputy Executive Director Filler Metals and Allied Materials, Int'l Filler Cassie R. Burrell.. [email protected] (253) Metals, Instrumentation for Welding, UNS Num- bers Assignment GOVERNMENT LIAISON SERVICES Director Hugh K. Webster... [email protected] Rhenda A. Mayo... [email protected] (260) Brian McGrath . [email protected] (311) Webster, Chamberlain & Bean, Washington, D.C., Serves as a liaison between Section members and Methods of Inspection, Mechanical Testing of (202) 785-9500; FAX (202) 835-0243. Identifies AWS headquarters. Informs members about AWS Welds, Welding in Marine Construction, Piping funding sources for welding education, re- benefits and activities. and Tubing search, and development. Monitors legislative and regulatory issues of importance to the weld- Selvis Morales [email protected] (313) ing industry. Welding Qualification, Structural Welding CERTIFICATION SERVICES Department Information (273) Matthew Rubin [email protected] (215) CONVENTION and EXPOSITIONS Machinery and Equipment, Robotics Welding, Senior Associate Executive Director Managing Director, Certification Operations Arc Welding and Cutting Processes Jeff Wetoex.. [email protected] (246) John Filippi..jfilippi@flM'i.o^ (222) Reino [email protected] (304) Corporate Director, Exhibition Sales Managing Director, Technical Operations Welding in Sanitary Applications, High-Energy Joe KraW.. [email protected] (297) Peter [email protected] (309) Beam Welding, Aircraft and Aerospace, Friction Organizes the annual AWS Welding Show and Manages and oversees the development, in- Welding, Railroad Welding, Thermal Spray Convention, regulates space assignments, regis- tegrity, and technical content of all certification tration items, and other Expo activities. programs. Note: Official interpretations of AWS standards may be obtained only by sending a request in writ- Director, Int'l Business & Certification Programs ing to the Managing Director, Technical Services. Brazing and Soldering Priti [email protected] (258) Oral opinions on AWS standards may be ren- Manufacturers' Committee Directs all int'l business and certification pro- dered. However, such opinions represent only the Jeff Weber., [email protected] (246) grams. Is responsible for oversight of all agencies personal opinions of the particular individuals handling AWS certification programs. fiving them. These individuals do not speak on ehatfofAWS, nor do these oral opinions con- RWMA — Resistance Welding stitute official or unofficial opinions or interpre- Manufacturing Alliance tations of AWS. In addition, oral opinions are in- Manager formal and should not be used as a substitute for Susan Hopkins., [email protected] (295) an official interpretation.

WELDING JOURNAL Nominees for National Office AWS Publications Sales Purchase AWS standards, books, Only Sustaining Members, Members, office of treasurer, an individual must be and other publications from Honorary Members, Life Members, or a member of the Society, other than a Stu- World Engineering Xchange (WEX), Ltd. Retired Members who have been mem- dent Member, must be frequently avail- orders@awspubs. com; www.awspubs.com bers for a period of at least three years able to the national office, and should be Toll-free (888) 935-3464 (U.S., Canada) shall be eligible for election as a director of executive status in business or industry (305) 824-1177; FAX (305) 826-6195 or national officer. with experience in financial affairs. It is the duty of the National Nominat- Director-at-Large: To be eligible for Welding Journal Reprints ing Committee to nominate candidates for election as a director-at-large, an individ- Copies of Welding Journal articles may national office. The committee shall hold ual shall previously have held office as be purchased from Ruben Lara. an open meeting, preferably at the Annual chairman of a Section; as chairman or (800/305) 443-9353, ext. 288; [email protected] Meeting, at which members may appear vice chairman of a standing, technical, to present and discuss the eligibility of all or special committee of the Society; or Custom reprints of Welding Journal candidates. as a District director. articles, in quantities of 100 or more, To be considered a candidate for the po- Interested persons should submit a let- may be purchased from sitions of president, vice president, treas- ter stating which office they seek, including FosteReprints urer, or director-at-large, the following a statement of qualifications, their willing- Claudia Stachowiak qualifications and conditions apply: ness and ability to serve if nominated and Reprint Marketing Manager President: To be eligible to hold the of- elected, and a biographical sketch. 866-879-9144, ext. 121 fice of president, an individual must have E-mail the letter to Gricelda Manalich, claudia @fostereprints. com served as a vice president for at least [email protected], c/o Gene Lawson, one year. chair. National Nominating Committee. Vice President: To be eligible to hold the The next meeting of the National AWS Foundation office of vice president, an individual must Nominating Committee is scheduled for AWS Foundation, Inc., is a not-for-profit cor- have served at least one year as a director, November 2009. The terms of office for poration established to provide support for other than executive director and secretary. candidates nominated at this meeting will educational and scientific endeavors of the Treasurer: To be eligible to hold the commence January 1, 2011. American Welding Society. Information on gift-giving programs is available upon request.

Chairman, Board of Trustees Honorary Meritorious Awards Ronald C. Pierce Executive Director, AWS The Honorary Meritorious Awards Welding Show held each fall. The dead- Ray Shook, ext. 210, [email protected] Committee makes recommendations for line for submissions is December 31 prior the nominees presented to receive the to the year of the awards presentations. Executive Director, Foundation Honorary Membership, National Send candidate materials to Wendy Sue Sam Gentry, ext. 331, [email protected] Meritorious Certificate, William Irrgang Reeve, secretary. Honorary Meritorious Memorial, and the George E. Willis Awards Committee, [email protected]; 550 Corporate Director, Solutions Opportunity Awards. These honors are presented dur- NW LeJeune Rd., Miami, FL 33126. Squad ing the FABTECH International & AWS Descriptions of these awards follow. Monica Pfarr, ext. 461, [email protected]

William Irrgang Memorial Award profession, or to one who is accredited Director, Solutions Opportunity Squad Sponsored by The Lincoln Electric Co. with exceptional accomplishments in the Connie Bowling, ext. 308, [email protected] in honor of William Irrgang, the award, development of the welding art, upon adminstered by AWS, is given each year whom the Society deems fit to confer an 550 NW LeJeune Rd., Miami, FL 33126 to the individual who has done the most honorary distinction. Honorary Members (305) 445-6628; (800) 443-9353, ext. 293 over the past five years to enhance the So- have full rights of membership. General Information: ciety's goal of advancing the science and (800) 443-9353, ext. 689; [email protected] technology of welding. It includes a $2500 National Meritorious Certificate Award honorarium and a certificate. This certificate award recognizes the re- cipient's counsel, loyalty, and dedication AWS Mission Statement George E. Willis Award to AWS affairs, assistance in promoting Sponsored by The Lincoln Electric Co. cordial relations with industry and other The mission of the American Welding in honor of George E. Willis, the award, organizations, and for contributions of time Society is to advance the science, adminstered by AWS, is given each year and effort on behalf of the Society. technology, and application of to an individual who promoted the ad- welding and allied processes, vancement of welding internationally by International Meritorious including joining, brazing, soldering, fostering cooperative participation in Certificate Award cutting, and thermal spraying. technology transfer, standards rationali- This honor recognizes recipients' sig- zation, and promotion of industrial good- nificant contributions to the welding in- will. It includes a $2500 honorarium and dustry for service to the international It is the intent of the American Welding a certificate. welding community in the broadest terms. Society to build AWS to the highest qual- The awardee is not required to be an AWS ity standards. Your suggestions are wel- Honorary Membership Award member. Multiple awards may be given. come. Please contact any staff member or The honor is presented to a person of The award consists of a certificate and a AWS President Victor Y. Matthews, as acknowledged eminence in the welding one-year AWS membership. listed on the previous page.

FEBRUARY 2009 ASCC CONFERENCE ual Stabilitv Conferei

PHOENIX, ARIZONA Conference: April 1-4, 2009 Phoenix Civic Plaza Convention Center Exhibits: April 1-3, 2009

Technical Seminars * Networking * Product Showcase for Structural Engineers, Detailers, Erectors, and Fabricators

Who attends? HL STEEL CONrLKLNCLisa premier education event More than 3,700 structural engineers, steel fabricators, erectors, aimed at providing structural engineers, steel fabricators, erectors, detailers, educators, and others involved in the design and and detailers with practical information and the latest design and construction of fabricated steel attend the conference each construction techniques. More than 60 technical sessions offer a variety year. In addition to conference seminars, attendees have many of educational opportunities: networking opportunities, including the annual Fabricator Creating the Desirable Workplace An Introduction to Earthquake Workshops, where fabricators can exchange ideas in a non- The Wal-Mart Effect and Your Business Engineering and Seismic Codes— competitive environment. Gusset Plates for Seismic Construction Part III: Design Examples Structural Integrity in Buildings BIM: "Cradle to Grave"—From the Steel Interchange LIVE! Structural Engineer's Perspective What about the exhibit hall? Who's Financially Responsible When a How Does Parking Play with Mixed- More than 3,700 structural engineers, steel fabricators, erectors, Job Goes Bad? Use? detailers, educators, and others involved in the design and Delegating Connection Responsibility Ethics and Accountability construction of fabricated steel attend the conference each to the Fabricator—What Is the EOR's Improving Shop Safety year. In addition to conference seminars, attendees have many Legal Responsibility? Estimating Rules of Thumb networking opportunities, including the annual Fabricator Rules of Thumb for Steel Design QMC's Top 10 CARs: Part I Workshops, where fabricators can exchange ideas in a non- Design of Frames Using Web-Tapered QMC's Top 10 CARs: Part II competitive environment. Members Current Sales Forecasts and Outlook Staggered Truss Systems: Lessons Contract Language and Risk Learned Management—Understanding Basic What will I learn? HSS Design Contract Language Learn about topics ranging from gusset plates for seismic con- Specifying Camber—Rules of Thumb Employee Retention (What's New? struction to structural integrity in buildings to HSS design. Some for Designers What Can We Do?) sessions focus on technical issues while other focus on fabrication, The Process of Renovation—Concept Trucking: Lease vs. Buy vs. Contract erection, or detailing. But all attendees are welcome to attend any to Completion! Fabricator Roundtable of the sessions, regardless of track. In addition to our regular techni- Safety by Design Connections: The Good, the Bad, and Better Base Plate Designs the Ugly cal sessions, we've also invited some of the industry's top profes- Connection Design: Dealing with RFIs: Use and Abuse (Do you Know sors and some of the leading experts to give their "best lecture." Load Paths, Transfer Forces, and the the Difference?) Speakers include Shankar Nair, Bill Thornton, Jim Malley, Tom Apparent Lack of Joint Equilibrium Document Control Management Ferrell, Abbas Aminmansour, Peter Birkemoe, Chia-Ming Uang, Cold-Formed and Hot-Rolled: The Best How to Get Rich in Detailing and Duane Ellifrit. And new this year, we're offering a two-day of Both Worlds Value-Added Selling: Competing "how to design" program from one of the nation's top structural What Fabricator Certification Means to Against Overseas Detailers engineering firms (this is a more formal version of the program theEOR OSHA Revisited Computerized Structural Design uses to train its new employees). Wind Design Considerations for Steel Fire Protection, Painting and Joists and Joist Girders Galvanizing (What the Detailer Trends in Offshoring/Outsourcing and Should Know) For more information, visit How Advances in Software Address Communicating and Coordinating the Migration Between Detailers An Introduction to Earthquake Stair and Miscellaneous Steel Detailing www.aisc.org/nascc Engineering and Seismic Codes— in 3D Part I: Ductility High Seismic—An Erector's Guide sponsored by An Introduction to Earthquake Safety First Engineering and Seismic Codes— Moving Steel to Make Iron Part II: Seismic Provisions Preparing a Site-Specific Erection Plan

IMCA cisciliccaD and much more! For Info go to www.aws.org/ad-index PROFESSIONAL PROGRAM ABSTRACT SUBMITTAL Annual FABTECH International & AWS Welding Show Chicago, IL - November 15-18, 2009

Submission Deadline: March 13, 2009 (Complete a separate submittal for each paper to be presented.) Primary Author (Full Name): Affiliation: Mailing Address:

City: State/Province Z\PM?}}..9.9P.$.. Country: Email: Co-Author(sJ; Name (Full Name): Name (Full Name): Affiliation Affiliation: Address: Address: City: State/Province City: Zip/Mail Code State/Province: Country: E-Mail: Zip/Mail Code: Country: E-Mail: Name (Full Name): Name (Full Name): Affiliation: Affiliation: Address: Address:

City: City: State/Province: State/Province: Zip/Mail Code: Zip/Mail Code: Country: E-Mail: Country: E-Mail: Answer the following about this paper Original submittal? Yes • NoQ Progress report? Yes • NoQ Review paper? Yes • NoQ Tutorial? Yes • NoD What are the welding/Joining processes used? What are the materials used? What is the main emphasis of this paper? Process Oriented • Materials Oriented • Modeling • To what industry segments is this paper most applicable? Has material in this paper ever been published or presented previously? Yes • No^ If "Yes", when and where? Is this a graduate study related research? Yes • NoQ If accepted, will the author(s) present this paper in person? Yes D Maybe D NoD Keywords: Please Indicate the top four keywords associated with your research below

Guidelines for abstract submittal and selection criteria: • Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated. • Complete this form using MSWord. Submit electronically via email to techpapers(a>aws.orq Technical/Research Oriented Applied Technology Education • New science or research. • New or unique applications. • Innovation in welding education at all • Selection based on technical merit. • Selection based on technical merit. levels. • Emphasis is on previously unpublished • Emphasis is on previously • Emphasis is on education/training work in science or engineering relevant to unpublished work that applies known methods and their successes. welding, joining and allied processes. principles of joining science or Papers should address overall • Preference will be given to submittals with engineering in unique ways. relevance to the welding industry. clearly communicated benefit to the • Preference will be given to submittals welding industry. with clearly communicated benefit to the welding industry. 0 Check the category that best applies:

• Technical/Research Oriented D Applied Technology • Education Proposed Title (max. 50 characters): Proposed Subtitle (max. 50 characters): Abstract: Introduction (100 words max.) - Describe the subject of the presentation, problem/issue being addressed and its practical implications for the welding industry. Describe the basic value to the welding community with reference to specific communities or industry sectors.

Technical Approach, for technical papers only (100 words max.) - Explain the technical approach, experimental methods and the reasons why this approach was taken.

Results/Discussion (300 words max.) - For technical papers, summarize the results with emphasis on why the results are new or original, why the results are of value to further advance the welding science, engineering and applications. For applied technology and education papers, elaborate on why this paper is of value to the welding community, describe key aspects of the work developed and how this work benefits the welding industry and education.

Conclusions (100 words max.) - Summarize the conclusions and how they could be put to use - how and by whom.

NOTE: Abstract must not exceed one page and must not exceed the recommended word limit given above Note: The Technical Program is not the venue for commercial promotions of a company or a product. All presentations should avoid the use of product trade names. The Welding Show provides ample opportunities for companies to showcase and advertise their processes and products. Return this form, completed on both sides, to

AWS Education Services Professional Program 2009 550 NW LeJeune Road Miami FL 33126 FAX 305-648-1655 MUST BE RECEIVED NO LATER THAN MARCH 13, 2009 NEW LITERATURE Metal Fabrication Products rapid solidification, and low-pressure die Pocket Welding Guide casting of high-integrity product. Automa- Pictured in Cataiog tion technology is addressed with ex- Released in 30th Edition panded coverage on continuous casting of The 30th edition of the popular Pocket aluminum and copper, specifications, se- Welding Guide has been completely re- lection, and properties of gray iron, duc- vised and updated with the addition of the tile irons, malleable irons, compacted latest filler metals, new photos of good graphite irons, high-alloy irons, cast steels, and bad welds, preheat temperatures for aluminum, copper, zinc, magnesium, metals, and the AISI designation system cobalt, nickel, titanium, zirconium, and for carbon and low-alloy steels. It includes cast metal matrix composites. The text troubleshooting guides, essentials for lists for $264, $212 to ASM members. good welding, welding symbols, joints, and Sample articles can be downloaded free positions, causes and cures for common at the Web site. welding problems, etc. The toolbox size guide is $4.95. Order online or by phone. ASM International www.asminternationaI.org Hobart Institute of Welding Technology (440) 338-5151 www.welding.org (800) 332-9448, ext. 5433; (937) 332-5433 Industrial PCs Handbook Updated for 2009 Updated Abrasive Products Catalog Offered

» PC SytttMS Handbook A new abrasive products catalog illus- More than 1600 products, including iQf Ur tiitatiiti mm4 li)|iiit*rt trates and describes various size alu- 200 new surface-finishing products, are minum oxide, zirconia, alumina, and ce- displayed in the company's latest catalog ramic abrasive belts for use with Dynafile, that is divided into three main color-coded Dynafile II, Dynabelter, and various other categories. Featured are flap discs, semi- tools. Included are a wide selection of alu- flex discs, resin fiber discs, quick-change minum oxide and silicon carbide sanding discs, flap wheels, hook and loop surface- discs for use with the palm-style and two- conditioning discs. Quickie Cut• cut-off handed random orbital sanders. Other wheels, depressed-center wheels, and sta- products pictured are scalloped-edge tionary saw wheels. The catalog can be abrasive discs, locking-type discs, flap viewed online in the USA section of the wheels, fiber discs, microfinishing rolls, Web site. sanding stars, abrasive bands, cut-off wheels, and Type 27 depressed-center CGW-Camel Grinding Wheels, USA grinding wheels. www.cgwheels.com (800) 447-4248 Dynabrade, Inc. Casting Handbook Issued trmm.tf^utt%tmmtk.t^m 1-IOC-141-1S35 www.dynabrade.com (716) 631-0100 The revised ASM Handbook, Vol. 15, The 220-page, full-color, 2009 PC Sys- Consumables Guide for Casting, updates and expands coverage on tems Handbook for Scientists and Engi- the principles and practices of casting in neers features an expanded line of indus- Wind Towers Published several ways. Melt processing methods trial PCs and monitors including periph- and equipment are described for iron, erals, accessories, data acquisition, and The Wind Tower Fabrication Consum- steel, and aluminum in terms of fluxing, communications. Covered also are exten- able Selection Guide is offered to assist degassing, molten metal filtration, refine- sive lines of workstations, chassis with fabricators in determining critical weld- ment, and modification. Solidification, front and rear slot access, motherboards, ing process factors, including consumable process modeling, and filling and feeding SBCs, and accessories such as pointing selection and welding procedures for wind concepts are updated to reflect the con- devices, KVMs, hard drives, removable tower welding. Included is an optimized tinuing improvements in casting methods drives, video cards, and signal extenders welding procedure to help fabricators in- and processing. The major methods of and amplifiers. Featured are new models crease productivity and reduce costs using green-sand, no-bake, and shell molding in the FoldAway• series employing 1U submerged arc wire and fluxes that meet are described further in individual arti- rack-mount monitor/key-board combina- the critical weld chemistry restrictions for wind tower fabrication. The ten products cles. Additional articles are devoted to the tions, and the CYRAQ® series with foundry practice of cast irons, steels, alu- NEMA 4X PCs and monitors in sizes detailed are Lincolnweld® L-61 (AWS minum, copper alloys, and zinc. Expert from 6/4 to 24 in. EM12K), general-purpose electrode for updates are also provided on many other a wide range of applications with single significant casting methods such as high- CyberResearch, Inc. or multipass submerged arc welding; L- pressure die casting, lost-foam, squeeze www.cyberresearch.com S3 (AWS EH12K) produces low-temper- casting, semisolid methods, spray casting. (800) 341-2525 or (203) 643-5000 ature impact properties ideal for the most

FEBRUARY 2009 demanding offshore applications; LA-85 (AWS ENi5) for use on weathering steels and applications requiring excellent low- temperature impact properties; L-70 (AWS EA1) for single- or multipass welds on pipe and other limited pass applica- tions where impact properties are re- quired; LA-90 (AWS EA3K) special- purpose wire; LA-81 (AWS EG) for ex- tremely high toughness, often used for arctic-grade line pipe or as a back bead on multipass welds, and for welding up to API X90 grade pipe; and three fluxes for tomotive, aerospace, medical, and other specific applications. Obtain Bulletin precision metalworking industries. High- GSM08-01 online or call. lighted in the new CD is the MSK multi- table format. Other sections detail con- functional measurement and control de- The Lincoln Electric Co. trol systems and application software for vice, which combines pneumatic and tac- www.lincolneIectric.com part programming, nesting, and produc- tile touching for both in-process and post- (888) 355-3213 tion management. process component inspection. The prod- ucts feature high accuracy and resolution Laser Fabricating Systems Farley Laserlab Cutting Systems repeatability, down to 0.1 micron, capa- www.farleylaserlab.com ble of air gauging small-diameter holes. Pictured in Cataiog (815) 874-1400 The air gauging stations are designed for use in machine tool spindle and tool man- A 36-page, well-illustrated, full-color CD Offers QC Air ufacturers, as well as end user shops, for catalog depicts the company's complete gauging HSK and CAT tooling, power lines of profiling and processing systems. Gauging Soiutions drawbars, and other spindle interface The five sections include laser cutting, components. Free copies of the CD are The company's newest CD provides precision plasma cutting, plasma and oxy- available on request. fuel cutting, plate working systems, and full product specifications and pricing on waterjet cutting. Twelve different ma- its lines of air gauging, tool taper clean- Stotz Gaging Co. chines are described with their technical ers, force check gauges, and test equip- www.stotz-usa.com specifications presented in a user-friendly ment for quality control for use in the au- (815) 297-1805

HELP FOUND BETTER CANDIDATES, BETTER RESULTS AWS JobFind works belter than other job sites because It specializes In the materials jowilng Industry Hire those hard-to-find Certified Welding Inspectors (CWIs), Welders. Engineers. Welding Managers. Consultants and more at www awspbfmd com You'll find more than 2.000 resumes ot top rob seekers in the *>dustry!

www.awsjobfind.comj THE TOOLS TO DO MORE AWS JobFind provides companies with the tools lo post, edit and manage their job listings easily and effectively, any day or time, have immediate access to an entire rtsum* database of qualified candidates, look for candidates who match their employment needs full-time, part-time or contract employees, receive and respond lo resumes. cover letters, etc via e-mad

POST JOBS, FIND JOBS AT THE INDUSTRY S CAREER MEETING PLACE VISIT WWW.AWSJ0BFIND.COM

WELDING JOURNAL PERSONNEL

Lincoln Expands Marketing MEMBER MILESTONE Capabiiities Feldstein Awarded ASME's J. Hall Taylor Medal

Joel G. Feldstein, an AWS Life Member, has been awarded the J. Hall Taylor Medal from the American Society of Mechanical Engineers (ASME). Feldstein was cited for his "professionalism and leadership in consensus building for pres- sure equipment codes and standards, and for technical excel- lence in the advancement of standards for welding in pressure vessel and piping construction." He has played a key role in the Boiler and Pressure Vessel Code process for more than 20 years. Lisa Byall Bruce Chantry As chair of the BPVC Standards Committee, he has worked to Joel Feldstein produce a new structure for the committee that facilitates and The Lincoln Electric Co., Cleveland, increases global participation. He also chairs the ASME Sub- Ohio, has promoted Lisa Byall and Bruce committee on Welding. Feldstein has been an active member of the AWS A5 Com- Chantry to the newly created position of mittee on Filler Metals and Allied Materials and the A5D Subcommittee on Stainless portfolio manager. Byall, with the com- Steel Filler Metals. pany for 16 years, most recently served as product manager, flux cored wires, and worked in the distributor training depart- sales support for the Asian automotive Joseph Zuclich the 2009 George M. ment and as a technical sales representa- market segment. Wilkening Award for "brilliant contribu- tive. She will be responsible for overseeing tions in bioeffects research." Barat, a cer- the welding consumable portfolio. tified laser safety officer, is with National Chantry, with the company for 13 years, Applied Robotics Names Ignition Facility at Lawrence Berkeley Na- most recently was product manager, ad- Applications Engineer tional Laboratory. He has published sev- vanced welding equipment. He will be re- eral textbooks, including Laser Safety Management, and contributed to Medical sponsible for overseeing the welding Applied Robotics Inc., Glenville, N.Y., Applications of Lasers, and the LIA'sLa^er equipment portfolio. has appointed Jim Crowder an applica- Safety Guide, tenth edition. He also serves tions engineer. Crowder, with ten years of on the ANSI Z136 Standards Committee engineering experience, previously and LBNL Laser Safety Committee. Aitra Names VP worked for Precision Valve Automation, Zuclich, a research laser biophysicist re- Halfmoon, N.Y., where he served as a tired from Northrop Grumman, has inves- ^^^^^ Altra Industrial product manager. ^fl ^k Motion, Braintree, tigated a broad field of laser exposure pa- ^ ^ Mass., a producer of rameters, specifically laser-human tissue ' mechanical power interactions and ocular hazards to define transmission prod- Aluminum Association laser safety limits. r ucts, has appointed Appoints Chairmen _ Mark Klossner vice ^^^ ^ ^J president and gen- The Aluminum Association, Arling- PMA Elects Board 7^^^^ eral manager of the ton, Va., has announced appointments Chairman ^^^^ ^^^^ Altra Engineered within its Associate Member Committee. Mark Klossner Couplings Group. Named were David Pownall as chairman, Precision Metalforming Association, Klossner, with the and Jeff Lawrence as vice chairman. Pow- Cleveland, Ohio, has elected Wayne company since 2004, most recently served nall is sales director for J. Mclntyre Ma- Boeckman chairman of the board of di- as managing director for the company's chinery Ltd., based in Nottingham, UK. rectors for 2009. Boeckman is president business unit Matrix International, based Lawrence is the North American sales and CEO of Quick-Way Stampings, Inc., in Brechin, Scotland. manager for Houghton International Inc., in Euless, Tex. headquartered in Valley Forge, Pa.

Genesis Appoints Director Orbltform Group Names Laser Institute Presents Brazil Representative Genesis Systems Group, LLC, Daven- Achievement Awards port, Iowa, has appointed Makoto Mat- The Orbitform Group, a manufacturer suoka senior director of new domestic Laser Institute of America, Orlando, of riveting machines and assembly au- business development, based at the com- Fla., has awarded Ken Barat its 2009 R. tomation equipment, has named Alceu pany's Rochester Hills, Mich., facility. James Rockwell Jr. Educational Achieve- Natali its representative in Brazil. Natali Prior to joining the company, Matsuoka ment Award "for exceptional accomplish- has more than 30 years of experience in in- was a contract employee for Genesis as ments in laser safety education"; and dustrial sales in the Brazilian market.

FEBRUARY 2009 Empire Industries Names welding automation. He also presented neers (ASME) nuclear certification pro- courses in welding processes for AWS gram. He was a Fellow of ASME, and a Manager groups, the Cleveland Engineering Soci- collector of jazz music and sports cars. He ety, and Cleveland State University. In gave up driving when he was 98. Bunn Empire Industries Ltd., Fort McMur- 1948, Fassinger became vice president of spent the last few years living with his fam- ray, AB, Canada, a supplier of steel fabri- plant manufacturing at Universal Welder ily in St. Petersburg, Fla., and Washington, cation and installation services, has named Corp. From 1957 to 1960, he was assistant D.C. He is survived by his daughters Libby Vince Tldder projects and maintenance chief engineer for Auto Arc Weld Manu- Bunn, Joanna George, and Karen Hill, manager for Sorge's Welding Ltd., and its facturing, a producer of wire feeders and and several grandchildren and great- wholly owned subsidiary, Lemax Machine special welding systems, and in 1975, he grandchildren. & Welding Inc. Tidder, a certified inter- became president of Techniweld, Inc., a provincial steam pipefitter, most recently Cleveland, Ohio, welding, fabricating, and served as site manager for Jacobs Indus- heavy machinery job shop. He later served trial Services. as vice president of Manager Systems Div., Scott-Tarbell Inc., a welding distributor (1960-1971), and as marketing manager for Cecil Equipment Co., a supplier of NEW PRODUCTS welding guidance systems (1971-1972). Obituaries From 1972 to 1974, Fassinger worked as a - continued from page 27 consultant for automatic welding applica- tions. He served in the Army National Charies R. Fassinger Guard 1947 to 1973, and in the Vietnam Weiding Ciamps, Magnetic war as a lieutenant colonel. He was active Toois Aiiow Fast Setup in the Army Reserve until 1982, and served the state deputy commander for the Ohio Military Reserve. He was very active in Rotary International in Miami, Fla., and was a past president of the Cleve- r land, Ohio, club. He is survived by his wife, Janet, daughters Susan Crawford and Jill Williams, a son Glen, five grandchildren, and a sister, Carol Fedak.

Wiiiiam Bennett Bunn FTT William (Bill) Bennett Bunn, 100, died November 15. Bunn, an AWS Life Mem- A series of heavy-duty clamps and fitup ber, joined the Society in 1937. He was magnets is offered. The F-clamps, built with the Florida West Coast Section. A with the strength of drop forged, heat- longtime Bradenton, Fla., resident, his ca- treated, nickel/chrome plated bar stock, reer spanned more than 50 years as a con- feature a screw with copper-coating to sultant inspecting and certifying the safety protect against weld spatter. They come in Charles Fassinger of nuclear reactor components manufac- light duty (500 lb), 8 in.; heavy duty (1000 tured in the United States and overseas. lb), 8,12, and 16 in.; and super duty (1250 He was an authority on containment ves- lb), 8, 12, and 16 in. The 2-axis clamp is a Charles R. Fassinger, 79, died Novem- sels for securing radioactive materials. He solution for a 90-deg fitup. Useful for ber 22 at his home in Nashville, Tenn. He was working for the New Jersey-based M. welding square and round tubes, angle, served AWS as its treasurer (1987-1991), W. Kellogg Co., a manufacturer of power and channel iron, it contains a floating and from 1991 to 2003 he held various plant components, when his firm was head and rotating spindle screw. Four staff positions, including education direc- hired to work on the first nuclear-powered locking pliers and welding clamps have a tor, assistant executive director, managing submarine, the USS Nautilus, that was heavy-duty gnarled head and nickel- director of technical services, and associ- commissioned in 1955. Bunn developed chrome plated handles. These are avail- ate executive director of the Industry Ac- an early fascination for welding and work- able in 4, 6, and 11 in. along with a long tion Committee. He served as District 10 ing with machinery along side of his father, neck version. The swivel magnet adjusts to director, was a member of the National a machine shop supervisor for a railroad. almost any angle to hold metal objects in Nominating Committee, chaired the Na- He studied civil and mechanical engineer- place while welding; both 3-in. magnets tional Show Committee in 1970 and 1974, ing at the University of Tennessee before swivel 360 deg and pull with 50 lb of and chaired the Cleveland Section graduating with a degree in chemical en- strength. The magnetic ground clamp, (1971-1972), where he was named Man of gineering in 1932. He worked at the Navy rated at 500 A, can stick to any weldable the Year for 1980. He wrote articles on Yard in Washington, D.C, for four years ferrous metal and has an orange rubber- welding steel for ASM International Met- before beginning work for Kellogg in ized release lever. A twist of the knob re- als Handbook, a paper, 10 Criteria for 1939. He also worked for Combustion En- lease on the quick release magnet engages Welding Automation, and operation manu- gineering in Chattanooga, Tenn., for or disengages a firm hold on thick steel. als for training and qualifying workers for nearly 20 years before retiring in 1975 to welding aluminum LNG ships. Fassinger Bradenton, Fla. During retirement, he Hobart Welding Products worked on the design of GMA welding continued to work as a consultant for the www.HobartWelders.com equipment and lectured nationally on American Society of Mechanical Engi- (877) 462-2781

WELDING JOURNAL POSTER ABSTRACT SUBMITTAL Annual FABTECH International & AWS Welding Show Chicago, IL - November 15-18,2009 (Complete a separate submittal for each poster.) Primary Author (Full Name): -SchpoJ/cofnp^nyi. Mailing Address:

City: State/Province: Zip/Mail Code: Country: Email: Poster Title (max. 50 characters): Poster Subtitle (max. 50 characters): _Co;^jt_h9_!ts_)j. Name (Full Name): Name (Full Name): Affiliation: Affiliation: Address: Address:

City: City: State/Province: State/Province: Zip/Mail Code: Zip/Mail Code: Country: Email: Country: Email: Poster Requirements and Selection Criteria: • Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated. Complete this form using MSWord. Submit electronically via email to techpapers(a)aws.orq or print and mail. • Maximum size - 44 inches tall x 30 inches wide. (Vertical format, please). • Must be legible from a distance of 6 feet. A minimum font size of 14 pt. is suggested. • Posters must be submitted to AWS as a single flat printed medium (e.g. laminated print or foam core board mount). • Any technical topic relevant to the welding industry is acceptable (e.g. welding processes & controls, welding procedures, welding design structural integrity related to welding, weld inspection, welding metallurgy, etc.). • Submittals that are incomplete and that do not satisfy these basic guidelines will not be considered for competition. Posters accepted for competition will be judged based on technical content, clarity of communication, novelty/relevance of the subject & ideas conveyed and overall aesthetic impression. Criteria by category as follows: (A) Student (B) Student (C) Student (D) Professional Students enrolled in 2 yr. college For students enrolled in For students enrolled in graduate For anyone working in the welding and/or certificate programs at time baccalaureate engineering or degree programs in engineering or industry or related field. of submittal. engineering technology programs engineering technology at time of Poster must demonstrate technical Presentation need not represent at the time of submittal. submittal. or scientific concepts. Emphasis is actual experimental work. Rather, Poster should represent the Poster should represent the placed on original contributions emphasis is placed on student's own experimental work. student's own experimental work. and the novelty of the presentation. demonstrating a clear Emphasis is place on Poster must demonstrate technical Potential relevance to the welding understanding of technical demonstrating a clear or scientific concepts. Emphasis is industry is important and should be concepts and subject matter. understanding of technical placed on originality and novelty of demonstrated. Practical application is important concepts and subject matter. ideas presented. (E) High School and should be demonstrated. Practical application and/or Potential relevance to the welding Junior or Senior high school potential relevance to the welding industry is important and should be students enrolled in a welding industry is important and should demonstrated. at the time of be demonstrated. submittal. Presentation should represent technical concepts and application to the welding industry. Practical application and creativity are important and should be demonstrated. Check the category that applies: D (A) Student 2-yr. or D (B) Student 4-yr. 0(0) Graduate D (D) Professional D (E) High School Certificate Program Undergraduate Student Poster Title (max. 50 characters): Poster Subtitle (max. 50 characters): Abstract: Introduction (100 words) - Describe the subject of the poster, problem/issue being addressed and it's practical implications for the welding industry.

Technical Approach & Results (200 words) - Explain the technical approach. Summarize the work that was done as it relates to the subject of the poster.

Conclusions (100 words) - Summarize the conclusions and how they could be used in a welding application.

Return this form, completed on both sides, via email to [email protected] MUST BE RECEIVED NO LATER THAN April 3, 2009 The most complete event on weld cracking Learn different types... Understand the causes... Discover solutions.

The most perplexing problem in the welding industry has to be weld cracking. Back by popular demand, this two-day conference is for those who want or need to get a handle on any weld cracking situation. The 2009 conference will also include an exhibition and networking opportunities to allow you plenty of time to talk to welding cracking experts and others in industry that face the challenges weld cracking can present.Topics to be covered in the conference include:

• The Rewards in Purchasing Filler Metal by the AWS 5.01 Specification • Cracking Problems with Grade 91 and Other Creep-Strength Enhanced Ferritic Steels • Hot Cracking in Aluminum Welds • New Technique Determines Solid-Liquid and Solid-State Phase Transformations During Processing • Hot Cracking in Welding of Austenitic Stainless Steels • Induction Heating as a Tool for Minimizing the Risk of Weld Cracking • Fracture Mechanics- Operating with Defects • Reheat Cracking in Weldments • Understanding and Preventing Solidification Cracking in Fusion Welds • How AWS Dl.l Mitigates Weld Cracking • Temper Bead Welding Technique: An Alternative to Stress-Relieving Welded Repairs • How to Avoid Cracking in Titanium Welds • Measuring Residual Stress Using X-Ray Diffraction <• Quality Improvements in Heat Treatment • Ultrasonic Phased Array Testing Well Suited for Weld Inspection and Crack Detection

For the latest conference and exhibitor information visit our website at www.aws.org/conferences or call 800-443-9353, ext.455.

To secure tabletop exhibit space or for questions about exhibiting at the conference, pleaseDiease cancall BUU-^3-V3W,ext.^i3.800-443-9353, ext.213. Hostedby: 1 JVWP conference . e k American Welding Society® . iMhen Vou attend w ;

"t*"''" > amm 1- r ONFi CLASSIFIEDS

CAREER OPPORTUNITIES

Sales Representatives/Regional ADJUNCT INSTRUCTORS NEEDED Account Managers AMERICAN WELDING SOCIETY

Magnatech is looking for experienced AWS is recruiting instructors with experience in the education and application of welding, sales professionals. We manufacture visual inspection, radiographic interpretation, metallurgy, NDE processes, and project a comprehensive line of orbital management, to name a few. Current or recent retirees from industry, manufacturers, academia, sales or higher education are encouraged to submit credentials and references. tube/pipe welding systems. Several Consultants with an impressive track record for solving customer welding problems through territories are open. Magnatech is an improved welder/inspector/engineer understanding and performance are also encouraged established U.S. company, with a 2 to apply. Expectations include AWS preparatory seminars for certification exams, customized in-plant training. Instruction for certification programs: Welding inspection, year 250% sales growth . Systems uti- radiographic inspection, sales technicians, welding supervisors, and nationally advertised lize GTAW and FCAW processes. Mod- workshops and conferences. AWS pays above the average for conducting week-long els available to weld 0.062" to 6' and seminars. Please electronically send resume, references, and a cover letter to: larger. Highly motivated self-starters Martica Ventura Assistant Director of Education Services with proven sales skills required. Mag- [email protected] natech provides factory technical sup- port, on-site product demonstrations American Welding Society and customer training to support you. 500 N.W. LeJeune Road Call Scott at 860-653-2573 x18 or Miami, FL33126 visit our website at: www.magnatech-lp.com FIELD SALES MANAGER Welding Department Come grow with us Manager Steiner Industries is a leading manufacturer of welding & industrial safety and protective products. Due to our growth and planned expansion, we are seeking a dynamic and experienced sales Employer: NDT Technology Institute professional to manage sales through our existing network of manufacturer's representatives in the Location: Dammam, Saudi Arabia welding and industrial distribution channels. Salary: US$100,000.00 Tax Free Reporting to the president, the Field Sales Manager will be responsible for managing existing Contract: Full Time and Permanent distribution, developing new business opportunities & planning for the growth in his or her region. Applications Close: 15 February 2009 Essential qualifications include: welding industry experience, exceptional written interpersonal, presentation & communication skills, and the desire to make things happen! Competitive compensa- Start Date: As soon as possible tion package including salary with bonus, travel allowance, health insurance, paid vacation and holidays, and 40IK plan. NDT Technology Institute is a private Junior College offering AAS, HND de- STEINER INDUSTRIES 5801 North Tripp Avenue grees and certificate programs in En- Chicago IL, 60646 i e-mail your resume to: [email protected] gineering and Technology. luiaikiaA Learn more about Stcincr at www.stoinorindustrios.com The person appointed must have ex- cellent leadership skills, communica- tion skills, industrial & academic expe- AWS JobFind rience, proven management experi- ence at a senior level and MUST be qualified as minimum to BSc degree in Welding Engineering and a Masters level (or equivalent) in Business Ad- ministration. Evidence of successful business development would also be @ Find Jobs. beneficial. Send a full CV to: www.aws.org^obfind [email protected] Job categories for welders, engineers, inspectors, and more than 1', other materials joining industry classifications!

WELDING JOURNAL EQUIPMENT FOR SALE OR RENT

Use Your Product Photo MITROWSKI RENTS Boiler Tube and Promotional Literature Made in U.S.A. Alignment Tools to Increase Your Sales in Tank Turning Rolls 10-Ton April 2009 thru 1000-Ton

• DB model fits 2 tubes on specific OD's ranging from 7/8" to 1-3/4". • HD model fits 1 tube on specific OD's ranging from 1-3/4" to 3-1/4" (Patented)

NEW ' Quickly & accurately aligns waterwall tubes with 1/4" or 3/8" membrane. Fits OD tube sizes: 7/8" through 3" (Patented) Used Equipment for Sale More alignment tools available at our website: www.nnitrowskiwelding.com [email protected] 1-800-TUBE FIT (882-3348) 800-218-9620 Tel: 304-756-3796 / Fax: 304-756-3834 713-943-8032

Generate more sales leads by showcasing your full-color catalog We Buy & Sell Surplus or product photo, a product description, website address, or Welding Rod & Wire other sales literature. All types, sizes & Quantities These showcases reach 3 Major Problems with 70,000 qualified buyers. Its your Thermal Stress Relief best exposure for just pennies per contact. And How Meta-Lax3 Technology Overcomes Them All Closes February 15, 2009. Call us first! Call our sales team at: FREE Report 1-800-443-9353 800-523-2791 PA: 610-825-1250 "Overcoming Thermal FAX: 610-825-1553 Rob Saltzstein at ext. 243 Stress Relief Problems" [email protected] BOnnL nijill 800-Metal-29 TECHnoLOGiES cKB! WWW IHICltll iJJ Lea Garrigan-Badwy www.bonal.com • [email protected] at ext. 220 [email protected]

Welding Positioners & Tliming Rolls New and Used gpendepot.com

Large selection in stock for Paim markers for professionals immediate delivery. (Mark, Vrtlim ' • l>\ kern, MJI \ < www.allfabcorp.com .i Sakur.i Sharpif, SK\1. UniPaint. Call, Fax or Email for a free catalog. Tht' worlds best selection of markers'

^^^^ Email: [email protected] Order (.inline at m.irkinRpon

3a FEBRUARY 2009 EQUIPMENT FOR SALE OR RENT

Reconditioned Turning Rolls WELDlPLUlLUSl Newa WELDING SOLUTIONS Positioners •useUsed Machinery & Manipulators Aronson - Pandjiris - IRCO - Webb RED-D-ARC Ransome - Jetline - Profax - MBC New and Used Positioners - Manipulators - Seamers Quality-Checked" Turning Rolls - Welding Systems Joe Fuller LLC Used Equipment Fronius • Lincoln • Miller www.joefuller.com www.red-d-arc. com email [email protected] An Excellent Selection of Used Welding Phone: 979-277-8343 and Positioning Equipment for Sale Fax: 281-290-6184 1-800-245-3660 Service Centers Across North America

Weld Plus can customize new or used ATTENTION!! RETOOLING? CHANGING PRODUCTS? welding machinery with CLOSING SHOP? G0IN' FISHING? TIG-MIG-SUB ARC upon request VERSA-TIG• We pay good prices for used welding machinery! MULTIPLE TIG TORCH We are looking for any used welding machinery like: Turning 800-288-9414 SELECTORS Rolls, Positioners, Manipulators, Seamers, etc. www.weldplus.com Send Photos to: | www.versa-tig.com [email protected] IWELDI PLUS or call 800.288.9414

CERTIFICATION & TRAINING SERVICES

AISC Fabricator & Erector Certification Training Mechanical Drawings Learn about document requirements and how to MMt-^^Educational Services. Inc. Created implement them into your program! We make drawings to your CWI PREPARATORY SeeusatAMSCC specifications to meet ASME Guarantee - Pass or Repeat FREE! "The Steel Conference" Y14.5andAWS2.4. Contact CAD Star at: 2 WEEK COURSE (10 DAYS) Booth #1041 Phoenix Civic Plaza Convention Center: April 1-3 cad [email protected] MORE HANDS-ON/PRACTICAL APPLICATIONS Pascagoula, MS Apr. 6-10 & 13-17 Convenient classes In Chicago: Houston, TX Feb. 18-27 312-861-3000 | [email protected] Baton Rouge, LA Mar. 18-27 www.atema.com Ellijay, GA Apr. 22-May 1 /b: ma SAT-FRI COURSE (7 DAYS) Place Your EXTRA INSTRUCTION TO GET A HEAD START Pascagoula, MS Apr. 9-10 & 13-17 Classified Ad Houston, TX Feb. 21-27 Baton Rouge, LA Mar. 21-27 Here! Ellijay, GA Apr. 25-May 1 Contact Frank Wilson, MON-FRI COURSE (5 DAYS) Advertising Production GET READY-FAST PACED COURSE! Pascagoula, MS Apr. 13-17 Manager Houston, TX Feb. 23-27 Baton Rouge, LA Mar. 23-27 (800) 443-9353, Ellijay, GA Apr. 27-May 1 ext. 465 Test follows on Saturday at same facility [email protected] FOR DETAILS CALL OR E-MAIL: (800) 489-2890 [email protected] Also offering API 510, API 570, RTFilm Interpretation, MT/PTAJT Thickness, Welding Procedure Fundamentals and 9-Year Recertification Courses'.

WELDING JOURNAL ADVERTISER INDEX

Abicor Binzel IBC International Titanium Assoc 9 www.abicorusa.com 800-542-4867 www.titanium.org 303-404-2221

Aelectronic Bonding 25 Joe Fuller, LLC 15 www.abiusa.net 401-662-1123 www.joefuller.com 979-277-8343

Arcos Industries, LLC 41 KMT Saw 56 www.arcos.us 800-233-8460 www.kmtsaw.com 269-321-8860

Astro Arc Polysoude 13 Koike Aronson, Inc./Ransome 7 www.astroarc.com 661-702-0141 www.koike.com 800-252-5232

Atlas Welding Accessories, Inc 32 Lincoln Electric Co OBC www.atlaswelding.com 800-962-9353 www.lincolnelectric.com 216-481-8100

AWS Certification Services 59 Midalloy 32 www.aws.org 800-443-9353 www.midalloy.com 800-776-3300

AWS Education Services 10,22,48,55,60,98 NASCC Steel Conference 89 www.aws.org 800-443-9353 www.aisc.org/nascc 312-670-2400

AWS Membership Services 14,53,93 National Bronze & Metals, Inc 36 www.aws.org 800-443-9353 www.nbmmetals.com 713-869-9600 National Standard 1 Bluco Corp 47 www.nationalstandard.com 800-777-1618 www.bluco.com 866-372-5826 North Star Imaging, Inc 45 Bruker AXS Handheld 21 www.handheldxrf.com 800-234-9729 www.4nsi.com 800-635-8392 Pferd 37 Cor-Met 47 www.pferdusa.com 800-342-9015 www.cor-met.com 810-227-3251 Select Arc, Inc IFC CS Unitec 27 www.csunitec.com 800-700-5919 www.select-arc.com 937-295-5215 Thermadyne/Stoody 19 Diamond Ground Products, Inc 15 www.thermadyne.com 866-279-2628 www.diamondground.com 805-498-3837 TEC Torch Co., Inc 27 Divers Academy International 25 www.diversacademy.com 800-238-3483 www.techtorch.com 760-747-3700 Triangle Engineering, Inc 58 E. H. Wachs Co 33 www.trieng.com 781-878-1500 www.wachsco.com 800-323-8185 Weld Hugger, LLC 36 Electron Beam Technologies, Inc 57 www.electronbeam.com 815-935-2211 www.weldhugger.com 877-935-3447 Weld Mold Co., USA 5 Fischer Engineering Co 40 www.weldmold.com 800-521-9755 www.fischerengr.com 937-754-1750 WESTEC Advanced Productivity Expo 26 Fronius USA, LLC 2 www.fronius-usa.com 810-220-4414 www.westeconline.com 800-733-4763 IFC = Inside Front Cover Heck Industries, Inc 57 IBC = Inside Back Cover www.heckind.net 800-886-5418 OBC = Outside Back Cover Hobart Inst. of Welding Tech 56 www.welding.org 800-332-9448 Visit Our Interactive Ad Index: www.aws.org/ad-index

FEBRUARY 2009 SUPPLEMENT TO THE WELDING JOURNAL, FEBRUARY 2009 (W R C Sponsored by the American Welding Society and the Welding Research Council ^ *-^ Hyperbaric GMA Welding of Duplex Stainless Steel at 12 and 35 Bar

Underwater welds show excellent mechanical properties when made under dry hyperbaric conditions BY O. M. AKSELSEN, H. FOSTERVOLL, AND C. H. AHLEN

Introduction cost reduction since the offshore vessel ABSTRACT alone used for the remote equipment is Hot-tapping is now a well-established approximately half the daily cost of an ABSTRACT. The present work was technology both onshore and offshore offshore vessel with diver support, with- conducted to assess the weldability of subsea in connection of branch pipelines out including the additional cost of diver duplex stainless steel under hyper- to production pipeline systems without qualification (Ref. 1). baric conditions relevant for future re- stopping production. The majority of the The fully remote hot tapping will be mote-controlled hot tap welding. This onshore hot taps is based on welding the done using gas metal arc welding was achieved by horizontal welding branch pipe to the pipeline with subse- (GMAW), which represents a new situa- with Inconel® 625 wire in V-grooves quent tapping by using hydraulic drilling. tion in the Norwegian oil and gas indus- o on plates in 2205 duplex steel in cham- So far, the subsea hot taps have been try. Up to now, all diver-assisted remotely ber of 12 and 35 bar. The made by divers using welded branch pipe controlled welding has been done by gas highest maximum hardness occurred connections, preinstalled hot tap tees, or tungsten arc welding (GTAW) through < in the heat-affected zone (HAZ) of by using retrofitted hot tap clamps with the Pipeline Repair System (PRS) pool. LU the root bead, where HVJQ values in elastomer seals between the clamp and Here, the research and development (/) the range from 260 to slightly above the main pipe. However, elastomer seals leading to this technology were launched 280 were measured. The results LU used as a single barrier are often regarded in the middle of the 1970s (Refs. 2-7), 0C showed that there is weld metal un- as a risk with reduced reliability and with studies on how the weld metal chem- dermatch with respect to the yield safety. The reason is that the elastomer ical composition and moisture pickup strength (~ 460-490 MPa) , while the can deteriorate mainly due to swelling in were affected by pressure (water depth) tensile strength (~ 740 MPa) was at hydrocarbon service with a subsequent in welding of low-alloy steels. More re- the same level as that of the base plate. cently, the effects of hydrogen and o extrusion in the gap between the clamp The notch toughness at -30 C was ex- and the main pipe. To use welded seals is have also been evaluated for higher- cellent for all positions tested (weld regarded as a method to improve the life- alloyed steels, such as duplex stainless metal, weld interface, and weld inter- time, reliability, and safety. So far, less steels (Ref. 8) and supermartensitic 13% LU face +2 mm), and is far beyond cur- than ten hot-taps have been carried out Cr stainless steels (Ref. 9). However, rent offshore requirements. The HAZ on subsea pipelines in the North Sea. since the remotely controlled GTAW has 5 and weld metal were also character- These hot-taps have provided very cost- been developed for industrial use off- ized with respect to their microstruc- effective solutions, but are based on an shore in pipeline tie-ins and repair, the tures. Although the welds were quite approach using divers and it is thus lim- development of reliable equipment similar, the 35 bar weld appeared to ited to water depths where diving may be (Refs. 10-12) has been a major issue. All have a thin zone (0-40 |j.m thickness) applied. On the Norwegian continental this is now available under the PRS pool, of ferrite in the HAZ close to the weld shelf this limitation is 180 m maximum. and has been overviewed in a recent interface. The weld metal microstruc- Accordingly, there is a need for diverless paper (Ref. 13), showing that more than ture consisted of primary and sec- and fully remote-controlled technology 70 offshore pipeline tie-ins have been ondary dendrite arms, which are the for future hot tapping. This new remote completed so far. first to solidify. During this part of the system will also represent a substantial Hyperbaric GMA welding has been solidification, solute elements are en- developed over the past decades at Cran- riched in the liquid. With falling tem- field University, and is fully demon- perature, the is probably ex- strated for orbital V-groove welding ceeded with subsequent formation of KEYWORDS (Refs. 14,15) with successful process op- intermetallic phases, as well as ni- eration at up to 2500-m water depth. It trides/carbides. Finally, the base metal Hyperbaric Welding has already been selected as the process dilution was subjected to microprobe Gas Metal Arc Welding method for a sleeve repair technique for analysis, showing large variations in GMAW pipelines for operation at up to 1000 m in weld metal chemical composition be- Duplex Stainless Steel tween different passes. The implica- Inconel® 625 Weld Metal O. M. AKSELSEN and H. FOSTERVOLL are tions of the results with respect to cor- Mechanical Properties with SINTEF, Trondheim, Norway. C. H. rosion and fracture toughness are Microstructures AHLEN is with StatoilHydro Research Center, discussed. Trondheim, Norway.

WELDING JOURNAL s 0 •n V 'f-

- Hyperbaric welding chamber. Fig. 2 — Dimensions ofworkpiece (in mm).

the first instance. More information plied with 0.9 mm diameter. The major infrared combustion, while oxygen and about equipment, including details on alloying elements are Cr (~21%), Mo nitrogen contents were found by inert gas the structural design and installation of (-9%), Nb (3.3%), and Fe (-1%). fusion analysis. An optical emission spec- the hot tap tee can be found elsewhere trometer was used to determine the con- (Ref. 16). However, the present investi- Welding tent of all other elements. gation is part of the development of ro- bust GMA welding technology to be used Welding tests at 12 bar (Weld 1) and Mechanical Testing m in future diverless, remote-controlled 35 bar (Weld 2) were carried out in a tie-in and hot tap welding. Welding tests cylindrical chamber with volume of 100 L Mechanical testing included both all- were carried out in a small chamber pres- and internal diameter of 350 mm — Fig. 1. weld-metal tensile testing and Charpy V- g surized to 12 and 35 bar, corresponding The chamber was equipped with a con- notch toughness testing at -30oC, and was to 110- and 340-m water depth. A con- ventional wire feeder and GMA welding carried out in agreement with the DnV z ventional (22% Cr, 5% Ni) duplex stain- gun rigged up for V-groove welding of offshore standard (Ref. 17). Tensile bars o less steel was selected as plate material plates in the flat position. The length of were cut from the weld metal with length since it may be an alternative for hot tap the workpieces were 500 mm with total axis parallel to the welding direction. The J3 branch pipes. It was intended to identify width of 130 mm and thickness of 20 mm. specimens were 48 mm long with a 24- m a robust welding wire which gives excel- A 60-deg V-groove was machined for mm gauge length of 4-mm diameter, 0) lent resistance against corrosion and hy- welding — Fig.2. The power source com- while the 12-mm-long sample heads were m drogen-induced cracking, and a strength prised three modified Fronius Trans- M8 threads. Two parallels were included. > level similar to that of the base metal. For pocket TP450s in series. The chamber Charpy V samples of 10- x 10-mm cross this purpose, a solid Inconel® 625 Ni- was pressurized with 99.996% pure sections and 55-mm lengths were cut J3 based superalloy wire was selected. It argon, and no separate shielding gas transverse to the welding direction. O was shown that excellent mechanical through the welding gun was used. Prior These were taken out from the welds at a properties are achievable. to pressurizing, the chamber was evacu- distance of 2 mm below the plate surface. ated to 0.1 bar. The oxygen content in the The notch was positioned to provide frac- Materials and Experimental chamber was below 200 ppm when the ture along the welding direction. A total Procedure welding started. The welding parameters number of 3 parallels were tested at used for both welds are shown in Table 2. -30oC. Three different notch positions Materials The interpass temperature was maximum were included, i.e., the weld metal center, 50oC. Welding was done without stiffen- the weld interface, and the weld interface The chemical compositions of the ers, and the plates were thus free to de- + 2 mm. These are shown schematically base metal and the welding wire are out- form. As expected, substantial angular in Fig. 3. For all positions, macro-etching lined in Table 1. The base metal is a 20- distortion was found. was done to locate the notch. For the weld mm-thick plate of classical 2205 duplex interface position, the intention was to stainless steel (UNS S31803, 22% Cr-5% Chemical Analysis achieve roughly 50% weld metal and 50% Ni) with 3% Mo and 0.18% N. Its room- HAZ along the notch. temperature yield and tensile strengths Samples were cut for full chemical are 518 and 744 MPa, respectively. The analysis for both Welds 1 and 2. These Metallography selected wire is Inconel® 625, which is a were taken in the weld center (mid thick- nickel-based (~66%) superalloy sup- ness). Sulfur and carbon were analyzed by One macro specimen was cut as cross

Table 1 — Chemical Composition of Wires and Base Material (elements in wt-%)

rial C Si Mn P S Cr Ni Mo Al Ti N duplex steel 0.016 0.4 1.4 0.023 0.001 22.3 5.7 3.1 0.18 lei 625 wireW 0.015 <0.05 0.03 < 0.005 0.0006 20.68 65.74 8.81 0.24 0.063

(a) With 3.23% Nb, <0.05% Co, 1.09% Fe.

FEBRUARY 2009, VOL. 88 \ iAmn* fraclM*- Itrritr: (. - U. / L. ^

Fig. 3 — Schematic illustration ofCharpy V-notch location. A — Weld metal center; B — weld interface; C — weld interface + 2

Fig. 4 — Schematic illustration of measurements (rough estimates) of o ferrite volume fractions in the FLAZ. < LU sections from each plate weld and pre- the one-sided welding without the use of the level in the base metal (0.18 wt-% N). pared using standard metallographic stiffeners, substantial angular distortion The weld metal oxygen content is low if) techniques. Vickers hardness traverses took place. Thorough examination in un- (120 ppm). The carbon content was also LU with 10-kg load (HVJQ) were run across etched and etched macro specimens in an low (0.01 wt-%). Finally, there is a slight OC the entire weld and the base metals both optical microscope did not reveal any pickup of Mn due to base metal dilution, in the cap and root positions. After macro critical weld defects. i.e., from 0.03 wt-% in the wire to photos were taken, the specimens were 0.18-0.19 wt-% in the welds. examined in more detail for microstruc- Weld Metal Chemical Composition ture characterization. For HAZ examina- Hardness Profiles tion, the specimens were etched in NaOH The weld metal chemical composition solution. The austenite-ferrite contents is outlined in Table 3. It is seen that some Hardness traverses were performed m were estimated based on the mean linear Ni is "lost" due to pickup of iron through on both the root and the cap side of the interception length concept, as briefly de- base metal dilution (6.7 wt-% Fe for both macro specimens. The maximum individ- g: fined in Ref. 18. This was done on micro- welds). The Ni content is slightly above 60 ual hardness values found in the base graphs taken at a magnification of 200x, wt-%, while the Inconel wire had almost metal, HAZ, and weld metal are plotted and is schematically illustrated in Fig. 4. 66 wt-%. Molybdenum is also somewhat in Fig. 5 and listed in Table 4, where min- Subsequently, the Inconel 625 weld metal lower in the weld than in the wire. The ni- imum, maximum, and average values are was examined based on electrolytical trogen concentration was found to be summarized. The highest individual level etching of specimens in 10% oxalic acid 220-230 ppm, which is much lower than was found in the HAZ of the root bead. (aqueous solution) for 20-30 s, operating ai loom LempeiaLuie wmi u v aim i rt. Table 2 — Welding Parameters Results and Discussion Parameter 12 bar (Weld No 1) 35 bar (Weld No 2) Welding current (average) 170 A 166 A Weld Defects Arc voltage (average) 28.8 V 29.8 V Welding speed 6 mm/s Both Welds 1 and 2 were completed Wire feed rate 10 m/min with 14 individual stringer beads. Due to Interpass Maximum 50oC

Table 3 — Weld Metal Chemical Composition (elements in wt-%)

Weld No. C Si Mn S Cr Ni Mo Nb Fe Al Ti N O l(12bar)00 0.01 <0.1 0.18 0.002 21.1 60.4 7.9 3.2 6.7 0.17 0.09 0.022 0.012 2(35bar)00 0.01 <0.1 0.19 0.002 20.9 60.8 7.7 3.2 6.7 0.17 0.09 0.023 0.012

(a) With 0.08% Cu.

WELDING JOURNAL -WMMI 350 WW2 300 ~*" (A 0) 290 ^^x .1. •D (5 ^ "X -^ .c 200 ^ E F 190

100 i 1 Mft7 *Nil 90 - • 0 —X 1 u 1

PoMton

Kg. 5 — Hardness distribution in Welds 1 and 2. Fig. 6 — Charpy V-notch toughness at -30oC (open rectangles: individual values, filled rectangles: average value).

m o z o J3 m m Fig. 7— HAZ microstructure of cap bead. A — Weld 1; B — Weld 2. > J3 O Table 4 — Hardness Distribution in the Welds

Weld No. Base Metal HAZ Weld Metal Min Max Mean Min Max Mean Min Max Mean

S8 217 222 229 (12 229 283 246 (17 193 220 204(6 indendations) indendations) indendations) S9 214 225 238 (10 239 284 249(9 201 220 208(7 indendations) indendations) indendations)

Table 5 — Results from All Weld Metal Tensile Testing

Weld No. Yield Strength Rp0,2, MPa Tensile Strength Rm, MPa Elongation at Fracture A5, % Yield to Tensile Ration Rp02/Rm Base metal 518 744 — 0.70 1 (12 bar) 491 739 67 0.66 2 (35 bar) 468 735 70 0.64

i.e., 283-284 HV10 for both welds, both and 240 HV10. These hardness values are Tensile Properties with average close to 250. The maximum similar to previously reported results weld metal hardness was relatively low, (Refs. 1, 19) using the Inconel wire in The results from all-weld-metal tensile 220 HVJQ with mean values of 204 and welding of low-alloy API X65 steels for a testing are summarized in Table 5. The 208 for Welds 1 and 2, respectively. The wide range in water depths (pressures be- average yield strengths were 491 and 468 base metal hardness varied between 220 tween 12 and 100 bar). MPa for Welds 1 and 2, respectively, with

FEBRUARY 2009, VOL. 88 1 0» I 0» t 07 RSsft* ? 06 0 ^^-^^C^i^--2^- A 2 fractio a t 0* innii' 5 02 ABSWMI; 01

0 90 (00 IW 200 2M 300 »0 400 Distance from weld interface |am

Kg. 8 — Variation in HAZ volume-fraction offerrite as function of distance Fig. 9 — Microstructure in primary weld metal, Weld 1. from the weld interface (the lines are "trend lines").

HBHflpi fVQton 1

RalwaM ^H H Fig. 10 — Close-up of area in Fig. 6, Weld 1.

corresponding tensile strengths of 739 than earlier reported and 735 MPa. This means that both welds values for X65 welds, represent an undermatch situation, i.e., where the Inconel 5 weld metal yield strength is lower than 625 weld metal had that of the base metal (518 MPa). How- toughness values be- ever, the yield strengths of both welds are yond 200 J (Ref. 19). higher than the minimum specified yield High toughness of strength for the base metal, satisfying cur- Inconel 625 weld rent requirements set to X65 pipe (65,000 metals are expected lb/in2 or 450 MPa in yield strength). The since there is no tran- tensile strength is similar to that of the sition temperature base metal. from ductile to brit- tle fracture for nickel Notch Toughness alloys. The weld in- terface toughness The results from impact testing are il- was also very good Fig. 11 — Overview of reheated weld metal. A — Weld 1; B — Weld 2. lustrated in Fig. 6. Three positions were with individual val- tested; 1) weld metal, 2) weld interface, ues in the range and 3) weld interface + 2 mm. It is seen 112-132 and 132-141 J for Welds 1 and 2, the weld, which may imply that the ratio that all positions possessed excellent respectively. Thus, the two welds are between the HAZ and the weld metal dis- toughness (> 100 J) at -30oC. Moreover, quite similar. In addition, the scatter in tributed along the notch in the Charpy the scatter is quite low between the dif- toughness is quite low in spite of the fact specimen will vary almost from 0 to 1.0. ferent parallels. For Weld 1, the weld that the impact value represents a mix- The Charpy specimens have not been ex- metal toughness exceeded 150 J, while ture between the duplex HAZ and the In- amined after the completion of testing, so Weld 2 had values slightly below 150 J. conel 625 weld metal. Moreover, the weld this ratio is not yet known. Therefore, it is However, this toughness is still a bit lower interface is expected to fluctuate along difficult to assess the present results in a

WELDING JOURNAL Fig. 12 — Variation in element concentration in Weld 2. A — Cap layer; B — through plate thickness.

consumables will ob- both Welds 1 and 2 for comparison of the viously be very im- nitrogen distribution. tt tm _ portant, and the In- A high-volume fraction of ferrite in conel 625 appears to the high-temperature region of HAZ in give satisfactory ro- duplex stainless steels is not surprising, bustness. but rather usual. This is due to the grain coarsening of the ferrite taking place dur- Microstructure ing the heating cycle followed by rapid Examination cooling, which together with the grain coarsening may prevent austenite forma- The HAZ mi- tion. Such high amount of ferrite is con- _fl» Jff.-*- crostructure of Weld sidered detrimental to notch toughness i 1 consists of ferrite and also the corrosion resistance through and austenite (Fig. possible precipitation of chromium ni- o 7A), but with more trides (C^N or CrN) in the ferrite which ferrite than in the may take place due to limited solubility of m base metal. Weld 2 nitrogen in ferrite. The Cr nitrides will 0) C*IPMNO also had similar mi- then reduce the PREN value of the ma- crostructure in the trix with a possible rise in the pitting cor- Fig. 13 — Pitting resistance equivalent (PREN) values across the cap layer m HAZ, but here there rosion susceptibility. In addition, an of Weld 2. The nitrogen contents are 0.18% in the 2205 base metal, 220 > was found a 40-80 eventual diffusion of nitrogen into the ppm in Weld 1, and 230ppm in Weld 2. The content in the Inconel 625 wire |j,m narrow layer at weld metal due to the large concentration 33 is not known. O the weld interface gradient may cause a further reduction of with only ferrite — the local pitting corrosion resistance. statistical manner, but there is no reason Fig.7B. This observation is probably Therefore, it is usual to specify a certain to believe that the toughness should sud- linked to the welding arc restriction with range in the ferrite content to satisfy off- denly drop to levels below the minimum increasing chamber pressure (water shore requirements in welding of duplex requirements set in current offshore depth), as the case when going from weld stainless steels. One example is discussed specifications. For X65 type of quality, deposition of Weld 1 at 12 bar to Weld 2 at later in this paper. the Charpy requirements are minimum 35 bar. The smaller arc area may thus, in The ferrite and austenite volume frac- single and average values of 38 J and 45 J, turn, cause more rapid cooling, which may tions were estimated using mean linear respectively (Ref. 17). For an X70 pipe, be sufficient to prevent austenite nucle- intercept technique to quantify the mi- the corresponding values are raised to 40 ation within a narrow band close to the crostructure in different distances from and 50 J. With these requirements in weld interface. An additional cause may the weld interface. It should be noticed mind, the welds are clearly acceptable in be diffusion of nitrogen from the HAZ to that the distance from the weld interface terms of mechanical properties. the weld metal due to the large concentra- is roughly approximated due its bowing However, the impact values are much tion gradient in nitrogen, i.e., from 0.18% nature. The results are shown in Fig. 8. lower than that previously reported for N in the base metal to 220-230 ppm in the This plot confirms the high-volume frac- weld interface notched specimens when weld metal. This diffusion may take place tion of ferrite in the HAZ of both welds welding low-alloy X65 steel with Inconel when the region close to the weld interface close to the weld interface, and that Weld 625 wire (Ref. 19). On the other hand, is brought up to the temperature of par- 2 contains almost ferrite only in a narrow the toughness level is beyond that re- tially melting or when it is fully ferritic region, as already noticed in the micro- ported in conventional (at 1 bar) flux where the diffusion is more rapid than in graph in Fig. 7B. The statistics are quite cored arc and submerged arc welding, austenite. An eventual verification of this poor here, and there is certainly also a which was in the range of 63-76 and phenomenon would be possible through large scatter. The results must therefore 100-141 for the weld interface and HAZ, more detailed microprobe analyses per- be treated with some care. It should be respectively (quoted in Ref. 20). For the forming several line scans across the nar- kept in mind that the DnV offshore stan- weld interface toughness, the welding row ferrite band and the weld interface in dard prescribes the volume-fraction of

FEBRUARY 2009, VOL. 88 ferrite to be within the range from 0.35 to region is very similar to that of the pri- tent differences in composition between 0.55 for the base metal, and between 0.35 mary weld metal. Still, redistribution of ferrite and austenite. This may explain and 0.65 for the HAZ and the weld metal alloying elements may take place, de- the small deviations between the data in in welding of duplex stainless steel with pending on the temperature and time Fig. 12 for the base metal and the chemi- matching consumables (Ref. 17). There- available for diffusion. cal composition data in Tables 1 (base fore, a part of the HAZ in both welds, metal) and 3 (weld metal). representing a distance from the weld in- Base Metal Dilution terface of 60 |im is clearly outside the Practical Implications specified range. In a welding procedure Base metal dilution may change the qualification situation, this fact would chemical composition locally, and may The quantitative effects of the varia- have to be dealt with through verification thus be important to corrosion resistance tions in chemical composition and base of sufficient mechanical and corrosion and local fracture toughness. Such dilu- metal dilution are not possible to assess properties through testing. tion was examined in different beads and from the present investigation. There are The weld metal microstructure of in the HAZ to obtain information on the numerous corrosion types that may take Weld 1 is shown in Fig. 9 and reveals den- local variations in chemical composition. place, including general corrosion, pit- drite solidification. Similar features were The chemical analyses were performed ting corrosion, crevice corrosion, stress found in the study of Weld 2 microstruc- with JEOL JXA-8500F instrument corrosion cracking, sulfide stress corro- tures. The primary dendrite arms (gray- equipped with a wavelength dispersive sion cracking, intergranular corrosion, brown) solidify first, followed by sec- spectrometer (WDS). Three individual galvanic corrosion, contact corrosion, ondary dendrite arms, and finally, the analyses were performed per location, and the subject in focus over the past interdendritic regions (blue) where en- and large variations were found for cer- decade, hydrogen-induced cracking richment in solute elements takes place, tain beads. The results are plotted in Fig. (HIC). primarily Nb and Mo. With falling tem- 12 in terms of element concentration (wt- Under certain conditions, particularly perature during cooling, the solubility of %) for Fe, Ni, Cr, Mo, and Nb. For the involving high of chlo- these solutes decreases with subsequent cap layer data plotted in Fig. 12A, is it rides (such as sodium chloride in seawa- formation of intermetallic phases and seen that the base metal dilution is fairly ter), moderately high temperatures and precipitation of particles. This point is high for sidewall beads, with more than exacerbated by low pH (i.e., acidic condi- shown in Fig. 10, where particles are en- 20 wt-% Fe in one of these beads. Here, tions), very localized corrosion can occur tirely present in the interdendritic re- the Ni content was reduced from about 66 leading to perforation of pipes and fit- o gions, further underlining the micro- wt-% in the welding wire to approxi- tings, etc. Grades high in chromium, and scopic segregation of solutes. These mately 44 wt-%, which confirms a base particularly molybdenum and nitrogen, particles may be carbides (e.g., NbC, metal dilution of about 20%. The Cr con- are more resistant to pitting corrosion. < black spots in the figures) or intermetal- tent in the weld metals (22-23 wt-%) The Pitting Resistance Equivalent Num- LU lic particles (e.g.. Laves phase, blue parti- were similar as their origins, namely the ber (PREN) has been found to give a if) cles in the figures). Due to the thermody- welding wire and the base metal. The Mo good indication of the pitting resistance LU namics with mutual full solid solubility and Nb concentrations are slightly lower of stainless steels. The PREN can be cal- between Nb and Mo, and between Cr and in the cap layer than in the wire due to culated as (in wt-%): Mo, there are several possible stoi- base metal dilution. In the central bead of chiometries of the intermetallic phases. the cap layer, there is as expected much PREN = Cr + 3.3 Mo + 16 N In the Ni-Nb binary system, Ni8Nb and lower base metal dilution with 7-9 wt-% NijNb may form on the Ni-rich side. For Fe, indicating a dilution of 6-8%. As ex- The PREN values for the base metal binary Cr-Nb mixture, the CrjNb may pected, the vertical (through thickness) and the weld metal are 35.4 and 50.1, re- exist. In binary Ni-Mo alloys, several element distribution plotted in Fig. 12B spectively. Since the weld metal repre- phases are possible, both stable and demonstrates that the highest base metal sents a mixture between these two ex- LU metastable phases may form. Previous dilution is found in the root pass. Here, tremes, the PREN would be expected to microprobe analyses of similar Inconel the Fe concentration is about 26 wt-%, fall between them. This is further evi- 5 625 weld metals (Ref. 19) have confirmed with Ni content of 56-58 wt-%. By con- denced by the plots in Fig. 13 illustrating the presence of Nb-rich particles present, trast, the mid-thickness central weld pass the PREN value distribution in the cap often with Ti, N, O, and C, indicating that revealed low dilution with 5-6 wt-% Fe layer of Weld 2. Similar results were the analysis volume comprises of NbN (or and 58-59 wt-% Ni. As with the horizon- found for Weld 1. Therefore, the welds NbCN), together with Ti-containing non- tal cap layer analyses, the Cr, Mo, and Nb should have sufficient resistance to pit- metallic inclusions. The intermetallic contents were fairly constant throughout ting with all PREN values above 43. How- particles seemed to be consistent with a the plate thickness along the weld center- ever, as previously noticed, high ferrite (Mel)2(Me2) kind of phase, suggesting line. The vertical analyses along the side- content in the HAZ may cause precipita- them to be Laves phase of the form wall of the groove showed large scatter in tion of Cr nitrides, which again may (Ni,Cr,Fe)2(Nb,Mo). Nb and Mo have the Ni content, i.e., 41-55 and 39-58 wt- change the resistance against localized large atomic radii, while Ni, Cr, and Fe % for Welds 1 and 2, respectively. These corrosion attacks. have smaller, but similar-sized radii. Due variations are also associated with similar Hydrogen-induced cracking may take to their presence, questions can be raised variation in the Fe content, which is due place under cathodic protection where concerning their effects on mechanical to pertinent variations in positioning the potential provides hydrogen genera- properties and corrosion resistance. (welding gun) of the individual stringer tion. Hydrogen atoms may enter the ma- However, intermetallic precipitates rep- beads in the groove. terial with subsequent degradation of ma- resent the major strengthening mecha- It should be noticed that the volume of terial toughness as a consequence. nism in higher-alloyed Ni-based superal- analysis is only in the order of 1 |im3, by Alternatively, hydrogen may enter the loys like Inconel 718. contrast to the large volume involved in material by a corrosion process by sour The reheated weld metal microstruc- base metal and weld metal chemical service (sulfide stress corrosion crack- ture is shown in Fig. 11. Due to the ab- analyses (typically 1 in. in diameter). Mi- ing). In order to resist sour service, a max- sence of solid-state phase transforma- croprobe analysis may detect eventual imum hardness level of 22 Rockwell C (= tions, the microstructure of the reheated macro/micro segregations, and the po- 248 Vickers hardness) is required (Ref.

WELDING JOURNAL 21). However, this is valid for carbon steel toughness values were very high, includ- ics and Arctic Engineering (OMAE), Paper No. only. For wrought and cast duplex stain- ing those of the weld interface. OMAE2005-67554, Halkidiki, Greece. less steels in the solution-annealed and • The weld metal microstructure 10. Habrekke, T, and Knagenhjelm, H. O liquid-quenched condition, hardness re- study revealed dendrite solidification 1989. Hyperbaric mechanized TIG welding for underwater tie-in and repair operations, using quirement is set to 28 HRC (= 286 HV) with primary and secondary dendrite the IMT (Integrated Modular Tool) system. maximum (Ref. 21). Heat treatments to arms, and interdendritic regions with en- Proc. Int. Conf. on Welding under Extreme Con- increase strength or hardness are not al- richment in solute elements, primarily Nb ditions, Int. Inst. Weld., Helsinki, Chap. V, pp. lowed. For welds in duplex stainless steels and Mo. The decreasing solubility of 247-260. (Ref. 22), the hardness may not exceed an these solutes during cooling resulted in 11. Berge, I. O., Habrekke, T, and Kna- average value of 310 HV10, and no indi- formation of intermetallic phases. Along genhjelm, H. O. 1991. Automation in under- vidual reading may exceed 320 HVJQ. In with this, precipitation of particles took water hyperbaric pipeline welding. Proc. 10th addition, the measured weld metal and place. Int. Conf. on Offshore Mechanics and Arctic En- HAZ ferrite volume fraction must be be- • Base metal dilution resulted in large gineering (OMAE), Stavanger, Norway, Vol. 111-A, pp. 163-167. tween 0.35 and 0.65 (Ref. 17). In the pre- local variations in the weld metal chemi- 12. Habrekke, T, Armstrong, M., and sent investigation, the highest HV value cal composition. The quantitative effects Berge, I. O. 1997. Deep water pipeline weld- in the HAZ was found to be 283 in the of these variations in chemical composi- ing and repairs using modern computer tech- HAZ of the root pass in Weld 1. It should tion cannot be assessed from the present nology to create a diverless future for Statoil. therefore satisfy current requirements set investigation, but the low hardness level Proc. 7th Int. Conf. on Computer Technology in to maximum hardness. The same is the should satisfy requirements set for sour Welding, San Francisco, NIST Special Publica- case for Weld 2, but here the ferrite vol- (or at least mildly sour) service. tion 923, pp. 31-41. ume fraction is almost 1.0 in a narrow re- 13. Akselsen, O. M., Aune, R., Fostervoll, gion (0-40 |im thickness) at the weld in- Acknowledgments H. and Harsvaer, A. H. 2006. Dry hyperbaric terface. The implication of this finding is welding of subsea pipelines. Welding loumal. Vol. 85(6): 52-55. not clear since all toughness values were The authors wish to thank StatoilHy- 14. Richardson, I. M., Woodward, N. I., very high, including those of the weld in- dro and Gassco for financial support. The and Billingham, I. 2002. Deepwater welding terface. However, it may influence the assistance by Morten P. Raanes (micro- for installation and repair — A viable technol- resistance against localized corrosion probe analyses) and Synn0ve Aldstedt ogy?. 12th Int Conf on Offshore and Polar En- attacks such as pitting. Such testing (metallography) is gratefully acknowl- gineering (ISOPE), Kita-Kyushu, Japan. m was outside the scope of the present edged. 15. Richardson, I. M., Woodward, N. J., investigation. and Billingham, J. 2002. Diverless underwater g References GMA welding, IIW-Doc. SCUW-197-02,Proc Conclusions 55th Annual Assembly of the International Insti- tute of Welding (IIW), IIW Selected Commit- z 1. Woodward, N. J., Fostervoll, H., Ak- tee for Underwater Welding (SCUW), Copen- selsen, O. M., Ahlen, C. H., Berge, J. O., and o The present work was carried out as hagen, Denmark, pp. 1-19, IIW. Armstrong. M. 2007. Evaluation of welding part of the development of hyperbaric gas 16. Apeland, K. E., Berge, J. O., Verley, R., J3 metal arc (GMA) welding for future re- procedures and consumables for hyperbaric Woodward, N. J., and Armstrong, M. 2004. GMAW for diverless retrofit tee hot tap appli- mote-controlled hot tap welding. The Deep water remote welding technology for m cations. 17th Int. Offshore and Polar Eng Conf. pipeline repair and hot-tapping. Proc Int. 0) welding trials for mechanical testing and (ISOPE), Lisbon, Portugal. Conf. & Ex. on Deep Offshore Technology metallographic inspection were per- 2. Grong, 0., Olson, D. L., and Chris- m (DOT), Houston, Tex. formed at 12 and 35 bar with 2205 duplex tensen, N. 1985. Metal Constr. 17, 810R-814R. > 17. DnV (2007), Det norske Veritas Off- stainless steel base metal and Inconel 625 3. Christensen, N. 1983. The metallurgy in shore Specification DNV-OS-F101: Subma- J3 solid wire. The following main conclu- underwater welding. Proc. Int. Inst. Weld. Conf. rine Pipeline Systems. Underwater Welding, Trondheim, Norway, pp. O sions can be drawn: 18. ASTM Standard. 1996. Designation: E 71-79, Pergamon Press. • The highest single hardness value 112-96, Standard Test Methods for Determining 4. Kvaale, P. E., Gjermundsen, K., and was 283 HV10, found in the HAZ of the Average Grain Size. 2205 duplex steel. All other values were Christensen, N. 1983. Moisture absorption of 19. Akselsen, O. M., Fostervoll, H, and basic electrodes under pressure up to 33 bar. Ahlen, C. H. 2008. Hyperbaric gas metal arc below about 250. However, it should be Proc. Int. Inst. Weld. Conf. Underwater Welding, welding of API X65 pipeline steel at 12,25, and noticed that these welds were allowed to Trondheim, Norway,, Pergamon Press. 35 Bar. 18th Int Offshore and Polar Eng Conf., freely distort since no stiffeners were 5. Knagenhjelm, H. O., Gjermundsen, K., (ISOPE) Vancouver, Canada. used. Kvaale, P. E., and Gibson, D. 1982. Hyperbaric 20. Nowacki, J. 2004. Duplex steel welding • Both welds represent a strength un- TIG welding to 500 m simulated depth. Proc. problems in the building of cargo ships. Weld. Int. Conf. Underwater Technology (OTC), dermatch situation where weld metal Int., Vol. 18, pp. 509-515. Bergen, Norway. yield strength is lower than that of the 21. NACE Standard MR0175-2003: Sulfide 6. Christensen, N., and Gjermundsen, K. base metal (518 MPa). The yield Stress Cracking Resistant MetallicMaterials for 1977. Effects of pressure on weld metal chem- strengths were 491 and 468 MPa for Oilfield Equipment. Houston, Tex. istry. Int. Inst. Weld. Document HW-doc. 212- Welds 1 and 2, respectively, with corre- 22. NACE Standard MR0103-2003, Mate- 395-77. sponding tensile strengths of 739 and 735 rials Resistant to Sulfide Stress Cracking in 7. Christensen, N., and Gjermundsen, K. Corrosive Petroleum Refining Environments. MPa. The tensile strength is similar to 1976. Effects of pressure on weld metal chem- Houston, Tex. that of the base metal. istry. Int. Inst. Weld. Document HW-doc. 212- • Three positions were tested with re- 384-76. spect to notch toughness; 1) weld metal, 8. Habrekke, T, Kvaale, P. E., and R0rvik, 2) weld interface, and 3) weld interface + G 1996: Hyperbaric welding of duplex stain- 2 mm. As shown, all positions possessed less steels. Proc. Int. Conf. Offshore Mechanics excellent toughness (> 100 J) at -30oC. and Arctic Engineering (OMAE), Firenze, Italy. • Some concern may be raised with re- 9. Aune, R., Knagenhjelm, H. O., and spect to the high ferrite volume fraction Harsvcer A. 2005. Hydrogen and oxygen pick- (~ 1.0) in a narrow (up to 40 |a,m) region up in hyperbaric TIG welding of supermarten- at the weld interface, although the impli- sitic 13% Cr stainless steel with matching filler cation of this finding is not clear since all wire. Proc. 24th Int. Conf. on Offshore Mechan-

FEBRUARY 2009, VOL. 88 Control of Longitudinal Bending Distortion of Built-Up Beams by High-Frequency Induction Heating

A new practical method was proposed to mitigate iongitudinal bending distortion ofbuiit-up beams during fabrication processes

BY J. U. PARK, S. C. PARK, AND C. H. LEE

built-up beams are to be made in a ing distortion on the cross-sectional part ABSTRACT month. Fillet welding is employed to pro- of a strip plate and verified the validity of duce built-up beams, connecting web his results by comparing them with ones Longitudinal bending distortion is in- plates to flange plates. During manufac- obtained from experiments. Masubuchi duced by fillet welding during the turing, fillet welding induces built-up (Ref. 5) estimated the residual distortion build-up process of T-section beams. beams to deform longitudinally (Ref. 1) of an aluminum plate with a T-section This distortion decreases productivity because the weld length is relatively long using one-dimensional thermal elastic- and the quality of welded structures (5~22 m) and weld metals deposited on plastic analysis and compared it with re- because it requires additional correc- the joint are located lower than the neu- sults obtained from experiments. Aoki tion work in the assembly stages of tral axis of the built-up beam. Accord- (Ref. 6) classified the factors affecting ship construction. Longitudinal bend- ingly, various methods have been used to distortion via numerical analysis and ex- o ing distortion is caused by the welding prevent or correct the longitudinal bend- periments by using the results of the study moment, which is calculated by multi- ing distortion in shipyards. The first one by Tsuji (Ref. 4) and proposed simple < plying the shrinkage force due to weld- is triangular heating on the web plate equations. Jang (Refs. 7,8) estimated the LU ing by the distance between the weld- using a gas burner after welding; the sec- magnitude of longitudinal distortion due CO ing heat source and a neutral axis on ond one is to produce plastic deformation to welding and the amount of triangular LU the cross section of built-up beams. using mechanical presses after welding. heating needed to correct the distortion. However, this distortion can be miti- But these methods have disadvantages in By the way, all these studies focus on the OC gated by induction heating on the web that distortion has to be corrected in a estimation of the amount of longitudinal plate of built-up beams, generating a separate stage of the manufacturing bending distortion, except Jang's (Refs. 7, O reverse moment of the same magni- process, which decreases productivity 8). However, his method has the disad- tude as the bending moment due to fil- and the quality of hull assembly. vantage that the distortion must be cor- let welding. In this study, location and As a result, these problems brought up rected in a separate stage of the manu- intensity of induction heat input were the necessity of research to estimate and facturing process after welding. determined based on experiments and prevent the longitudinal bending distor- Therefore, this study focuses on ex- LU simple equations. The mechanism of tion, and a series of studies was done by plaining the mechanism of the longitudi- longitudinal bending distortion in the Sasayama (Ref. 2). He estimated the nal bending distortion in built-up beams 5 build-up process was investigated amount of longitudinal bending distor- using three-dimensional thermal elastic- using three-dimensional thermal elas- tion with a change of leg length of weld- plastic analysis, and proposing a new con- tic-plastic analysis. A new control ing using simple beam theory. Okerblom trol method of this distortion by using in- method of longitudinal bending dis- (Ref. 3) presented simple equations to es- duction heating with verification of its tortion was proposed using high- timate the amount of longitudinal bend- validity by comparing the results of nu- frequency induction heating with ing distortion through thermal elastic- merical analysis and experiments for the verification of its validity. plastic analysis and verified his large T-section structures. theoretical results by comparing against experimental results. Tsuji (Ref. 4) also Longitudinal Bending Distortion performed a thermal elastic-plastic and Its Control Method Introduction analysis to estimate the amount of weld- During a manufacturing process for Built-up beams are widely used to im- built-up beams, fillet welding causes tran- prove the longitudinal strength of ship KEYWORDS sient and residual longitudinal bending structures. In general, four Very Large distortion in the built-up beam. The Crude-oil Carriers (VLCCs) are built in a Distortion Control mechanism of the distortion can be ex- year. In this case, about 1050 pieces of Built-Up Beams plained through three-dimensional ther- Finite Element Analysis mal elastic-plastic analysis using the finite /. U. PARK is with Civil Engineering Dept., Induction Heating element method. Major parameters Chosun University, S. C. PARK is with Dept. of Distortion known to have influences on inducing Mechatronics, Koje College, and C H. LEE is Longitudinal Bending and mitigating longitudinal bending dis- with Civil and Environmental Engineering tortion are evaluated by investigating the Dept, Chung-Ang University, Korea. numerical analysis results.

WELDING JOURNAL Table 1 - - Dimensions and Heat Input for Finite Element Analysis

Model Flange Plate Web Plate Length Heat Input of Ni (mm) Type (mm) mm) L (mm) Ind. Heating (cal/mm3-s) Width Thickness Width Thickness

Al 150 18 250 11.5 3000 A2 150 18 250 11.5 3000 0.640 95 A3 150 18 250 11.5 3000 0.932 95 A4 150 18 250 11.5 3000 0.448 95 Fig. 1 — Finite element analysis model for the A5 150 22 300 11.5 3000 0.640 122.6 built-up beam.

ment analysis program was employed and Al, the amount of final longitudinal bend- the total numbers of elements and nodes ing distortion was found to be 3.5 mm at Wl used were 1440 and 2232, respectively. the middle of beam length, but a distor- Eight-node isoparametric solid elements tion of about 100 mm was observed in a 1 and body heat flux model with Gaussian large T-section structure with a length of heat distribution were used for numerical 20,000 mm of the built-up beam. analysis. The upward convex longitudinal Qi Also, three-dimensional transient bending distortion is produced by the K heat transfer analysis was performed for welding moment (Mw), because the Ww tNi fillet welding with a moving heat source welded joint is located lower than the T- NIN.A A and subsequently three-dimensional neutral axis of the cross section of the thermal elastic-plastic stress analysis was built-up beam as shown in Fig. 5. The Qw Nw carried out with previously calculated welding moment is represented by multi- thermal loads, considering temperature- plying the shrinkage force P(Qw) of the dependent thermal and mechanical prop- welded joint by the distance (Nw) from WFt erties of the material. the neutral axis of the cross section of the m ^ A cross section of fillet welded T-joint built-up beam to the welding heating F\K with induction heating on both sides of source (Qw). The magnitude of longitu- o Fig. 2 — Cross section of the built-up beam with web plate is shown in Fig. 2; Nw is the dis- dinal bending distortion increases with induction heating. tance from the neutral axis to the welding the increase of the shrinkage force and z heat source, and Ni is the distance from the distance from the neutral axis to the o the neutral axis to the induction heat welding heat input (Qw). source. Table 1 shows the specimen di- The longitudinal bending distortion mensions and induction heat input condi- produced by the welding moment can be tions used for the finite element analysis. mitigated by generating an induction heat- All the specimens were made of 11.5, ing moment (Mi = Qi x Ni) with the same 18, and 22 mm thicknesses of AH32 (315 magnitude of the welding moment and ori- MPa yield strength) steel plates. The sub- entating it in the direction opposite to the merged arc welding process was used for welding moment. In large T-section struc- fillet welding with 720 A, 26 V, 1004 tures, the welding moment can be obtained mm/min welding speed, AWS-A5.17 with the neutral axis of the cross section of EM13K/L-50 welding wire of 2 mm in di- the built-up beam, the location of the weld- ameter, and two fillet welds of leg length ing heating source, and the amount of Fig. 3 — Shape of longitudinal bending distor- of 5 mm were made simultaneously on welding heat input. Also, the induction tion of the built-up beam. each side of the web and flange joint. The heating moment can be generated by con- welding heat input, in the analysis, is 1118 trolling the amount of induction heat input J/mm and the arc efficiency is determined (Qi) and the distance (Ni) from the neutral Numerical Modeling and Analysis to be 0.9 from a previous study. axis to the induction heating source. As- suming that the amount of the induction Figure 1 shows the finite element Mechanism and Control Method of heat input is constant, the distance from analysis model for the built-up beam. A Longitudinal Bending Distortion the neutral axis to the induction heating 1:4 model was employed considering the source is obtained by Ni = Qw x Nw/Qi. As symmetry of the built-up beam with two Figure 3 shows the shape of magnified a result, the longitudinal bending distor- fillet welds deposited simultaneously on residual bending distortion obtained from tion can be controlled by heating the de- each side of the joint and the huge com- the results of the three-dimensional ther- termined location with the induction heat- putational time consumed in analyzing mal elastic-plastic stress analysis for ing, simultaneously operating with the the distortion behavior of T-section joint Model Al, while Fig. 4 shows the transient welding process. of 3000 mm in weld length using a mov- and residual longitudinal bending distor- ing heat source model. The boundary tion behavior for Model Al with elapsed conditions for the numerical analysis times at the top edge of the web plate. Characteristics of Longitudinal were taken considering the symmetric During welding. Model Al deformed Bending Distortion by Induction condition of built-up beams and the pre- downward (-z direction) due to the ex- Heating vention of rigid body motion. Under pansion of the welded joint, but finally de- these conditions, welding distortion was formed upward (+z direction) due to the The control method of longitudinal generated freely without additional re- shrinkage of the welded joint after cooling bending distortion in the above section is straints. The verified in-house finite ele- down to room temperature. For Model verified by varying the induction heating

FEBRUARY 2009, VOL. 88 0 l-Zls" t-45s» t-66s« t-90»» t-100** l-«.T Mw=P(Qw).Nw x Mw=P(Qw).Nw i N.A Nw B 0 «'•"••ii**r6OOOatt«O06OOOOOO«)f««l 1 P(Qw) —#» ^^_ P(Qw) N -2 :•?•. o 't. • •« 00« o I 6 I Fig. 5— Welding moment for longitudinal bending distortion of the T-joint. • • 1 0 250 500 750 1.000 1.250 1.500 I htitnx rfi*t| X -»\I»I Mini 1 Fig. 4 — Distribution of longitudinal bending distortion (Model Al).

Hiith Frcqurao VoMaft ji tu

Ay <,.ln.U..U, -J r^ u.mm |i ^i •• lai •• T"^

i Ull til

\ \ M.l-.h

WELDING JOURNAL " t-21s"t-45s» t-66»» t-90»+ i-lOOs* t-« T • A4(30%Oown)» A3(30HUpil i 20 I 10- -.•*••••" 1 ^li:;:::::::: I °o*'K- > I 1 ' *^t::;;;::::::: '"•••B*,*

5 • > • i i •20 250 500 750 1.000 1.250 1.500 0 250 500 750 1.000 1.250 1.500 Dirtac* tkmf \-w* mm l Diitfuicc tkini \-»\n

Fig. 8 — Longitudinal bending distortion by fillet welding and induction Fig. 9 — Longitudinal bending distortion by fillet welding and induction heating (Model A2). heating (Models A3 andA4).

the induction-heated part reached room Table 2 - — Dimensions and Heat Input for Experimental Validation temperature. Model Flans e Plate Web Plate Length Temperature Ni (mm) Type (mm) (mm) L (mm) (°C) Effects of the Temperature of Induction Width Thickness Width Thickness Heating

El 150 18 450 11.5 20,600 390 200 To examine the effects of temperature m E2 150 18 450 11.5 20,600 430 200 variations due to induction heating on the E3 150 18 450 11.5 20,600 470 200 longitudinal bending distortion, the in- g E4 150 18 450 11.5 20,600 430 145 duction heating coil was set to be located E5 150 18 300 11.5 20,600 430 165 200 mm upward from the neutral axis E6 150 18 300 11.5 20,600 430 205 z E7 150 18 300 11.5 20,600 430 225 throughout the experiment, and the tem- E8 150 22 500 11.5 20,200 430 240 perature of induction heating changed o o E9 150 18 450 11.5 20,600 430 225 from 390 C (Model El) to 470°C (Model J3 E3). These induction temperatures were m measured, using an infrared temperature 0) measurement instrument, at a location 647 J/mm by Equation 1. The amount of Experiments for Large T-Section 100 mm away from the heating coil after m induction heat input and location (Ni) Structures induction heating. > calculated by Equation 1 can be applied Figure 12 shows the longitudinal J3 to determine the output power of the in- The control method of longitudinal bending distortion after fillet welding O duction heating instrument with various bending distortion, which was verified by with a change of temperature of induc- induction coil shapes. In the case of the numerical analysis in the above sec- tion heating. As the temperature of in- Model A5, the location (Ni) of induction tion, was verified by experiment. In this, duction heating becomes higher, longitu- heating was calculated as 122.6 mm by effects of the induction heat input and lo- dinal bending distortion increased in a Equation 1 because the distance (Nw) cation of induction heating on the longi- downward direction (-z direction) be- from the neutral axis of the cross section tudinal bending distortion were exam- cause of the increase of the moment by in- of the built-up beam to the welded joint duction heating (Mi = Qi x Ni). For ined, and finally the control method of o was 71 mm, and this value was used in this longitudinal bending distortion by induc- Model E3 (470 C), it produced about 50 analysis. tion heating was applied to large T-sec- mm longitudinal bending distortion at Figure 10 shows the behavior of the tion structures. the middle of the built-up beam length. transient and residual longitudinal bend- ing distortion by fillet welding only, while Specimen Dimensions and Experimental Effects of Location of Induction Heating Fig. 11 indicates the transient and resid- Conditions ual longitudinal bending distortion by in- To examine the effects of induction duction heating and fillet welding. From Table 2 presents the specimen dimen- heating location on longitudinal bending the analysis results, the longitudinal sions and heat input for experimental distortion, the temperature of induction bending distortion was measured as validation. The welding conditions and heating was set to 430oC (the tempera- about 2.5 mm at the middle of web plate induction heating coil used for the ex- ture at 100 mm away from heating coil in of the built-up beam length by welding periments were the same as those in the welding direction) throughout the exper- only, while the longitudinal bending dis- above section. However, the conditions iment, and the distance (Ni) from the tortion was produced as almost zero at of induction heating changed with the neutral axis to the induction heating the middle of length of T-joint by induc- experimental conditions. The amount of source changed from 145 mm (Model E4) tion heating and fillet welding. Conse- longitudinal bending distortion was to 225 mm (Model E7). quently, the validity of distortion control measured, using string and caliper, at The amount of longitudinal bending method by induction heating was verified the top edge of the web plate when the distortion with a change of location of in- by numerical analysis. temperature of both the welded part and duction heating is shown in Fig. 13, and

FEBRUARY 2009, VOL. 88 • t-Zls* t-45s#t-66s»t-90s-»t-10(H» t-RT t-21»« t-45i* t»66»* t-90t» t-100»* t-R T ».•«.«* JLl&4****A*«*AAi

N "• (lit••ooo»ooooooo««o»»«oooooi rt -> •JjOoI**•••••••••••••••••• o *••!" 2 I *f« "0 QOQaaoao on o •:: 1/3 s • •-... 5 •6 1 I 0 250 500 750 1.000 1.250 1.500 250 500 750 1,000 1.250 1.500 Iliwanu.- »Umt X-axMnunl

Fig. 10 — Longitudinal bending distortion by fillet welding (Model A5). Fig. ii — Longitudinal bending distortion by welding and induction heat- ing (Model A5).

a hEl OEZ E3 J 1- E7»E6DES OE4 '0 II • • :X> o • • • • 8 s 50 o d .0-. e • D & -10 o •"o"' o ' o ' Q a ... N iU a u a • o o • • • 30 I • \ I • "l o o 10 1/3 o c > • m • < 5 0 0 5 • • • " a -10- •1 LU -50 4.000 8.000 12.00016.000 20.000 CO 0 4.000 8.000 12.000 16.000 20.000 I>I»I«KC jkmg X-anmnnti DuUncc A>ap X • JMW mm I

Fig. 12—Longitudinal bending distortion with a change of induction heat- Fig. 13 — Longitudinal bending distortion with a change of location ofin- ing temperature. duction heating.

the longitudinal bending distortion was induction heating produced to be within ±10 mm in the were calculated by case of Model E7. However, as the dis- Equation 1 and the [•E8-1 PE8-2»E9-1 OE9-2" tance from the neutral axis to the induc- experiment described tion heating source decreased, upward in this section. convex distortion to a maximum of 50 mm The longitudinal occurred. This is because as the distance bending distortion of from the neutral axis to the induction large T-section struc- heating source decreased, the bending tures is shown in Fig. moment induced by induction heating be- 14, which includes came less than the bending moment in- the experimental re- duced by fillet welding. sults performed twice with the same 4.000 8.000 12.00016.000 20.000 Verification of the Validity by experimental condi- I>IM«ICC alocig X-«\JVImmi Experiments tions for the built-up beam. Based on the Based on the results from the numeri- results of the experi- Fig. 14 — Longitudinal bending distortion for large T-section structures cal analysis in the above section and the ex- ments, longitudinal (Models E8 and E9). periments in this section, it was found that bending distortion longitudinal bending distortion can be was found to be controlled through physical parameters, within ±10 mm at the middle of length of Conclusions namely the temperature and location of large T-section structures. These results induction heating. The validity of this con- mean that although the dimensions of the This study proposes induction heating clusion was investigated by applying the built-up beam change, the longitudinal as a new method to mitigate longitudinal above results to large T-section structures. bending distortion can be controlled by bending distortion due to fillet welding Models E8 and E9 in Table 2 were used, the temperature and location of induc- during manufacturing built-up beams. and the temperature and the location of tion heating calculated from Equation 1. With this method, longitudinal bending

WELDING JOURNAL distortion can be controlled simultane- moment (Mi) is generated by controlling K. 1999. Production mechanism for out-of- ously with fillet welding, resulting in im- the intensity of induction heat input and plane deformation in fillet welding and inves- provement of productivity and the qual- the distance (Ni) from the neutral axis to tigation of generality. Journal of the Japanese ity of block assembly. Also, this study the induction heating source. Welding Society 17(2). describes the mechanism of the longitu- 3. From the experiments performed to 2. Sasayama, T., Masubuchi, K., and dinal bending distortion and the effects of investigate the effects of intensity of in- Moriguchi, S. 1955. Longitudinal deformation induction heating parameters on longitu- duction heat input and its location on the of a long beam due to fillet welding. Welding dinal bending distortion through numer- longitudinal bending distortion, it is Journal 34(12): 581. ical analysis and experimental results. found that longitudinal bending distor- 3. Okerblom, N. O. 1958. The calculations The following results are obtained. tion decreases as the temperature of in- of deformations of welded metal structures. 1. Based on the results from three- duction heating becomes higher and the Her Majesty's Stationery Office. dimensional thermal elastic-plastic analy- distance from the neutral axis to induc- 4. Tsuji, I., and Yamaguchi, K. 1967. Dis- sis, the longitudinal bending distortion is tion heating source increases. But there is tortion and shrinkage stresses in edge welding produced by the welding moment (Mw), a possibility of providing too much induc- of beams. Journal of the Western Society of which can be obtained by multiplying the tion moment and in effect ending up with Naval Architects of Japan, Vol. 42. shrinkage force P(Qw) in the welded part more distortion in the opposite direction. 5. Masubuchi, K., and Papazoglou, V. J. by the distance (Nw) from the neutral axis 4. By applying the temperature and lo- 1978. Analysis and control of distortion in on a cross section of the built-up beam to cation of induction heating obtained welded aluminum structures. SNAME Trans- the welding heat source. Also, the magni- from the numerical analysis and experi- action, Vol. 86. tude of the longitudinal bending distor- mental results to large T-section struc- 6. Aoki, H., Nagai, K., Kuwajima, H., and tion increases as the shrinkage force and tures, it is concluded that longitudinal Watanabe, M. 1981. Estimation of welding de- distance from the neutral axis to the weld- bending distortion can be controlled by formations for actual plate girders. Journal of ing heat source increase. the temperature and the location of in- the Japanese Welding Society 50(10). 2. The longitudinal bending distortion duction heating for large T-section struc- 7. Jang, C. D., and Seo, S. 1.1995. Basic stud- induced by the bending moment due to tures with dimensional changes. ies for the automatic fabrication of welded built- welding can be mitigated by generating up beams. Journal of Ship J'roduction 11(2). an induction moment (Mi) with the same 8. Jang, C. D., and Seo, S. I. 1994. On the magnitude as the bending moment, and References prediction of deformation of welded built-up m orientating it in the opposite direction of beams. Journal of the Society of Naval Architects the bending moment. Then, the induction 1. Kim, Y. C, Chang, K. H., and Horikawa, of Korea 31(3). i O J3 m Preparation of Manuscripts for Submission 0) to the Welding Journal Research Suppiement m > All authors should address themselves to the 6) Acknowledgment, References and Appendix. J3 following questions when writing papers for submission Keep in mind that proper use of terms, abbreviations, to the Welding Research Supplement: and symbols are important considerations in processing O • Why was the work done? a manuscript for publication. For welding terminology, the • What was done? Welding Journal adheres to AWS A3.0:2001, Standard • What was found? Welding Terms and Definitions. • What is the significance of your results? Papers submitted for consideration in the Welding • What are your most important conclusions? Research Supplement are required to undergo Peer With those questions in mind, most authors can Review before acceptance for publication. Submit an original and one copy (double-spaced, with 1-in. margins logically organize their material along the following lines, 1 using suitable headings and subheadings to divide the on 8 /2 x 11-in. or A4 paper) of the manuscript. A paper. manuscript submission form should accompany the 1) Abstract. A concise summary of the major manuscript. elements of the presentation, not exceeding 200 words, Tables and figures should be separate from the to help the reader decide if the information is for him or manuscript copy and only high-quality figures will be her. published. Figures should be original line art or glossy 2) Introduction. A short statement giving relevant photos. Special instructions are required if figures are background, purpose, and scope to help orient the submitted by electronic means. To receive complete reader. Do not duplicate the abstract. instructions and the manuscript submission form, please 3) Experimental Procedure, Materials, Equipment. contact the Peer Review Coordinator, Erin Adams, at 4) Results, Discussion. The facts or data obtained (305) 443-9353, ext. 275; FAX 305-443-7404; or write to and their evaluation. the American Welding Society, 550 NW LeJeune Rd., 5) Conclusion. An evaluation and interpretation of Miami, FL 33126. your results. Most often, this is what the readers remember.

FEBRUARY 2009, VOL. 88 Three-Dimensional Analysis of Molten Pool in GMA-Laser Hybrid Welding

Analytical models of GMA and laser keyhole welding are merged to achieve the simulation of hybrid welding considering the multiple reflections of laser and the Fresnel absorption theory

BY J.-H. CHO AND S.-J. NA

ABSTRACT Introduction and pores instantaneously in the weld- ment during the process, as it is possible A computational analysis of a molten Welding is a complex multiphysics to monitor the bead formation process. pool in laser-GMA hybrid welding is topic related to plasma physics, electro In spite of these advantages, it is difficult achieved including free-surface track- magnetism, and fluid dynamics including to construct the system in the actual pro- ing using the well-known volume of metallurgy. In addition, it is impossible to duction area, as it is expensive compared fluid (VOF) method. The suggested observe the welding process directly be- to conventional monitoring methods. Ad- three-dimensional transient numeri- cause the pool and arc plasma are very ditionally, there are concerns regarding cal model includes all known analyti- bright, and their temperatures are ex- health problems related to radiation. Fur- cal key features of arc welding includ- ceedingly high. Therefore, various types thermore, the information available o ing electromagnetic force, , of research have been reported to moni- through this system remains insufficient and arc pressure. In addition to the tor the welding process. A representative if one wishes to comprehend the physical basic GTA model, molten droplets are method is the checking of the current or meanings of the welding process. The < artificially generated and allowed to voltage of gas tungsten arc (GTA) or gas achieved images are two-dimensional, LU fall down to the pool to cover the metal arc (GMA) welding (Refs. 1-3). gray-scaled, and comparatively rough, CO GMAW process. A keyhole analysis There are more sophisticated methods making it difficult to understand the de- LU model is merged to a GMAW simula- that directly record the pool images using tails of the flow in the X-ray images. tion model with the assumption that a CCD camera or that use such a camera In this area, computer simulations can OC the interaction between the laser and combined with optical filters and various greatly facilitate the comprehension of the arc is negligible for convenience. light sources such as specific laser or halo- molten pool dynamics. Although the O The keyhole model is established on a gen lamps (Refs. 4,5). However, all of the analysis of a molten pool based on com- unique phenomena that includes mul- aforementioned techniques are indirect putational fluid dynamics is not a com- tiple reflections, Fresnel absorption techniques; specifically, they do not pro- plete answer to the questions regarding model, and the recoil pressure in laser vide any information concerning the phe- heat and mass transfer problems in the welding apart from the inverse nomena occurring inside the weld pool. welding process, it provides a passable LU Bremsstrahlung absorption. The re- In other words, they merely present the answer. Simulation results show the flow sult shows the flow patterns of the predictability of bead shapes, resulting in of the molten pool and the formation of 5 molten pool in GMA-laser hybrid a lack of scientific information regarding the weldment as well as its historical tem- welding, and they are compared to the flow and related phenomena. perature profile. Hence, a number of previously reported observation re- An impressive method that enables studies regarding weld pool analysis have sults. The molten flow at the bottom of the pool to be observed directly is a real- been reported since the 1980s. the keyhole rises up slowly, and there- time X-ray imaging system (Refs. 6,7). X- In early simulations of arc welding, it fore a vortex can be observed through- rays transmitted through the workpiece was impossible to accomplish a flow out the molten pool. However, the in a laser keyhole welding process are fo- analysis of molten metal that included flow pattern became increasingly cused on a CCD camera and are then re- free-surface tracking (Refs. 8, 9). How- complicated. The flow of the keyhole constructed as gray-scaled images in real ever, due to advances in computer and root is split into three main streams, time. It is very useful to see the keyhole numerical techniques, knowledge of the and one stream is continuously main- total flow patterns of the molten pool tained in the vortex. have been achieved that include the ex- pression of the free surface (Refs. 10,11), KEYWORDS as well as the inclusion of droplets via a feeding wire (Refs. 12,13). Gas Metal Arc Welding For keyhole dynamics in the laser (GMAW) welding process, a geometrically assumed Laser keyhole such as a cylindrical hole in a Hybrid Welding plate was typically used to analyze the ef- J.-H. CHO and S.-J. NA ([email protected] are Volume of Fluid (VOF) fects in early studies that did not incor- with Department of Mechanical Engineering, Keyhole porate the expression of the free surface Korea Advance Institute of Science and Tech- Fresnel nology, Yuseong-gu, Daejeon, Republic of Korea. of molten material, as mentioned above (Ref. 14). Currently, keyhole dynamics

WELDING JOURNAL i

Fig. 1 — Schematic diagram of laser-GMA hybrid welding simulation.

including the evolutionary free-surface with other normal shape achieved by VOF (Ref. 15) or the fluidic problems. level-set method are typically reported They are the conti- (Refs. 16, 17). One of the most important nuity equation, the features of keyhole simulation is the mul- momentum equa- tiple reflection effect. If the laser beam is tion, which here is considered as a bundle of rays, it can be referred to as the Fig.2- - 3-D perspective views of simulation results. A — t=0.45 s; B — f= easily understood that each of the rays Navier-Stokes 1.8 s. travels inside the keyhole through multi- equation, and the ple reflections at the keyhole wall until it energy equation. escapes out of it. Therefore, the ray trac- The metallic fluid in this simulation is as- m dw 1 , dw , dw . dw ing profile inside the keyhole is entirely sumed as incompressible, laminar, and + — uA vA wA — dependent on the external shape of the Newtonian. dt K y dy z dz g keyhole, which means the keyhole surface Based on these assumptions, the gov- exposed to laser rays (Ref. 18). Conse- erning equations are expressed as follows. z -1^+/ +G (4) quently, the exact keyhole profile and a First, the continuity equation (Ref. 19), pdz z z o ray tracing algorithm are needed for every implies that the conservation of the mate- single time step in a simulation in order to rial has the form shown in Equation 1. J3 obtain a precise energy distribution map Here, VF denotes the volume fraction m of the keyhole surface. in the cell in the VOF method (Ref. 20) and/^, f,, and/ indicate the viscous accel- 0) In this paper, the analysis of a three- *-(uA MvA +—\wA 1 = 0 z y (1) eration rates as in Equations 5-7. m dimensional molten pool analysis is dx{ •' dy\ y dz > achieved for a laser-GMA hybrid welding process. Analytical models for GMA and 1 J3 laser keyhole welding are merged to real- In Equation 1, M, v, and w denote the O ize the hybrid welding process in a com- velocity component according to each axis P^ puter simulation. A real-time ray tracing in the Cartesian coordinates. Ax, Ay, and _a_ technique (Ref. 23) that takes into ac- A denote the fractional area open to the (Az \ + -[AX z av count a discrete grid cell in the VOF flow in each direction, t is the time, and p, (5) method is adopted to realize a multiple re- P, |i, and G denote the density, pressure, a z 4 — flection effect for every time step accord- viscosity, and gravitational acceleration in I dzx ing to the present keyhole profile. There the momentum equation, respectively. are several assumptions and simplifica- They can be expressed as follows: 1 tions used in the analysis. First, it is as- sumed that the arc plasma and the laser do du du du du not interact; consequently, they are only — + '•uA 4 vA 4 m4 mathematically superposed in the simula- V J > liA x )+^A x dt a*: ay dz dx\ x vl dy\ y v tion. Secondly, both the arc and the laser A (6) are considered as surface heat flux with a = (2) +—\A x Gaussian distribution. Lastly, the effect of pck 4 az\ z ^ shielding gas is not considered in the analysis. The simulation was conducted /=" using the commercial package Flow3D. PK Suggested analytical model is already val- dv av av av idated by comparing the simulation result — + —iuA c — 4-vA — 4 wA dt ar > ay dz + 41 to the experiment (Refs. 23, 24). K^) -i-ay^' ': (7) (3) Molten Pool Dynamics fy pay az fe) To execute the molten pool analysis, three governing equations are essential, as

FEBRUARY 2009, VOL. 88 A (B •.n

lam M ^^^^ • Nil t Mi

«* OX IM IM ,- •} XM AM KM I

C IKI

_ - tm M • __£' -^^ ^M^ ^^ _ N«l 1 A ^'' ^^fl •

^ 5 fl • •» «• ui IM IM Ui 1*4B • •-i in i •

Fig. 3 — Temperature profiles of cross-sectioned side views in the simulation result. A —1=0.45 s; B —1=0.9 s; C —1=1.35 s; D —1=1.8 s. o < Where LU CO du_l du dv dw LU ^ =-2^ — + — + — dx 3 dx dy dz OC , 9v 1 du dv dw — + — + — O ^ U 3 dx dy dz dw 1 du dv dw -2n — + — + — dz 3 dx dy dz LU 3v 3M du dw T =-|ax —+ — \,'z v [dx dy dz dx 5 dv dw (8) v \dz dy Additionally, the energy equation based on the enthalpy method and the continuum formulation is described below.

dh (F-vU=pv-(xvrj (9) dt c

h = C •T+fL (10) P £f ' ^ J&J 1^^^^ Where/denotes "^T^ ^_ 0,fTT

WELDING JOURNAL In this equation, h and K indicate the enthalpy and the thermal conductivity, re- spectively, and T, TL, and Ts, correspond- ingly, denote the temperature, liquidus temperature, and solidus temperature. In terms of the energy transfer, the laser beam is a type of complex heat source model that interacts with various materials. However, it is generally treated as a surface heat flux boundary condition in an analysis, and there is a widely ac- cepted simple expression in the form of a Gaussian function related to the TEM00 mode in laser activity with a mathematical form as in the following equation (Ref. 21):

2 2 x,y,z 3G-exp (12) Ttr

r =r - (13) L 0

In Equation 12, Q indicates the nomi- nal laser power and the coefficient 3 indi- m cates that 95% of the total power exists in- side the area of the effective radius rL. Particularly, the laser beam is modeled to g have a diverging property along the trav- z eling path in this research. This is more re- alistic than earlier models of a collimated o beam. Therefore, the beam model be- J3 comes a three-dimensional function by ap- pending Equation 13 to Equation 12. The m beam radius is set so as to increase linearly 0) along the path, with a focal radius r0 at the m z0 position in the z axis. > The electric arc is modeled as a type of Table 1 — Material Properties and Coefficients Used in Analysis surface heat flux with a Gaussian distribu- Properties Value J3 tion shape. Its mathematical form is, O therefore, similar to that of Equation 12 Density 7490 kg/m3 exclusive of the diverging effective radius, Thermal conductivity 35 W/mK which is changed to a fixed radius as in the Specific heat 606 J/kgK following: Latent heat of vaporization 6084 kJ/kg Latent heat of fusion 260 kJ/kg f \ Liquidus temperature 1787.5 K x2 y2 x -exp + (14) Solidus temperature 1729.2 K

FEBRUARY 2009, VOL. 88 was found to be 0.24 in this simulation; therefore, the total GMAW efficiency was set at 80%, which refers to Ref. 28. The third and fourth terms on the right side of this equation denote the heat losses caused by ambient air convection and heat radiation. Accordingly, hA is the con- vection coefficient, which is 40 W/m2 K here, and T^ is the temperature of the ambient air, set here as 293 K. os, er, and qvap indicate the Stefan-Boltzmann con- stant, the emissivity, and the heat loss caused by vaporization, respectively. Equation 18 calculates the pressure boundary condition for the top surface in- cluding the surface tension in a flow. |i de- notes the dynamic viscosity, y and Rc indi- cate the surface tension coefficient and the radius of the surface curvature, respectively. All of the other boundaries, such as the rear, front, and side, are set as continuous surfaces. This implies that the material ex- ists continuously so the normal deriva- tives of all the properties at the boundary are equal to zero. The zero derivative con- dition is intended to represent a smooth continuation of the flow through the boundary. In addition to the high power density o of the laser, the main driving force that makes the keyhole deeper is the multiple < reflections of the laser beam in the key- LU hole. If the laser is regarded as a bundle CO of ray beams, all of the rays coming into LU the keyhole experience multiple reflec- tions on the wall and finally reach the bot- 0C tom of the keyhole. These superposed rays inside the keyhole raise the total en- O Fig. 5 — Temperature profiles of cross-sectioned front views in simulation result atpostions, x=1.43. A ergy absorption and obtain a deeper pen- —1=0.25s;B — t=0.27s; C — t=0.29s; D —1=0.38s; E —1=0.4s;F—t=0.42 s; G — (=0.52s; etration. In this research, the ray tracing H — t=l.lls. technique is triggered on for every time step following to the self-evolved three- dimensional keyhole profile. Detailed de- LU scriptions can be found in an earlier pub- lished report by the author (Ref. 23). 5 be used in this simulation (Ref. 22). The molten surface of the metal is re- [T-T] garded as specular in this paper; thus, it T-T, LV was deemed reasonable to adopt the Fres- P s0.54Pexp Aff. (16) 4 4 nel reflection model (Ref. 25), which is R 0 ^ LV RTF, -oe|r -r -^A (IT)v / LV J s r{ °° J vap widely accepted for the calculation of laser absorption rate. Reflectivity^at the In Equation 15, |i,0 is the permeability molten surface is mainly dependent on in a vacuum. P denotes the atmospheric dV 0 P +-L (18) the angle between the incident ray and pressure and lsHLV\s, the latent heat of va- dn R A R surface normal § as follows, and the ab- porization. T, T , and R indicate the sur- LV sorption rate riy is then 1- Rf. face temperature, liquid-vapor equilib- In Equation 17, n denotes the normal rium temperature, and universal gas component,^is the thermal conductivity, constant, respectively. The value 0.54 in and T is the surface temperature. x\ de- Equation 15 is a factor that depends on notes the heat input efficiency, i.e., the the environmental pressure. This was also heat absorption rate, and the subscripts L 1+1 -ecm]) adopted in this research. and A indicate the laser and arc, respec- Heat source models and pressure tively. The efficiency for the laser heat R, l+(l + eaH|)l (19) models are prepared for application as source is determined by the Fresnel re- e 2 - 2ecos(|) + 2oos 2 § boundary conditions. For the top surface, flection model and multiple reflections in + which is directly exposed to the heat the keyhole, which are discussed in later E +2ecmt)+2cDs (|) sources of the arc and the laser, and for paragraphs. On the other hand, the effi- J the arc and recoil pressure, the mathe- ciency of the arc is predetermined as 0.56. matical expressions are as follows: The heat input efficiency of the droplets

WELDING JOURNAL by the following equation set (Refs. 9,26).

m exp 471VV A A) (

1-exp l-Z- (21) V A)

H I' exp y An2r2r A V AJ

1-exp 1- (22) AJ

H I' m An2r2c

1-exp (23) AJ

In these equations, |i,„ is the magnetic permeability of the material, / is the arc current, and c is the thickness of the work- piece. For the coordinate value, x and y denote the distance from the arc position o according to each axis, and z indicates the distance from the top of the workpiece J] along the z axis. m 1 '^ ^ r^ 1 m Results and Discussion > J The material adopted for the simula- tions was ASTM A131 steel with a thick- J3 ness of 10 mm. The analytic domain was O set as 42 mm in length, 10 mm in width, and 13 mm in height including the void re- Fig. 6 — Flow patterns of simulation result in cross-sectioned front views atx=2.31. A- •t=0.84s:B — t=0.95s;C — t=1.03s;D — t=1.9s. gion of the top 3 mm for free-surface tracking. In the Cartesian coordinate sys- tem, the ranges of the domain are (2 mm, 44 mm) in the.r axis, (5 mm, 1.5 mm) in the y axis, and (-0.5 mm, 0.8 mm) in the z axis, temperature of the keyhole wall is at the respectively. The inter-grid distance is 2e, boiling point, which could affect the Fres- equal to 0.1 mm along the three axes; con- (20) nel absorption. Moreover, the method sequently, there is a total of 2,860,000 ele- 1,2 used to calculate the Fresnel absorption is ment cells. The physical properties of the /coe 2 approximated, and the use of a large value material and coefficients used in the sim- -K 0) of e could offset the approximations (Ref. ulation are shown in Table 1. It took 328 25). Therefore, the value of e can be de- hours to complete the simulation. The value of e is related to the electri- termined by trial and error to fit the simu- Figure 1 shows a schematic diagram of cal conductance per unit depth of metal lation result to the experimental result. the solution domain of the simulations. In os„ and Zx and e2 denote the real part of the The aim of this research is not to deter- this figure, the F value denotes the filled dielectric constants of metal and plasma, mine the proper coefficient; rather, the portion of the fluid (material) in a cell respectively. Additionally, e0 indicates the paper is purely focused on observing the using the VOF method; i.e., F=1 indicates permittivity of a vacuum, and co is one of fluidic phenomena achieved using a nu- that the cell is fully filled with fluid, F=0 the laser properties representing the an- merical method. indicates that it is empty, and 0

FEBRUARY 2009, VOL. 88 lively, and the welding speed is set at 1 m/min. The instance of a 2-s GMA-laser hybrid welding process is simulated and analyzed. In addition to the arc heat source model, it is necessary to determine the ef- fect of droplets as a heat source in GMAW. Conventionally, droplets are treated as an additional surface heat flux with a Gauss- ian distribution when the free-surface tracking is not readily available. In this study, the droplets are assumed to be at a temperature 2400 K and are essentially generated to have the mass and momen- tum and to have fallen into the pool by the gravity and electromagnetic force. The di- ameter of the droplets is assumed to be equal to that of the electrode wire; conse- quently, the generation frequency 167 Hz is determined according to the wire feed rate of 8 m/min. The initial velocity of the droplet is assumed to have only the verti- cal (z-axis) component and its magnitude is 50 cm/s (Ref. 13). Figure 2 shows three-dimensional per- spective scenes of the simulation result. Droplets of welding wire are continuously generated in the void region and fall into the pool. It is observable that the surface of the molten pool is slightly dimpled due o to the arc pressure in the figures. Directly behind the dimpled arc region, the key- < hole opening is shown, resembling a cav- LU ity. Given that the distance between the CO arc and the laser is only 3 mm, the keyhole LU opening is located in the dimpled shape. Therefore, the keyhole and dimple are OC merged and can be observed as one large hole in a lateral cross-section plane near O the top surface level of the workpiece. It is important to note that the shape of the free surface is maintained in a macro- scopic view while the heat sources are moving forward. However, an unstable LU keyhole continuously repeats the genera- tion and collapse process. Additionally, 5 the inertia of the falling droplets causes the pool to oscillate. This is discussed in detail in the following paragraphs. The solid and liquid regions and their boundaries are displayed in Fig. 3, which also shows the temperature profiles. In the series of figures, it is possible to observe the droplets generated above the workpiece as well as the dimpled shape at the arc posi- tion. Moreover, it is easy to compare the penetration depths of the GMA and laser welding processes. The difference is clearly distinct as the penetration depth of the GMA process does not exceed 1.5 mm while the depth of the keyhole is more than 6 mm. It is important that the free surface of the keyhole does not appear in these fig- ures, not because the model is incorrect, but because the output file is not saved in a sufficient number of shot intervals. The re- sults are saved every 10 ms. The keyhole is continuously repeating the generation and Fig. 7 — Flow patterns of the simulation result in cross-sectioned top views at z=0.47. A —1=1.03 s; collapse process with a time interval B — t=1.04s: C —1=1.05s: D —1=1.06s.

WELDING JOURNAL which can be de- tors — Fig. 6A. Directly after this action, duced by analyzing a keyhole is generated with the downward Fig. 4A and C. In flows at the liquid metal. A bubble is seen Fig. 4A, the flow vec- in Fig. 6B, which is not in the process of tors are directed to escaping, but is only pushed downward by the center at the the recoil pressure. However, it escapes middle of the key- from the pool, and that void region is hole walls. With this filled with liquid metal and the cross- tendency, a trapped section bead shape is then determined, as bubble in the middle seen in Fig. 6C. Flows at this moment are of the pool is ob- all downward as the circular returned served for an instant flow from the bottom of the keyhole that in Fig. 4C due to the was caused by the vortex reaches this po- m collapse of the key- sition and forms the pool. All of the flows Fig. 8 — Flow patterns of simulation result in 3-D perspective views. A hole. gradually disappear from the bottom due t=0.53 s; B — t=1.0s;C —1=1.96 s. g Figure 5 shows a to the solidification, and finally the re- series of cross-sec- maining flows that are pushed up shape z tioned front views. the top bead, as in Fig. 6D. o The sectioned plane Complexities of the flow patterns are is located at the posi- shown in the cross-section top views — shorter than 10 ms; therefore, the free sur- tion x=1.43, which is in the transverse Fig. 7. The position of the section plane face of the keyhole is not observed during middle range of the workpiece. This loca- was selected as z=0.47 mm, which is only m every time step. tion was chosen to observe the entire 3 mm below the top surface of the work- 0) Nonetheless, the generation of the welding process from melting to resolidi- piece in order to observe both the key- m keyhole was fortuitously captured at 0.53 fication. As seen in the figures, the work- hole and the arc dimple simultaneously. s, as seen in Fig. 4. These figures show the > piece is melted by the pure arc first and As shown in the figures, the keyhole and flow patterns of the molten pool. Figure J3 the droplets are then added to the pool the arc dimple are continuously repeating 4A shows the moment of keyhole gener- and cause the penetration to become the merge and separation action. It is im- O ation. There is a small amount of liquid somewhat deeper. Directly after the portant to note that when they are sepa- metal in the front keyhole wall and the droplets transfer, the front keyhole walls rated, flows around the arc dimple move free surface of the keyhole is slightly in- begin to appear. In this section, it is ob- toward the keyhole opening. However, clined, as was shown in a previous report servable that the penetration gradually the flows near the arc are outward and be- (Refs. 27,29), as the laser is a moving heat deepens in the figures from 5D to 5F, came more complex when they were source. Near the bottom of the keyhole, which coincides with the fact the keyhole merged. In the case of the separation, flow is downward due to the repulsive is slightly inclined, as mentioned in the flow patterns toward the keyhole finally force caused by the recoil pressure. The previous paragraph. Trapped bubbles are create a single hole and the outward pat- molten flow reached the bottom at the also seen in the figures due to the col- terns of the merged hole tend to separate solid/liquid boundary and is directed lapse. After the simulation, there are no the keyhole and the arc dimple. Due to backward and is finally lifted up owing to pores in the weldment, which can be ex- this mechanism of flow patterns, the key- the buoyancy. This circular pattern pected owing to the trapped bubbles in hole and arc dimple are repeatedly causes a vortex, as seen in the figures. The the pool. It was believed that all of the merged and separated. It can be derived vortex serves to stir the pool to form an bubbles escaped through the keyhole be- that this phenomenon is repeated every alloy. There is only one circular vortex at cause the welding speed was not rapid 30 ms by analyzing the figures. the beginning of the process as seen in enough to leave a bubble behind the key- Figure 8 shows the three-dimensional Fig. 4A; however, while the heat sources hole. In Fig. 5G, all of the void regions are flow patterns concluded from all of the are marching forward, the flow pattern filled with liquid metal and the weld pool procedures mentioned previously. Essen- becomes more complex as the root flow begins to solidify with upper streams, tially, the pool has complex flow patterns. at the bottom is split into two main which finally form the top bead shape, as However, it is worth noting that the streams as shown in Fig. 4B. It ultimately shown in Fig. 5H. drawn mainstreams dominate the bead- branches out to three streams, as seen in Flows in the front section are dis- shaping procedure. As seen here, the Fig. 4C, but the circular vortex at the be- played in Fig. 6. A droplet is falling into flows became more complicated while in ginning is maintained and continues to the dimpled shape of the pool caused by the process of moving forward. The flow move forward. The collapse of the key- the arc pressure with downward flow vec- from the keyhole root is split into three hole begins from the middle of the walls.

FEBRUARY 2009, VOL. 88 main streams as seen in the figure. How- Engineering Manufacture 215: 1271-1280. actions A 33 A: 1831-1842. ever, one vortex induced by the keyhole 3. Kim, C. H., and Na, S. I. 2001. A study 18. Ki, H., Mohanty, P. S., and Majumder, phenomenon is maintained in spite of the of an arc sensor model for gas metal arc weld- I. 2002. Multiple reflections and its influence complex circumstances. ing with rotating arc Part 2: Simulation of an on keyhole evolution. Journal of Laser Appli- arc sensor in mechanically rotating gas metal cations 14: 39^15. arc welding. Proc. Institution of Mechanical En- 19. Hirt, C. W, and Sicilian, J. M. 1985. A Conclusions gineers. Part B, Journal of Engineering Manu- porosity technique for the definition of obsta- facture 215: 1281-1288. cles in rectangular cell meshes. Proc. Fourth In- A simulation model for the analysis of 4. Wu, C. S., Gao, I. Q., Liu, X. E, and ternational Conf. Ship Hydro., National Acad- the molten pool in the laser-arc hybrid Zhao, Y. H. 2002. Vision-based measurement emy of Science, Washington, D.C, September. welding process is proposed and an analy- of weld pool geometry in constant-current gas 20. Hirt, C. W, and Nichols, B. D. 1981. sis is achieved using the Flow-3D com- tungsten arc welding. Proc. Institution of Me- Volume of fluid method for the dynamics of mercial package. The model consists of chanical Engineers. Part B, Journal of Engineer- free boundaries. Journal of Computational the three major governing equations of ing Manufacture 217: 879-882. Physics 39: 201-225. 5. Zhang, Y. M., Wu, L., Chen, D. H., and 21. Cho, Y. T 2005. A study on the analysis the continuity, momentum, and energy Walcott, B. L. 1993. Determining joint pene- and monitoring of plasma in laser arc hybrid equations. Additionally, the VOF tration in GTAW with vision sensing of weld welding. PhD thesis. KAIST pp. 21, 22. method is adopted to realize the tracking face geometry. Welding Journal 72(10): 463-s 22. Lee, J. Y., Ko, S. H., Farson, D. E, and of the free surface of the pool. Physical to 469-s. Yoo, C. D. 2002. Mechanism of keyhole for- phenomena of arc welding in the molten 6. Fujinaga, S., Takenaka, H., Narikiyo, T, mation and stability in stationary laser weld- pool, such as the electromagnetic force, and Katayama, S. 1998. Observation of key- ing. Journal of Physics D: Applied Physics 35: surface tension, and arc pressure are ap- hole behavior during high power YAG laser 1570-1576. plied as the boundary conditions or the welding with microfocused X-ray transmission 23. Cho, J. H., and Na, S. I. 2006. Imple- body force of the fluid. To obtain the key- imaging system. Laser Materials Processing mentation of real-time multiple reflection and Conference. 158-167. Fresnel absorption of laser beam in keyhole. hole dynamics via laser welding, the ef- 7. Matsunawa, A., Seto, N., Mizutani, M., Journal of Physics D: Applied Physics 39: fect of multiple reflections in the keyhole and Katayama, S. 1999. X-ray observation of 5372-5378. is realized with a ray-tracing technique, keyhole dynamics in high power laser welding. 24. Cho, J. H., and Na, S. I. 2006. Three-di- which is suitable for the discrete grid cell International Welding Conference; (IWC 99) On mensional analysis of molten pool in laser- system in the FVM and the VOF meth- Welding & Allied Technology, "Challenges in GMA hybrid welding. Proc. of LAMP 2006, ods. In addition, the Fresnel reflection 21st century." pp. 46-53. #06-183. model is employed as an energy absorp- 8. Kim, I. S., and Basu, A. 1998. A mathe- 25. Ducharme, R., Williams, K, Kapadia, tion mechanism for the laser beam on matical model of heat transfer and fluid flow in P., Dowden, J., Steen, B., and Glowacki, M. o metal surfaces. The simulation results the gas metal arc welding process. Journal of 1994. The laser welding of thin metal sheets: Materials Processing Technology 77: 17-24. An integrated keyhole and weld pool model can be summarized as follows. 9. Tsao, K. C, and Wu, C. S. 1988. Fluid with supporting experiments. Journal of < 1) Due to the flow of the keyhole bot- flow and heat transfer in GMA weld pools. Physics D: Applied Physics 27: 1619-1627. LU tom, a vortex exists that mainly influences Welding Journal 67(3): 70-s to 75-s. 26. Kumar, A., and DebRoy, T 2003. Cal- CO the shaping of the top bead. 10. Ohring, S., and Lugt, H. I. 1999. Nu- culation of three-dimensional electromagnetic LU 2) Trapped bubbles are observed in merical simulation of a time-dependent 3-D force field during arc welding. Journal of Ap- the pool because keyhole collapse begins GMA weld pool due to a moving arc. Welding plied Physics 94: 1267-1277. 0C from the middle height of its depth. Journal 78(12): 416-s to 424-s. 27. Matsunawa, A., and Katayama, S. 2002. 3) The welding speed is not fast 11. Kim, C. H., Zhang, W, and DebRoy, T. Keyhole instability and its relation to porosity O enough to leave the bubbles behind the 2003. Modeling of temperature field and so- formation in high power laser welding. Proc. keyhole; therefore, it is inferred that the lidified surface profile during gas metal arc fil- Joining of Advanced and Specialty Materials, let welding. Journal of Applied Physics 94: pp. 8-15. trapped air escapes through the keyhole. 2667-2679. 28. DuPont, I. N., and Marder, A. R. 1995. 4) The keyhole and the arc dimple are 12. Wang, Y., and Tsai, H. L. 2001. Im- Thermal efficiency of arc welding process. continuously repeating the merge and pingement of filler droplets and weld pool dy- Welding Journal 74(12): 406-s to 416-s. LU separation process every 30 ms in a lateral namics during gas meal arc welding process. 29. Fujinaga, S., Takenaka, H., Narikiyo, T, cross-section at a height of 0.47 mm. International Journal of Heat and Mass Transfer Katayama, S., and Matsunawa A. 2000. Direct 5 However, these parameters are depen- 44:2067-2080. observation of keyhole behavior during pulse dent on welding conditions, therefore will 13. Cao, Z., Yang, Z., and Chen, X. L. 2004. modulated high-power NdYAG laser irradia- not remain the same for other conditions. Three-dimensional simulation of transient tion. Journal of Physics D: Applied Physics 33: 5) The width of the bead is determined GMA weld pool with free surface. Welding 492-A97. Journal 85: 169-s to 176-s. mainly by the GMA heat source and the 14. Mahrle, A., and Schmidt, J. 2002. The penetration depth is strongly influenced influence of fluid flow phenomena on the laser by the laser. beam welding process. International Journal of Heat and Fluid Flow 23: 288-297. Acknowledgment 15. Zhang, W H., Zhou, I., and Tsai, H. L. 2003. Numerical modeling of keyhole dynam- This work was supported by POSCO ics in laser welding. Proc. of SPIE 4831: and Brain Korea 21 project. 180-185. 16. Ki, H., Mohanty, P. S., and Majumder, Change of Address? References I. 2002. Modeling of laser keyhole welding: Part I. Mathematical modeling, numerical 1. Bicknell, A., Smith, J. S., and Lucas, J. methodology, role of recoil pressure, multiple Moving? 1994. Arc voltage sensor for monitoring of reflections, and free surface evolution. Metal- penetration in TIG welds. IEE Proc. Set Meas. lurgical and Materials Transactions A 33A: Make sure delivery of your Welding Tech. 141: 513-520. 1817-1830. Journal is not interrupted. Contact the 2. Kim, C. H., and Na, S. I. 2001. A study 17. Ki, H., Mohanty, P. S., and Majumder, Membership Department with your of an arc sensor model for gas metal arc weld- I. 2002. Modeling of laser keyhole welding: new address information — (800) 443- ing with rotating arc Part 1: Dynamic simula- Part II. Simulation of keyhole evolution, ve- 9353, ext. 217; [email protected]. tion of wire melting. Proc. Institution of Me- locity, temperature profile, and experimental chanical Engineers. Part B, Journal of verification. Metallurgical and Materials Trans-

WELDING JOURNAL CAN WE TALK? The Welding Journal staff encourages an exchange of ideas with you, our readers. If you'd like to ask a question, share an idea or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with the right person.

Publisher Production Manager Peer Review Coordinator Andrew Cullison Zaida Chavez Erin Adams [email protected], Extension 249 [email protected]. Extension 265 [email protected]. Extension 275 Article Submissions Design and Production Peer Review of Research Papers

Editor Advertising Saies Director Mary Ruth Johnsen Rob Saltzstein [email protected], Extension 238 [email protected]. Extension 243 Feature Articles Advertising Sales Welding Journal Dept. 550 N.W. LeJeune Rd. Associate Editor Advertising Saies & Miami, FL 33126 Howard Woodward Promotion Coordinator (800) 443-9353 [email protected]. Extension 244 Lea Garrigan Badwy FAX (305) 443-7404 Society News [email protected]. Extension 220 Personnel Production and Promotion

Associate Editor Sr. Advertising Production Manager Kristin Campbell Frank Wilson [email protected]. Extension 257 [email protected]. Extension 465 New Products Advertising Production News of the Industry

WELp||^ REPRINTS

Take Advantage of your Editorial Exposure Reprints of Welding Journal are a simple way to put information directly into the hands of your target audience. Having been featured in a well-respected publication adds the credibility of a third-party endorsement to your message.

CUSTOMIZED REPRINTS The publication's masthead will be placed above the article Reprints are ideal for: content and/or Images; and your logo and contact Information can be prominently featured at the end of the reprint. Customized reprints are printed on quality 80# gloss stock. • PR Materials and Media Kits WEB-POSTING CUSTOMIZED ePRINTS • Direct Mail Enclosures Extend your exposure to the online audience with a customized web-postlng ePrlnt available In various tlmeframes. You may also • Trade Shows/Promotional Events purchase permission for e-mail distribution.

PLAQUES/POSTERS AND FRAMED PRINTS • Conferences/Speaking Engagements Plaques, posters, and/or framed prints are suitable for trade-shows, special events, polnt-of-purchase, or office display. • Recruitment and Training Packages

MINIPRINTS/POSTCARDS • Customer and Prospect Customized reprint postcards make a perfect direct-mail campaign. Communications/Presentations Double-sided mlnlprlnts are also available. Give yourself a competitive advantage with reprints! .. For additional information, please contact FosteReprints, the official reprint provider for Welding Journal. FosteRepmts Email: [email protected] or call 866-879-9144 LMIl'MIUKini'l^H'. IMPORTANCE TO EFFIC OMEGA• MIG-GUNS • 250 - 450 amperes

ALPHA® MIG-GUNS • 180 - 450 amperes

Technology for the Welder's World. ABICOR ^^ BINZEL3J

Alexander Binzel Corporation 650 Medimmune Ct., Suite 1 10 Frederick, Maryland 21703 Phone: 800.542.4867 Fax: 301.846.4497

www.abicorusa.com I CHOOSE LINCOLN FOR INDUSTRY LEADING SUBMERGED ARC WELDING.

Welding Consumables Equipment Solutions With the highest quality flux The Power Wave® platform Ranging from pipe mills, wind and electrodes available, sets the standard for the towers, offshore structures, Lincoln Electric can provide industry, no other company and heavy fabrication, Lincoln you with consumables that can match Lincoln Electric Electric is the global leader will increase productivity, in quality, productivity, with submerged arc welding while reducing costs. Our or versatility. And with solutions. We have the people state of the art testing methods Production Monitoring• and knowledge for any ensure high quality results software, you are guaranteed challenge, anywhere. every time. a quality weld every time.

[LINCOLN 1^ H ELECTRIC THE WELDING EXPERTS* For Info go to www.aws.org/ad-index